Chevrolet - Silverado 1500 4wd V8 - Workshop Manual - 2004 - 2004 (2)

Door Window Channel Front Door Window Glass Weatherstrip: Service and Repair Door Window Channel Window Run Channel Replacement - Front Door Removal Procedure 1. Remove the window. 2. Remove the window glass weatherstrip. 3. Remove the window run channel bolts. 4. Remove the front and the rear window run channels from the door. Installation Procedure 1. Install the front and the rear window run channels to the door. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the front and the rear window run channel bolts. 1. Tighten the front bolt to 9 N.m (80 lb in). 2. Tighten the rear bolt to 9 N.m (80 lb in). 3. Install the window glass weatherstrip. 4. Install the window. Page 1075 1. If a NEW control module is being installed, program the new module. 2. Install the shift control module to the bracket. 3. Connect the shift control module electrical connectors. 4. Start the engine and test the automatic transfer case system for proper shift operation. Transfer Case Control Module Reprogramming Transfer Case Control Module Reprogramming Set-up for Module Programming/Reprogramming Important: Ensure that the vehicle battery is fully charged and that a battery charger is no longer connected. If performing this procedure for module replacement, install a new module before proceeding. Before reprogramming, close the doors and wait two minutes to allow other modules to stop communicating via the class 2 data line. Failure to do so could result in a failed reprogramming procedure. ^ Turn OFF all accessories. ^ Turn ON the ignition, with the engine OFF. Page 8684 Electronic Brake Control Module (ECBCM) - C2 (30 Series and HP2 Page 469 Electrical Symbols Part 6 Page 13575 Body Control Module: Description and Operation BODY CONTROL MODULE (BCM) The body control module (BCM) monitors several inputs in order to arm and disarm the CTD system. The BCM controls the alarm function outputs. When the BCM detects an unauthorized entry (any door opened), the BCM applies ground to the horn, the park lamp and the headlamp relays. The BCM will send messages to the security telltale in the instrument cluster through the Class 2 serial data link. The BCM has the following 8 basic modes for operating the CTD system. The more detailed descriptions are below. - Off state - Idle state - Disarmed state - Ready-to-arm state - Arm initiated state - Arm delay state - Armed state - Alarm state The BCM has the following 6 discrete inputs in order to monitor the CTD system: - Ignition 1 - Driver door latch (door jamb) switch - Passenger door latch (door jamb) switch - Door lock relay - Door key switch - Passenger door unlock relay The BCM applies ground once per second for approximately 2 minutes, or until a valid input to disarm the system is received by the BCM. The Body Control Module (BCM) contains the theft deterrent system logic. The BCM reads the Passlock(TM) data from the Passlock(TM) sensor. If the Passlock(TM) data is correct, the BCM will pass theft. The BCM will then transmit the fuel continue password to the VCM/PCM. During the tamper mode the vehicle may start. The vehicle will then stall. If the BCM receives the wrong Passlock(TM) data, the VTD will immediately go into the tamper mode. The tamper mode will lock-out the vehicle fuel injectors for 10 minutes. The SECURITY indicator will flash while the VTD is in the tamper mode. If the Passlock(TM) sensor sends a correct password to the BCM when the ignition is in the ON position, the BCM will send a fuel enable signal to the VCM/PCM. The VCM/PCM will not disable the fuel due to any BCM message for the remainder of the ignition cycle. Page 10716 8. Install the inner bearing. 9. Important: Each time you replace the wheel hub bearings, install a new oil seal in order to prevent the wheel hub from leaking. Install the new oil seal using the J 44420 (2) and the J 8092 (1). 10. Install the rotor, if necessary. 11. Apply a light coat of high melting point EP bearing lubricant to the axle housing spindle. 12. Install the wheel hub to the axle housing. 13. Install the adjusting nut to the hub using the J 2222-C. 14. Adjust the wheel bearings. 15. Install the axle shaft. 16. Install the brake caliper. 17. Install the tire and wheel assembly. Page 5531 7. Install the engine sight shield. 8. Install the air cleaner outlet duct. 9. Refill the cooling system. Refer to Draining and Filling Cooling System in Cooling System. 10. Connect a scan tool in order to test for proper throttle-opening and throttle-closing range. 11. Operate the accelerator pedal and monitor the throttle angles. The accelerator pedal should operate freely, without binding, between a closed throttle, and a wide open throttle (WOT). 12. Verify that the vehicle meets the following conditions: - The vehicle is not in a reduced engine power mode. - The ignition is ON. - The engine is OFF. 13. Start the engine. 14. Inspect for coolant leaks. Page 10223 Electrical Symbols Part 8 Interior - Erratic Memory Seat Operation Memory Positioning Module: All Technical Service Bulletins Interior - Erratic Memory Seat Operation Bulletin No.: 04-08-50-016C Date: August 12, 2005 TECHNICAL Subject: Memory Seat May Not Return to Requested Position (Reprogram Driver Seat Module) Models: 2003-2005 Cadillac Escalade, Escalade ESV, Escalade EXT 2003-2005 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2003-2005 GMC Sierra, Yukon, Yukon XL, Yukon Denali All with Seat FRT, Individual (Non BKT) (RPO AN3) 2003-2005 HUMMER H2 with Seat, Front Bucket Deluxe (RPO AR9) Supercede: This bulletin is being revised to update the correction information. Please discard Corporate Bulletin Number 04-08-50-016B (Section 08 - Body and Accessories). Condition Some customers may comment that with repeated cycling of the memory seat between the "exit" and one of the "presets", the position of the seat may "creep" forward or rearward out of expected adjustment. Cause There is a coding deficiency in the software for the memory seat module. Correction Technicians are to reprogram the driver seat module with an updated software calibration. The previous bulletin stated to use a service calibration that was released with TIS satellite data update version 4.5. Feedback has proved that calibration to be ineffective in eliminating the memory seat creep condition. An updated service calibration was released with TIS satellite data update version 6.5 available June 13, 2005. This new calibration has additional memory seat creep protection. As always, make sure your Tech 2(R) is updated with the latest software version. Important: After programming is complete, move the seat all the way rearward and down, then bump the seat slightly forward and up. This position will be just off the end of travel hard stops. Reset both memory seat exit positions at this position. Having the seat set at just off the hard stops will aid in reducing the creep condition. Warranty Information Brakes/Wheels - Excessive Debris Build Up Wheels: All Technical Service Bulletins Brakes/Wheels - Excessive Debris Build Up Bulletin No.: 04-05-23-005 Date: June 22, 2004 INFORMATION Subject: Availability of Rear Wheel Mud Flaps to Reduce Debris Build-up on Rear Brake Calipers and/or Rear Wheels Models: 1999-2004 Chevrolet Silverado Pickup Models 1999-2004 GMC Sierra Pickup Models This bulletin is to inform dealers of the release of rear wheel mud flaps. The above models that are exposed to extensive off-paved roads may benefit from the mud flaps. The mud flaps have been developed to minimize the amount of stones and/or mud that can impact and collect on the rear caliper and/or wheel rim. Please advise customers that the installation of these mud flaps and following the recommended off-road driving information provided in their Owner's Manual should greatly reduce the possibility of accelerated rear brake component wear and/or rim damage. Install the mud flap forward of each rear wheel using the following procedure. Important: Always work from outboard to inboard, drilling one hole at a time and securing with a fastener. Follow the sequence of the procedure. This will prevent distortion of the mud flap. 1. Raise the vehicle. Support the vehicle. 2. Locate the pickup box side panel rear brace. 3. Remove the existing outboard upper fastener on the brace. 4. Install the mud flap through the "V" of the brace. Install the previously removed fastener in the hole (2) of the mud flap to the brace. Do not tighten the fastener at this time. 5. Using the mud flap as a template, locate and mark the location of the hole (1) in the pickup box wheel house. Page 9573 Fuse Block- I/P C2 Page 14644 Front Passenger Seat (1 Of 2) (With RPO Code AN3) Page 11078 Control Module HVAC: Locations HVAC Control Module Page 12834 Page 5483 Disclaimer Page 4489 Electrical Symbols Part 12 Page 6897 7. Align the hole in the pinion shaft with the bolt hole in the differential case. 8. Notice: Refer to Fastener Notice in Service Precautions. Install the new pinion shaft locking bolt. ^ For the 8.6 inch axle, tighten the pinion shaft locking bolt to 36 Nm (27 ft. lbs.). ^ For the 9.5 inch axle, tighten the pinion shaft locking bolt to 50 Nm (37 ft. lbs.). 9. Install the rear cover and the gasket. 10. Install the brake caliper. 11. Install the tire and wheel assembly. 12. Fill the rear axle. Use the proper fluid. 13. Lower the vehicle. 9.75 Inch Axle Rear Axle Shaft Replacement (9.75 Inch Axle) Removal Procedure 1. Release the park brake. 2. Raise the vehicle. Refer to Vehicle Lifting. 3. Remove the tire and wheel assembly. 4. Remove the rear steering gear assembly. 5. Remove the steering knuckle assembly. 6. Remove the lock clip from the axle shaft end. The lock clip is spring loaded and fits securely in the axle shaft slot and may need to be push off the shaft end with a screw driver or related tool. Pushing the axle shaft inwards towards the gears my help in removal of the lock clip. Page 892 Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. 1. Disconnect the connector from the component. 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. Automatic Transmission - 4L60-E/4L65-E Transmission Speed Sensor: Locations Automatic Transmission - 4L60-E/4L65-E Automatic Transmission Electronic Component Views (M30/M32) Electronic Components Page 12876 2. Connect the Techline Information System (TIS) terminal to the Tech2(R). 3. Scroll to the bottom of the Controller List, and select the "ONSA TIS2WEB Pass-Thru OnStar(R) Activation (Replaced/Upgraded Units Only)" option using the Service Programming System (SPS). Important: Do not use the clear DTC function. This will only temporarily turn the LED to green. 4. Upon completion of the OnStar(R) TIS2WEB step, disconnect the TIS terminal from the Tech2(R) and perform the VCIM/OnStar(R) Set-up Procedure using the Tech2(R). The set up procedure is located under the special function menu option. Important: Failure to perform the above steps will result in a red LED, DTC being set and limited or incomplete OnStar(R) services, and will require a customer return visit to the dealership. 5. The default language for the new VCIM will be English. To change to French or Spanish, access the special functions menu on the Tech 2(R), and follow the instructions accordingly. 7. Skip to the next step if the vehicle to be upgraded is not listed below: ^ 2002-2004 Cadillac DeVille ^ 2002-2004 Cadillac Seville ^ 2005 Cadillac STS Set up the Dash Integration Module (DIM) using the following procedure: 1. On the Tech2(R) select the correct Year, Make and Model. 2. Enter Dash Integration Module (DIM) > Special Functions > Set Options > Misc. Options 1 > and turn off phone (if the vehicle does not have the UV8 option). 3. Enter Nav Radio Present and set to "No Nav" (if the vehicle does not have a navigation radio). 4. Turn the ignition off and open the door to turn off the RAP. 5. Turn the ignition on and enter the Vehicle Comm. Interface Module > Special Functions > Set Up OnStar /VCIM. 6. When prompted select "No Phone" (if the vehicle does not have the UV8 phone) and "No Nav" (if the vehicle does not have a navigation radio). 7. Turn the ignition off and open the door to turn off the RAP. Important: OnStar(R) Emergency Services are immediately available after these steps, however, full configuration, including activation of Hands-Free Calling, may take up to 24 hours to complete. Processing the Module Exchange Processing the Module Exchange For this program, submitting a credit request for the removed OnStar(R) VCIM (the core) will be performed through a website. When this process is followed, the removed Analog / Digital-Ready VCIM, in most cases, will not be mailed back to the distributor, but can be scrapped by the dealership. U.S. Dealers 1. Return the removed Analog / Digital-Ready OnStar(R) VCIM to the Parts Manager. 2. The Parts Manager will log onto www.autocraft.com. 3. Select Account Maintenance. 4. Select Outstanding Cores. Page 3217 7. Install the PCV hose. 8. Apply threadlock GM P/N 12345382 (Canadian P/N 10953489), or equivalent to the threads of the bracket bolts. 9. Install the ignition coil bracket. 10. Install the ignition coil bracket studs. ^ Tighten the studs to 12 Nm (106 inch lbs.). Automatic Transmission - 4L60-E/4L65-E Shift Solenoid: Diagrams Automatic Transmission - 4L60-E/4L65-E A/C - Window Defroster Contact/Tab Repair Information Back Window Glass: Customer Interest A/C - Window Defroster Contact/Tab Repair Information INFORMATION Bulletin No.: 03-08-48-006H Date: April 11, 2011 Subject: Repair Information for Reconnection of Rear Window Defroster Contact or Tab Models: 2000-2012 GM Passenger Cars and Trucks 2003-2009 HUMMER H2 2006-2010 HUMMER H3 2005-2009 Saab 9-7X 2007-2010 Opel GT 2007-2008 Daewoo G2X Equipped With Electric Rear Window Defroster - RPO C49 Supercede: This bulletin is being revised to add the 2012 model year. Please discard Corporate Bulletin Number 03-08-48-006G (Section 08 - Body and Accessories). Repair Suggestions Soldering Defroster Contact Tabs In many cases the terminal tab will still be in the connector when you examine the vehicle. For Chevrolet Tahoe, Suburban, GMC Yukon, and Cadillac Escalade vehicles (with moveable glass), always replace the defroster tab (GM P/N 25916031) and the defroster electrical power connector (P/N 12034110). For all other vehicles, reconnect the original defroster tab. In most applications it is preferable to create a new solder connection to reattach a separated rear defroster tab. If you take note of the steps below, it is possible to create a new solder joint that is equal to, or stronger than, the original. The generic procedure below is not very time intensive, but does include minor preparation work to create a good bonding surface. Be sure to follow each of the steps, as combined they will produce the strongest bond possible. Please consider the following before attempting the repair: - Soldering introduces significant heat to the glass window of the vehicle. When performing the re-connection of the tab, use only the heat required to do the job. Pre-heat the soldering iron and have the solder in your other hand, ready to go, the moment you have enough heat to melt the solder. - If it is winter, bring the vehicle into the service garage and remove any snow from the back window area. Allow time for the glass to warm to the temperature inside the building. Soldering creates a "hot spot" in the glass. DO NOT solder on cold glass. Caution Heating the glass excessively, or repeatedly without time to cool, may result in glass breakage. ALWAYS wear safety glasses when performing this repair! - You MUST use a silver-bearing solder to make the connection. DO NOT attempt this repair with conventional tin/lead alloy solders. Silver bearing solder will adhere to the electrical buss bar, making a strong and lasting repair. - Protect surfaces under the area to be soldered. It is very easy to drip solder when performing this repair. Placing a shop towel under the soldering area is sufficient protection. Soldering Procedure 1. It is imperative to remove and replace the rear defroster electrical power connector by crimping a new connector to the feed wire. The proper connector P/N 12034110 can be found in the Packard Electrical Assortment, Tray 18, Position 5. - Insert Delphi pick 12094430 to depress the locking tab on the terminal. - Insert Delphi pick 12094429 to release the secondary lock tab. Important DO NOT re-use the existing defroster tab on new-style full-size utility vehicles with moveable glass. 2. Connect the electrical connector to the defroster tab. Fully engage the connector. An improperly seated connector may cause excessive resistance and impede the proper operation of the defroster. Add a small bead of solder to mate the electrical connector tab to the defroster tab. Page 10690 It will be necessary to reprogram the PCM for speedometer accuracy. Contact Techline to obtain a VCI number. Then refer to the table for the appropriate calibration part number based on the model year and axle ratio. Calibration Information Documentation Make a copy of the "Accessory Wheel and Tire Information Form" included in this bulletin. Page 813 Junction Block - I/P Wire Entry Part 1 Page 5080 Put unused material on the shelf for future use. Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Page 6405 1. Lubricate the input speed sensor seal with automatic transmission fluid. 2. Install the input speed sensor (1). Notice: Refer to Fastener Notice in Service Precautions. 3. Install the input speed sensor bolt. ^ Tighten the bolt to 11 Nm (96 inch lbs.). 4. Connect the input speed sensor electrical connector (1). 5. Lower the vehicle. Page 9832 Relay Box: Locations Relay Block - I/P Location View Page 16014 Electrical Symbols Part 10 Page 1360 Door Latch Assembly (Door Jamb Switch) - Driver - C2 Page 11850 Passlock Sensor Service and Repair Windshield Washer Reservoir: Service and Repair WASHER PUMP/RESERVOIR REPLACEMENT REMOVAL PROCEDURE 1. Remove the battery and battery tray from the vehicle. 2. Remove the inner wheel housing from the vehicle. 3. Disconnect the electrical connector from the washer pump. 4. Disconnect the electrical connector from the washer solvent level sensor. 5. Disconnect the washer hose from the washer pump. 6. Remove the upper bolt from the washer solvent container. 7. Remove the lower bolts from the washer solvent container. 8. Remove the washer solvent container from the vehicle. INSTALLATION PROCEDURE Page 1073 1. If a NEW control module is being installed, program the new module. 2. Install the shift control module to the bracket. 3. Connect the shift control module electrical connectors. 4. Start the engine and test the automatic transfer case system for proper shift operation. Page 2611 Fuse Block - Underhood - Secondary Wire Entry (With RPO Code HP2) Part 1 Page 7216 Electrical Symbols Part 8 Page 5398 Fuel Filler Hose: Service and Repair Filler Tube Replacement (1500 Crew Cab) FILLER TUBE REPLACEMENT (1500 CREW CAB) REMOVAL PROCEDURE 1. Remove the fuel tank filler housing to body TORX(R) screws (1) and retainer (2). 2. Remove the fuel tank filler housing to fuel tank fill pipe bolts. 3. Remove the fuel tank filler housing. 4. Partially raise and suitably support the vehicle. Refer to Vehicle Lifting. Page 15153 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors USING CONNECTOR TEST ADAPTERS IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-B Connector Test Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Page 9585 Junction Block - Rear Lamps - C1 Part 1 Page 5674 Vehicle Speed Sensor(VSS) Page 13107 Page 15824 Steering Wheel And Column Sub-System Components Page 7385 Page 3806 circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links CIRCUIT PROTECTION - FUSIBLE LINKS Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Flat Wire Repairs FLAT WIRE REPAIRS NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Heated Oxygen Sensor (HO2S) Wiring Repairs HEATED OXYGEN SENSOR (HO2S) WIRING REPAIRS TOOLS REQUIRED J 38125-D Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: - Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-D. Repairing Damaged Wire Insulation REPAIRING DAMAGED WIRE INSULATION Page 15392 Fuel Pressure Gage Installation and Removal Fuel Pressure Release: Service and Repair Fuel Pressure Gage Installation and Removal FUEL PRESSURE GAGE INSTALLATION AND REMOVAL INSTALLATION PROCEDURE TOOLS REQUIRED J 34730-1A Fuel Pressure Gage CAUTION: - Refer to Gasoline/Gasoline Vapors Caution in Service Precautions. - Refer to Fuel Gage Leak Caution in Service Precautions. 1. Remove the engine sight shield. 2. Remove the fuel rail pressure fitting cap. 3. Connect the J 34730-1A to the fuel pressure valve. Wrap a shop towel around the fitting while connecting the gage in order to avoid spillage. 4. Install the bleed hose on J 34730-1A into an approved container. REMOVAL PROCEDURE 1. Remove the bleed hose on the J 34730-1A from the approved container. 2. Remove the shop towel from around the fitting and discard into an approved container. 3. Disconnect the J 34730-1A from the fuel pressure valve. 4. Install the fuel rail pressure fitting cap. 5. Install the engine sight shield. Page 5157 Accelerator Pedal Position (APP) Sensor Part 2 Diagrams Headlamp Alignment Actuator: Diagrams Headlamp Leveling Actuator - Left (Export) Page 1592 Intake Air Temperature (IAT)/Mass Air Flow (MAF) Sensor Page 11197 Hose/Line HVAC: Service and Repair Evaporator Tube Replacement (Without RPO Code HP2) EVAPORATOR TUBE REPLACEMENT (W/O HP2) TOOLS REQUIRED J 39400-A Halogen Leak Detector REMOVAL PROCEDURE 1. Recover the refrigerant from the A/C system. Refer to Refrigerant Recovery and Recharging. 2. Remove the evaporator tube nut from the evaporator. 3. Remove the evaporator tube from the evaporator. 4. Remove the right park/turn signal lamp. 5. Remove the grille from the vehicle. 6. Remove the evaporator tube nut from the condenser. 7. Remove the evaporator tube from the condenser. 8. Remove the evaporator tube from the vehicle. 9. Discard all of the used sealing washers. Cap all of the open connections. INSTALLATION PROCEDURE 1. Install the evaporator tube to the condenser using new sealing washers. NOTE: Refer to Fastener Notice in Service Precautions. Page 521 Front Passenger Door Module (FPDM) - C1 (With RPO Code YE9) Page 3371 1. Apply sealant GM P/N 12346004, (Canadian P/N 10953480), or equivalent, to the threads of the oil pressure sensor. Notice: Refer to Fastener Notice in Service Precautions. 2. Using J 41712 or equivalent, install the oil pressure sensor. ^ Tighten the oil pressure sensor to 30 Nm (22 ft. lbs.). 3. Connect the oil pressure sensor electrical connector (1). 4. If necessary, install the engine sight shield. Page 8741 4. If equipped with a 4.8L, 5.3L, or 6.0L engine, remove the negative cable clip from the positive cable clip. 5. Remove the engine wiring harness ground/negative cable bolt. 6. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 7. If equipped with a 8.1L engine, remove the negative cable clip from the positive cable clip. 8. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 9. Remove the engine wiring harness ground/negative cable bolt. 10. Reposition the wiring harness ground and negative cables. 11. Remove the forward lamp wiring harness ground/negative cable bolt. 12. Lower the vehicle. 13. Remove the negative battery cable. Page 2631 Location View Page 14622 Power Seat Motor Position Sensor: Diagrams Seat Bolster Motor/Position Sensor - Driver (With RPO Code AN3) Page 4490 Electrical Symbols Part 13 Fuel Pressure Gage Installation and Removal Fuel Pressure: Testing and Inspection Fuel Pressure Gage Installation and Removal FUEL PRESSURE GAGE INSTALLATION AND REMOVAL INSTALLATION PROCEDURE TOOLS REQUIRED J 34730-1A Fuel Pressure Gage CAUTION: - Refer to Gasoline/Gasoline Vapors Caution in Service Precautions. - Refer to Fuel Gage Leak Caution in Service Precautions. 1. Remove the engine sight shield. 2. Remove the fuel rail pressure fitting cap. 3. Connect the J 34730-1A to the fuel pressure valve. Wrap a shop towel around the fitting while connecting the gage in order to avoid spillage. 4. Install the bleed hose on J 34730-1A into an approved container. REMOVAL PROCEDURE 1. Remove the bleed hose on the J 34730-1A from the approved container. 2. Remove the shop towel from around the fitting and discard into an approved container. 3. Disconnect the J 34730-1A from the fuel pressure valve. 4. Install the fuel rail pressure fitting cap. 5. Install the engine sight shield. Page 3724 Lower the vehicle. Parts Information Warranty Information Page 14870 Seat Recliner Motor Position Sensor - Driver (With RPO Code AN3) Page 15857 The 1999 though early 2003 wiring harness jumper that plugs into the relay block will have a reddish/brown 6-way connector and a tag with the last four digits of the wiring harness part number. Second design 2003-05 may have a white plastic connector with part number 5418 as well. ^ The 1999 jumper is/was P/N 12171982 with a pink/purple tag identifier of 1982. This number has been superseded to 15366255, with a pink/purple tag identifier of 6255. ^ The 2000 jumper harness is P/N 15366255. The pink/purple tag identifier is 6255. ^ The 2001-2002 jumper is P/N 15086884. The orange tag identifier is 6884. ^ The 2003-05 jumper is P/N 15085418. The orange tag identifier is 5418. When transferring the brake controller with the wiring jumper attached from a 2001-2002 vehicle to a 2003-05 vehicle, a change to the jumper harness connector must be performed. Page 578 1. Position the module into the vehicle. 2. Connect the lower electrical harness connectors (2). 3. Slide the module (2) to the left to engage the lower retainers. NOTE: Refer to Fastener Notice in Service Precautions. 4. Install the module retaining screws (3). Tighten Tighten the screws to 3 N.m (26 lb in). 5. Connect the upper electrical harness connectors (3). 6. Install the seat cushion. 7. If a new memory seat module was installed, calibrate the seat. Refer to Memory Seat Calibration Procedure. Page 6981 8. Remove the adjusting nut. 9. Remove the hub from the axle housing. 10. Remove the rotor, if necessary. 11. Remove the oil seal from the wheel hub using a suitable seal removal tool. 12. Remove the inner hub bearing. 13. Remove the inner hub bearing cup using a brass drift and a hammer. Page 13520 Electrical Symbols Part 11 Page 1383 Parts Information Parts are currently available from GMSPO. Warranty Information Locations Power Seat Motor: Locations Passenger Presence Components - Under Front Passenger Seat Page 9418 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors USING CONNECTOR TEST ADAPTERS IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-B Connector Test Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Drivetrain - Service 4WD Light/DTC C0374 Set Speed Sensor: All Technical Service Bulletins Drivetrain - Service 4WD Light/DTC C0374 Set TECHNICAL Bulletin No.: 05-04-21-003C Date: April 15, 2008 Subject: Service 4WD Light Illuminated, DTC C0374 Set (Inspect Wiring Harness to Transfer Case Speed Sensors,, Replace Wiring Harness) Models: 2004-2007 Buick Rainier 2003-2006 Chevrolet Avalanche, Suburban, Tahoe 2003-2007 Chevrolet Silverado Classic, TrailBlazer, TrailBlazer EXT 2003-2006 GMC Yukon, Yukon XL 2003-2007 GMC Envoy, Envoy XL, Sierra Classic 2003-2004 Oldsmobile Bravada 2005-2007 Saab 9-7X With Four Wheel Drive or All-Wheel Drive and Active All-Wheel Drive (RPO NP4) or Active Two-Speed (RPO NP8) Transfer Case Supercede: This bulletin is being revised to update the Model and Warranty Information. Please discard Corporate Bulletin Number 05-04-21-003B (Section 04 - Driveline/Axle). Condition Some customers may comment on intermittent illumination of the Service 4WD light. Upon investigation, the technician may find DTC C0374 set. The customer may also comment on intermittent erratic operation of the 4WD or AWD system after driving through rain/snow or simply going through a car wash. Cause The speed sensor signal may have become corrupted. Possible openings in the speed sensor wire insulation (twisted pairs) can allow water intrusion. Also wire connections contaminated by water may result in short circuits and erroneous speed sensor readings. This most often occurs on the rear speed sensor circuit. Correction Inspect the wiring harness to the transfer case speed sensors. On Rainier, TrailBlazer, Envoy and 9-7X models, fabricate a replacement speed sensor harness between the C101 connector and the speed sensors. Completely inspect and test all wiring. Refer to Speed Signal Front Axle Actuator and Indicators schematic in SI. Replace the affected twisted pairs. Do not over-twist the two wires in the replacement harness. Wires should be twisted at a rate of 9 revolutions per foot. Use service connector pack, P/N 88987993 at the speed sensor end and terminal, P/N 15326267, at C101. Terminal testing tools and service terminals can be found in Terminal Repair Kit J 38125. Terminals are available from SPX/Kent-Moore. The smaller transfer case harness splices into the larger chassis harness a few inches in front of the crossmember. The chassis harness routes along the left side of the frame under the driver door area. Use nylon tie straps to secure the fabricated harness to the main chassis harness between the transfer case and C101. On the full-size pickup and full-size utility models, replace the 2.2 m (88 in) pigtail harness that runs from the C151 connector under the hood to the transfer case. Use either harness P/N 15832722 or 15224663 depending on vehicle equipment. Refer to Propshaft Speed Sensors Front Axle Actuator and Transfer Case Shift Control Switch schematic in SI. Important: Technicians should verify the integrity of the splice joints after the repair. All splice joints and connections should seal properly against water or a repeat condition can occur. Page 12578 Service and Repair Headliner: Service and Repair Headliner Replacement Caution: Do not attempt to repair or alter the head impact energy-absorbing material glued to the headliner or to the garnish trims. If the material is damaged, replace the headliner and/or the garnish trim. Failure to do so could result in personal injury. Removal Procedure 1. Remove the I/P top trim panel. 2. Remove the hinge pillar trim. 3. Disconnect the headliner wire connectors from the junction block located next to the clutch or brake pedal. 4. Remove the wire harness retainers along the windshield pillar and I/P assembly. 5. Remove the rear quarter trim panels, if necessary. 6. Remove the overhead console, if equipped. 7. Remove the DVD player, if equipped. 8. Remove both front sunshades. 9. Remove the rear coat hook, if equipped. 10. Remove the interior dome lamp. 11. Remove the assist handles, if equipped. 12. Disengaging the front of the headliner from the roof. 13. If replacing the crew cab headliner, remove the rear window from the vehicle. Refer to Rear Window Replacement (Pickup) in Heated Glass Element. 14. Remove the headliner from the vehicle by grasping the headliner on the left and the right sides near the front of the cab. Installation Procedure Page 8673 For vehicles repaired under warranty, use the table. Disclaimer OnStar(R) - System Inoperative/No LED Lamp ON Fuse: Customer Interest OnStar(R) - System Inoperative/No LED Lamp ON Bulletin No.: 04-08-46-005 Date: December 21, 2004 TECHNICAL Subject: OnStar(R) Generation 6 (Digital) System Inoperative/Has No Power, LED Light Not On (Remove/Reinstall OnStar(R) Fuse and Replace VCIM or Follow SI Diagnostics) Models: 2004-2005 Buick Rainier, Rendezvous 2005 Buick Allure (Canada), LaCrosse, LeSabre, Terrazza 2004-2005 Cadillac Escalade, Escalade ESV, Escalade EXT 2005 Cadillac CTS, DeVille 2004-2005 Chevrolet Avalanche, Silverado, Suburban, Tahoe, TrailBlazer, TrailBlazer EXT 2005 Chevrolet Colorado, Express, Impala, Monte Carlo, Uplander 2004-2005 GMC Denali, Denali XL, Envoy, Envoy XL, Envoy XUV, Sierra, Yukon, Yukon XL 2005 GMC Canyon, Savana 2004-2005 Pontiac Aztek 2005 Pontiac Bonneville, Grand Prix, Montana SV6, Vibe with Digital Gen 6 OnStar(R) (RPO UE1) Condition Some customers may comment any or all of the following conditions: ^ The OnStar(R) system may be inoperative. ^ The OnStar(R) system may have no power. ^ The OnStar(R) LED light may not be on. The technician may also not be able to communicate with the OnStar(R) Vehicle Communication Interface Module VCIM) with a Tech 2(R). Correction Remove the OnStar(R) fuse from the fuse box, wait five minutes and reinstall the fuse. If the OnStar(R) system DOES NOT return to normal functionality, then follow the diagnostics in SI for this condition. If the OnStar(R) system DOES return to normal functionality, you will need to replace the VCIM. If the VCIM is not replaced, there is the possibility that the customer will return to the dealership with the same conditions at a later date. Please contact the GM Technical Assistance Center (TAC), to obtain a new VCIM. The TAC consultant will verify your diagnosis and, if appropriate, order a replacement part. Replacement parts are usually shipped out within 24 hours, and a pre-paid return package label will be included for returning the faulty part. By returning the faulty part, you will avoid a significant non-return core charge. After the VCIM has been replaced, press the blue OnStar(R) button and request a full reconfiguration. When contacting TAC regarding this concern, the availability of certain information from the vehicle will streamline the process for the dealership technician as well as minimize the time necessary for TAC to provide the correct diagnosis. Please refer to Corporate Bulletin Number 01-00-89-011B for further information concerning the information necessary before contacting TAC. Dealers in Canada should refer to GM Service Policies & Procedures Section 5.3.1 "DEALER REQUIREMENTS FOR ASSISTANCE". Warranty Information Automatic Transmission - 4L60-E/4L65-E Transmission Position Switch/Sensor: Service and Repair Automatic Transmission 4L60-E/4L65-E Park/Neutral Position Switch Replacement ^ Tools Required J 41364-A Park Neutral Switch Aligner Removal Procedure 1. Apply the park brake. 2. Shift the transmission into neutral. 3. If equipped with 4-wheel drive (4WD), remove the front propeller shaft. 4. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 5. Disconnect the park/neutral position (PNP) switch electrical connector (2). 6. Remove the manual shaft lever nut. Engine Controls - MIL ON/Rough Idle/Misfire/DTC's Set Oxygen Sensor: Customer Interest Engine Controls - MIL ON/Rough Idle/Misfire/DTC's Set Bulletin No.: 05-06-04-063 Date: October 12, 2005 TECHNICAL Subject: LM7, L59 or L33 Engines with Cold Start Rough or Incorrect Idle, Misfire, Malfunction Indicator Lamp (MIL) or Flashing Requiring 02 Sensor Replacement (Reprogram PCM) Models: 2004-2005 Cadillac Escalade 2004-2005 Chevrolet Avalanche, Silverado 1500, Suburban, Tahoe 2005 Chevrolet Silverado Hybrid (HP2) 2004-2005 GMC Sierra 1500, Yukon, Yukon XL 2005 GMC Sierra Hybrid (PH2) with Vortec 5300 5.3L V-8 Engine (VINs T, Z, B - RPOs LM7, L59, L33) Condition Some customers may comment on a Malfunction Indicator Lamp (MIL) On or that the MIL is flashing. An actual engine misfire may or may not be felt along with an incorrect idle speed. Typically this occurs during cold winter months, on cold engine starts. Some vehicles may have been previously serviced for the same condition. Technicians may also find the following DTCs stored with the Tech 2(R) P0131, P0133, P0134, P0137, P0138, P0140, P0151, P0153, P0154, P0157, P1133, which may be in conjunction with P0171, P0174, P0300 and P1138. Cause Water shock occurs when water droplets are present in the exhaust. The water in the exhaust contacts the sensor element inside the H02 sensor, causing the H02 sensor element to crack. Correction Upon diagnostic investigation, the technician may find that the H02 sensor requires replacement. In addition to replacing the affected H02 sensor, these vehicles should also be reflashed with the latest PCM calibration. An updated PCM calibration will be available to dealerships as part of TIS 2000 incremental satellite update 11.0 (NAO version 25.010) or greater. Always, make sure your Tech 2 is updated with the latest software version. Important: If a DTC P0420 or P0430 is stored along with DTC(s) P0300, the catalytic converter diagnostics in Service Information (SI) must be followed to determine if the catalytic converters are operating properly. Warranty Information For vehicles repaired under warranty, use the table. Page 5093 1. Install the EVAP vent valve with pipe. 2. Install the EVAP pipe to the retaining clips. NOTE: Refer to Fastener Notice in Service Precautions. 3. Install the EVAP vent valve bracket bolt. Tighten Tighten the bolt to 12 N.m (106 lb in). 4. Close the pipe retaining clips. 5. Connect the EVAP vent valve electrical connector (1). 6. Lower the vehicle. Body - Replacement Fender Hood Hinge Hole Too Large Hood Hinge: All Technical Service Bulletins Body - Replacement Fender Hood Hinge Hole Too Large INFORMATION Bulletin No.: 08-08-63-003 Date: November 26, 2008 Subject: Hood Hinge Pivot Hole Too Large On Some Replacement Fenders Models: 1999-2007 Chevrolet Silverado Classic 2001-2006 Chevrolet Avalanche, Suburban, Tahoe 1999-2007 GMC Sierra Classic 2001-2006 GMC Yukon Models Technicians installing GMSPO service replacement fenders may find that the fender side hood hinge pivot bolt attachment hole is too large (12 mm). The hood hinge pivot bolt attachment hole on some service fenders may be too large (12 mm), causing improper retention of the pivot bolt. To correct this condition, add a M8 X 32 mm O.D. X 2 mm thick washer between the hinge halves on the inboard side of the fender side hood hinge. This will provide the proper surface for the shoulder of the pivot bolt to contact as it is tightened. Refer to the illustration above. Parts Information Disclaimer Locations Knock Sensors Service and Repair Gear Sensor/Switch: Service and Repair Encoder Motor Sensor Replacement Removal Procedure Important: For ease of reassembly, shift the transfer case to 2HI prior to removing any components. 1. Remove the encoder motor. 2. Place the encoder motor on a clean work bench, 3. Remove the 2 screws (2) from the motor cover. 4. Remove the 2 screws (1) from the casting. 5. Remove the cover. 6. Remove and save the shim on the output gear. 7. Remove and discard the orange rubber seal from the cover. 8. Remove the output gear (1). Page 8506 Page 2913 onto the subject vehicle. - After match mounting, the tire/wheel assembly must be rebalanced. If match mounting tires to in-spec wheels produces assembly values higher than these, tire replacement may be necessary. Replacing tires at lower values will probably mean good tires are being condemned. Because tires can sometimes become temporarily flat-spotted, which will affect force variation, it is important that the vehicle be driven at least 16 km (10 mi) prior to measuring. Tire pressure must also be adjusted to the usage pressure on the vehicle's tire placard prior to measuring. Most GM vehicles will tolerate radial force variation up to these levels. However, some vehicles are more sensitive, and may require lower levels. Also, there are other tire parameters that equipment such as the Hunter GSP9700 cannot measure that may be a factor. In such cases, TAC should be contacted for further instructions. Important - When mounting a GM wheel to a wheel balancer/force variation machine, always use the wheel's center pilot hole. This is the primary centering mechanism on all GM wheels; the bolt holes are secondary. Usually a back cone method to the machine should be used. For added accuracy and repeatability, a flange plate should be used to clamp the wheel onto the cone and machine. This system is offered by all balancer manufacturers in GM's dealer program. - Any type of service equipment that removes tread rubber by grinding, buffing or truing is NOT recommended, and may void the tire warranty. However, tires may have been ground by the tire company as part of their tire manufacturing process. This is a legitimate procedure. Steering Wheel Shake Worksheet When diagnosing vibration concerns, use the following worksheet in conjunction with the appropriate Vibration Analysis-Road testing procedure in the Vibration Correction sub-section in SI. Specifications Ignition Cable: Specifications Spark Plug Wire Resistance ................................................................................................................ .................................................... 1000 ohms per foot Page 14362 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly, Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Pull to Seat Connectors PULL TO SEAT CONNECTORS TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Page 12586 4.1. Unplug the SRS control module's connector (A). 4.2. Cut off the cable tie (B), detach the connector's rear end face (C), and pull out the connecting rail (D). 4.3. Extract pin 15, cut off the cable terminal and insulate the end with tape (E). Fold back the cable and secure it with tape (F). 4.4. Fit the connecting rail and end face. 4.5. Plug in the connector (A) and secure the cables with cable ties (B). 5. Remove the parcel shelf trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6. M03: Replace the optic cable on the right-hand side Page 3036 Parts Information Warranty Information Wheels All GM Accessories sold and permanently installed on a GM vehicle PRIOR to new vehicle delivery will be covered under the provisions of the New Vehicle Limited Warranty. For the U.S., in the event GM Accessories are installed AFTER the New Vehicle Delivery, or are replaced under the New Vehicle Warranty, they will be covered (parts and labor) for the balance of the vehicle warranty, but in no event less than 12 months/12,000 miles. This coverage is only effective for GM Accessories permanently installed by a GM dealer or a GM approved ADI (Accessory Distributor/Installer). For Canada, in the event GM Accessories are installed AFTER the New Vehicle Delivery, they will be covered (parts and labor) for the balance of the vehicle warranty, or up to 12 months/Unlimited kilometers depending on month installed. For replacement after the new vehicle warranty expires, but within the 12 months/unlimited kilometers coverage, refer to claim type "B" guidelines. GM Accessories sold over-the-counter, or those not requiring installation, will continue to receive the standard GM Dealer Parts Warranty of 12 months from the date of purchase (parts only). Tires Any approved tire installed on a GM Vehicle PRIOR to delivery will be covered under the provisions of the New Vehicle Limited Warranty. Tires are covered against defects in material and workmanship. Tires are warranted for defects "without" prorated charge for tread mileage. Subsequent replacements under this warranty will continue to be covered for the remainder of the New Vehicle Limited Warranty. Any approved tire installed on a GM Vehicle PRIOR to delivery may continue to be warranted on a prorated basis by the tire manufacturer once the New Vehicle Limited Warranty expires. Any approved tire installed AFTER delivery will be covered under the provisions of the tire manufacturer warranty. USA dealers should refer to GM Warranty Administration Bulletin 00-03-10-003I and GM Parts Process / Policy Bulletin IB03-001 for more information. Canadian dealers should refer to GM Warranty Administration Bulletin 01-03-10-003B. GM Warranty Claims Processing Only GM dealerships have the ability to file warranty claims for GM Parts and Accessories. Therefore, any warranty claims filed against such parts must be handled by the servicing GM dealership. This includes those parts purchased from a GM-approved ADI (Accessory Distributor / Installer). Service and Repair Maintenance Indicator - A/T: Service and Repair This vehicle does not use a Trans Fluid Life index, and has no monitor to reset. Service and Repair Sun Visor: Service and Repair Sunshade Replacement Removal Procedure 1. Remove the screws. 2. Disconnect the electrical connector, if equipped. 3. Remove the sunshade. Installation Procedure 1. Connect the electrical connector, if equipped. 2. Install the sunshade. Notice: Refer to Fastener Notice in Service Precautions. 3. Install the sunshade screws. Tighten the screw to 2 N.m (18 lb in). Page 15274 Door Latch Assembly (Door Jamb Switch) - RR - C2 (Crew Cab Only) Page 7046 Page 2464 Disclaimer Page 391 Page 8606 Use clean, new power steering fluid only. 12. Fill the pump reservoir with fluid to the FULL COLD level. 13. Attach J 43485, Power Steering Bleeder Adapter, to J 35555, Metal Mityvac, or equivalent. 14. Place J 43485 on or in the pump reservoir filler neck. 15. Apply a vacuum of 68 kPa (20 in Hg) maximum. 16. Wait 1 minute. 17. Remove J 43485 and J 35555. 18. Reinstall the pump reservoir cap. 19. Start the engine. Allow the engine to idle. 20. Turn the steering wheel 180-360 degrees in both directions 5 times. 21. Switch the ignition off 22. Verify the fluid level. 23. Release the park brake and unblock the wheels. Hydro-Boost(R) Replacement -- Kodiak, TopKick Tools Required ^ J 35555 Metal Mityvac ^ J 43485 Power Steering Bleeder Adapter Removal 1. Block the wheels. 2. Disconnect the electrical connectors from the electrohydraulic pump and the flow switch. Page 9854 Relay Box: Service and Repair Body Wiring Harness Junction Block Replacement BODY WIRING HARNESS JUNCTION BLOCK REPLACEMENT REMOVAL PROCEDURE 1. Remove the cover retaining nut. 2. Remove the cover by pushing in the tabs. 3. Remove the harness from the front of the junction block. 4. Remove the junction block from the bracket by pressing to release the tabs. 5. Remove the junction block in order to gain access to the rear of the block to remove the retaining bolts. 6. Remove the retaining bolts. 7. Separate the wire harness block from the junction block by inserting a screw driver in between. 8. Remove the junction block from the vehicle. INSTALLATION PROCEDURE 1. Install the wire harness block to the junction block. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the retaining bolts. Tighten Tighten the bolts to 6 N.m (53 lb in). 3. Install the junction block to the bracket. Page 12400 Disclaimer Page 7832 4. Important: When installing the pressure control solenoid, the electrical connector (2) must be in the position shown. Install the pressure control solenoid (377). 5. Install the pressure control solenoid retainer (378) and retainer bolt (364A). ^ Tighten the bolt to 11 Nm (97 inch lbs.). 6. Install the TCC PWM solenoid to the control valve body. 7. Install the TCC PWM solenoid retainer. 8. Connect the internal wiring harness electrical connectors to the following components: ^ Transmission fluid pressure switch (1) ^ 1-2 shift control solenoid (2) ^ 2-3 shift control solenoid (3) ^ Pressure control solenoid (4) Procedures Body Control Module: Procedures BODY CONTROL MODULE (BCM) PROGRAMMING/RPO CONFIGURATION INTRODUCTION The procedures below are designed to set-up the body control module (BCM) correctly during BCM related service. Before you start, read these procedures carefully and completely. IMPORTANT: The following procedures must be followed: 1. Programming the BCM. 2. Programming Theft Deterrent System Components, if equipped with Passlock System. PROGRAMMING THE BCM IMPORTANT: After the procedure is completed, the personalization settings of the BCM are set to a default setting. Inform the customer that the personalization must be set again. Perform the BCM special function Request BCM Info. for service programming system (SPS), then follow the SPS instructions. Refer to Service Programming System (SPS) in Programming. PROGRAMMING THEFT DETERRENT SYSTEM COMPONENTS IMPORTANT: This procedure has to be performed only for vehicles equipped with Passlock System. Perform the Programming Theft Deterrent System Components in Theft Deterrent after successfully finishing the Setup New BCM procedure. If the Programming Theft Deterrent System Components in the Theft Deterrent procedure is not performed after a BCM replacement, one of the following conditions will occur: The vehicle will not be protected against theft by the PASSLOCK system. - The engine will not crank or start. IMPORTANT: After programming, perform the following to avoid future misdiagnosis: 1. Turn the ignition OFF for 10 seconds. 2. Connect the scan tool to the data link connector. 3. Turn the ignition ON, with the engine OFF. 4. Use the scan tool in order to retrieve history DTCs from all modules. 5. Clear all history DTCs. Page 4131 5. Connect the VSS electrical connector (2). 6. Lower the vehicle. 7. Refill the fluid as required. Page 3635 2. Install the heater core cover. NOTE: Refer to Fastener Notice in Service Precautions. 3. Install heater core cover screws. Tighten Tighten the screws to 1.6 N.m (14 lb in). 4. Install the heater/vent module. Page 4568 Top Of Engine Page 14565 1. Position the module into the vehicle. 2. Connect the lower electrical harness connectors (2). 3. Slide the module (2) to the left to engage the lower retainers. NOTE: Refer to Fastener Notice in Service Precautions. 4. Install the module retaining screws (3). Tighten Tighten the screws to 3 N.m (26 lb in). 5. Connect the upper electrical harness connectors (3). 6. Install the seat cushion. 7. If a new memory seat module was installed, calibrate the seat. Refer to Memory Seat Calibration Procedure. Page 11399 Solar Sensor: Diagrams Sunload Sensor Page 9794 Location View Speaker - LF Door Speaker: Diagrams Speaker - LF Door Speaker - LF Door - With RPO Code UQ5 Page 8814 Control Module References Part 2 Engine - Noise/Damage Oil Filter Application Importance Oil Filter: Technical Service Bulletins Engine - Noise/Damage Oil Filter Application Importance INFORMATION Bulletin No.: 07-06-01-016B Date: July 27, 2009 Subject: Information on Internal Engine Noise or Damage After Oil Filter Replacement Models: 2010 and Prior Passenger Cars and Trucks (Including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X Supercede: This bulletin is being updated to add model years. Please discard Corporate Bulletin Number 07-06-01-016A (Section 06 - Engine/Propulsion System). Important Engine damage that is the result of an incorrect or improperly installed engine oil filter is not a warrantable claim. The best way to avoid oil filter quality concerns is to purchase ACDelco(R) oil filters directly from GMSPO. Oil filter misapplication may cause abnormal engine noise or internal damage. Always utilize the most recent parts information to ensure the correct part number filter is installed when replacing oil filters. Do not rely on physical dimensions alone. Counterfeit copies of name brand parts have been discovered in some aftermarket parts systems. Always ensure the parts you install are from a trusted source. Improper oil filter installation may result in catastrophic engine damage. Refer to the appropriate Service Information (SI) installation instructions when replacing any oil filter and pay particular attention to procedures for proper cartridge filter element alignment. If the diagnostics in SI (Engine Mechanical) lead to the oil filter as the cause of the internal engine noise or damage, dealers should submit a field product report. Refer to Corporate Bulletin Number 02-00-89-002I (Information for Dealers on How to Submit a Field Product Report). Disclaimer Underhood Electrical Center or Junction Block Replacement Relay Box: Service and Repair Underhood Electrical Center or Junction Block Replacement UNDERHOOD ELECTRICAL CENTER OR JUNCTION BLOCK REPLACEMENT REMOVAL PROCEDURE 1. Disconnect the negative battery cable. 2. Remove the left fender upper brace. 3. Remove the electrical center brace cover assemble by lifting the cover (3) outwards to clear the tabs. 4. Remove all fuses and relays. Page 2546 Refrigerant: Service and Repair REFRIGERANT RECOVERY AND RECHARGING TOOLS REQUIRED - J 43600 ACR 2000 Air Conditioning Service Center - J 45037 A/C Oil Injector CAUTION: Avoid breathing the A/C Refrigerant 134a (R-134a) and the lubricant vapor or the mist. Exposure may irritate the eyes, nose, and throat. Work in a well ventilated area. In order to remove R-134a from the A/C system, use service equipment that is certified to meet the requirements of SAE J 2210 (R-134a recycling equipment). If an accidental system discharge occurs, ventilate the work area before continuing service. Additional health and safety information may be obtained from the refrigerant and lubricant manufacturers. - For personal protection, goggles and gloves should be worn and a clean cloth wrapped around fittings, valves, and connections when doing work that includes opening the refrigerant system. If R-134a comes in contact with any part of the body severe frostbite and personal injury can result. The exposed area should be flushed immediately with cold water and prompt medical help should be obtained. NOTE: R-134a is the only approved refrigerant for use in this vehicle. The use of any other refrigerant may result in poor system performance or component failure. - To avoid system damage use only R-134a dedicated tools when servicing the A/C system. - Use only Polyalkylene Glycol Synthetic Refrigerant Oil (PAG) for internal circulation through the R-134a A/C system and only 525 viscosity mineral oil on fitting threads and O-rings. If lubricants other than those specified are used, compressor failure and/or fitting seizure may result. - R-12 refrigerant and R-134a refrigerant must never be mixed, even in the smallest of amounts, as they are incompatible with each other. If the refrigerants are mixed, compressor failure is likely to occur. Refer to the manufacturer instructions included with the service equipment before servicing. The J 43600 is a complete air conditioning service center for R-134a. The ACR 2000 recovers, recycles, evacuates and recharges A/C refrigerant quickly, accurately and automatically. The unit has a display screen that contains the function controls and displays prompts that will lead the technician through the recover, recycle, evacuate and recharge operations. R-134a is recovered into and charged out of an internal storage vessel. The ACR 2000 automatically replenishes this vessel from an external source tank in order to maintain a constant 5.45-6.82 kg (12-15 lbs) of A/C refrigerant. The ACR 2000 has a built in A/C refrigerant identifier that will test for contamination, prior to recovery and will notify the technician if there are foreign gases present in the A/C system. If foreign gases are present, the ACR 2000 will not recover the refrigerant from the A/C system. The ACR 2000 also features automatic air purge, single pass recycling and an automatic oil drain. Refer to the J 43600 ACR 2000 manual for operation and setup instruction. Always recharge the A/C System with the proper amount of R-134a. Refer to Refrigerant System Capacities for the correct amount. A/C REFRIGERANT SYSTEM OIL CHARGE REPLENISHING If oil was removed from the A/C system during the recovery process or due to component replacement, the oil must be replenished. Oil can be injected into a charged system using J 45037 . For the proper quantities of oil to add to the A/C refrigerant system, refer to Refrigerant System Capacities. Page 4166 Camshaft Position Sensor: Service and Repair CAMSHAFT POSITION (CMP) SENSOR REPLACEMENT REMOVAL PROCEDURE IMPORTANT: Clean the area around the CMP sensor before removal in order to prevent debris from entering the engine. 1. Remove the camshaft position (CMP) sensor bolt. 2. Remove the CMP sensor. INSTALLATION PROCEDURE 1. Install the CMP sensor. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the CMP sensor bolt. Tighten Tighten the bolt to 29 N.m (21 lb ft). Locations Upper Steering Column Automatic Transmission - 4L60-E/4L65-E Band Apply Servo: Service and Repair Automatic Transmission - 4L60-E/4L65-E 2-4 Servo ^ Tools Required J 29714-A Servo Cover Depressor Removal Procedure 1. Remove the exhaust pipe. 2. Remove the heat shield bolts. 3. Remove the heat shield. 4. Remove the oil pan bolt below the servo. 5. Install the J 29714-A. 6. Tighten the bolt on J 29714-A in order to compress the servo cover. 7. Remove the servo cover ring. 8. Remove the J 29714-A. Page 7440 1. Install the locating pins to the NEW encoder motor. 2. Position a NEW actuator insulator gasket to the transfer case. 3. Install the encoder motor. Notice: Refer to Fastener Notice in Service Precautions. 4. Install encoder motor bolts. ^ Tighten the bolts, in the sequence shown, to 20 Nm (15 ft. lbs.). 5. Connect the encoder motor electrical connector. Ensure that the retention clips activate. 6. Install the front propeller shaft. 7. Install the transfer case shield, if equipped. Rear Axle Shaft Seal Replacement - Outer Seals and Gaskets: Service and Repair Rear Axle Shaft Seal Replacement - Outer Rear Axle Shaft Seal Replacement - Outer Removal Procedure 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Remove the tire and wheel assembly. 3. Remove the axle shaft. 4. Remove the axle shaft seal. Installation Procedure 1. Install the axle shaft seal. 2. Install the axle shaft. 3. Install the tire and wheel assembly. 4. Lower the vehicle. Page 5844 Parts Information Warranty Information (excluding Saab U.S. Models) Warranty Information (Saab U.S. Models) Page 10061 Installation Procedure 1. Install the booster inlet hose to the pump. Notice: Refer to Installing Hoses Without Twists or Bends Notice in Service Precautions. Important: Following this sequence ensures correct routing and orientation. Important: Ensure that the hose contacts the power steering pump as shown. 2. Install the gear inlet hose to the gear (5). Page 6592 Page 2880 Tire Pressure Sensor: Technical Service Bulletins Tire Monitor System - TPM Sensor Information INFORMATION Bulletin No.: 08-03-16-003 Date: May 12, 2008 Subject: Warranty Reduction - Transfer of Tire Pressure Monitoring (TPM) Sensors to Replacement Wheels and Allowable TPM Sensor Replacements Models: 2000-2009 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2009 HUMMER H2 2006-2009 HUMMER H3 2005-2009 Saab 9-7x with On-Wheel TPM Sensors TPM Sensor / Wheel Warranty Reviews During the last warranty review period it was noted that wheels being returned under the GM New Vehicle Warranty were being shipped back to General Motors with the TPM sensor still attached to the wheel. Return rates ran as high as 60% with the TPM sensors still attached. Operational TPM sensors should not be returned to GM and are to be transferred to replacement wheels if they become necessary. Important: Operational TPM Sensors that are returned under warranty to General Motors will be charged back to the dealer.Sensors have a 10 year /150,000 mile (240,000 km) battery life, and should be transferred if one or more wheels are replaced. TPM Valve Stem / Grommet (0-ring) Replacement When the TPM sensors are transferred to new wheels you should replace the component used to seal the TPM sensor stem to the wheel. On sensors with an aluminum stem and visible nut on the outside of the wheel a replacement grommet (0-ring) should be used to assure a proper seal. The sensor retaining nut (except Aveo) should be tightened to 7 N.m (62 lb in) for all vehicles except Pontiac Vibe (4.0 N.m (35.4 lb in)). Important: ^ DO NOT overtorque the retaining nut. Notice: ^ Factory installed TPM Sensors come with plastic aluminum or nickel-plated brass stem caps. These caps should not be changed. Chrome plated steel caps may cause corrosion of aluminum valve stems due to incompatibility of the metals. On current style sensors the entire rubber stem is replaceable. The service interval on the revised TPM sensor with replaceable stem is the same as for any other traditional valve stem. Replace the stem at the time of tire replacement sensor transfer or whenever air seepage is suspected at the valve stem. When replacing the valve stem tighten the screw to 1.3 N.m (11.5 lb in). For either style of TPM sensor see the service parts guide for the correct GM part numbers to order and use. Disclaimer Page 7002 8. Install the inner bearing. 9. Important: Each time you replace the wheel hub bearings, install a new oil seal in order to prevent the wheel hub from leaking. Install the new oil seal using the J 44420 (2) and the J 8092 (1). 10. Install the rotor, if necessary. 11. Apply a light coat of high melting point EP bearing lubricant to the axle housing spindle. 12. Install the wheel hub to the axle housing. 13. Install the adjusting nut to the hub using the J 2222-C. 14. Adjust the wheel bearings. 15. Install the axle shaft. 16. Install the brake caliper. 17. Install the tire and wheel assembly. Page 9343 For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to refer to the table above. Disclaimer Rear Front Steering Knuckle: Service and Repair Rear Steering Knuckle Replacement ^ Tools required J 24319-B Universal Steering Linkage Puller Removal Procedure 1. Notice: Refer vehicle Lifting. Raise the vehicle. Refer to Vehicle Lifting. 2. Remove the tire and wheel. 3. Remove the wheel hub and bearing. 4. Remove the upper ball joint. 5. Remove the lower ball joint. 6. Remove the outer tie rod retaining nut and bracket (2). 7. Disconnect the outer tie rod from the steering knuckle using the J 24319-B (1). 8. Remove the park brake cable retaining bolt (3) from the steering knuckle. Page 8038 Electronic Brake Control Module: Locations ABS Component Views Electronic Brake Control Module (EBCM) Page 4928 Page 7096 12. If seating the retainer is difficult, spring the yoke slightly with a firm blow from a dead blow hammer. 13. It may be necessary to lubricate the snap ring with a slight amount of chassis grease so the snap ring seats in the bearing cup groove. Page 9223 C250 Brake/Clutch Harness To Brake Clutch Jumper Harness (With RPO Codes 5X7, 5G4, 5Y0, And TRW) Page 10583 Disclaimer Page 15147 Electrical Symbols Part 11 Page 16067 Electrical Symbols Part 10 Page 8478 8. Inspect the machined surface that was covered by the master cylinder on the front of the hydraulic brake booster at the location (1) shown for a stamped number. The stamped number will be a number 1, 2, 3, or 4. ^ If a stamped number 1 is visible, then the relief valve must be replaced. Proceed to the next step. ^ If a stamped number 2, 3, or 4 is visible, then no further action is required. Proceed to Step 14 and reinstall the master cylinder. ^ If no stamped number is visible, then no further action is required. Proceed to Step 14 and reinstall the master cylinder. 9. Cover the master cylinder with a clean shop towel in order to protect it from fluids or cleaners. Also, place a shop towel under the hydraulic brake booster to absorb any fluid that may leak out of the unit when the relief valve is removed in the next step. 10. Using the tool (2) included with the new relief valve, unscrew the original relief valve (1) from the hydraulic brake booster. Notice DO NOT blow compressed air into the bore or use any commercially available cleaners to flush the valve bore in the next step. This could damage the booster or master cylinder. 11. Inspect the two 0-rings on the original valve for signs of damage. If an 0-ring is missing, broken, or damaged, inspect the bore in the hydraulic brake booster for any pieces or debris using a non-metallic type tool or a clean "lint-free" towel. Important A torque wrench must be used when tightening the valve in the next step. In addition, a 3/8 inch drive to 1/4 inch drive adapter will be needed if your torque wrench is a 3/8 inch drive. Important After tightening the NEW relief valve in the next step, a small gap may exist between the head on the valve and the hydraulic brake booster. This condition is normal. 12. Insert the NEW relief valve into the bore. Tighten Tighten to 17 Nm (13 lb ft). Page 887 Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA and/or the secondary locks. Micro .64 Connectors MICRO .64 CONNECTORS TOOLS REQUIRED J 38125-D Terminal Repair Kit REMOVAL PROCEDURE Follow the steps below in order to remove terminals from Micro 64 connectors. 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. 2. Disconnect the connector from the component. Page 12687 DTC B2483: Global Positioning System (GPS) Antenna Malfunction Short to Ground DTC B2484: Global Positioning System (GPS) Antenna Malfunction Open Circuit Conditions for Running the DTCs The ignition is in RUN or ACC position System voltage is between 9.5 - 15.5 volts. The above conditions are met for more than 1 second. Conditions for Setting the DTCs B2462 02: The CIM detects a short to ground on the navigation antenna signal circuit. B2462 04: The CIM detects an open/high resistance on the navigation antenna signal circuit. B2483: The CIM detects a short to ground on the navigation antenna signal circuit. B2484: The CIM detects an open/high resistance on the navigation antenna signal circuit. Action Taken When the DTCs Set The OnStar(R) status LED turns red. The OnStar(R) Call Center cannot locate the vehicle. Conditions for Clearing the DTCs The condition responsible for setting the DTC no longer exists. A history DTC will clear once 50 consecutive malfunction-free ignition cycles have occurred. Circuit/System Testing Turn OFF the ignition. 1. Disconnect the navigation antenna coax cable from the VCIM. 2. Ignition ON, test for 4.5-5.5 volts between the VCIM coax cable center conductor terminal at the VCIM and ground. ^ If not within the specified range, replace the VCIM. Refer to the appropriate vehicle in SI. 3. Reconnect the coax cable to the VCIM. 4. Disconnect the coax cable from the navigation antenna. 5. Test for 4.55.5 volts between the coax cable center conductor and the outer shield. ^ If not within the specified range, replace the coax cable. 6. If all circuits test normal, replace the navigation antenna. Refer to the appropriate vehicle in SI. DTC B2470 DTC Descriptor DTC B2470 04: Cellular Phone Antenna Circuit Malfunction Open Circuit Circuit/System Description The cellular antenna is connected to the vehicle communication interface module (VCIM) with an RG-58 coax cable. The VCIM collects the data from the cellular antenna once every second. Seat Bolster Motor/Position Sensor - Driver (With RPO Code AN3) Seat Bolster Motor/Position Sensor - Driver (With RPO Code AN3) Page 15272 Door Latch Assembly (Door Jamb Switch) - LR - C2 (Crew Cab Only) Service and Repair Steering Angle Sensor: Service and Repair Rear Position Sensor Replacement Removal Procedure 1. Notice: Refer vehicle Lifting. Raise the vehicle. Refer to Vehicle Lifting. 2. Remove the steering gear protection shield (1) retaining bolts (3). 3. Disconnect the electrical connector (1). 4. Notice: When removing the rear position cover from the steering gear be careful not to damage to the rear position sensor. Remove the rear wheel position sensor cover (4) from the steering gear by prying on the cover using the slot. 5. Remove the rear wheel position sensor retaining bolts (3). 6. Important: Check the inner tie rod boot for wear or damage. If the boots are damaged replace the steering gear actuator. 7. Important: Page 8248 24. Fill the brake master cylinder reservoir to the maximum-fill level with Delco Supreme 11®, GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. 25. Slowly depress and release the brake pedal. Observe the feel of the brake pedal. 26. If the brake pedal feels spongy perform the following steps: 1. Inspect the brake system for external leaks. 2. Using a scan tool, perform the antilock brake system automated bleeding procedure to remove any air that may have been trapped in the BPMV. Refer to ABS Automated Bleed Procedure in Antilock Brake System. 27. Turn the ignition key ON, with the engine OFF. Check to see if the brake system warning lamp remains illuminated. 28. Important: If the brake system warning lamp remains illuminated, DO NOT allow the vehicle to be driven until it is diagnosed and repaired. If the brake system warning lamp remains illuminated, refer to Symptoms - Hydraulic Brakes. Page 11918 7.1. Remove the console (A) together with the OnStar(R) control modules. 7.2. Remove the connectors (B). Important: The optic cable must not be bent with a radius less than 25 mm (1 in). Important: Secure the wiring harness so that there is no risk of chafing and rattling. 7.3. Fold back the wiring harness and tape over the connectors (C). Fold back the wiring harness once more and secure with cable ties (D). 7.4. Fit the parcel shelf trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 8. CV: Removing the OnStar(R) control modules and securing the wiring: Adjustment/Replacement. 8.1. Open the luggage compartment floor. Page 13935 The information shown is for the 1999-2002 wiring harnesses and for the 2003-05 wiring harness. To modify a 12171982, 15366255 or 15086884 harness for use in a 2003-05 vehicle, switch the wires in cavities "A" and "D". To modify a 15085418 harness for use in a 1999-2002 vehicle (see model list at the front of this bulletin for applicable models), switch the wires in cavities "A" and "D". Warranty Information When the correct wiring harness P/N is matched to the specific model year of the vehicle, everything works properly. Therefore, conversion of an incorrect wiring jumper to match the vehicle would not be considered a warrantable repair. Disclaimer Page 12668 Vehicles Built with Upgradeable OnStar(R) System Analog Modules Note: Diagram Information and Instructions Door Module: Diagram Information and Instructions Truck Zoning TRUCK ZONING Truck Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that corresponds to where they are located in the vehicle. The table explains the numbering system. Page 2677 Junction Block - I/P - C8 Page 8349 6. Remove the reservoir from the master cylinder by pulling the reservoir straight up and away from the cylinder. 7. Remove the seals from the master cylinder. Installation Procedure 1. Inspect the reservoir for cracks or deformation. If found, replace the reservoir. 2. Clean the reservoir with denatured alcohol, or equivalent. 3. Dry the reservoir with non-lubricated, filtered air. 4. Lubricate the new seals and the outer surface area of the reservoir-to-housing barrels with Delco Supreme 11® (GM P/N 12377967) or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. 5. Install the lubricated seals, make sure they are fully seated. 6. Install the reservoir to the master cylinder by pressing the reservoir straight down on the master cylinder until the pin holes are aligned. 7. Carefully install the reservoir retaining pins to secure the reservoir. 8. Place the brake fluid level sensor into the reservoir, press into place to secure the sensor retaining tabs. 9. Remove the master cylinder from the vice. 10. Install the master cylinder. 11. Release the park brake. 12. Bleed the hydraulic brake system. Master Cylinder Reservoir Filling Master Cylinder Reservoir Filling Caution: Refer to Brake Fluid Irritant Caution in Service Precautions. Notice: When adding fluid to the brake master cylinder reservoir, use only Delco Supreme 11®, GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. The use of any type of fluid other than the recommended type of brake fluid, Page 12035 6. See wiring diagram shown above for details. 5. Replace the OnStar(R) Vehicle Communication Interface Module (VCIM) in the vehicle with the provided Digitally-Capable VCIM. Refer to the Communication Interface Module Replacement procedure in the Cellular Communication section of SI. This kit may include a new VCIM bracket. If it does, use this new bracket on the vehicle and discard the original bracket. The kit may also include a small wiring jumper cable. If it does, plug the wiring jumper cable into the connector on the VCIM and the other end to the corresponding vehicle wiring harness connector. ^ For 2001, 2002 and 2003 Chevrolet Impala and Monte Carlo, do not reinstall the black plastic OnStar(R) module cover onto the vehicle after the VCIM and module bracket have been installed. This black plastic cover will no longer fit on the vehicle. ^ The upgrade kit for 2002 Sevilles and DeVilles, and some 2003 Sevilles and DeVilles, will contain a large bracket. To install the new VCIM into this bracket you'll need to carefully line up the notch in the VCIM with the tab in the bracket. Page 10459 9. Install the retaining ring. 10. Install the axle shaft. 11. Inspect the lubricant level and add, if necessary. 12. Lower the vehicle. Seat Back Frame Replacement - Front Seat Back Frame: Service and Repair Seat Back Frame Replacement - Front SEAT BACK FRAME REPLACEMENT - FRONT REMOVAL PROCEDURE 1. Remove the seat from the vehicle. 2. Remove the head restraint and guides. 3. Remove the seat trim panel. 4. Disconnect the lumbar cable (6) underneath the seat cushion (disconnect the lumbar wire harness if equipped with power lumbar). 5. Remove the seat back trim cover and pad. 6. Remove the lumbar assembly (or power lumbar/bolster assembly if equipped). 7. Remove the seat belt retractor. 8. Remove the inboard pivot bolt (1). 9. Remove the recliner arm attachment bolts (2). 10. Remove the frame from the vehicle. 11. Transfer all necessary components to the new seat back frame. INSTALLATION PROCEDURE 1. Position the seat back frame on the seat. NOTE: Refer to Fastener Notice in Service Precautions. Brakes - ABS Lamp ON/DTC's C0265/C0201/U1041 Set Electronic Brake Control Module: Customer Interest Brakes - ABS Lamp ON/DTC's C0265/C0201/U1041 Set TECHNICAL Bulletin No.: 04-05-25-002E Date: March 11, 2009 Subject: ABS Light On, DTCs C0265, C0201, U1041 Set and/or Loss of Communication with Brake Module (Reground EBCM Ground) Models Supercede: This bulletin is being revised to add step 2 to the procedure and update the Parts and Warranty Information. Please discard Corporate Bulletin Number 04-05-25-002D (Section 05 - Brakes). Condition Some customers may comment that the ABS light is on. Upon further inspection, DTCs C0265 and C0201 may be set in the brake module. It is also possible for DTC U1041 to set in other modules. There may also be a loss of communication with the brake module. Cause A poor connection at the EBCM ground is causing unnecessary replacement of brake modules. Important: The EBCM ground is different for each application. Refer to the list below for the proper ground reference: ^ Midsize Utilities = Ground 304 ^ SSR = Ground 400 ^ Fullsize Trucks and Utilities = Ground 110 Correction Important: Do not replace the brake module to correct this condition. Perform the following repair before further diagnosis of the EBCM. Perform the following steps to improve the connection of the EBCM Ground: 1. Remove the EBCM Ground. The EBCM Ground is located on the frame beneath the driver's side door. If multiple grounds are found in this location, the EBCM ground can be identified as the heavy (12-gauge) wire. 2. If the original fastener has a welded on nut, remove the nut from the frame, and if required, enlarge the bolt hole to accommodate the new bolt and nut. 3. Clean the area, front and back, using a tool such as a *3M(TM) Scotch-Brite Roloc disc or equivalent. Page 3888 Conditions for Setting the DTC occur, the PCM executes the Action Taken When the DTC Sets. Some DTCs alert the driver via the MIL or a message. Other DTCs do not trigger a driver warning, but are stored in memory. The PCM also saves data and input parameters when most DTCs are set. This data is stored in the Freeze Frame and/or Failure Records. The DTCs are categorized by type. The DTC type is determined by the MIL operation and the manner in which the fault data is stored when a particular DTC fails. In some cases there may be exceptions to this structure. Therefore, when diagnosing the system it is important to read the Action Taken When the DTC Sets and the Conditions for Clearing the DTC in the supporting text. There are different types of DTCs and different actions taken when the DTCs set. Refer to Diagnostic Trouble Code (DTC) Type Definitions for a description of the general characteristics of each DTC type. DTC STATUS When the scan tool displays a DTC, the status of the DTC is also displayed. The following DTC statuses are indicated only when they apply to the DTC that is set. Fail This Ign. (Fail This Ignition): Indicates that this DTC failed during the present ignition cycle. Last Test Fail: Indicates that this DTC failed the last time the test ran. The last test may have run during a previous ignition cycle if an A or B type DTC is displayed. For type C DTCs, the last failure must have occurred during the current ignition cycle to appear as Last Test Fail. MIL Request: Indicates that this DTC is currently requesting the MIL. This selection will report type B DTCs only when they have requested the MIL (failed twice). Test Fail SCC (Test Failed Since Code Clear): Indicates that this DTC that has reported a failure since the last time DTCs were cleared. History: Indicates that the DTC is stored in the PCM History memory. Type B DTCs will not appear in History until they have requested the MIL (failed twice). History will be displayed for all type A DTCs and type B DTCs (which have requested the MIL) that have failed within the last 40 warm-up cycles. Type C DTCs that have failed within the last 40 warm-up cycles will also appear in History. Not Run SCC (Not Run Since Code Clear): DTCs will be listed in this category if the diagnostic has not run since DTCs were last cleared. This status is not included with the DTC display since the DTC can not be set if the diagnostic has not run. This information is displayed when DTC Info is requested using the scan tool. Page 12346 - Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-D in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-D if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Page 3328 Parts Information Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 12107 High OR Low The above conditions are met for more than 3 seconds. Circuit/System Verification These DTCs cannot be retrieved with a current status. To diagnose use the Scan Tool Does Not Communicate with a Class 2 Device. Refer to SI. An intermittent condition is likely to be caused by a short on the Class 2 serial data circuit. To diagnose use the Scan Tool Does Not Communicate with a Class 2 Device. Refer to SI. DTC B2455 DTC Descriptors DTC B2455 01: Cellular Phone Microphone Circuit Short to Battery DTC B2455 02: Cellular Phone Microphone Circuit Short to Ground DTC B2455 04: Cellular Phone Microphone Circuit Open Circuit Circuit/System Description Without RPO UAV The vehicle communication interface module (VCIM) uses the cellular phone microphone to allow driver communication with OnStar(R). With RPO UAV The vehicle communication interface module (VCIM) and navigation radio use the cellular phone microphone to allow driver communication with OnStar(R), as well as to operate the voice recognition/voice guidance feature of the navigation radio. Conditions for Running the DTC The ignition is in RUN or ACC position. System voltage is between 9.5 - 15.5 volts. The above conditions are met for more than 10 seconds. Conditions for Setting the DTC B2455 01: A short to battery is detected on the cellular microphone signal circuit. B2455 02: A short to ground is detected on the cellular microphone signal circuit. B2455 04: An open circuit is detected on the cellular microphone signal circuit. Action Taken When the DTC Sets The VCIM and/or navigation radio (RPO UAV) will not receive any signal from the microphone. The OnStar(R) status LED turns red. Voice recognition will not function. Conditions for Clearing the DTC Page 895 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. REPLACEMENT PROCEDURE After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Insure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the Terminal Removal Procedure. Repairing Connector Terminals REPAIRING CONNECTOR TERMINALS TOOLS REQUIRED J 38125-D Terminal Repair Kit Use the following repair procedures in order to repair the following: - Push to Seat terminals - Pull to Seat terminals - Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-D contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100 World terminals. Soldering Micro-Pack 100 World terminals may damage the terminal. Circuit Protection - Circuit Breakers CIRCUIT PROTECTION - CIRCUIT BREAKERS A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Page 6845 Pinion Gear: Service and Repair Drive Pinion and Ring Gear Replacement 8.6 Inch, 9.5 Inch, 11.5 Inch Axles Drive Pinion and Ring Gear Replacement (8.6 Inch, 9.5 Inch, 11.5 Inch Axles) ^ Tools Required - J 22536 Pinion Driver, 8.6 inch, 9.5 inch axles - J 44421 Pinion Remover, 11.5 inch axle Removal Procedure 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Remove the differential assembly. 3. Remove the pinion yoke and the oil seal. 4. Install the J 22536 , 8.6 inch or 9.5 inch axle, or the J 44421, 11.5 inch axle as shown. Ensure that the J 22536 or the J 44421 is firmly seated on the pinion. 5. Drive the pinion out using the J 22536 or the J 44421 and a hammer. Strike the J 22536 or the J 44421 slowly. Do not let the pinion fall out of the rear axle housing. 6. Remove the collapsible spacer from the pinion. Discard the spacer. 7. Remove the pinion bearings and the cups. 8. Important: The ring gear bolts on the 8.6 inch and the 9.5 inch axles have left-hand threads. The ring gear bolts on the 11.5 inch axle have right-hand threads. Remove the gear bolts. Discard the bolts. 9. Notice: Refer to Ring Gear Removal Notice in Service Precautions. Remove the ring gear from the differential. Drive the gear off with a brass drift if necessary. Installation Procedure Page 6259 1. Install the filter neck seal. 2. Install the oil filter. 3. Install the oil pan gasket to the pan. 4. Install the magnet into the bottom of the pan, if necessary. 5. Install the oil pan and bolts. ^ Tighten the oil pan bolts to 24 Nm (18 ft. lbs.). 6. Position the bracket with cable. Install the transmission range selector cable bracket (2) and bolts to the transmission. ^ Tighten the selector bracket bolts to 25 Nm (18 ft. lbs.). 7. Connect the range selector cable end (2) to the transmission range selector lever ball stud (1). Page 7663 7. Insert a flat-tipped screwdriver or small pry bar in the space between the outer race of the seal and the transfer case. 8. Remove the outer part of the seal. Installation Procedure Page 5388 9.2. Turn the ignition OFF for 10 seconds. 9.3. Turn the ignition ON, with the engine OFF. 9.4. Inspect for fuel leaks. Fuel Hose/Pipes Assembly Replacement 1 FUEL HOSE/PIPES ASSEMBLY REPLACEMENT (PICKUP AND CAB/CHASSIS) REMOVAL PROCEDURE IMPORTANT: Clean the fuel feed pipe connection and surrounding area prior to disconnecting the fitting in order to avoid possible fuel system contamination. 1. Remove the fuel tank. 2. Disconnect and remove the fuel feed line (1) from the sending unit and retaining clips. 3. Cap the fuel feed and evaporative emission (EVAP) openings in order to prevent possible fuel/EVAP system contamination. INSTALLATION PROCEDURE 1. Remove the caps from the fuel feed/return, and EVAP lines. 2. Install and connect the fuel feed (1) line to the sending unit and retaining clips. 3. Install the fuel tank. Fuel Hose/Pipes Assembly Replacement 2 FUEL HOSE/PIPES ASSEMBLY REPLACEMENT REMOVAL PROCEDURE IMPORTANT: Clean the fuel feed/return pipes connections and surrounding areas prior to disconnecting the fittings in order to avoid possible fuel system contamination. Page 4675 Control Module References Part 4 OnStar(R) - Number Incorrect/Incorrectly Assigned Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Number Incorrect/Incorrectly Assigned INFORMATION Bulletin No.: 05-08-46-004C Date: December 23, 2010 Subject: OnStar(R) Phone Number Concerns (Phone Number Incorrect/Assigned to Another Vehicle/Phone) That Occur During Diagnosis of OnStar(R) System Models: 2000-2011 GM Passenger Cars and Trucks Equipped with OnStar(R) (RPO UE1) Supercede: This bulletin is being revised to update model years up to 2011. Please discard Corporate Bulletin Number 05-08-46-004B (Section 08 - Body and Accessories). During diagnosis of an OnStar(R) concern, the technician may be told that the OnStar(R) phone number is incorrect or tied to another vehicle and/or phone of some kind. To resolve these concerns, the Tech 2(R) with software version 22.005 (or higher), has the capability to change the OnStar(R) phone number. Service Procedure 1. With the Tech 2(R), build the vehicle to specifications within the Diagnostics area of the Tech 2(R). 2. For vehicles with physical-based diagnostics - under Body, go to the OnStar(R) section. Then select the Special Functions menu. For vehicles with functional-based diagnostics - under Body and Accessories, go to the Cellular Communication section. Select Module Setup and then Vehicle Communication Interface Module. 3. Locate the Program Phone Number prompt and select it. The original phone number will be displayed on the Tech 2(R) screen. 4. Contact the OnStar(R) team at the GM Technical Assistance Center (TAC) to obtain a new phone number. 5. Highlight the digits of the phone number one at a time and enter the new phone number using the number keys on the Tech 2(R). 6. Press the Soft key at the base of the screen for Done once these numbers have been changed on the screen. 7. Press the Soft key for Done again. The area code or new phone number has now been programmed into the phone. 8. Cycle the ignition to Off and open the driver's door. 9. Press the blue OnStar(R) button to make sure that a normal connection can be made to the OnStar(R) call center. If applicable, make sure the Hands-Free Calling (HFC) works properly by making a phone call. 10. If the system is working properly, fax or voicemail a case closing into the OnStar(R) team at TAC with the results. Dealers in Canada should submit case closing information through the GM infoNET. Please follow this diagnostic process thoroughly and complete each step. If the condition exhibited is resolved WITHOUT completing every step, the remaining steps do not need to be performed. If the procedure above does not resolve the condition, you must contact TAC for further assistance. This diagnostic approach was developed specifically for this condition and should not automatically be used for other vehicles with similar symptoms. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use: Warranty Information (Saab Models) For vehicles repaired under warranty, use the table. Page 7105 Flex Plate: Service and Repair Engine Flywheel Replacement Removal Procedure 1. Remove the automatic transmission, if equipped. Important: Note the position and direction of the engine flywheel before removal. 2. Remove the engine flywheel bolts. 3. Remove the automatic transmission engine flywheel, if applicable. 4. Remove the clutch, if equipped with a manual transmission. Important: Note the position and direction of the engine flywheel before removal. 5. Remove the engine flywheel bolts. 6. Remove the manual transmission engine flywheel, if applicable. 7. If required, clean and inspect the engine flywheel. Page 2673 Junction Block - I/P - C4 Part 2 Page 1658 2. Install the HO2S. Tighten Tighten the sensor to 42 N.m (31 lb ft). 3. If equipped with a 6.0L engine, connect the HO2S electrical connector. 4. If equipped with a 4.8L or 5.3L engine, connect the HO2S electrical connector. 5. Install the HO2S to the clips 6. Disconnect the CPA retainer. 7. Lower the vehicle. Page 10035 Power Steering Fluid: Fluid Type Specifications POWER STEERING SYSTEM GM Power Steering Fluid GM P/N 89021184 (Canadian P/N 89021186) or equivalent POWER STEERING SYSTEM (PHT) Power Steering Fluid GM P/N 88901975 (Canadian P/N 88901976) Page 15169 Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses CIRCUIT PROTECTION - FUSES The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the Page 16213 Back Window Glass: Service and Repair Rear Window Replacement (Pickup) Removal Procedure Tools Required * J 24402-A Cold Knife Glass Sealant Remover * J 39040 Quarter Window Remover * Urethane Adhesive Kit GM P/N 12346392 or Equivalent * Isopropyl Alcohol or Equivalent * Cartridge-type Caulking Gun * Commercial-type Utility Knife * Razor Blade Scraper * Suction Cups * Plastic Paddle Caution: If a window is cracked but still intact, crisscross the window with masking tape in order to reduce the risk of damage or personal injury. Important: Before cutting out a window, apply a double layer of masking tape around the perimeter of the painted surfaces and interior trim. 1. Remove the window lower garnish molding. 2. Remove both rear seat headrests (extended cab). 3. Lower rear seat back. Caution: If broken glass falls into the defroster outlets, it can be blown into the passenger compartment and cause personal injury. 4. Cover to protect the following parts from broken glass: 1. Upper dash pad 2. Defroster outlets and A/C outlets 3. Seats and carpeting Caution: When working with any type of glass or sheet metal with exposed or rough edges, wear approved safety glasses and gloves in order to reduce the chance of personal injury. Important: Keep the cutting edge of the tool against the window. 5. This will allow the urethane adhesive to be separated from the window. * Leave a base of urethane on the pinchweld flange. * The only suitable lubrication is clear water. * Use J 24402-A, J 39040 or equivalent in order to remove the window. 6. Open the window, if equipped. Page 3912 Steps 15 - 18 Page 14894 Seat Bolster/Lumbar Switch - Front Passenger (With RPO Code AN3) Page 16071 Electrical Symbols Part 14 Page 366 Important: The optic cable must not be bent with a radius less than 25 mm (1 in). 6.12. Place the optic cable in the wiring harness channels on the right-hand side. Thread through the existing cable ties (C) if possible, otherwise, secure with a cable tie to the existing one. Close the cover on the channels. Ensure the catches lock. 6.13. Secure the optic cable along the right-hand rear wheel housing, next to the ordinary wiring harness securing points and by the SRS unit (D). 6.14. Thread the optic cable up next to the safety belt by the old optic cable and place on the parcel shelf. 6.15. Unplug the connectors (E) from the OnStar(R) control modules. 6.16. Remove the console (F) together with the OnStar(R) control modules. Page 11805 1. Install the digital radio extension cable (5) to the I/P. 2. Engage the antenna cable clips (4, 6) to the I/P. 3. Connect the antenna cable (2) to the digital receiver (3). 4. Connect the digital radio antenna extension cable to the digital radio antenna cable (1). 5. Install the I/P upper trim panel. 6. Close the I/P storage compartment. Page 2028 Power Window Switch: Service and Repair Switch Replacement - Door Lock and Side Window Driver SWITCH REPLACEMENT - DOOR LOCK AND SIDE WINDOW - DRIVER REMOVAL PROCEDURE 1. Remove the front door trim panel. 2. Disconnect the electrical connectors. 3. Remove the screw that retains the switch panel bezel (1) from the front door panel. 4. Remove the switch panel bezel from the door panel using a flat-bladed tool. 5. Using a wide plastic flat-bladed tool, release the retaining clips on both sides of the door module. 6. Remove the door module from the switch panel bezel. Electrical - Aftermarket Fuse Warning Fuse: All Technical Service Bulletins Electrical - Aftermarket Fuse Warning Bulletin No.: 07-08-45-002 Date: September 05, 2007 ADVANCED SERVICE INFORMATION Subject: Service Alert: Concerns With Aftermarket Fuses in GM Vehicles Models: 2008 and Prior GM Passenger Cars and Light Duty Trucks (including Saturn) 2008 and Prior HUMMER H2, H3 2008 and Prior Saab 9-7X Concerns with Harbor Freight Tools "Storehouse" Branded Blade Type Fuses General Motors has become aware of a fuse recall by Harbor Freight Tools/Storehouse for a variety of aftermarket fuses. In two cases, these fuses have not provided protection for the wiring system of the vehicles they were customer installed in. Upon testing the 15 amp version, it was found that the fuse still would not "open" when shorted directly across the battery terminals. How to Identify These Fuses Packed in a 120 piece set, the fuse has a translucent, hard plastic, blue body with the amperage stamped into the top. There are no white painted numbers on the fuse to indicate amperage. There are no identifying marks on the fuse to tell who is making it. The fuses are known to be distributed by Harbor Freight Tools but there may be other marketers, and packaging of this style of fuse. It would be prudent to replace these fuses if found in a customers vehicle. Likewise, if wiring overheating is found you should check the fuse panel for the presence of this style of fuse. All GM dealers should use genuine GM fuses on the vehicles they service. You should also encourage the use of GM fuses to your customers to assure they are getting the required electrical system protection. GM has no knowledge of any concerns with other aftermarket fuses. If additional information becomes available, this bulletin will be updated. Disclaimer Page 11243 6. Leak test the fitting(s) of the repaired or reinstalled component using the J 39400-A. 7. Install the air cleaner. CKP System Variation Learn Procedure Crankshaft Position Sensor: Service and Repair CKP System Variation Learn Procedure CKP SYSTEM VARIATION LEARN PROCEDURE 1. Install a scan tool. 2. Monitor the powertrain control module (PCM) for DTCs with a scan tool. If other DTCs are set, except DTC P0315, refer to Diagnostic Trouble Code (DTC) List for the applicable DTC that set. 3. Select the crankshaft position (CKP) variation learn procedure with a scan tool. 4. The scan tool instructs you to perform the following: 4.1. Accelerate to wide open throttle (WOT). 4.2. Release throttle when fuel cut-off occurs. 4.3. Observe fuel cut-off for applicable engine. 4.4. Engine should not accelerate beyond calibrated RPM value. 4.5. Release throttle immediately if value is exceeded. 4.6. Block drive wheels. 4.7. Set parking brake. 4.8. DO NOT apply brake pedal. 4.9. Cycle ignition from OFF to ON. 4.10. Apply and hold brake pedal. 4.11. Start and idle engine. 4.12. Turn A/C OFF. 4.13. Vehicle must remain in Park or Neutral. 4.14. The scan tool monitors certain component signals to determine if all the conditions are met to continue with the procedure. The scan tool only displays the condition that inhibits the procedure. The scan tool monitors the following components: - CKP sensors activity-If there is a CKP sensor condition, refer to the applicable DTC that set. - Camshaft position (CMP) sensor activity-If there is a CMP sensor condition, refer to the applicable DTC that set. - Engine coolant temperature (ECT)-If the ECT is not warm enough, idle the engine until the engine coolant temperature reaches the correct temperature. 5. Enable the CKP system variation learn procedure with a scan tool. IMPORTANT: While the learn procedure is in progress, release the throttle immediately when the engine starts to decelerate. The engine control is returned to the operator and the engine responds to throttle position after the learn procedure is complete. 6. Accelerate to WOT. 7. Release when the fuel cut-off occurs. 8. Test in progress 9. The scan tool displays Learn Status: Learned this ignition. If the scan tool indicates that DTC P0315 ran and passed, the CKP variation learn procedure is complete. If the scan tool indicates DTC P0315 failed or did not run, refer to DTC P0315. If any other DTCs set, refer to Diagnostic Trouble Code (DTC) List for the applicable DTC that set. 10. Turn OFF the ignition for 30 seconds after the learn procedure is completed successfully. 11. The CKP system variation learn procedure is also required when the following service procedures have been performed, regardless of whether DTC P0315 is set: - A CKP sensor replacement - An engine replacement - A PCM replacement - A harmonic balancer replacement - A crankshaft replacement - Any engine repairs which disturb the CKP sensor relationship Page 3770 Body Control Module: Locations Body Control Module (BCM) Page 6525 Transmission Cooler: Technical Service Bulletins A/T - Oil Cooler Flushing Frequently Asked Questions File In Section: 07 - Transmission/Transaxle Bulletin No.: 03-07-30-027 Date: June, 2003 INFORMATION Subject: Most Frequently Asked Questions and Answers for J 45096 TransFlow Transmission Oil Cooling System Flushing Machine Models: 2004 and Prior Passenger Cars and Light Duty Trucks with Automatic Transmission/Transaxle 2004 and Prior HUMMER H2 This bulletin is issued to help answer the most frequently asked questions and concerns about essential tool J 45096. Q: Why doesn't the machine work below 18°C (65°F)? A: The flow characteristics of ATF at temperatures below 18°C (65°F) does not provide accurate flow test results with the electronics used in the J 45096. Q: Why didn't the unit come with a tank heater? A: The vast majority of dealerships do not require a heater to keep the ATF above 18°C (65°F). As a result, the heater was deleted as a cost-savings measure. A tank heater, J 45096-10, is currently available from Kent-Moore if your dealership requires it. Refer to Corporate Bulletin Number 03-07-30-002A for suggestions on warming the ATF without using a heater blanket. Q: Why does the machine fail new oil coolers? A: Several reasons have been found. The most likely reason is the air pressure at the air hose connected to the J 45096 is less than 586 kPa (85 psi). Other reasons include a twisted hose inside the J 45096 at the bulkhead as a result of the nut turning when the waste or supply hose was installed, the internal pressure regulator was improperly set at the factory or a problem with the cooler lines on the vehicle. Perform the J 45096 self-test as described on pages 9 and 10 of the Operation Manual. If a problem is still detected, refer to Troubleshooting on page 19 of the Operation Manual. If a problem still persists, contact Kent-Moore Customer Service at 1-800-345-2233. Q: What is the difference between steel and aluminum oil coolers? A: The aluminum oil cooler tube is slightly thinner in construction than the steel oil cooler tube, which affects the oil flow rate. The fitting that is protruding out of the radiator tank easily identifies the aluminum oil cooler. Refer to the Quick Reference card provided with the J 45096 in order to identify the proper flow rate for the aluminum oil cooler. Q: Why can't I use TransFlow for Allison transmission cooling Systems? A: Validation of TransFlow is currently under development for light duty trucks equipped with the Allison automatic transmission. TransFlow is based on the existing MINIMUM flow rate specification through the transmission oil cooling system. The Allison transmission oil cooling system only has MAXIMUM oil flow rates specified and J 45096 does not have the capability to test the transmission oil cooling system at the maximum oil flow rate specification. Q: Why doesn't GM publish a specification for auxiliary transmission oil coolers? A: The auxiliary oil cooler used with GM vehicles does not contain an internal turbulator plate like the radiator tank oil cooler does. Therefore, there is no internal restriction that would affect the flow rate through the oil cooling system so a specification for auxiliary oil cooler is not required. Keep in mind, kinks and damage to the auxiliary cooler and lines can affect the flow rate through the system. Q: Why did GM drop the labor time for transmission repairs? A: The labor for flushing and flow testing the transmission oil cooling system is included with the R&R; labor of the "K" labor operations that require transmission removal. The time required to use the J 45096 to perform the flush and flow test is much less than that of the J 35944-A. The warranty labor savings allowed GM to provide the J 45096 at no cost to dealerships. Page 12981 3. Disconnect the electrical connector and remove the speaker. INSTALLATION PROCEDURE 1. Connect the electrical connector. 2. Install the speaker by snapping the top retainer into place. 3. Install the trim panel. Page 3794 TOOLS REQUIRED J 34142-B 12 V Unpowered Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. When testing for voltage: 1. Attach 1 lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach 1 lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Using Connector Test Adapters USING CONNECTOR TEST ADAPTERS NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-B Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires USING FUSED JUMPER WIRES TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Connector Position Assurance Locks CONNECTOR POSITION ASSURANCE LOCKS The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Terminal Position Assurance Locks TERMINAL POSITION ASSURANCE LOCKS The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Push to Seat Connectors PUSH TO SEAT CONNECTORS TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Service and Repair Accumulator HVAC: Service and Repair ACCUMULATOR REPLACEMENT TOOLS REQUIRED J 39400-A Halogen Leak Detector REMOVAL PROCEDURE 1. Recover the refrigerant. Refer to Refrigerant Recovery and Recharging. 2. Remove the evaporator tube nut from the evaporator. 3. Remove the evaporator tube from the evaporator. 4. Remove the nut from the evaporator tube (3). Page 3126 Camshaft: Service and Repair Camshaft Replacement Removal Procedure 1. Raise the hood to the service position; perform the following: 1. Remove the hood hinge bolts (1). 2. Raise the hood until vertical. 3. Install the hood hinge bolts until snug in the service position (2). 2. Remove the radiator support. 3. Remove the front cover. 4. Remove the valve lifters. 5. Remove the camshaft sensor bolt and sensor. 6. Rotate the crankshaft until the timing marks on the crankshaft and the camshaft sprockets are aligned. Page 4151 Fuel Composition Sensor Description and Operation Radiator Support: Description and Operation Radiator Support Description The radiator support assembly is made of aluminum alloy. You can repair minor damage with ER-4043 welding wire and 100 percent argon shielding gas. The upper tie-bar (1) and the vertical support (2) portion of the radiator support assembly are bolt-on components. The tie-bar and the vertical support (2) are available as part of the radiator support assembly, or can be ordered separately. Page 7577 10. Place the J 9522-3 on the open horizontal bearing cups. Press the lower bearing cup out of the yoke ear. 11. If you do not completely remove the bearing cup, lift the cross and insert the J 9522-5 between the seal and the bearing cup you are removing. Continue pressing the bearing cup out of the yoke. 12. Rotate the propeller shaft. Press the opposite bearing cup out of the drive shaft yoke. 13. Remove the old slip yoke and universal joint. 14. Inspect the retaining ring grooves for dirt, corrosion, or pieces of the old ring. 15. Inspect the bearing cup bores for burrs or imperfections. 16. Clean the retaining ring grooves. Corrosion, dirt, rust, or pieces of the old retaining ring may prevent the bearing cups from pressing into place or prevent the bearing retainers from properly seating. 17. Install the new nickel-plated slip yoke and universal joint. See parts table below for parts information. 18. Remove the bearing cups from the universal joint. 19. Assemble one bearing cup part way into one side of the yoke. Turn the yoke ear toward the bottom. 20. Assemble the cross into the yoke so that the trunnion seats freely into the bearing cup. Page 12676 ^ SP303 The following modules, components, and splice pack are connected to the star portion of the class 2 serial data circuit: ^ SP300 ^ Audio amplifier ^ Driver door module (DDM) ^ Driver door switch assembly (DDSA) ^ Memory seat module (MSM) ^ Left rear door module (LRDM) AND ^ SP303 ^ Antenna module ^ Front passenger door module (FPDM) ^ Rear integration module (RIM) ^ Right rear door module (RRDM) ^ Theft deterrent module (TDM) ^ Vehicle communication interface module (VCIM). Refer to Data Communication Schematics and Data Link Communications Description and Operation in SI. Part 2 Conditions for Running the DTC Voltage supplied to the module is in the normal operating voltage range of 9 - 16 volts. DTCs B1327, B1328, U1300, U1301, U1305 are not set as current. The vehicle power mode requires serial data communication to occur. Conditions for Setting the DTC A message containing a critical operating parameter has not been received within the last 5 seconds after establishing class 2 serial data communication. Action Taken When the DTC Sets The module uses a default value for the missing parameter. Conditions for Clearing the DTC A current DTC clears when the malfunction is no longer present. A history DTC clears when the module ignition cycle counter reaches the reset threshold, without a repeat of the malfunction. Diagnostic Aids When a malfunction such as an open fuse to a module occurs while modules are communicating, a DTC U1001-1254 Loss of XXX Communications is set current. When the modules stop communicating the current DTC U1001-1254 Loss of XXX Communications is cleared but the history DTC remains. When the modules begin to communicate again, the module with the open fuse will not be learned by the other modules so U1000 or U1255 is set current by the other modules. If the malfunction occurs when the modules are not communicating, only U1000 or U1255 is set. Page 7445 Case Adapter: Service and Repair Transfer Case - NVG 246-NP8 Transfer Case Adapter Replacement Removal Procedure 1. Remove the transfer case. 2. Support the transmission with a suitable jack stand. 3. Remove the transmission mount nuts. 4. Remove the crossmember bolts. 5. Remove the crossmember. 6. Remove the transmission mount bolts. Page 9096 5. Push on the tab (3) so that the electrical center can be rotated on the studs located at (2). 6. Remove all connectors by removing the bolt (1) for each connector. 7. Disconnect all connectors from the electrical center block. 8. Push on the tabs (2) in order to lift the electrical center (1) out of the housing. 9. To replace the engine electrical center bracket remove the 4 retaining bolts (1). 10. Remove the engine electrical center bracket assembly from the fender. INSTALLATION PROCEDURE Page 3104 1. Install the stud. 2. Install the 4 washers and the lug nut to the stud. 3. Tighten the lug nut in order to draw the stud into the flange until the stud fully seats. 4. Remove the lug nut and the washers. 5. Install the axle shaft for the vehicles with 9.5 in ring gear. 6. Install the rear hub assembly for the vehicles with 10.5/11.5 in ring gear, with single wheels. 7. Install the rear axle hub for vehicles with dual wheels. Refer to Rear Axle Hub, Bearing, Cup, and/or Seal Replacement. 8. Install the rotor, except dual wheels. 9. Install the tire and wheel. 10. Remove the safety stands. 11. Lower the vehicle. Page 14373 circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links CIRCUIT PROTECTION - FUSIBLE LINKS Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Flat Wire Repairs FLAT WIRE REPAIRS NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Heated Oxygen Sensor (HO2S) Wiring Repairs HEATED OXYGEN SENSOR (HO2S) WIRING REPAIRS TOOLS REQUIRED J 38125-D Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: - Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-D. Repairing Damaged Wire Insulation REPAIRING DAMAGED WIRE INSULATION Page 9623 Location View Electrical - Trailer Brakes Apply With Headlamps ON Trailer Lighting Module: Customer Interest Electrical - Trailer Brakes Apply With Headlamps ON Bulletin No.: 02-05-22-004C Date: April 05, 2005 TECHNICAL Subject: Trailer Brakes Applied When Headlights/Park Lamps Are On, Brake Controller Illumination (Modify Brake Controller Wiring Harness) Models: 2002-2005 Cadillac Escalade, Escalade EXT 1999-2005 Chevrolet Silverado 2000-2005 Chevrolet Suburban, Tahoe 2002-2005 Chevrolet Avalanche 1999-2005 GMC Sierra 2000-2005 GMC Yukon, Yukon XL 2003-2005 HUMMER H2 Supercede: This bulletin is being revised to add additional model years. Please discard Corporate Bulletin Number 02-05-22-004B (Section 05 - Brakes). Condition Some customers may comment that when the headlamps or park lamps are on, the brakes on the trailer are always applied, or that the back lighting for the trailer brake controller only illuminates when the brakes are applied. Cause The cause of this condition may be due to wiring changes within the vehicle electrical system for the 2003 model year. Correction Inspect the brake controller wiring harness jumper that is plugged into the vehicle relay block-body. The relay block-body is located under the left side of the instrument panel near the left kick panel, behind a plastic cover. Service and Repair Global Positioning System Module: Service and Repair COMMUNICATION INTERFACE MODULE REPLACEMENT REMOVAL PROCEDURE IMPORTANT: The vehicle communication interface module (VCIM) has a specific set of unique numbers that tie the module to each vehicle. These numbers, the 10-digit station identification (STID) and the 11-digit electronic serial number (ESN), are used by the National Cellular Network and Onstar(R) to identify the specific vehicle. Because these numbers are tied to the vehicle identification number of the vehicle, you must never exchange these parts with those of another vehicle. 1. Remove the instrument panel (I/P) top trim panel. 2. Disconnect the wire connectors (2) from the module. 3. Disconnect the coaxial cable (3) from the module. 4. Remove the nuts (2) retaining the module to the bracket. 5. Remove the module (3) from the vehicle. INSTALLATION PROCEDURE 1. If replacing the VCIM, record the 10-digit STID number, and the 11-digit ESN number from the labels on the new module. Page 6287 Vehicle Speed Sensor (VSS) Tow/Haul Switch Location Page 4730 results from the alteration or modification of a vehicle using non-GM approved parts or accessories. Dealers should be especially cautious of accessory companies that claim the installation of their product will not void the factory warranty. Many times these companies have even given direction on how to quickly disassemble the accessory in an attempt to preclude the manufacturer from finding out that is has been installed. Any suspect repairs should be reviewed by the Fixed Operations Manager (FOM), and in Canada by the Warranty Manager (WM) for appropriate repair direction. If it is decided that a goodwill repair is to be made on the vehicle, even with the installation of such non-GM approved components, the customer is to be made aware of General Motors position on this issue and is to sign the appropriate goodwill documentation required by General Motors. It is imperative for dealers to understand that by installing such devices, they are jeopardizing not only the warranty coverage, but also the performance and reliability of the customer's vehicle. Disclaimer Page 5489 Location View The Fuel Pump Relay is located in the Underhood Fuse Block. The Underhood Fuse Block is located in the left side of the engine compartment to the rear of the battery. Page 481 When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage TESTING FOR A SHORT TO VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity TESTING FOR CONTINUITY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents TESTING FOR ELECTRICAL INTERMITTENTS Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground - Testing for Continuity - Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 msRECORD and emits an audible tone (beep). Page 12581 2. Disconnect the C2 32-way blue connector from the VIU and tape the connector to a secure location. Refer to Cellular Communications Connector End Views and related schematics in SI, if required. Important: DO NOT perform the OnStar(R) reconfiguration and/or programming procedure. 3. Secure the VIU in its original brackets and/or mounting locations and reinstall the VIU and interior components that were removed to gain access to the VIU. Refer to OnStar Vehicle Interface Unit Replacement in SI. 2002 Through 2006 Model Year Vehicles (Except Saab Vehicles) 2002 through 2006 Model Year Vehicles (Except Saab Vehicles) Important: The Tech 2 diagnostic tool must be updated with version 28.002 or later in order to successfully perform the VCIM setup procedure and disable the analog system. 1. Connect the Tech 2 to the data link connector (DLC), which is located under the instrument panel of the vehicle. 2. Turn the Tech 2 ON by pressing the power button. Important: Tech 2 screen navigation to get to the setup procedure depends on the year and make of the vehicle. The actual name of the setup procedure (Setup New OnStar or VCIM Setup) depends on model year and vehicle make as well. Example Tech 2 navigation to the setup procedure Tech 2 screen is provided below. ^ Diagnostics >> (2) 2002 >> Passenger Car >> Body >> C >> OnStar >> Special Functions >> Setup New OnStar >> ^ Diagnostics >> (5) 2005 >> Passenger Car >> (4) Buick >> C >> Body >> Vehicle Comm. Interface Module >> Module Setup >> VCIM Setup >> 3. Setup VCIM using the Tech 2. Follow on-screen instructions when you have reached the setup Tech 2 screen. 2000-2002 Saab 9-3 (9400) 4D/5D; 2000-2003 Saab 9-3 (9400) CV 2000-2002 Saab 9-3 (9400) 4D/5D; 2000-2003 Saab 9-3 (9400) CV 1. Remove the ground cable from the battery's negative terminal. 2. Apply the handbrake brake. 3. Detach the floor console. 4. Remove the switch and the floor console: 3.1. Twist loose the immobilizer unit (A), bayonet fitting. Unplug the unit's connector. 3.2. Remove the ignition switch cover (B) by first undoing the rear edge of the cover and then unhooking the front edge. Unplug the ignition Page 16086 Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. 1. Disconnect the connector from the component. 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. Page 15173 - Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-D in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-D if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Page 8687 7. Disconnect the BPMV electrical connector from the EBCM. 8. Clean the BPMV to EBCM mounting surfaces with a clean cloth. Installation Procedure Important: ^ Do not reuse the old mounting screws. Always install new mounting screws with the new EBCM. ^ Do not use RTV or any other type of sealant on the EBCM gasket or mating surfaces. 1. Connect the BPMV electrical connector to the EBCM. Page 265 2. Click on the Analog-to-Digital Program link to start the ordering process. 3. To order a kit, you will need the information shown above. 4. After submitting the order, the "Terms and Conditions of Your OnStar(R) Service" page will display. This is your confirmation that the upgrade kit order has been created. U.S. Dealers will also receive an e-mail from Autocraft within several hours of ordering an upgrade kit (Canadian Dealers will receive an e-mail from MASS Electronics). 5. Print the "Terms and Conditions of Your OnStar(R) Service" page, and have the customer sign a copy. 6. A copy of this form should be stapled to the customer's copy of the Repair Order and one copy should be retained in the customer service folder. 7. If the kit you ordered is available, you will receive the upgrade kit within 4 business days of entering your order through the OnStar(R) Online Enrollment webpage. 8. To check on kit availability or the status of your order, U.S. Dealers can log onto the distributor's website at www.autocraft.com. Canadian dealers can call MASS Electronics at 877-410-6277. Upgrade Kit Installation 1. Skip to the next step if the vehicle to be upgraded is not shown above. Page 3819 Control Module References Part 5 Page 1269 5. Notice: Refer to Fastener Notice in Service Precautions. Install the WSS mounting bolt. ^ Tighten the WSS mounting bolt to 18 Nm (13 ft. lbs.). 6. Install the WSS cable mounting clip to the knuckle. 7. Install the WSS cable mounting clip to the upper control arm. 8. Install the WSS cable mounting clip to the frame attachment point. 9. Connect the WSS cable electrical connector. Page 14921 Heated Seat Switch - Front Passenger (FPDM C5) Door Latch Assembly (Door Jamb Switch) - Driver C2 Door Switch: Diagrams Door Latch Assembly (Door Jamb Switch) - Driver C2 Door Latch Assembly (Door Jamb Switch) - Driver C2 Page 8477 ^ If the color of the relief valve is silver or aluminum, continue to the next step. Important If present, the stamped number being described in the next step would be on the mounting surface for the master cylinder on the hydraulic brake booster. The number may be difficult to see if there is any corrosion on the unpainted surface. As a result, it may be necessary to clean the surface with a piece of emery or sandpaper. 3. Inspect the hydraulic brake booster at the location shown (4) for a stamped number. The location (4) is the same surface that the master cylinder mounts on, just above the outboard mounting bolt and nut (5). Also inspect for a paint mark (3) near the master cylinder outboard mounting bolt (5). If a stamped number is found it will be a 1, 2, 3, or 4. If a paint mark is found, it will be yellow, pink, or white. ^ If a yellow, pink, or white paint mark IS visible, no further inspection or repairs are required. Disregard any stamped number found when a yellow, pink, or white paint mark is visible. ^ If there are NO paint marks and there IS a stamped number 2, 3, or 4 visible, no further inspection or repairs are required. ^ If there are NO paint marks and there IS a stamped number 1 visible, then proceed to the next step. ^ If there are NO paint marks and there are NO stamped numbers visible, then proceed to the next step. Caution Care should be taken when working around the accumulator since it contains high-pressure compressed gas and hydraulic fluid. 4. With the ignition in the OFF position, pump the brake pedal a minimum of ten times. 5. On van models, remove the two bolts that attach the diagonal brace between the left front fender and radiator support. Remove the brace and the water deflector that is attached to it. 6. On all models, remove the two nuts that attach the master cylinder to the hydraulic brake booster. A 13 mm wrench installed on the bolt head may be required to prevent the bolt from spinning. Important On full size pickups and utilities, the bracket that attaches the brake combination valve will need to be removed from the mounting bolts at the same time that the master cylinder is removed and repositioned in the next step. Notice When repositioning the master cylinder in the next step, use care not to pinch, kink, or damage the brake hoses or pipes. 7. Remove and reposition the master cylinder away from the hydraulic brake booster so that the machined surface on the front of the booster where the master cylinder was mounted is visible. Page 7261 Power Take-Off: Electrical Diagrams Power Take-Off (PTO) Diagram Page 14843 3. Notice: Refer to Fastener Notice in Service Precautions. Install a new 4 mm bolt (1), with LOCTITETM , to the brake pedal position sensor. ^ Tighten the bolt to 9 Nm (80 inch lbs.). 4. Calibrate the brake pedal position sensor. Page 15483 Fuel Gauge Sender: Service and Repair Fuel Level Sensor Replacement - 2 FUEL LEVEL SENSOR REPLACEMENT REMOVAL PROCEDURE 1. Remove the sending unit. 2. Disconnect the fuel pump electrical connector. 3. Remove the fuel level sensor electrical connector retaining clip. 4. Disconnect the fuel level sensor electrical connector. Page 9080 Fuse Block: Application and ID Fuse Block - Underhood - Secondary Location View Page 6631 Page 4305 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly, Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Pull to Seat Connectors PULL TO SEAT CONNECTORS TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Engine Controls - 4L60E/4L65E A/T 2nd Gear Start PROM - Programmable Read Only Memory: Customer Interest Engine Controls - 4L60E/4L65E A/T 2nd Gear Start Bulletin No.: 05-07-30-013 Date: May 09, 2005 TECHNICAL Subject: 4L60-E/4L65-E Automatic Transmission Second Gear Start, Lack/Loss of Power When Accelerating From a Stop (Reprogram Powertrain Control Module (PCM) Models: 2004-2005 Cadillac Escalade 2004-2005 Chevrolet Avalanche, Express, Silverado, Suburban, Tahoe 2004-2005 GMC Savana, Sierra, Yukon 2004-2005 HUMMER H2 with 4L60-E (RPO M30) or 4L65-E (RPO M32) Automatic Transmission Condition Some customers may comment on a slip on launch, low power on a launch or a second gear start when accelerating from a stop. This condition is usually very intermittent, occurring only once in a few thousand miles of driving. A Tech 2 or VDR snapshot of the event may show 2nd gear being commanded for approximately two seconds, then 1st gear commanded as would be expected. Cause This condition may be caused by an intermittent VSS signal, which causes the PCM to command second gear. Important: There are other conditions that can cause the transmission to start in a gear higher than first. The following are a few of these conditions. ^ Some DTCs can cause the transmission to start in a higher gear. Check for the presence of DTCs and repair as appropriate before proceeding. ^ Debris on top of the spacer plate or in the valve body or a leaking shift solenoid can cause a 4L60-E or 4L65-E transmission to start in a gear higher than first. A start in a higher gear caused by any of these conditions typically occurs with much greater frequency. Refer to Service Bulletin 01-07-30-036D or newer for diagnostic information of these conditions. ^ Placing the shift lever in the D2 position will cause a 4L60-E or 4L65-E transmission to start in second gear. Correction Important: ^ This bulletin ONLY applies to 2004-2005 models year vehicles listed above. ^ Some DTCs can cause the transmission to start in a higher gear. Check for the presence of DTCs and repair as appropriate before proceeding. 1. Using a scan tool, check for the presence of DTCs. If DTCs are present, refer to the appropriate SI Document before proceeding with this calibration. Important: These calibrations also contain the 2-3 shift clunk calibration as detailed in bulletin 05-07-30-012. 2. Technicians are to reprogram the PCM with an updated software calibration. This new service calibration was released with TIS satellite data update version 5 or later available May 1, 2005. Refer to Service Programming System (SPS) in Vehicle Control Systems in the appropriate SI Document. Warranty Information Page 15052 8. Install the large shoulder (M8) bolts into the reinforcement and front panel (total of 4) and the small (M6) bolts into the reinforcement and side outer panel (total of 6) with the nuts. Tighten ^ Tighten the M8 bolts to 25 Nm (18 lb-ft.). ^ Tighten the M6 bolts to 9 Nm (79 lb-in). 9. Remove all metal shavings from the pickup box afier installation. 10. Install the bedliner if equipped with the aid of an assistant. The bedliner may need to be trimmed in order to obtain the necessary clearance for the reinforcements. Ladder Rack and/or Side Tool Box Applications - Reinforcement Kit Installation 1. Install the LH and RH front L-shaped reinforcements using the procedure above. 2. Remove the LH and RH rear taillamp assemblies. This is necessary to gain access to install the rearmost bolt of the rear reinforcement. 3. Place the LH and RH rear reinforcements into position on the pickup box. 4. Mark the holes necessary for drilling and remove the reinforcements. 5. Drill 7.5 mm (0.30 in) holes into the weld flange of the side outer panel. 6. Apply anti-corrosion material to the drilled holes as necessary. Refer to step 6 under Front Reinforcement Installation procedure. 7. Place the rear reinforcements back onto the pickup box. 8. Install the M6 bolts through the reinforcement and side panel with the nuts. Tighten Tighten the bolts to 9 Nm (79 lb-in). 9. Install the LH and RH rear taillamp assemblies. 10. Place the LH and RH center reinforcement into position on the pickup box. Keyless Entry - Inoperative Keyless Entry Module: All Technical Service Bulletins Keyless Entry - Inoperative Bulletin No.: 04-08-52-005 Date: June 15, 2004 TECHNICAL Subject: Remote Keyless Entry (RKE) System Inoperative (Reprogram Passenger Door Module (PDM)) Models: 2004 Cadillac Escalade, Escalade ESV, Escalade EXT 2004 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2004 GMC Sierra, Yukon, Yukon XL Condition Some customers may comment on any of the following conditions: ^ The RKE key fob does not function. ^ The "Service Tire Pressure Monitoring System" message is displayed, if equipped. ^ The passenger door will not unlock from the passenger's or driver's door switches. ^ The passenger door window is inoperative. Correction Reprogram the PDM with the Tech 2(R). Currently the Tech 2(R) software is not available for the 2004 model year. Engineering is aware of this and are working to release a new service calibration. In the meantime, build the Tech 2(R) as a 2003 model year and perform the reprogram using the procedure listed below. 1. Turn the ignition switch to the ON position. 2. Connect the Tech 2(R) to the vehicle's diagnostic link connector (DLC), power it up and press enter. ^ Select: Diagnostics. ^ Select model year: 2003. ^ Select: Light truck. ^ Select: Body. ^ Select the proper Product line. ^ Select the proper HVAC Type. ^ Select the proper Radio System type. ^ Select: Passenger Door Module. ^ Select: Special Functions. ^ Select: Refresh. Important: You must remove the described fuse in the next step for the "Refresh" program to be performed. If you do not remove the fuse for five seconds, the Tech 2 will continue to display "Test in Progress" and the program will not complete. ^ Remove the PDM fuse for 5 seconds from the fuse center located behind the panel on the left end of the instrument panel. Page 10227 Electrical Symbols Part 12 Page 5977 7. Remove the pressure control solenoid retainer bolt (364A) and retainer (378). 8. Remove the pressure control solenoid (377). 9. Remove the TCC solenoid bolts and the valve body bolts which retain the internal wiring harness. 10. Using J 28458 , release the pass-through electrical connector from the transmission case. 1. Use the small end of the J 28458 over the top of the connector. 2. Twist in order to release the four tabs retaining the connector. 3. Pull the harness connector down through the transmission case. 11. Remove the TCC solenoid (with O-ring seal) and wiring harness. Page 10179 Disclaimer Page 11900 Page 10443 Suspension Travel Bumper: Service and Repair Rear Suspension Spring Bumper Replacement Removal Procedure 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Remove the jounce bumper mounting bolt. 3. Remove the jounce bumper. The 15 series utilities are snap fit. Installation Procedure 1. Install the jounce bumper. The 15 series utilities are snap fit. 2. Install the jounce bumper bolt. ^ Tighten the bolt to 32 Nm (24 ft. lbs.). Notice: Refer to Fastener Notice in Service Precautions. 3. Remove the safety stands. 4. Lower the vehicle. Page 14971 Tailgate Release Handle: Service and Repair Handle Replacement - Endgate Handle Replacement - Endgate Removal Procedure 1. Loosen the handle bolts. 2. Remove the handle bezel by prying gently on the upper retainer tabs. 3. Disengage the linkage rods (1). 4. Remove the handle bolts. 5. Remove the handle assembly from the endgate. Installation Procedure 1. Position the handle assembly on the endgate. 2. Install the handle bolts loosely. Page 10769 The information shown is for the 1999-2002 wiring harnesses and for the 2003-05 wiring harness. To modify a 12171982, 15366255 or 15086884 harness for use in a 2003-05 vehicle, switch the wires in cavities "A" and "D". To modify a 15085418 harness for use in a 1999-2002 vehicle (see model list at the front of this bulletin for applicable models), switch the wires in cavities "A" and "D". Warranty Information When the correct wiring harness P/N is matched to the specific model year of the vehicle, everything works properly. Therefore, conversion of an incorrect wiring jumper to match the vehicle would not be considered a warrantable repair. Disclaimer Torsion Bar Replacement Torsion Bar: Service and Repair Torsion Bar Replacement Torsion Bar Replacement ^ Tools Required J 36202 Torsion Bar Unloading/Loading Tool Removal Procedure 1. Raise and support the vehicle. Refer to Vehicle Lifting. Notice: Use care when handling the torsion bars in order to avoid chipping or scratching the coating. Damage to the coating will result in premature failure of the torsion bars. 2. Install the J 36202 to the adjustment arm and the crossmember. 3. Increase the tension on the adjustment arm until the load is removed from the adjustment bolt and the adjuster nut. 4. Remove the adjustment bolt (3) and the adjuster nut (4). Important: Mark the adjustment bolt and count the number of times that is required to remove the adjustment bolt. 5. Remove the adjustment bolt (3) and the adjuster nut (4), for vehicles with MN8, MT1 AND MW3. 6. Remove the J 36202 , allowing the torsion bar to unload. Page 844 Relay Box: Service and Repair I/P Electrical Center or Junction Block Replacement - Right INSTRUMENT PANEL ELECTRICAL CENTER OR JUNCTION BLOCK REPLACEMENT - RIGHT REMOVAL PROCEDURE 1. Remove the right side end panel. 2. Push in the tabs in order to remove the fuse block. 3. Pull out the fuse block out of the I/P in order to remove the retaining bolt. 4. Loosen the bolt. 5. Insert a screw driver between the wire harness block and fuse block in order to separate. 6. Separate the fuse block from the I/P harness block. 7. Remove the I/P wiring harness block from the vehicle. INSTALLATION PROCEDURE 1. Install the fuse block to the I/P wire harness block. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the retaining bolt. Tighten Tighten the bolt to 6 N.m (53 lb in) 3. Install the fuse block to the I/P until it clicks in place. Page 12701 Diagnostic Tips Review # 1 - Delphi Super Nav and Black Tie Nav Engine, A/T - Shift/Driveability Concerns/MIL ON Air Filter Element: Customer Interest Engine, A/T - Shift/Driveability Concerns/MIL ON Bulletin No.: 04-07-30-013B Date: February 01, 2007 INFORMATION Subject: Automatic Transmission Shift, Engine Driveability Concerns or Service Engine Soon (SES) Light On as a Result of the Use of an Excessively/Over-Oiled Aftermarket, Reusable Air Filter Models: 2007 and Prior GM Cars and Light Duty Trucks 2007 and Prior Saturn Models 2003-2007 HUMMER H2 2006-2007 HUMMER H3 2005-2007 Saab 9-7X Supercede: This bulletin is being revised to add models and model years. Please discard Corporate Bulletin Number 04-07-30-013A (Section 07 - Transmission/Transaxle). The use of an excessively/over-oiled aftermarket, reusable air filter may result in: Service Engine Soon (SES) light on Transmission shift concerns, slipping and damaged clutch(es) or band(s) Engine driveability concerns, poor acceleration from a stop, limited engine RPM range The oil that is used on these air filter elements may be transferred onto the Mass Air Flow (MAF) sensor causing contamination of the sensor. As a result, the Grams per Second (GPS) signal from the MAF may be low and any or all of the concerns listed above may occur. When servicing a vehicle with any of these concerns, be sure to check for the presence of an aftermarket reusable, excessively/over-oiled air filter. The MAF, GPS reading should be compared to a like vehicle with an OEM air box and filter under the same driving conditions to verify the concern. The use of an aftermarket reusable air filter DOES NOT void the vehicle's warranty. If an aftermarket reusable air filter is used, technicians should inspect the MAF sensor element and the air induction hose for contamination of oil prior to making warranty repairs. Transmission or engine driveability concerns (related to the MAF sensor being contaminated with oil) that are the result of the use of an aftermarket reusable, excessively/over-oiled air filter are not considered to be warrantable repair items. Page 4115 Install the parking lock bracket bolts. ^ Tighten the bolts to 24 Nm (18 ft. lbs.). 13. Install the PNP switch. 14. Install the transmission filter. 15. Fill the transmission to the proper level with Dexron® III transmission fluid. Page 7648 2. Using the J 37668-A, install a NEW front output shaft seal. Important: Ensure the drain hole on the boot of the rear output shaft seal is facing down toward the ground. 3. Install the rear propeller shaft. 4. Check the fluid level. Add fluid, if necessary. 5. Install the transfer case shield, if equipped. Transfer Case Input Shaft Seal Replacement Transfer Case Input Shaft Seal Replacement ^ Tools Required J 42738 Front Output Shaft Seal Installer Removal Procedure 1. Remove the transfer case. 2. Remove the input shaft seal, using a flat-tipped screwdriver. Installation Procedure Interior - Power Seat Switch Knobs Loose/Missing Power Seat Switch: Customer Interest Interior - Power Seat Switch Knobs Loose/Missing Bulletin No.: 05-08-50-017 Date: December 14, 2005 TECHNICAL Subject: Power Front Seat (RPO AN3) Switch Knobs Loose or Missing (Replace Switch Knobs) Models: 2002-2006 Cadillac Escalade, Escalade EXT 2003-2006 Cadillac Escalade ESV 2002-2006 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2002-2006 GMC Sierra, Yukon, Yukon XL with Individual Front Seat Non-Bucket (RPO AN3) and Driver Front Seat Power Adjuster (AG1) and/or Passenger Front Seat Power Adjuster (AG2) Condition Some customers may comment that the power front seat adjuster switch knobs are loose and fall off or are missing. Correction Replace the front seat adjuster switch knob. These knobs were formerly available only as part of the power seat adjuster switch. DO NOT replace the switch if the knob only needs to be replaced. Parts Information Warranty Information Page 14285 WA5322/33 - WA534F/54 Page 6997 6. Install the wheel hub and bearing (5) and splash shield (6) to the vehicle, 15 series. 7. Install the wheel hub and bearing mounting bolts, the 15 series. 8. Install the wheel hub and bearing mounting bolts, 25/35 series. ^ Tighten the wheel hub to knuckle bolts to 180 Nm (133 ft. lbs.). 9. Install the nut (2) and washer (3) retaining the wheel drive shaft assembly to the wheel hub and bearing. ^ Tighten the nut to 240 Nm (177 ft. lbs.). 10. Install the wheel speed sensor and brake hose mounting bracket bolt to the steering knuckle. ^ Tighten the brake hose clip bolt to 12 Nm (106 inch lbs.). 11. Install the rotor. Refer to Brake Rotor Replacement - Front in Disc Brakes. 12. Install the tire and wheel. 13. Lower the vehicle. Page 7652 1. Install the J 43484 (2) to the J 8092 (1). 2. Install the seal onto the J 43484. 3. Using the J 43484 (2) and the J 8092 (1), install the seal. 4. Install the front propeller shaft. 5. Check the fluid level, add fluid if necessary. 6. Install the transfer case shield, if equipped. Transfer Case Output Shaft Seal Replacement - Rear Transfer Case Output Shaft Seal Replacement - Rear ^ Tools Required J 37668-A Seal Installer - J 45380 Transfer Case Rear Bushing Remover and Installer Removal Procedure 1. Remove the transfer case shield, if equipped. 2. Remove the rear propeller shaft. 3. Remove the rear output shaft seal. Page 8041 Electronic Brake Control Module (ECBCM) - C2 (30 Series and HP2 Page 3240 Drive Belt: Testing and Inspection Drive Belt Excessive Wear Drive Belt Excessive Wear Diagnosis Diagnostic Aids Excessive wear on a drive belt(s) is usually caused by incorrect installation or the incorrect drive belt(s) for the application. Minor misalignment of the accessory drive pulley(s) will not cause excessive wear, but will probably cause the drive belt(s) to make a noise or fall off. Excessive misalignment of the accessory drive pulley(s) will cause excessive wear and may also make the drive belt(s) fall off. Test Description Steps 1 - 6 The number(s) below refer to the step(s) in the diagnostic table. 2. This inspection is to verify that the drive belt(s) is correctly installed on all of the accessory drive pulleys. Wear on the drive belt(s) may be caused by mis-positioning the drive belt(s) by one or more grooves on a pulley(s). 3. The installation of a drive belt(s) that is too wide or too narrow will cause wear on the drive belt(s). The drive belt(s) ribs should match all of the grooves on the pulleys. 4. This inspection is to verify that the drive belt(s) is not contacting any part of the engine or body while the engine is operating. There should be sufficient clearance when the accessory drive components load varies. The drive belt(s) should not come in contact with an engine or a body component when snapping the throttle. Page 3623 9. Install the engine harness clip to the PCM cover. 10. Install the A/C line retainer to the fan shroud. 11. Install the air cleaner outlet duct. 12. Tighten the air cleaner outlet duct clamp at the throttle body. Tighten the clamp screws to 7 Nm (62 inch lbs.). 13. Tighten the air cleaner outlet duct clamp at the mass airflow sensor. Tighten the clamp screws to 7 Nm (62 inch lbs.). W/O RPO M74 Fan Shroud Replacement - Upper (W/O M74) Removal Procedure 1. Loosen the air cleaner outlet duct clamps from the throttle body. 2. Loosen the air cleaner outlet duct clamps from the mass airflow sensor. 3. Remove the air cleaner outlet duct. 4. If equipped remove the throttle body heater hose retainer from the fan shroud. 5. If equipped remove the inlet radiator hose retainer from the fan shroud. Page 9304 Location View Page 1465 Turn Signal Multifunction Switch - C3 Page 7556 2. Connect the selector switch electrical connectors (2, 3). 3. Slide the selector switch into the housing until the switch snaps into place. Important: Make sure that the selector switch is seated properly in the housing before installing the I/P cluster bezel. 4. Install the I/P cluster bezel. Page 2500 Fluid - Differential: Service and Repair Rear Drive Axle 8.6 Inch Axle Lubricant Level Inspection - Rear Drive Axle (8.6 Inch Axle) 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Make sure the vehicle is level. 3. Inspect the rear axle for leaks. Repair as necessary. 4. Clean the area around the rear axle fill plug. 5. Remove the rear axle fill plug. 6. Fabricate a dipstick from a pipe cleaner or similar item. Form the pipe cleaner into an "L". 7. Insert the pipe cleaner into the fill plug opening with the stem facing down. 8. Remove the pipe cleaner and measure the distance from the bend in the pipe cleaner to the lubricant level. The distance between the bend and the lubricant level should be 15-40 mm (0.6-1.6 inch). 9. If the measurement is greater than 40 mm (1.6 inch), add lubricant until the level is between 15-40 mm (0.6-1.6 inch) from the bottom edge of the fill plug hole. Use the proper fluid. 10. Notice: Refer to Fastener Notice in Service Precautions. Install the rear axle fill plug. ^ Tighten the rear axle fill plug to 33 Nm (24 ft. lbs.). 11. Lower the vehicle. 9.5, 10.5 Inch Axle Lubricant Level Inspection - Rear Drive Axle (9.5, 10.5 Inch Axle) 1. Raise the vehicle. Refer to Vehicle Lifting in General Information. 2. Make sure the vehicle is level. 3. Inspect the rear axle for leaks. Repair as necessary. 4. Clean the area around the rear axle fill plug. 5. Remove the rear axle fill plug. 6. Inspect the lubricant level. The lubricant level should be between 0-10 mm (0-0.4 inch) below the fill plug opening. Page 3808 SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-D. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: - The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair Tools Required J 38125-D Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-D. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Page 11361 Air Temperature Sensors - Lower Left Page 5526 Throttle Body: Description and Operation THROTTLE BODY ASSEMBLY The throttle body assembly consists of the throttle body, the throttle position (TP) sensors, and the throttle actuator motor. The throttle body functions similar to a similar to a conventional throttle body with the following exceptions: - An electric motor opens and closes the throttle valve. - The throttle blade is spring loaded in both directions and the default position is slightly open. - There are 2 individual TP sensors within the throttle body assembly. The TP sensors 1 and 2 are potentiometer type sensors, each with the following circuits: - A 5-volt reference circuit - A low reference circuit - A signal circuit The TP sensors are used to determine the throttle plate angle. The control module provides each TP sensor a 5-volt reference circuit and a low reference circuit. The TP sensors then provide the control module with signal voltage proportional to throttle plate movement. Both TP sensor signal voltages are low at closed throttle and increase as the throttle opens. Page 5118 Tighten Tighten the nut to 10 N.m (89 lb in). 19. Lower the vehicle. 20. Remove the caps from the fuel rail and EVAP pipes. 21. Connect the EVAP canister purge tube (3). 22. Connect the fuel feed and return pipes (1) at the fuel rail. 23. Install the fuel fill cap. 24. Connect the negative battery cable. 25. Use the following procedure in order to inspect for leaks: 25.1. Turn the ignition ON, with the engine OFF, for 2 seconds. 25.2. Turn the ignition OFF for 10 seconds. 25.3. Turn the ignition ON, with the engine OFF. 25.4. Inspect for fuel leaks. EVAP Hoses/Pipes Replacement - Chassis (1500 Crew Cab) EVAPORATIVE EMISSION (EVAP) HOSES/PIPES REPLACEMENT - CHASSIS (1500 CREW CAB) REMOVAL PROCEDURE IMPORTANT: Clean the fuel and evaporative emission (EVAP) connections and surrounding areas prior to disconnecting the fittings in order to avoid possible system contamination. 1. Relieve the fuel system pressure. Refer to Fuel Pressure Relief Procedure. 2. Disconnect the fuel feed line (1) fitting at the engine. 3. Disconnect the EVAP canister purge tube (2) fitting. 4. Cap the fuel rail and EVAP lines in order to avoid possible system contamination. 5. Raise and support the vehicle. Refer to Vehicle Lifting. Page 10025 Pitman Arm: Service and Repair Pitman Arm Replacement ^ Tools Required J 6632-01 Pitman Arm Puller - J 29107-A Pitman Arm Puller Removal Procedure 1. Raise and suitable support the vehicle. Refer to Vehicle Lifting. 2. Remove the power steering gear. Refer to Power Steering Gear Replacement (Rack and Pinion) Power Steering Gear Replacement (Non Rack and Pinion) in Power Steering System. 3. Install the power steering gear into a vise. 4. Remove the pitman arm nut and washer. 5. Remove the pitman arm from the pitman shaft using J 6632-01 or J 29107-A. Installation Procedure 1. Install the pitman arm to the power steering gear. 2. Notice: Refer to Fastener Notice in Service Precautions. Install a new pitman arm washer and nut. Page 14805 4. Press the button a second time, 2 light bars will glow indicating the MEDIUM temperature setting for the entire seat. 5. Press the button a third time, 1 light bar will glow indicating the LOW temperature setting for the entire seat. 6. Press the button a fourth time to turn the entire heated seat OFF. 7. To heat ONLY the seat back, press the vertical (LH) button one time. ^ An ON/OFF indicator light over the heated seat back symbol will glow to designate that ONLY the seat back is being heated. ^ All 3 light bars over the horizontal (RH) button will glow indicating the HIGH temperature setting for ONLY the seat back. 8. Press the button a second time, 2 light bars will glow indicating the MEDIUM temperature setting for ONLY the seat back. 9. Press the button a third time, 1 light bar will glow indicating the LOW temperature setting for ONLY the seat back. 10. Press the button a fourth time to turn the heated seat back OFF. Switch Diagnostics Important: In order to eliminate unnecessary part replacement and comeback repairs, it is essential that the appropriate diagnostic tables and aids found in the applicable manuals are followed. 1. Verify the condition prior to making any repairs. Refer to Seats and Seat Controls in the applicable Owners Manual or this bulletin for proper heated seat switch operation information. 2. If an improperly operating front heated seat condition exists, refer to the Diagnostic Information and Procedures in the Seats sub-section of the applicable Service Manual in order to diagnose the system accurately. 3. When measuring the resistance of the seat heater elements, ensure the values are within the updated range of 1.5-5.5 ohms. Refer to DTC B2425 or B2430-Clearing the DTC in the Diagnostic Information and Procedures in the Seats sub-section of the applicable Service Manual. Customer Information Some heated seat components from the above listed vehicles have been returned to the Warranty Parts Center (WPC) for heat function not operating properly. Analyses of these parts show 'no out of specification condition' or No Trouble Found (NTF). 1. Provide customers with the knowledge that if bumped, either one of the heated seat switches can be activated/deactivated accidentally. 2. Ensure customers have a thorough understanding of how the heated seat switches function. Disclaimer Fuel Level Sensor Fuel Gauge Sender: Description and Operation Fuel Level Sensor FUEL LEVEL SENSOR The fuel level sensor consists of a float, a wire float arm, and a ceramic resistor cord. The position of the float arm indicates the fuel level. The fuel level sensor contains a variable resistor, which changes resistance in correspondence to the amount of fuel in the fuel tank. The powertrain control module (PCM) sends the fuel level information via the class 2 circuit to the instrument panel (I/P) cluster. This information is used for the I/P fuel gage and the low fuel warning indicator, if applicable. The PCM also monitors the fuel level input for various diagnostics. Page 8557 2. Remove the master cylinder from the booster. Do not remove the pipes from the master cylinder. Set the master cylinder aside in the engine compartment. 3. Disconnect the power brake booster inlet hose, the steering gear inlet hose, and the power brake booster outlet hose from the booster assembly. 4. Disconnect the electrical connector from the stop lamp switch. 5. Remove the retainer from the brake pedal pin. 6. Remove the stop lamp switch and the pushrod to the power brake booster from the brake pedal pin. 7. Unsnap the stop lamp switch from the power brake booster pushrod. 8. Remove the 4 booster to bulkhead nuts. 9. Remove the booster assembly. 10. Remove the gasket. Installation Page 13262 Claim Information - GM, Saturn Canada and Saab Canada Only Claim Information - Saturn US Only Customer Reimbursement Claims - Special Attention Required Customer reimbursement claims must have entered into the "technician comments" field the CSO # (if repair was completed at a Saturn Retail Facility) date, mileage, customer name, and any deductibles and taxes paid by the customer. Claim Information - Saab US Only Page 14383 Control Module References Part 2 Page 8562 Use clean, new power steering fluid only. 12. Fill the pump reservoir with fluid to the FULL COLD level. 13. Attach J 43485, Power Steering Bleeder Adapter, to J 35555, Metal Mityvac, or equivalent. 14. Place J 43485 on or in the pump reservoir filler neck. 15. Apply a vacuum of 68 kpa (20 in Hg) maximum. 16. Wait 1 minute. 17. Remove 1 J43485 and J 35555. 18. Reinstall the pump reservoir cap. 19. Start the engine. Allow the engine to idle. 20. Turn the steering wheel 180-360 degrees in both directions 5 times. 21. Switch the ignition off 22. Verify the fluid level. 23. Release the park brake and unblock the wheels. Entertainment System - Headphone Foam Pad Replacement Headphones / Earphones: Technical Service Bulletins Entertainment System - Headphone Foam Pad Replacement Bulletin No.: 05-08-44-005A Date: July 19, 2007 INFORMATION Subject: Information on Rear Seat Headphone Foam Ear Pad Replacement if Worn or Damaged Models: 2001-2008 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2008 HUMMER H2, H3 2005-2008 Saab 9-7X with Rear Seat Entertainment System (RPOs U32, U42) Supercede: This bulletin is being revised to add models and model years and update the shipping costs. Please discard Corporate Bulletin Number 05-08-44-005 (Section 08 - Body and Accessories). Foam ear pads on the rear headphone may become worn or damaged. The headphone foam ear pads may wear out when not handled and stored carefully. If the headphone foam ear pads become damaged or worn out, the foam pads can be replaced separately from the headphone set. It is not necessary to replace the complete headphone set. Parts Information All pricing information listed in this bulletin is in U.S. dollars and is subject to change without notice. The headphone replacement foam ear pads can be ordered in pairs directly through the supplier. Have your customer call Unwired at 1-888-293-3332, then prompt zero (0). The replacement, P/N CS-980 (thick earfoam), can be ordered for $3.50 (USD) per pair plus $2.50 USPS shipping. Disclaimer Page 2718 Fuse Block - Underhood - Secondary Wire Entry (With RPO Code HP2) Part 2 Page 16278 Windshield Washer Pump: Service and Repair WASHER PUMP REPLACEMENT REMOVAL PROCEDURE 1. Remove the washer solvent container. 2. Remove the washer pumps from the reservoir. INSTALLATION PROCEDURE 1. Install the washer pumps into the reservoir. 2. Install the washer solvent container. Page 10718 Wheel Bearing: Service and Repair With Rear Wheel Steering Wheel Hub and Bearing Replacement ^ Tools Required J 45859 Axle Remover Removal Procedure 1. Notice: Refer vehicle Lifting. Raise the vehicle. Refer to Vehicle Lifting. 2. Remove the tire and wheel. 3. Remove the brake rotor. 4. Remove the axle nut dust cover (4). 5. Remove the cotter pin (2) and retainer (3) from the wheel drive shaft nut. 6. Remove the wheel drive shaft retaining nut. 7. Remove the wheel hub and bearing retaining bolts. Page 10582 Acceptably Prepared (Cleaned-Up) Wheel Surface 6. Once the corrosion has been eliminated, you should coat the repaired area with a commercially available tire sealant such as Patch Brand Bead Sealant or equivalent. Commercially available bead sealants are black rubber-like coatings that will permanently fill and seal the resurfaced bead seat. At 21°C (70°F) ambient temperature, this sealant will set-up sufficiently for tire mounting in about 10 minutes.Coated and Sealed Bead Seat 7. Remount the tire and install the repaired wheel and tire assembly. Refer to Tire and Wheel Removal and Installation in SI. Parts Information Patch Brand Bead Sealer is available from Myers Tires at 1-800-998-9897 or on the web at www.myerstiresupply.com. The one-quart size can of sealer will repair about 20 wheels. Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use: Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table above. Page 5337 1. Lubricate the NEW crossover fuel pipe O-rings (7, 20) with clean engine oil. 2. Install the NEW crossover fuel pipe O-rings (7, 20) onto the crossover pipe rail assembly (25). 3. Install the crossover pipe rail assembly (25) to the left hand rail assembly (14) and the right hand rail assembly (15). NOTE: Refer to Fastener Notice in Service Precautions. IMPORTANT: When installing the retaining clip attaching screws for the crossover pipe, always start them by hand. This will prevent consequent stripping of the threads on the rail. 4. Install the crossover fuel pipe retainer clip (21). Loosely install the retaining clip attaching screw (22). 5. Lubricate the NEW fuel return pipe O-ring (6) with clean engine oil. 6. Install the NEW fuel return pipe O-ring (6) on the fuel return pipe (1). 7. Install the fuel return pipe (1). 8. Install the fuel return pipe retainer (2). Loosely install the fuel return pipe attaching screw (3). IMPORTANT: When installing the retaining clip attaching screws for the crossover pipe, always start them by hand. This will prevent consequent stripping of the threads on the rail. 9. Install the crossover fuel pipe retainer clip (5). Loosely install the retaining clip attaching screw (4). Tighten 1. Tighten the crossover fuel pipe retainer clip attaching screws (4, 22) to 3.8 N.m (34 lb in). 2. Tighten the fuel return pipe attaching screw (3) to 5 N.m (44 lb in). 3. Install the fuel pressure connection core assembly (24) to the crossover pipe rail assembly (25). 4. Connect the fuel feed pipe quick connect fitting to the fuel rail. 5. Install the fuel fill cap. 6. Connect the negative battery cable. Page 6123 Disclaimer Page 8116 Important: After drilling the holes, apply the appropriate anti-corrosion primer. Refer to the GM Refinish Material Booklet # 4901 M-D (English) or # 4901-D-F (French) for additional information. 6. Center punch the marked location and drill a 6.35 mm (1/4 in) hole. Install the plastic retainer in the hole (1) of the mud flap. 7. Tighten fastener at the hole (2) location of the mud flap. Tighten Tighten the fastener to 25 N.m (18 lb ft). 8. For vehicles with short box, use the following procedure: 8.1. Push the mud flap to make contact with the rear side of the underbody cross sill and mark the location of the hole (3) of the mud flap. 8.2. Center punch the marked location and drill a 5.159 mm (13/64 in) hole. 8.3. Install the screw. Tighten Tighten the screw to 4 N.m (35 lb in). 8.4. Repeat the above steps for hole locations 4 and 6. 9. For vehicles with long box, use the following procedure: Service and Repair Door Lock Cylinder: Service and Repair Lock Cylinder Replacement - Door Removal Procedure 1. Raise the window completely. 2. Remove the front door trim panel. 3. Remove the water deflector. 4. Remove the outside door handle. 5. Remove the clip that retains the lock cylinder lever to the lock cylinder. 6. Remove the lock cylinder retainer. Remove the lock cylinder from the outside door handle. Installation Procedure 1. Install the lock cylinder into the outside door handle. 2. Install the clip. 3. Install the outside door handle. 4. Install the front door water deflector. 5. Install the front door trim panel. Locations Upper Steering Column Procedures Body Control Module: Procedures BODY CONTROL MODULE (BCM) PROGRAMMING/RPO CONFIGURATION INTRODUCTION The procedures below are designed to set-up the body control module (BCM) correctly during BCM related service. Before you start, read these procedures carefully and completely. IMPORTANT: The following procedures must be followed: 1. Programming the BCM. 2. Programming Theft Deterrent System Components, if equipped with Passlock System. PROGRAMMING THE BCM IMPORTANT: After the procedure is completed, the personalization settings of the BCM are set to a default setting. Inform the customer that the personalization must be set again. Perform the BCM special function Request BCM Info. for service programming system (SPS), then follow the SPS instructions. Refer to Service Programming System (SPS) in Programming. PROGRAMMING THEFT DETERRENT SYSTEM COMPONENTS IMPORTANT: This procedure has to be performed only for vehicles equipped with Passlock System. Perform the Programming Theft Deterrent System Components in Theft Deterrent after successfully finishing the Setup New BCM procedure. If the Programming Theft Deterrent System Components in the Theft Deterrent procedure is not performed after a BCM replacement, one of the following conditions will occur: The vehicle will not be protected against theft by the PASSLOCK system. - The engine will not crank or start. IMPORTANT: After programming, perform the following to avoid future misdiagnosis: 1. Turn the ignition OFF for 10 seconds. 2. Connect the scan tool to the data link connector. 3. Turn the ignition ON, with the engine OFF. 4. Use the scan tool in order to retrieve history DTCs from all modules. 5. Clear all history DTCs. Page 5671 Vehicle Speed Sensor (VSS) Tow/Haul Switch Location Automatic Transmission Electronic Component Views (M33 Only) Automatic Transmission Electronic Component Views (M33 Only) NVG 246-NP8 Control Module: Locations NVG 246-NP8 Transfer Case Shift Control Module Transfer Case Shift Control Module 1 - I/P Harness 2 - Transfer Case Shift Control Module Connectors 3 - Transfer Case Shift Control Module 4 - Instrument Panel Page 14091 9. Use J 38125-12A to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. REPAIR PROCEDURE The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. 1. Cut the wire as close to the terminal as possible. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. Engine Controls - Aftermarket Accessory Usage Engine Control Module: All Technical Service Bulletins Engine Controls - Aftermarket Accessory Usage INFORMATION Bulletin No.: 04-06-04-054B Date: November 18, 2010 Subject: Info - Non-GM Parts and Accessories (Aftermarket) Models: 2011 and Prior GM Passenger Cars and Trucks Supercede: This bulletin is being revised to add model years and update to the new U.S. Fixed Operation Manager (FOM) and Canada Warranty Manager (WM) names. Please discard Corporate Bulletin Number 04-06-04-054A (Section 06 - Engine/Propulsion System). The recent rise and expansion of companies selling non-GM parts and accessories has made it necessary to issue this reminder to dealers regarding GM's policy on the use and installation of these aftermarket components. When a dealer is performing a repair under the New Vehicle Limited Warranty, they are required to use only genuine GM or GM-approved parts and accessories. This applies to all warranty repairs, special policy repairs or any repairs paid for by GM. Parts and accessories advertised as being "the same" as parts manufactured by GM, but not sold through GM, do not qualify for use in warranty repairs, special policy repairs or any repairs paid for by GM. During a warranty repair, if a GM original equipment part is not available through GM Customer Care and Aftersales (GM CC&A;), ACDelco(R) distributors, other GM dealers or approved sources, the dealer is to obtain comparable, non-GM parts and clearly indicate, in detail, on the repair order the circumstances surrounding why non-GM parts were used. The dealer must give customers written notice, prior to the sale or service, that such parts or accessories are not marketed or warranted by General Motors. It should also be noted that dealers modifying new vehicles and installing equipment, parts and accessories obtained from sources not authorized by GM are responsible for complying with the National Traffic and Motor Vehicle Safety Act. Certain non-approved parts or assemblies, installed by the dealer or its agent not authorized by GM, may result in a change to the vehicle's design characteristics and may affect the vehicle's ability to conform to federal law. Dealers must fully understand that non-GM approved parts may not have been validated, tested or certified for use. This puts the dealer at risk for potential liability in the event of a part or vehicle failure. If a GM part failure occurs as the result of the installation or use of a non-GM approved part, the warranty will not be honored. A good example of non-authorized modification of vehicles is the result of an ever increasing supply of aftermarket devices available to the customer, which claim to increase the horsepower and torque of the Duramax(TM) Diesel Engines. These include the addition of, but are not limited to one or more of the following modifications: - Propane injection - Nitrous oxide injection - Additional modules (black boxes) that connect to the vehicle wiring systems - Revised engine calibrations downloaded for the engine control module - Calibration modules which connect to the vehicle diagnostic connector - Modification to the engine turbocharger waste gate Although the installation of these devices, or modification of vehicle components, can increase engine horsepower and torque, they may also negatively affect the engine emissions, reliability and/or durability. In addition, other powertrain components, such as transmissions, universal joints, drive shafts, and front/rear axle components, can be stressed beyond design safety limits by the installation of these devices. General Motors does not support or endorse the use of devices or modifications that, when installed, increase the engine horsepower and torque. It is because of these unknown stresses, and the potential to alter reliability, durability and emissions performance, that GM has adopted a policy that prevents any UNAUTHORIZED dealer warranty claim submissions to any remaining warranty coverage, to the powertrain and driveline components whenever the presence of a non-GM (aftermarket) calibration is confirmed - even if the non-GM control module calibration is subsequently removed. Refer to the latest version of Bulletin 09-06-04-026 (V8 Gas Engines) or 06-06-01-007 (Duramax(TM) Diesel Engines) for more information on dealer requirements for calibration verification. These same policies apply as they relate to the use of non-GM accessories. Damage or failure from the use or installation of a non-GM accessory will not be covered under warranty. Failure resulting from the alteration or modification of the vehicle, including the cutting, welding or disconnecting of the vehicle's original equipment parts and components will void the warranty. Additionally, dealers will NOT be reimbursed or compensated by GM in the event of any legal inquiry at either the local, state or federal level that Page 12277 For vehicles repaired under warranty, use the table. Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table. Disclaimer Wheels/Tires - Refinishing Aluminum Wheels Wheels: All Technical Service Bulletins Wheels/Tires - Refinishing Aluminum Wheels INFORMATION Bulletin No.: 99-08-51-007E Date: March 17, 2011 Subject: Refinishing Aluminum Wheels Models: 2012 and Prior GM Passenger Cars and Trucks Supercede: This bulletin is being revised to add additional model years. Please discard Corporate Bulletin Number 99-08-51-007D (Section 08 - Body and Accessories). This bulletin updates General Motor's position on refinishing aluminum wheels. GM does not endorse any repairs that involve welding, bending, straightening or re-machining. Only cosmetic refinishing of the wheel's coatings, using recommended procedures, is allowed. Evaluating Damage In evaluating damage, it is the GM Dealer's responsibility to inspect the wheel for corrosion, scrapes, gouges, etc. The Dealer must insure that such damage is not deeper than what can be sanded or polished off. The wheel must be inspected for cracks. If cracks are found, discard the wheel. Any wheels with bent rim flanges must not be repaired or refinished. Wheels that have been refinished by an outside company must be returned to the same vehicle. The Dealer must record the wheel ID stamp or the cast date on the wheel in order to assure this requirement. Refer to Refinisher's Responsibility - Outside Company later in this bulletin. Aluminum Wheel Refinishing Recommendations - Chrome-plated aluminum wheels Re-plating these wheels is not recommended. - Polished aluminum wheels These wheels have a polyester or acrylic clearcoat on them. If the clearcoat is damaged, refinishing is possible. However, the required refinishing process cannot be performed in the dealer environment. Refer to Refinisher's Responsibility - Outside Company later in this bulletin. - Painted aluminum wheels These wheels are painted using a primer, color coat, and clearcoat procedure. If the paint is damaged, refinishing is possible. As with polished wheels, all original coatings must be removed first. Media blasting is recommended. Refer to GM Aluminum Refinishing Bulletin #53-17-03A for the re-painting of this type of wheel. - Bright, machined aluminum wheels These wheels have a polyester or acrylic clearcoat on them. In some cases, the recessed "pocket" areas of the wheel may be painted. Surface refinishing is possible. The wheel must be totally stripped by media blasting or other suitable means. The wheel should be resurfaced by using a sanding process rather than a machining process. This allows the least amount of material to be removed. Important Do not use any re-machining process that removes aluminum. This could affect the dimensions and function of the wheel. Painting is an option to re-clearcoating polished and bright machined aluminum wheels. Paint will better mask any surface imperfections and is somewhat more durable than clearcoat alone. GM recommends using Corsican SILVER WAEQ9283 for a fine "aluminum-like" look or Sparkle SILVER WA9967 for a very bright look. As an option, the body color may also be used. When using any of the painting options, it is recommended that all four wheels be refinished in order to maintain color uniformity. Refer to GM Aluminum Refinishing Bulletin #53-17-03A for specific procedures and product recommendations. Refinisher's Responsibility - Outside Company Important Some outside companies are offering wheel refinishing services. Such refinished wheels will be permanently marked by the refinisher and are warranted by the refinisher. Any process that re-machines or otherwise re-manufactures the wheel should not be used. A refinisher's responsibility includes inspecting for cracks using the Zyglo system or the equivalent. Any cracked wheels must not be refinished. No welding, hammering or reforming of any kind is allowed. The wheel ID must be recorded and follow the wheel throughout the process in order to assure that the same wheel is returned. A plastic media blast may be used for clean up of the wheel. Hand and/or lathe sanding of the machined surface and the wheel window is allowed. Material removal, though, must be kept to a minimum. Re-machining of the wheel is not allowed. Paint and/or clear coat must not be present on the following surfaces: the nut chamfers, the wheel mounting surfaces and the wheel pilot hole. The refinisher must permanently ID stamp the wheel and warrant the painted/clearcoated surfaces for a minimum of one year or the remainder of the new vehicle warranty, whichever is Page 15300 Fuel Gauge: Description and Operation FUEL GAGE The IPC displays the fuel level as determined by the PCM. The IPC receives a class 2 message from the PCM indicating the fuel level percent. The fuel gage defaults to empty if: - The PCM detects a malfunction in the fuel level sensor circuit. - The IPC detects a loss of class 2 communications with the PCM. When the fuel level is less than a pre-determined value, the low fuel indicator illuminates. Reviewing the fuel system description will further explain how the system functions. Refer to: - Fuel System Description in Computers and Control Systems - 4.3L - Fuel System Description (Pickup and Utility)Fuel System Description (Cab Chassis) in Computers and Control Systems - 4.8L, 5.3L and 6.0L - Fuel System Description in Computers and Control Systems - 6.6L - Fuel System Description in Computers and Control Systems - 8.1L Page 5346 7. Install the EHCU (1). 8. Install the bolts (4) attaching the EHCU bracket to the frame (5). Tighten Tighten the bolts to 25 N.m (18 lb ft). 9. Connect the brake lines to the BPMV. Tighten Tighten the fittings to 25 N.m (18 lb ft). 10. Connect the chassis electrical harness connectors to the EBCM. 11. Install the transfer case harness to the clip bracket. 12. Install the clip to the bracket on the frame. 13. If equipped with 4WD, install the fuel line clip to the bracket on the transfer case. Wheels - Changing Procedures/Precautions Wheels: All Technical Service Bulletins Wheels - Changing Procedures/Precautions INFORMATION Bulletin No.: 06-03-10-010A Date: June 09, 2010 Subject: Information on Proper Wheel Changing Procedures and Cautions Models: 2011 and Prior GM Passenger Cars and Trucks 2010 and Prior HUMMER Models 2005-2009 Saab 9-7X 2005-2009 Saturn Vehicles Attention: Complete wheel changing instructions for each vehicle line can be found under Tire and Wheel Removal and Installation in Service Information (SI). This bulletin is intended to quickly review and reinforce simple but vital procedures to reduce the possibility of achieving low torque during wheel installation. Always refer to SI for wheel lug nut torque specifications and complete jacking instructions for safe wheel changing. Supercede: This bulletin is being revised to include the 2011 model year and update the available special tool list. Please discard Corporate Bulletin Number 06-03-10-010 (Section 03 Suspension). Frequency of Wheel Changes - Marketplace Driven Just a few years ago, the increasing longevity of tires along with greater resistance to punctures had greatly reduced the number of times wheels were removed to basically required tire rotation intervals. Today with the booming business in accessory wheels/special application tires (such as winter tires), consumers are having tire/wheel assemblies removed - replaced - or installed more than ever. With this increased activity, it opens up more of a chance for error on the part of the technician. This bulletin will review a few of the common concerns and mistakes to make yourself aware of. Proper Servicing Starts With the Right Tools The following tools have been made available to assist in proper wheel and tire removal and installation. - J 41013 Rotor Resurfacing Kit (or equivalent) - J 42450-A Wheel Hub Resurfacing Kit (or equivalent) Corroded Surfaces One area of concern is corrosion on the mating surfaces of the wheel to the hub on the vehicle. Excessive corrosion, dirt, rust or debris built up on these surfaces can mimic a properly tightened wheel in the service stall. Once the vehicle is driven, the debris may loosen, grind up or be washed away from water splash. This action may result in clearance at the mating surface of the wheel and an under-torqued condition. Caution Before installing a wheel, remove any buildup on the wheel mounting surface and brake drum or brake disc mounting surface. Installing wheels with poor metal-to-metal contact at the mounting surfaces can cause wheel nuts to loosen. This may cause a wheel to come off when the vehicle is moving, possibly resulting in a loss of control or personal injury. Whenever you remove the tire/wheel assemblies, you must inspect the mating surfaces. If corrosion is found, you should remove the debris with a die grinder equipped with a fine sanding pad, wire brush or cleaning disc. Just remove enough material to assure a clean, smooth mating surface. The J 41013 (or equivalent) can be used to clean the following surfaces: - The hub mounting surface - The brake rotor mounting surface - The wheel mounting surface Use the J 42450-A (or equivalent) to clean around the base of the studs and the hub. Lubricants, Grease and Fluids Page 3099 Wheel Fastener: Specifications TORQUE SPECIFICATIONS Torque Specifications Wheel Nuts .......................................................................................................................................... ................................................. 190 Nm (140 ft. lbs.) Page 981 Engine Control Module: Description and Operation Throttle Actuator Control (Tac) System POWERTRAIN CONTROL MODULE The PCM determines the driver's intent, then calculates the appropriate throttle response. This information is sent to the TAC module through a dedicated serial data line. Page 12246 Labor Time Information Automatic Transmission - 4L60-E/4L65-E Shift Solenoid: Diagrams Automatic Transmission - 4L60-E/4L65-E A/T - 4L60/65E, No Reverse/2nd or 4th Gear Sun Gear: All Technical Service Bulletins A/T - 4L60/65E, No Reverse/2nd or 4th Gear TECHNICAL Bulletin No.: 00-07-30-022D Date: June 10, 2008 Subject: No Reverse, Second Gear or Fourth Gear (Replace Reaction Sun Shell with More Robust Heat Treated Parts) Models: 1993 - 2005 GM Passenger Cars and Light Duty Trucks 2003 - 2005 HUMMER H2 with 4L60/65-E Automatic Transmission (RPOs M30 or M32) Supercede: This bulletin is being revised to add 2005 model year to the parts information. Please discard Corporate Bulletin Number 00-07-30-022C (Section 07 - Transmission/Transaxle). Condition Some customers may comment on a no reverse, no second or no fourth gear condition. First and third gears will operate properly. Cause The reaction sun gear (673) may not hold inside the reaction sun shell (670). Correction Important: There are FOUR distinct groups of vehicles and repair procedures involved. Vehicles built in the 2001 model year and prior that make use of a reaction shaft to shell thrust washer: ^ The sun shell can be identified by four square holes used to retain the thrust washer. Use reaction sun shell P/N 24228345, reaction carrier to shell thrust washer (699B) P/N 8642202 and reaction sun gear shell thrust washer (674) P/N 8642331er (674) P/N 8642331along with the appropriate seals and washers listed below. ^ Vehicles built in the 2001 model year and prior that have had previous service to the reaction sun shell: It is possible that some 2001 and prior model year vehicles have had previous service to the reaction sun shell. At the time of service, these vehicles may have been updated with a Reaction Sun Shell Kit (Refer to Service Bulletin 020730003) without four square holes to retain the thrust washer. If it is found in a 2001 model year and prior vehicles that the reaction sun shell DOES NOT have four square holes to retain the thrust washer, these vehicles must be serviced with P/Ns 24229825 (674), 24217328 and 8642331 along with the appropriate seals and washers listed below. ^ Vehicles built in the 2001 model year and later that make use of a reaction shaft to shell thrust bearing: The sun shell can be identified by no holes to retain the thrust washer. Use reaction sun shell, P/N 24229825, reaction carrier shaft to shell thrust bearing (669A), P/N 24217328 and reaction sun gear shell thrust washer (674), P/N 8642331 along with the appropriate seals and washers listed below. ^ Vehicles built from November, 2001 through June, 2002: These vehicles should have the reaction carrier shaft replaced when the sun shell is replaced. Use shell kit P/N 24229853, which contains a sun shell (670), a reaction carrier shaft (666), a reaction carrier shaft to shell thrust bearing (669A) and a reaction sun gear shell thrust washer (674). The appropriate seals and washers listed below should also be used. When servicing the transmission as a result of this condition, the transmission oil cooler and lines MUST be flushed. Refer to Corporate Bulletin Number 02-07-30-052. Follow the service procedure below for diagnosis and correction of the no reverse, no second, no forth condition. Important: If metallic debris is found on the transmission magnet, the transmission must be completely disassembled and cleaned. Metallic debris is defined as broken parts and pieces of internal transmission components. This should not be confused with typical "normal" fine particles found on all transmission magnets. Failure to properly clean the transmission case and internal components may lead to additional repeat repairs. 1. Remove the transmission oil pan and inspect the magnet in the bottom of the pan for metal debris. Refer to SI Document ID # 825141. Transfer Case - NVG 149-NP3 Case Adapter: Service and Repair Transfer Case - NVG 149-NP3 Transfer Case Adapter Replacement Removal Procedure 1. Remove the transfer case. Refer to Transfer Case Assembly Replacement. 2. Remove the transfer case adapter bolts. 3. Remove the adapter. 4. Remove the adapter seal. Installation Procedure 1. Install a NEW seal onto the adapter. Important: Always use a new seal for the adapter. Do not use any type of sealant or adhesive in place of, or with the seal. 2. Install the adapter. Important: The transfer case adapter must be installed so that the adapter is evenly seated to the transmission before installing the retaining nuts. Notice: Refer to Fastener Notice in Service Precautions. 3. Install the adapter bolts. ^ Tighten the bolts to 50 Nm (37 ft. lbs.). 4. Install the transfer case. Refer to Transfer Case Assembly Replacement. Specifications Fuel Pressure: Specifications Fuel Pressure (Key ON Engine OFF) .............................................................................................................................................. 385-425 kPa (55-62 psi) Page 10631 Acceptably Prepared (Cleaned-Up) Wheel Surface 6. Once the corrosion has been eliminated, you should coat the repaired area with a commercially available tire sealant such as Patch Brand Bead Sealant or equivalent. Commercially available bead sealants are black rubber-like coatings that will permanently fill and seal the resurfaced bead seat. At 21°C (70°F) ambient temperature, this sealant will set-up sufficiently for tire mounting in about 10 minutes.Coated and Sealed Bead Seat 7. Remount the tire and install the repaired wheel and tire assembly. Refer to Tire and Wheel Removal and Installation in SI. Parts Information Patch Brand Bead Sealer is available from Myers Tires at 1-800-998-9897 or on the web at www.myerstiresupply.com. The one-quart size can of sealer will repair about 20 wheels. Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use: Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table above. Page 968 Page 14473 Memory Seat Module - C2 Page 434 - HVAC Actuator - Inflatable Restraint Sensing and Diagnostic Module (SDM) - Any AIR BAG module - Seatbelt Lap Anchor Pretensioner - Seatbelt Retractor Pretensioner - An SIR system connection or connector condition resulting in the following DTCs being set: B0015, B0016, B0019, B0020, B0022, or B0023 - Powertrain Control Module (PCM) - Remote Control Door Lock Receiver (RCDLR) - Transmission Control Module (TCM) Correction Important DO NOT replace the control module, wiring or component for the following conditions: - The condition is intermittent and cannot be duplicated. - The condition is present and by disconnecting and reconnecting the connector the condition can no longer be duplicated. Use the following procedure to correct the conditions listed above. 1. Install a scan tool and perform the Diagnostic System Check - Vehicle. Retrieve and record any existing history or current DTCs from all of the control modules (refer to SI). ‹› If any DTC(s) are set, refer to Diagnostic Trouble Code (DTC) List - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). ‹› If DTCs are not set, refer to Symptoms - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). 2. When identified, use the appropriate DTC Diagnostics, Symptoms, Schematics, Component Connector End Views and Component Locator documents to locate and disconnect the affected harness connector(s) which are causing the condition. Note Fretting corrosion looks like little dark smudges on electrical terminals and appear where the actual electrical contact is being made. In less severe cases it may be unable to be seen or identified without the use of a magnifying glass. Important DO NOT apply an excessive amount of dielectric lubricant to the connectors as shown, as hydrolock may result when attempting to mate the connectors. Use ONLY a clean nylon brush that is dedicated to the repair of the conditions in this bulletin. 3. With a one-inch nylon bristle brush, apply dielectric lubricant to both the module/component side and the harness side of the affected connector(s). 4. Reconnect the affected connector(s) and wipe away any excess lubricant that may be present. 5. Attempt to duplicate the condition by using the following information: - DTC Diagnostic Procedure - Circuit/System Description - Conditions for Running the DTC - Conditions for Setting the DTC - Diagnostic Aids - Circuit/System Verification ‹› If the condition cannot be duplicated, the repair is complete. ‹› If the condition can be duplicated, then follow the appropriate DTC, Symptom or Circuit/System Testing procedure (refer to SI). Repair Order Documentation Page 6759 Put unused material on the shelf for future use. Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Page 9454 Auxiliary Power Outlet Switch (With RPO Code HP2) Page 13151 8.5. Close the luggage compartment floor. 9. Fold down the left-hand rear side hatch in the luggage compartment. 10. M03: Replace the optic cable on the left-hand rear side: 10.1. Place the optic cable so that it is positioned behind the terminal housing on top of REC (A). 10.2. Remove the locking strip (B) on the 2-pin connector (H2-9) for the optic cable. 10.3. Open the terminal housing (C) with a screwdriver. Remove the secondary catch (D) on the connector and disconnect the optic cable coming from the OnStar(R) control modules. Page 4806 2. Install the fuel level sensor retaining clip. 3. Connect the fuel level sensor electrical connector. 4. Install the fuel level sensor electrical connector retaining clip. Page 5106 1. Remove the fuel tank. 2. Disconnect and remove the EVAP line (1) from the roll over valve, sending unit and retaining clips. 3. Cap the fuel feed/return, and EVAP lines in order to prevent possible fuel/EVAP system contamination. INSTALLATION PROCEDURE 1. Remove the caps from the fuel feed/return, and EVAP lines. 2. Install and connect the EVAP line (1) to the roll over valve, sending unit and retaining clips. 3. Install the fuel tank. EVAP System Hoses/Pipes Replacement (1500 Crew Cab) EVAPORATIVE EMISSION (EVAP) SYSTEM HOSES/PIPES REPLACEMENT (1500 CREW CAB) REMOVAL PROCEDURE IMPORTANT: Clean the evaporative emission (EVAP) line connections and surrounding areas prior to disconnecting the fittings in order to avoid possible fuel system contamination. Page 14869 Seat Rear Vertical Position Sensor - Driver (With RPO Code AN3) Page 12294 For vehicles repaired under warranty, use the table. Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table. Disclaimer Page 4343 Body Control Module: Electrical Diagrams Door Control Module Diagram 1 Page 3566 Water Pump: Service and Repair Water Pump Replacement (4.8L, 5.3L, and 6.0L Engines) Removal Procedure 1. Drain the cooling system. 2. Loosen the air cleaner outlet duct clamps at the following locations: ^ Throttle body ^ Mass Airflow/Intake Air Temperature (MAF/IAT) sensor 3. Remove the radiator inlet hose clip from the outlet duct. 4. Remove the air cleaner outlet duct. 5. If necessary, remove the engine sight shield. 6. Remove the radiator vent inlet hose from the radiator hose clips. 7. Reposition the inlet hose clamp at the water pump. 8. Remove the inlet hose from the water pump. 9. Remove the fan blade. 10. Remove the accessory drive belt. Replacement - Accessory (4.8L, 5.3L, and 6.0L Engines) Drive Belt Replacement - Accessory (5.3L Engine w/RPO HP2) in Engine Mechanical - 4.8L, 5.3L, and 6.0L. Locations Discharge Air Temperature Sensor / Switch: Locations Air Temperature Sensors - Upper Left And Right Page 6798 Grade ................................................................................................................................................... .................................................................... Synthetic Viscosity .......................................................... ......................................................................................................................................................... 75W-90 Page 5357 7. Install the EHCU (1). 8. Install the bolts (4) attaching the EHCU bracket to the frame (5). Tighten Tighten the bolts to 25 N.m (18 lb ft). 9. Connect the brake lines to the BPMV. Tighten Tighten the fittings to 25 N.m (18 lb ft). 10. Connect the chassis electrical harness connectors to the EBCM. 11. Install the transfer case harness to the clip bracket. 12. Install the clip to the bracket on the frame. 13. Install the fuel line clip to the bracket on the transfer case, if equipped with 4WD. Page 15183 Control Module References Part 5 Brakes - ABS Lamp ON/DTC's C0265/C0201/U1041 Set Grounding Point: Customer Interest Brakes - ABS Lamp ON/DTC's C0265/C0201/U1041 Set TECHNICAL Bulletin No.: 04-05-25-002E Date: March 11, 2009 Subject: ABS Light On, DTCs C0265, C0201, U1041 Set and/or Loss of Communication with Brake Module (Reground EBCM Ground) Models Supercede: This bulletin is being revised to add step 2 to the procedure and update the Parts and Warranty Information. Please discard Corporate Bulletin Number 04-05-25-002D (Section 05 - Brakes). Condition Some customers may comment that the ABS light is on. Upon further inspection, DTCs C0265 and C0201 may be set in the brake module. It is also possible for DTC U1041 to set in other modules. There may also be a loss of communication with the brake module. Cause A poor connection at the EBCM ground is causing unnecessary replacement of brake modules. Important: The EBCM ground is different for each application. Refer to the list below for the proper ground reference: ^ Midsize Utilities = Ground 304 ^ SSR = Ground 400 ^ Fullsize Trucks and Utilities = Ground 110 Correction Important: Do not replace the brake module to correct this condition. Perform the following repair before further diagnosis of the EBCM. Perform the following steps to improve the connection of the EBCM Ground: 1. Remove the EBCM Ground. The EBCM Ground is located on the frame beneath the driver's side door. If multiple grounds are found in this location, the EBCM ground can be identified as the heavy (12-gauge) wire. 2. If the original fastener has a welded on nut, remove the nut from the frame, and if required, enlarge the bolt hole to accommodate the new bolt and nut. 3. Clean the area, front and back, using a tool such as a *3M(TM) Scotch-Brite Roloc disc or equivalent. Page 15022 2. Remove the tailgate from the vehicle. 3. Remove the two bolts attaching the right side hinge to the tailgate. Important: On Chevrolet Silverado and GMC Sierra models, the NEW hinge being installed must be primed and painted in the body color prior to installation. New hinges for the Chevrolet Avalanche and Cadillac Escalade EXT come pre-painted in a glossy back primer, these hinges must still be painted black. 4. Install a NEW hinge to the tailgate and install the two bolts. Tighten Tighten the bolts to 25 Nm (18 lb-ft). 5. Reinstall the tailgate on the vehicle. If one or both tailgate support cables require replacement, proceed to the section titled "Support Cable Replacement". If neither support cables require replacement, no further action is required. Support Cable Replacement - Escalade EXT, Avalanche, New Style Silverado and Sierra, Kodiak, TopKick The following procedure should only be performed if sealant was found in one or both support cables in the earlier inspection. Important: If the support cable (2) has NOT been replaced previously, there will be a toothed nut (1) located between the latch (4) and the tailgate that will prevent the bolt (3) from being removed in the next step. The nut is an assembly aid used in the assembly plant. The nut does NOT need to be reinstalled or replaced when installing a new support cable in this recall. Page 9538 Location View Door Handle Replacement Front Door Interior Handle: Service and Repair Door Handle Replacement Door Handle Replacement - Inside Removal Procedure 1. Remove the trim panel. 2. Remove the inside door handle mounting bolts. 3. Slide the inside door handle forward to release the unit from the door. 4. Disconnect the control rod from the inside door handle. 5. Remove the door handle assembly from the door. Installation Procedure 1. Connect the control rod to the inside door handle. 2. Slide the handle into place. Notice: Refer to Fastener Notice in Service Precautions. 3. Install the inside door handle retaining bolts. Page 1067 Control Module: Diagrams Service and Repair Global Positioning System Module: Service and Repair COMMUNICATION INTERFACE MODULE REPLACEMENT REMOVAL PROCEDURE IMPORTANT: The vehicle communication interface module (VCIM) has a specific set of unique numbers that tie the module to each vehicle. These numbers, the 10-digit station identification (STID) and the 11-digit electronic serial number (ESN), are used by the National Cellular Network and Onstar(R) to identify the specific vehicle. Because these numbers are tied to the vehicle identification number of the vehicle, you must never exchange these parts with those of another vehicle. 1. Remove the instrument panel (I/P) top trim panel. 2. Disconnect the wire connectors (2) from the module. 3. Disconnect the coaxial cable (3) from the module. 4. Remove the nuts (2) retaining the module to the bracket. 5. Remove the module (3) from the vehicle. INSTALLATION PROCEDURE 1. If replacing the VCIM, record the 10-digit STID number, and the 11-digit ESN number from the labels on the new module. Page 9306 Application Table Page 13096 Page 13430 Control Module References Part 1 Page 15917 For vehicles repaired under warranty, use the table. Disclaimer Page 4643 Electrical Symbols Part 14 Page 12189 DTC B2483: Global Positioning System (GPS) Antenna Malfunction Short to Ground DTC B2484: Global Positioning System (GPS) Antenna Malfunction Open Circuit Conditions for Running the DTCs The ignition is in RUN or ACC position System voltage is between 9.5 - 15.5 volts. The above conditions are met for more than 1 second. Conditions for Setting the DTCs B2462 02: The CIM detects a short to ground on the navigation antenna signal circuit. B2462 04: The CIM detects an open/high resistance on the navigation antenna signal circuit. B2483: The CIM detects a short to ground on the navigation antenna signal circuit. B2484: The CIM detects an open/high resistance on the navigation antenna signal circuit. Action Taken When the DTCs Set The OnStar(R) status LED turns red. The OnStar(R) Call Center cannot locate the vehicle. Conditions for Clearing the DTCs The condition responsible for setting the DTC no longer exists. A history DTC will clear once 50 consecutive malfunction-free ignition cycles have occurred. Circuit/System Testing Turn OFF the ignition. 1. Disconnect the navigation antenna coax cable from the VCIM. 2. Ignition ON, test for 4.5-5.5 volts between the VCIM coax cable center conductor terminal at the VCIM and ground. ^ If not within the specified range, replace the VCIM. Refer to the appropriate vehicle in SI. 3. Reconnect the coax cable to the VCIM. 4. Disconnect the coax cable from the navigation antenna. 5. Test for 4.55.5 volts between the coax cable center conductor and the outer shield. ^ If not within the specified range, replace the coax cable. 6. If all circuits test normal, replace the navigation antenna. Refer to the appropriate vehicle in SI. DTC B2470 DTC Descriptor DTC B2470 04: Cellular Phone Antenna Circuit Malfunction Open Circuit Circuit/System Description The cellular antenna is connected to the vehicle communication interface module (VCIM) with an RG-58 coax cable. The VCIM collects the data from the cellular antenna once every second. Page 5491 Fuel Pump (FP) Relay-Secondary (w/Dual Tanks) Page 16022 Refer to the table as a guide in selecting the correct test adapter for frontprobing connectors: Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure SCAN TOOL SNAPSHOT PROCEDURE Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: - Snapshot - taken from the Snapshot menu choice - Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information Page 15768 Turn Signal Multifunction Switch - C1 Page 6911 12. Position the inboard end (tripot end) of the halfshaft assembly into the base of the J-36652-01 for the 1500 models (except 1500 HD) or J 36652-98 for the 1500 HD, 2500, 3500 and Hummer H2 models. 13. Install the top half of the J-36652-01 for the 1500 models (except 1500 HD) or J 36652-98 for the 1500 HD, 2500, 3500 and HUMMER H2 models. 14. Align the swage ring (2) and the swage ring clamp. 15. Insert the bolts. Hand tighten the bolts until the bolts are snug. 16. Align the following during this procedure: ^ The tripot boot (3) ^ The tripot housing (1) ^ The swage ring (2) ^ Tighten each bolt 180 degrees at a time. Alternate between the bolts until both sides of the top half of the tool touch the bottom half . ^ Loosen the bolts and remove the halfshaft assembly from the tool. Service and Repair Glove Compartment: Service and Repair Compartment Replacement - Instrument Panel (I/P) Removal Procedure 1. Close the IP compartment door. 2. Drill out the 2 rivets (2). 3. Remove IP storage compartment door retaining screws (1) from the instrument panel. 4. Remove the IP compartment door. Installation Procedure 1. Install the IP compartment door. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the IP compartment retaining screws (1) to the instrument panel. Tighten the screws to 1.9 N.m (17 lb in). Door Latch Assembly (Door Jamb Switch) - Driver C2 Door Switch: Diagrams Door Latch Assembly (Door Jamb Switch) - Driver C2 Door Latch Assembly (Door Jamb Switch) - Driver C2 Page 6011 Page 6370 9. Install the exhaust pipe hanger bracket and bolts. ^ Tighten the bolts to 17 Nm (12 ft. lbs.). 10. Instal the insulator and nuts to the bracket. ^ Tighten the nuts to 17 Nm (12 ft. lbs.). 11. Tighten the right exhaust pipe nuts. ^ Tighten the nuts to 50 Nm (37 ft. lbs.). 12. Tighten the left exhaust pipe nuts. ^ Tighten the nuts to 50 Nm (37 ft. lbs.). 13. Install the transmission crossmember. 14. Install the transmission crossmember bolts/nuts. ^ Tighten the bolts/nuts to 95 Nm (70 ft. lbs.). Page 577 Memory Positioning Module: Service and Repair Memory Seat Control Module Replacement MEMORY SEAT CONTROL MODULE REPLACEMENT REMOVAL PROCEDURE 1. Remove the seat cushion. 2. Disconnect the upper electrical harness connectors (3). 3. Remove the module (2) retaining screws (1). 4. Slide the module to the right to disengage the lower retainers. 5. Disconnect the lower electrical harness connectors (2). 6. Remove the module from the vehicle. INSTALLATION PROCEDURE Page 14810 Front Passenger Door Module (FPDM) - C5 (Heated Seat Switch) Page 13518 Electrical Symbols Part 9 Page 8055 Traction Control Switch: Diagrams ABS Connector End Views Traction Control Switch (NW7) Page 15148 Electrical Symbols Part 12 Page 6508 Vehicle Speed Sensor (VSS) Tow/Haul Switch Location Page 7998 3. Remove the right rear speed sensor. Installation Procedure 1. Notice: Refer to Fastener Notice in Service Precautions. Install the right rear speed sensor. ^ Tighten the speed sensor to 15 Nm (11 ft. lbs.). 2. Connect the right rear speed sensor electrical connector (3). 3. Lower the vehicle. Page 891 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Micro-Pack 100W Connectors MICRO-PACK 100W CONNECTORS TOOLS REQUIRED J 38125-D Terminal Repair Kit REMOVAL PROCEDURE There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2)has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. IMPORTANT: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Page 15449 Door Switch: Diagrams Door Latch Assembly (Door Jamb Switch) - Front Passenger C2 Door Latch Assembly (Door Jamb Switch) - Front Passenger C2 Page 6855 4. If only replacing the left side seal, perform the following steps: 4.1. Place an alignment mark between the inner axle shaft and the wheel drive shaft. 4.2. Disconnect the wheel drive shaft from the inner axle shaft. 4.3. Remove the inner axle shaft using a hammer and a brass drift. 4.4. Remove the inner axle shaft seal using a suitable seal remover tool. 5. If replacing both the left side seal and bearing, perform the following steps: 5.1. Remove the differential carrier assembly. 5.2. Place the differential carrier assembly into a vise. - Clamp only on the mounting flange of the differential carrier assembly case. 5.3. Remove the inner axle shaft using a hammer and brass drift. 5.4. Install the J 29369-1, 8.25 inch axle, or the J 29369-2, 9.25 inch axle (1), behind the inner axle shaft seal or the inner axle shaft bearing as necessary. Page 2723 Junction Block - I/P Wire Entry Part 2 Page 12575 Service and Repair Wheel Seal: Service and Repair Wheel Hub, Bearing, and Seal Replacement (4WD) ^ Tools Required J 45859 Axle Remover Removal Procedure 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Remove the tire and wheel. 3. Remove the rotor. Refer to Brake Rotor Replacement - Front in Disc Brakes. 4. Remove the wheel speed sensor and brake hose mounting bracket bolt from the steering knuckle. 5. Remove the wheel drive shaft nut retaining cover. 6. Important: Page 11697 Impact Sensor: Diagrams Inflatable Restraint Front End Sensor - Left Service and Repair Compressor Clutch Relay: Service and Repair COMPRESSOR RELAY REPLACEMENT REMOVAL PROCEDURE 1. Remove the cover from the underhood convenience center (1). 2. Remove the compressor relay (2). INSTALLATION PROCEDURE 1. Install the compressor relay (2). 2. Install the cover to the underhood convenience center (1). Page 15746 2. Connect the backup lamp switch electrical connector (3). 3. Lower the vehicle. Page 2670 Junction Block - I/P - C2 Part 1 Page 5201 Fuel: Technical Service Bulletins Fuel System - 'TOP TIER' Detergent Gasoline Information INFORMATION Bulletin No.: 04-06-04-047I Date: August 17, 2009 Subject: TOP TIER Detergent Gasoline (Deposits, Fuel Economy, No Start, Power, Performance, Stall Concerns) - U.S. Only Models: 2010 and Prior GM Passenger Cars and Trucks (including Saturn) (U.S. Only) 2003-2010 HUMMER H2 (U.S. Only) 2006-2010 HUMMER H3 (U.S. Only) 2005-2009 Saab 9-7X (U.S. Only) Supercede: This bulletin is being revised to add model years and additional sources to the Top Tier Fuel Retailers list. Please discard Corporate Bulletin Number 04-06-04-047H (Section 06 Engine/Propulsion System). In Canada, refer to Corporate Bulletin Number 05-06-04-022F. A new class of fuel called TOP TIER Detergent Gasoline is appearing at retail stations of some fuel marketers. This gasoline meets detergency standards developed by six automotive companies. All vehicles will benefit from using TOP TIER Detergent Gasoline over gasoline containing the "Lowest Additive Concentration" set by the EPA. Those vehicles that have experienced deposit related concerns may especially benefit from the use of TOP TIER Detergent Gasoline. Intake valve: - 10,000 miles with TOP TIER Detergent Gasoline Intake valve: - 10,000 miles with Legal Minimum additive Gasoline Brands That Currently Meet TOP TIER Detergent Gasoline Standards As of August 1, 2009, all grades of the following gasoline brands meet the TOP TIER Detergent Gasoline Standards: - Chevron - Chevron-Canada - QuikTrip - Conoco Phillips 66 - 76 Page 2623 Application Table Part 4 Page 4496 When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage TESTING FOR A SHORT TO VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity TESTING FOR CONTINUITY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents TESTING FOR ELECTRICAL INTERMITTENTS Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground - Testing for Continuity - Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 msRECORD and emits an audible tone (beep). Page 7158 1. Apply sealant GM P/N 12346004 (Canadian P/N 10953480), or equivalent to the oil drain and fill plug threads. 2. Notice: Refer to Fastener Notice in Service Precautions. Using J 36511 install the oil drain plug. ^ Tighten the plug to 30 Nm (22 ft. lbs.). 3. Remove and drain the drain pan used to catch the used transmission fluid. 4. Fill the transmission to just below the bottom of the fill plug hole. Page 3166 Engine Block Heater: Service and Repair Coolant Heater Replacement Coolant Heater Replacement (4.8L, 5.3L, and 6.0L Engines) Removal Procedure 1. Drain the cooling system. 2. Raise and suitably support the vehicle. 3. Disconnect the coolant heater electrical connector (2). 4. Important: Do not score the surface of the engine block hole when removing the coolant heater. Remove the coolant heater from the engine block. 5. Remove any burrs, sealer, paint or other rough spots. Installation Procedure 1. If re-using the old coolant heater, apply thread sealant GM P/N 12346004 (Canadian P/N 10953480), or equivalent to the threads. 2. Notice: Refer to Fastener Notice in Service Precautions. Install the coolant heater to the engine block. Tighten the coolant heater to 50 Nm (37 ft. lbs.). Page 12126 Page 889 7. Insert the J 38125-13A (GM P/N 12031876-1) tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the Terminal Repair Kit to ensure that the correct release tool is used. 8. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. REPAIR PROCEDURE Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. Page 10324 5. Remove the upper ball joint retaining nut. 6. Disconnect the upper control arm from the steering knuckle using the J 42188-B. 7. Remove the upper control arm nuts and the adjustment cams (2) for the 15 Series 2WD, 4WD, and 25/35 Series 2WD. 8. Remove the upper control arm bolts (4) for the 15 Series 2WD, 4WD, and 25/35 Series 2WD. 9. Remove the upper control arm nuts and the adjustment cams (2) for the 25/35 Series 4WD. 10. Remove the upper control arm bolts (4) for the 25/35 Series 4WD. 11. Remove the upper control arm. Installation Procedure 1. Install the upper control arm. Page 10833 AIR TEMPERATURE ACTUATOR REPLACEMENT - RIGHT REMOVAL PROCEDURE 1. Remove the I/P carrier. 2. Disconnect the electrical connector (4) from the right air temperature actuator (3). 3. Remove the screws from the right air temperature actuator (3). 4. Remove the right air temperature actuator (3) from the HVAC module assembly (2). INSTALLATION PROCEDURE 1. Install the right air temperature actuator (3) from the HVAC module assembly (2). NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the screws to the right air temperature actuator (3). Tighten Tighten the screws to 2 N.m (18 lb in). 3. Connect the electrical connector to the right air temperature actuator. 4. Install the I/P carrier. 5. Reprogram the air temperature actuator. Refer to Re-Calibrating Actuators. See: Testing and Inspection/Component Tests and General Diagnostics Mode Actuator Replacement (With RPO Code D07) MODE ACTUATOR REPLACEMENT (W/ D07) REMOVAL PROCEDURE Page 13413 7. Insert the J 38125-13A (GM P/N 12031876-1) tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the Terminal Repair Kit to ensure that the correct release tool is used. 8. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. REPAIR PROCEDURE Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. Page 6629 Page 12994 Steps 6-7 The numbers below refer to the step numbers on the diagnostic table. 2. Lack of communication may be due to a partial malfunction of the class 2 serial data circuit or due to a total malfunction of the class 2 serial data circuit. The specified procedure will determine the particular condition. 3. This step tests for valid system power moding in all ignition switch positions. 5. The presence of DTCs which begin with "U" indicate some other module is not communicating. The specified procedure will compile all the available information before tests are performed. Page 5400 5. Position the fuel tank fill pipe ground wire to the frame. Ensure the anti-rotation tab is positioned correctly. 6. Install the fuel tank fill pipe ground wire bolt. Tighten Tighten the bolt to 9 N.m (80 lb in). 7. Lower the vehicle. 8. Install the fuel tank filler housing. 9. Install the fuel tank filler housing to fuel tank fill pipe bolts. Tighten Tighten the bolts to 2.3 N.m (20 lb in). OnStar(R) - Aftermarket Device Interference Information Navigation System: All Technical Service Bulletins OnStar(R) - Aftermarket Device Interference Information INFORMATION Bulletin No.: 08-08-46-004 Date: August 14, 2008 Subject: Information on Aftermarket Device Interference with OnStar(R) Diagnostic Services Models: 2009 and Prior GM Passenger Car and Truck (including Saturn) 2009 and Prior HUMMER H2, H3 Models 2009 and Prior Saab 9-7X with OnStar(R) (RPO UE1) This bulletin is being issued to provide dealer service personnel with information regarding aftermarket devices connected to the Diagnostic Link Connector (DLC) and the impact to OnStar(R) diagnostic probes and Vehicle Diagnostic e-mails. Certain aftermarket devices, when connected to the Diagnostic Link Connector, such as, but not limited to, Scan Tools, Trip Computers, Fuel Economy Analyzers and Insurance Tracking Devices, interfere with OnStar's ability to perform a diagnostic probe when requested (via a blue button call) by a subscriber. These devices also prohibit the ability to gather diagnostic and tire pressure data for a subscriber's scheduled OnStar(R) Vehicle Diagnostic (OVD) e-mail. These aftermarket devices utilize the Vehicles serial data bus to perform data requests and/or information gathering. When these devices are requesting data, OnStar(R) is designed not to interfere with any data request being made by these devices as required by OBD II regulations. The OnStar(R) advisor is unable to definitively detect the presence of these devices and will only be able to inform the caller or requester of the unsuccessful or incomplete probe and may in some cases refer the subscriber/requester to take the vehicle to a dealer for diagnosis of the concern. When performing a diagnostic check for an unsuccessful or incomplete OnStar(R) diagnostic probe, or for concerns regarding completeness of the OnStar(R) Vehicle Diagnostic (OVD) e-mail, verify that an aftermarket device was not present at the time of the requested probe. Regarding the OVD e-mail, if an aftermarket device is interfering (including a Scan Tool of any type), the e-mail will consistently display a "yellow" indication in diagnostics section for all vehicle systems except the OnStar(R) System and Tire Pressure data (not available on all vehicles) will not be displayed (i.e. section is collapsed). Successful diagnostic probes and complete OVD e-mails will resume following the removal or disconnecting of the off-board device. Disclaimer Page 15400 Odometer: Description and Operation ODOMETER The IPC contains a season odometer, a trip odometer and a hourmeter. Momentarily press the trip/reset switch on the IPC in order to toggle between the season odometer, the trip odometer, and the hourmeter. Press the trip/reset switch for greater than 1 second, while the trip odometer is displayed, in order to reset the trip odometer. For vehicles with steering controls, the Personal Trip On/Off (Business Trip On/Off) must be turned On in order for the trip odometer to accumulate. When the Personal Trip On/Off (Business Trip On/Off) parameter is displayed and the select button is pressed on the steering wheel, the On/Off state of the Personal Trip (Business Trip) shall be changed to the opposite state. The IPC displays the vehicle mileage and trip mileage as determined by the IPC. The IPC calculates the mileage based on the vehicle speed signal circuit from the PCM. The odometer will display 'error' if an internal IPC memory failure is detected. The odometer can be configured to display either miles or kilometers. The odometer is capable of displaying values from 0 - 999,999 mi or km. If the ignition is in the OFF or UNLOCK/ACC position, the odometer can be displayed by pressing the trip reset stem. The odometer will remain displayed for 5 seconds. Page 9047 Junction Block - Rear Lamps - C2 With Full Floating 10.5 2. Drive the axle shaft bearing into the axle housing until the tool bottoms against the tube. 3. Install the axle shaft seal using the J 21128 (8.6 inch axle) or the J 29713 (9.5 inch axle). 4. Drive the tool into the bore until the axle shaft seal bottoms flush with the tube. 5. Install the axle shaft. 6. Install the rear axle housing cover. 7. Install the tire and wheel assembly. 8. Fill the rear axle. 9. Lower the vehicle. Page 7864 For vehicles repaired under warranty, use the table. Disclaimer Page 3880 Engine Control Module: Diagrams Powertrain Control Module (PCM) C2 Page 1963 2. Connect the front speed sensor electrical connector (5). 3. Install the transfer case shield, if equipped. Transfer Case Speed Sensor Replacement - Left Rear Transfer Case Speed Sensor Replacement - Left Rear Removal Procedure 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. Disconnect the left rear speed sensor electrical connector (4). 3. Remove the left rear speed sensor. Installation Procedure Page 3034 Provide all information required on the form. Make a copy of the completed form for the customer to keep in the vehicle along with their Owner's Manual. File the original completed form in the Dealership's Vehicle Service History folder. Because this is not a warranty repair, dealers will incur a charge to obtain a VCI number. A VCI number will only be available for the following models: 1999-2007 Chevrolet Silverado and GMC Sierra (1500 Series Only) EXCLUDES 1999-2000 vehicles equipped with 4.3L engine (RPO L35) EXCLUDES vehicles equipped with Quadrasteer (RPO NYS) EXCLUDES Parallel Hybrid Truck (RPO HP2) EXCLUDES 2001-2004 vehicles equipped with Traction Control (RPO NW7) combined with 3.42 Axle Ratio (RPO GU6) Refer to the Model Application Chart to in the beginning of this bulletin to verify usage. Calibrations are not available for 1999 and 2000 model year vehicles with 3.08 axle. Calibrations are not available for 1999 and 2000 model year vehicles equipped with 4.3L engine (RPO L35). If original equipment tires/wheels are reinstalled, it will be necessary to reset the programming of the PCM and the ABS module to the original specifications. Labels After installing the recommended P275/55R20 tires, place the provided label on the vehicle. The label should be located on the doorjamb, near the original tire label, and should not cover up the original tire label. Be sure that the surface is clean and dry. The surface temperature should not be less than 21°C (70°F). The label is provided as a guide for tire inflation pressures and information relevant to occupant/cargo capacities. Page 15195 Electrical Symbols Part 2 Page 9447 Control Module References Part 4 Page 2333 1. Notice: Refer to Power Steering Hose Disconnected Notice in Service Precautions. Install a drain pan under the vehicle. 2. Remove the power steering gear inlet hose (1) from the brake booster. 3. Remove the power steering gear inlet hose from the power steering gear. 4. Remove the power steering gear inlet hose from the vehicle. Installation Procedure 1. Notice: Refer to Installing Hoses Without Twists or Bends Notice in Service Precautions. Route the hose in the same position the hose occupied prior to removal. 2. Install the power steering gear inlet hose (1) to the brake booster (2). Hand tighten only. 3. Notice: Refer to Fastener Notice in Service Precautions. Install the power steering gear inlet hose to the power steering gear. ^ Tighten both power steering gear inlet hose fittings to 28 Nm (20 ft. lbs.). 4. Remove the drain pan from under the vehicle. 5. Bleed the power steering system. Refer to Bleeding the Power Steering System. (Without Hydroboost) Power Steering Gear Inlet Pipe/Hose Replacement (Without Hydroboost) Removal Procedure 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Remove the engine protection shield. Page 10738 Page 3103 Wheel Fastener: Service and Repair Rear Suspension Wheel Stud Replacement ^ Tools Required J 43631 Ball Joint Remover Removal Procedure 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Remove the tire and wheel. 3. Remove the rotor, except dual wheel vehicles. 4. Remove the wheel stud from the axle flange using the J 43631. 5. Remove the axle shaft for vehicles with 9.5 in ring gear. 6. Remove the rear hub assembly for vehicles with 10.5/11.5 in ring gear, with single wheels. 7. Remove the rear axle hub for vehicles with dual wheels. Refer to Rear Axle Hub, Bearing, Cup, and/or Seal Replacement. 8. Remove the wheel stud from the axle flange using the J 43631. 9. Remove the wheel stud from the hub flange using the J 43631. 10. Place the hub and rotor assembly in a press to remove the wheel stud. Installation Procedure Page 12546 Page 2408 Parts Information Parts are currently available from GMSPO. Warranty Information Instruments - Service Tire Monitor Message is Displayed Fuse: Customer Interest Instruments - Service Tire Monitor Message is Displayed Bulletin No.: 05-08-49-018A Date: May 11, 2006 ADVANCE SERVICE INFORMATION RESOLUTION Subject: EI 05065 - Service Tire Monitor Message Displayed (Pull/Reinstall IPC Fuse or Verify Correct Passenger Door Module (PDM) and Tires) Models: 2004 Chevrolet Silverado 2004 GMC Sierra Supercede: This bulletin is being revised to provide correction action. Please discard Corporate Bulletin Number 05-08-49-018 (Section 08 - Body and Accessories). Condition Some customers may comment that the "SERVICE TIRE MONITOR" message is being displayed on the DIC. Correction DO NOT REPLACE THE INSTRUMENT PANEL CLUSTER. If the DIC is displaying the SERVICE TIRE MONITOR message: 1. Verify if the vehicle has an electronic aftermarket module spliced into the ALDL Class 2 data line (purple wire). 2. If the vehicle HAS an aftermarket module spliced into the Class 2 line, pull the IPC fuse (located underhood) for 25 seconds. Important: Due to the electronic aftermarket module, the SERVICE TIRE MONITOR message may reoccur. 3. Reinstall the IPC fuse. This will clear the SERVICE TIRE MONITOR message from the display. 4. If the vehicle DOES NOT have an aftermarket module spliced into the Class 2 line, verify the vehicle is equipped with the correct PDM (Passenger Door Module) and tires. Warrant Information This repair is not covered under the vehicle warranty due to the installation of an aftermarket module. Disclaimer Page 953 results from the alteration or modification of a vehicle using non-GM approved parts or accessories. Dealers should be especially cautious of accessory companies that claim the installation of their product will not void the factory warranty. Many times these companies have even given direction on how to quickly disassemble the accessory in an attempt to preclude the manufacturer from finding out that is has been installed. Any suspect repairs should be reviewed by the Fixed Operations Manager (FOM), and in Canada by the Warranty Manager (WM) for appropriate repair direction. If it is decided that a goodwill repair is to be made on the vehicle, even with the installation of such non-GM approved components, the customer is to be made aware of General Motors position on this issue and is to sign the appropriate goodwill documentation required by General Motors. It is imperative for dealers to understand that by installing such devices, they are jeopardizing not only the warranty coverage, but also the performance and reliability of the customer's vehicle. Disclaimer Locations Impact Sensor: Locations Front End Sensors Page 15472 For vehicles repaired under warranty, use the table. Disclaimer Page 2663 Fuse Block- I/P C1 Part 4 Page 13358 - HVAC Actuator - Inflatable Restraint Sensing and Diagnostic Module (SDM) - Any AIR BAG module - Seatbelt Lap Anchor Pretensioner - Seatbelt Retractor Pretensioner - An SIR system connection or connector condition resulting in the following DTCs being set: B0015, B0016, B0019, B0020, B0022, or B0023 - Powertrain Control Module (PCM) - Remote Control Door Lock Receiver (RCDLR) - Transmission Control Module (TCM) Correction Important DO NOT replace the control module, wiring or component for the following conditions: - The condition is intermittent and cannot be duplicated. - The condition is present and by disconnecting and reconnecting the connector the condition can no longer be duplicated. Use the following procedure to correct the conditions listed above. 1. Install a scan tool and perform the Diagnostic System Check - Vehicle. Retrieve and record any existing history or current DTCs from all of the control modules (refer to SI). ‹› If any DTC(s) are set, refer to Diagnostic Trouble Code (DTC) List - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). ‹› If DTCs are not set, refer to Symptoms - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). 2. When identified, use the appropriate DTC Diagnostics, Symptoms, Schematics, Component Connector End Views and Component Locator documents to locate and disconnect the affected harness connector(s) which are causing the condition. Note Fretting corrosion looks like little dark smudges on electrical terminals and appear where the actual electrical contact is being made. In less severe cases it may be unable to be seen or identified without the use of a magnifying glass. Important DO NOT apply an excessive amount of dielectric lubricant to the connectors as shown, as hydrolock may result when attempting to mate the connectors. Use ONLY a clean nylon brush that is dedicated to the repair of the conditions in this bulletin. 3. With a one-inch nylon bristle brush, apply dielectric lubricant to both the module/component side and the harness side of the affected connector(s). 4. Reconnect the affected connector(s) and wipe away any excess lubricant that may be present. 5. Attempt to duplicate the condition by using the following information: - DTC Diagnostic Procedure - Circuit/System Description - Conditions for Running the DTC - Conditions for Setting the DTC - Diagnostic Aids - Circuit/System Verification ‹› If the condition cannot be duplicated, the repair is complete. ‹› If the condition can be duplicated, then follow the appropriate DTC, Symptom or Circuit/System Testing procedure (refer to SI). Repair Order Documentation Page 11972 Check - Vehicle. The Diagnostic System Check will provide the following information: ^ The identification of the control modules which command the system ^ The ability of the control modules to communicate through the serial data circuit ^ The identification of any stored diagnostic trouble codes (DTCs) and their status The use of the Diagnostic System Check will identify the correct procedure for diagnosing the system and where the procedure is located. Visual/Physical Inspection Perform the following visual inspections; ^ Inspect for aftermarket devices which could affect the operation of the Radio/Audio System. Refer to Checking Aftermarket Accessories in SI. ^ Inspect the easily accessible and visible system components for obvious damage or conditions which could cause the symptom. Intermittent Conditions Faulty electrical connections or wiring may be the cause of intermittent conditions. Refer to Testing for Intermittent Conditions and Poor Connections in SI. Symptom List Page 14851 4. Connect the electrical connectors. 5. Install the front door trim panel. 6. If equipped with camper mirrors program the door module. Refer to Service Programming System (SPS) in Programming. Switch Replacement - Door Lock and Side Window - Passenger SWITCH REPLACEMENT - DOOR LOCK AND SIDE WINDOW - PASSENGER REMOVAL PROCEDURE 1. Remove the front door trim panel. 2. Disconnect the electrical connectors. 3. Remove the screw that retains the switch panel bezel (1) from the front door panel. 4. Remove the switch panel bezel from the door panel using a flat-bladed tool. Page 1601 1. Install the knock sensors. Tighten Tighten the sensor to 20 N.m (15 lb ft). 2. Connect the knock sensor electrical connectors. 3. Push down on the rubber covers. 4. Install the intake manifold. Page 911 Control Module References Part 6 Page 4849 HO2S Page 14321 WA994L/67 - WA994L/67 Page 3552 Spark Plug: Testing and Inspection SPARK PLUG INSPECTION - Verify that the correct spark plug is installed. An incorrect spark plug causes driveability conditions. Refer to Ignition System Specifications for the correct spark plug. - Ensure that the spark plug has the correct heat range. An incorrect heat range causes the following conditions: Spark plug fouling - Colder plug - Pre-ignition causing spark plug and/or engine damage - Hotter plug - Inspect the terminal post (1) for damage. Inspect for a bent or broken terminal post (1). - Test for a loose terminal post (1) by twisting and pulling the post. The terminal post (1) should not move. - Inspect the insulator (2) for flashover or carbon tracking, or soot. This is caused by the electrical charge traveling across the insulator (2) between the terminal post (1) and ground. Inspect for the following conditions: Inspect the spark plug boot for damage. - Inspect the spark plug recess area of the cylinder head for moisture, such as oil, coolant, or water. A spark plug boot that is saturated will cause arcing to ground. Diagram Information and Instructions Body Control Module: Diagram Information and Instructions Truck Zoning TRUCK ZONING Truck Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that corresponds to where they are located in the vehicle. The table explains the numbering system. Page 15099 Front Door Window Glass Weatherstrip: Service and Repair Door Window Sealing Strip Sealing Strip Replacement - Front Door Window Belt Outer - Front Removal Procedure Important: The outer belt sealing strip seals between the inner and outer door panels and the window at the belt line. The outer sealing strip is replaceable. Do not remove the inner sealing strip, because the strip is attached to the glass run channel. 1. Lower the window. 2. Remove the outside mirror. 3. Remove the outer sealing strip from the door, lifting up on the forward end in order to unhook the rear of the strip from the window run channel. Installation Procedure 1. Hook the rear end of the sealing strip into the window run channel. Lower and press the strip into place. 2. Install the outside mirror. 3. Raise the window. Page 8900 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Page 1298 Rear of the Engine Diagrams Backup Lamp - Switch (Manual Trans) Page 4545 Steps 24 - 29 The numbers below refer to the step numbers on the diagnostic table. 2. A partial malfunction in the class 2 serial data circuit uses a different procedure from a total malfunction of the class 2 serial data circuit. The following modules communicate on the class 2 serial data circuit: The audio amplifier (AMP). early production.Refer to Radio/Audio System Description and Operation in Radio, Stereo and Compact Disc for more information. - The body control module (BCM) - The CD changer (CDX) - The driver door module (DDM) Capacity Specifications Engine Oil: Capacity Specifications Engine Oil With Filter Change ............................................................................................................................... .............................................................. 5.7L (6.0 Qt) NOTE: ALL capacity specifications are approximate. When replacing or adding fluids, fill to the recommended level and recheck fluid level. Locations Instrument Panel Switches-LH Page 10225 Electrical Symbols Part 10 Page 2339 6. Remove the power steering gear inlet hose (4) from the power steering gear. 7. Remove the power brake booster outlet hose (2) retaining clamp (3) to remove the power brake booster outlet hose from the power steering pump. 8. Remove the power brake booster inlet hose from the power steering pump. 9. Remove the power steering hose assembly from the vehicle. Installation Procedure Specifications Piston: Specifications Piston - Piston Diameter - Measured Over Skirt Coating ............................................................................................ 96.002-96.036 mm (3.779-3.78 inch) Piston - Piston to Bore Clearance - Production ............................................................................................... -0.036 to 0.016 mm (-0.0014 to 0.0006 inch) Piston - Piston to Bore Clearance - Service Limit with Skirt Coating Worn Off ............................................................................. 0.071 mm (0.0028 inch) Page 5312 Step 3 Body - Vehicle Glass Distortion Information Back Window Glass: All Technical Service Bulletins Body - Vehicle Glass Distortion Information INFORMATION Bulletin No.: 00-08-48-005D Date: September 10, 2010 Subject: Distortion in Outer Surface of Vehicle Glass Models: 2011 and Prior GM Passenger Cars and Trucks 2009 and Prior HUMMER H2 2010 and Prior HUMMER H3 2005-2009 Saab 9-7X 2010 and Prior Saturn Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 00-08-48-005C (Section 08 - Body and Accessories). Distortion in the outer surface of the windshield glass, door glass or backlite glass may appear after the vehicle has: - Accumulated some mileage. - Been frequently washed in automatic car washes, particularly "touchless" car washes. This distortion may look like a subtle orange peel pattern, or may look like a drip or sag etched into the surface of the glass. Some car wash solutions contain a buffered solution of hydrofluoric acid which is used to clean the glass. This should not cause a problem if used in the correct concentration. However, if not used correctly, hydrofluoric acid will attack the glass, and over time, will cause visual distortion in the outer surface of the glass which cannot be removed by scraping or polishing. If this condition is suspected, look at the area of the windshield under the wipers or below the belt seal on the side glass. The area of the glass below the wipers or belt seal will not be affected and what looks like a drip or sag may be apparent at the edge of the wiper or belt seal. You may also see a line on the glass where the wiper blade or the belt seal contacts the glass. Important The repair will require replacing the affected glass and is not a result of a defect in material or workmanship. Therefore, is not covered by New Vehicle Warranty. Disclaimer Junction Block - I/P Relay Box: Application and ID Junction Block - I/P Location View Location View Page 14105 Control Module References Part 3 Page 9362 15. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 16. Install the electrical ground wire terminal to the rivet stud. 17. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 18. Install the M6 conductive nut to the rivet stud and: Tighten Tighten to 8 Nm (71 lb in). 19. Verify proper system operation. M6 Weld Nut Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M6 weld nut at the electrical ground location is damaged or stripped, a M7 conductive self-threading bolt may be used to secure the ground wire terminal. 2. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the weld nut and allow to dry. 3. Remove any loose metal particles from the damaged or stripped weld nut with a stiff brush. 4. Select a M7 conductive self-threading bolt. Refer to the Parts Information section of this bulletin 5. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M7 conductive self-threading bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 6. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 7. Install the electrical ground wire terminal to the M7 conductive self-threading bolt. 8. Install the M7 conductive self-threading bolt and: Tighten Tighten to 9 Nm (80 lb in). 9. Verify proper system operation. M6 Weld Nut Alternative Repair Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the electrical ground location is accessible from both sides of the panel, a M6 conductive bolt and a M6 conductive nut may be used to secure the electrical ground wire terminal. Refer to the Parts Information section of this bulletin. 2. Select a location adjacent the damaged M6 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the new electrical ground site. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the ground location and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 8.5 mm (0.33 in) diameter hole through the panel. 5. Remove paint and primer from the area surrounding the 8.5 mm (0.33 in) hole until bare metal is visible. 6. Select a M6 conductive bolt. Refer to the Parts Information section of this bulletin. 7. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 8. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 9. Install the electrical ground wire terminal and the M6 conductive bolt to the ground location. 10. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 11. Install the M6 conductive nut to the bolt and: Page 4138 Accelerator Pedal Position Sensor: Description and Operation ACCELERATOR PEDAL POSITION (APP) SENSOR The accelerator pedal assembly contains 2 individual APP sensors within the assembly. The APP sensors 1 and 2 are potentiometer type sensors, each with the following circuits: - A 5-volt reference circuit - A low reference circuit - A signal circuit The APP sensors are used to determine the pedal angle. The control module provides each APP sensor a 5-volt reference circuit and a low reference circuit. The APP sensors then provide the control module with signal voltage proportional to pedal movement. Both APP sensor signal voltages are low at rest position and increase as the pedal is applied. Page 13053 12.2. Cars with brackets for e.g. an amplifier: Remove the pin strap (A) from the bracket and remove the tape (B) holding the optic cables. 12.3. Remove the locking strip (C) on the 2-pin connector (H2-9). Open the terminal housing with a screwdriver. Remove the secondary catch (E) on the connector and remove the optic cables coming from the OnStar(R) control modules. 12.4. Loosen one of the optic cables remaining in H2-9 (F), connect it to the connector and fit the secondary catch (E). Connect the connector so that the optic cables are opposite each other (G). Connect the terminal housing (D) and refit the locking strip (C). All Except 9.75 Inch Axle Carrier Bearings: Service and Repair All Except 9.75 Inch Axle Differential Side Bearings Replacement (All Except 9.75 Inch Axle) ^ Tools Required J 22912-01Split Plate Bearing Puller - J 8092 Universal Driver Handle - 3⁄4 in - 10 - J 21784 Side Bearing Installer - J 22888-D Side Bearing Remover Kit - J 29710 Differential Side Bearing Installer - J 36597 Side Bearing Puller Pilot - 9.25 Axle - J 44420 Differential Bearing and Hub Seal Installer Removal Procedure 1. Remove the differential assembly. 2. Remove the differential side bearings by doing the following: 1. For the 8.6 inch, 9.5 inch, 11.5 inch axles, install the differential assembly into a vise. 2. For the 10.5 inch axle, place a block of wood on each side of the differential assembly.Install the differential assembly into a vise. 3. Install the J 22888-20A (2) and the J 8107-4, 8.6 inch axle, or the J 36597, 9.5 inch or 10.5 inch axle, or the J 8107-5, 11.5 inch (1) axle, over the differential case side bearing bore. 4. Remove the differential side bearings using the J 22888-20A. Installation Procedure 1. For the 8.6 inch, the 9.5 inch, and the 10.5 inch axles, install the differential side bearings by doing the following: 1. In order to protect the differential case, install the J 8107-4, 8.6 inch axle, or the J 36597, 9.5 inch or 10.5 inch axles, in the case on the side opposite the bearing installation. 2. Install the J 21784, 8.6 inch axle, or the J 29710, 9.5 inch or 10.5 inch axles (2), and the J 8092 (1) onto the differential case bearing as shown. 3. Drive the bearing onto the case using the J 21784 or the J 29710 and the J 8092. Page 12371 Page 9852 1. Install the engine electrical center bracket assembly to the front fender. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the 4 retaining bolts (1). Tighten Tighten the 4 retaining bolts (1) to 9 N.m (80 lb in). 3. Align the electrical center block (1) stubs in the slots so that the tabs (2) retains it in place. Page 15889 Steering Wheel And Column Sub-System Components Page 12672 ^ An OnStar(R) Call Center button press WILL NOT connect the vehicle with OnStar(R). The vehicle must be upgraded to reactivate the account. The customer will hear a demo message stating that there is not a current OnStar(R) subscription for the vehicle. The message will also instruct the customer how to upgrade and reactivate services. ^ OnStar(R) personal calling (OPC) will not be available, as this feature requires the customer to have a current OnStar(R) account. Attempts to use this feature will result in cellular connection failure messages and the inability to connect to the number dialed. Note For deactivated vehicles, a no connect response should be considered normal system operation. Further diagnosis and subsequent repair is only necessary should the customer elect to become an active OnStar(R) subscriber and upgrade the account subscription. OnStar(R) Cellular, GPS, and Diagnostic Limitations The proper operation of the OnStar(R) System is dependent on several elements outside the components integrated into the vehicle. These include the National Cellular Network Infrastructure, the cellular telephone carriers within the network, and the GPS. The cellular operation of the OnStar(R) system may be inhibited by factors such as the users range from a digital cellular tower, the state of the cellular carrier's equipment, and the location where the call is placed. Making an OnStar(R) key press in areas that lack sufficient cellular coverage or have a temporary equipment failure will result in either the inability of a call to complete with a data transfer or the complete inability to connect to the OnStar(R) Call Center. The OnStar(R) system may also experience connection issues if the identification numbers for the module, station identification number (STID), electronic serial number (ESN) or manufacturers electronic ID (MEID), are not recognized by the cellular carriers local signal receiving towers. The satellites that orbit earth providing the OnStar system with GPS data have almost no failures associated with them. In the event of a no GPS concern, the failure will likely lie with the inability of the system to gain GPS signals because of its location, i.e. in a parking structure, hardware failure, or being mistaken with an OnStar(R) call which has reached the Call Center without vehicle data. During diagnostic testing of the OnStar(R) system, the technician should ensure the vehicle is located in an area that has a clear unobstructed view of the open sky, and preferably, an area where digital cellular calls have been successfully placed. These areas can be found by successfully making an OnStar(R) keypress in a known good OnStar(R) equipped vehicle and confirming success with the OnStar(R) Call Center advisor. Such places can be used as a permanent reference for future OnStar(R) testing. Mobile Identification Number and Mobile Directory Number The vehicle communication interface module (VCIM) utilizes 2 numbers for cellular device identification, call routing and connection. They are: ^ A mobile identification number (MIN) ^ A mobile directory number (MDN) Note The MIN represents the number used by the cellular carrier for call routing purposes. The MDN represents the number dialed to reach the cellular device. Diagnostic Information Symptoms - Cellular Communication The following steps must be completed before using the symptom table. 1. Perform the Diagnostic System Check - Vehicle, before using the Symptom Tables in order to verify that the following are true: ^ There are no DTCs set. ^ The control modules can communicate via the serial data link. 2. Review the system operation in order to familiarize yourself with the system functions. Refer to Radio/Audio System Description and Operation in SI. Diagnostic Starting Point - Displays and Gages Begin the displays and gages system diagnosis with Diagnostic System Check - Vehicle or the audible warning system diagnosis with Diagnostic System Page 16302 2. Install the drive link onto the wiper motor crank arm with the J 39529. 3. Install the wiper transmission assembly on the vehicle with the 2 bolts. Tighten Tighten the 2 bolts to 9 N.m (80 lb in). 4. Connect the electrical connector to the wiper motor. Page 6345 For vehicles repaired under warranty, use the table. Disclaimer Page 9198 C198 I/P Harness To Chassis Harness Page 6941 1. Inspect all of the parts for unusual wear, cracks, or other damage. Replace the CV joint assembly if necessary. 2. Put a light coat of the recommended grease on the inner (6) and the outer race (8) grooves. 3. Hold the inner race (1) at 90 degrees to the centerline of the cages (2). 4. Align the lands of the inner race (1) with the windows of the cage (2). Page 14411 Door Module: Service and Repair DOOR CONTROL MODULE PROGRAMMING AND SETUP Driver Door Module After replacing the driver door module (DDM), perform the programing procedure. Refer to Service Programming System (SPS). See: Testing and Inspection/Programming and Relearning Passenger Door Module After replacing the passenger door module (PDM), perform the following programing and setup procedures: ‹› Service Programming System (SPS). See: Testing and Inspection/Programming and Relearning ‹› Transmitter Programming. See: Testing and Inspection/Programming and Relearning ‹› Control Module Setup. See: Testing and Inspection/Programming and Relearning Page 10829 Air Door Actuator / Motor: Description and Operation HVAC CONTROL MODULE Mode Actuator The mode actuator is a 5-wire bi-directional electric motor that incorporates a feedback potentiometer. Ignition 3 voltage, low reference, control, 5-volt reference and position signal circuits enable the actuator to operate. The control circuit uses either a 0, 2.5 or 5-volt signal to command the actuator movement. When the actuator is at rest, the control circuit value is 2.5 volts. A 0 or 5-volt control signal commands the actuator movement in opposite directions. When the actuator shaft rotates, the potentiometer's adjustable contact changes the door position signal between 0.5 volts. The HVAC control module uses a range of 0-255 counts to index the actuator position. The door position signal voltage is converted to a 0-255 count range. When the module sets a commanded, or targeted value, the control signal is changed to either 0 or 5 volts depending upon the direction that the actuator needs to rotate to reach the commanded value. As the actuator shaft rotates the changing position signal is sent to the module. Once the position signal and the commanded value are the same, the module changes the control signal to 2.5 volts. AIR DISTRIBUTION Mode Actuator The mode actuator is an electronic stepper motor with feedback potentiometers. The HVAC control module sends different signals to the mode door actuator through the mode door control circuit. Zero volts drives the actuator in one direction while 5 volts moves the actuator in the opposite direction. When the actuator receives 2.5 volts, the actuator rotation stops. A 5-volt reference signal is sent out over the 5-volt reference circuit to the mode actuator. When you select a desired mode setting, logic determines the value of the mode actuator signals. The HVAC control module's software uses this reference voltage in order to determine the position of the mode actuator through the mode door position signal circuit. The motor moves the mode door to the desired position. AIR TEMPERATURE ACTUATOR The air temperature actuators are a 5-wire bi-directional electric motor that incorporates a feedback potentiometer. Ignition 3 voltage, low reference, control, 5-volt reference, and position signal circuits enable the actuator to operate. The control circuit uses either a 0, 2.5, or 5-volt signal to command the actuator movement. When the actuator is at rest, the control circuit value is 2.5 volts. A 0 or 5-volt control signal commands the actuator movement in opposite directions. When the actuator shaft rotates, the potentiometers adjustable contact changes the door position signal between 0.5 volts. The HVAC control module uses a range of 0-255 counts to index the actuator position. The door position signal voltage is converted to a 0-255 count range. When the module sets a commanded, or targeted, value, the control signal is changed to either 0 or 5 volts depending upon the direction that the actuator needs to rotate to reach the commanded value. As the actuator shaft rotates, the changing position signal is sent to the module. Once the position signal and the commanded value are the same, the module changes the control signal to 2.5 volts. RECIRCULATION ACTUATOR The HVAC control module controls the air intake through the recirculation actuator. Recirculation is not available when the mode is in defrost. When the mode is in defog, Recirculation will only be available for 10 minutes. The operator must activate the blower for Recirculation operation. The A/C high-pressure recirculation switch can cause the HVAC system to recirculate air. If the recirculation switch is pressed into the ON position when the mode switch is in an unavailable mode position, then the recirculation switch LED will flash 3 times. When the high side pressure reaches 2206-2620 kPa (320-380 psi), the PCM will place the HVAC system in recirculation mode. The high side pressure is lowered when the inside air cools the refrigerant within the A/C evaporator. When the high-side pressure reaches 1447-1861 kPa (210-270 psi), the PCM will place the HVAC system out of recirculation mode. Page 2536 Power Steering Fluid: Fluid Type Specifications POWER STEERING SYSTEM GM Power Steering Fluid GM P/N 89021184 (Canadian P/N 89021186) or equivalent POWER STEERING SYSTEM (PHT) Power Steering Fluid GM P/N 88901975 (Canadian P/N 88901976) Page 14089 Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. 1. Disconnect the connector from the component. 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. Instruments - IPC Odometer Programming Reference Guide Odometer: All Technical Service Bulletins Instruments - IPC Odometer Programming Reference Guide INFORMATION Bulletin No.: 07-08-49-020D Date: December 06, 2010 Subject: IPC Odometer Programming Method Quick Reference Guide Models: 2003-2011 GM Passenger Cars and Trucks (Including Saturn) 2003-2010 HUMMER H2, H3 2005-2009 Saab 9-7X Attention: This bulletin applies to vehicles sold in the U.S. and Canada Only. Supercede: This bulletin is being revised to add information for the 2011 model year and add new 2011 vehicles. Please discard Corporate Bulletin Number 07-08-49-020C (Section 08 - Body and Accessories). The purpose of this bulletin is to provide a reference guide to help identify which season odometer programming method to use after replacing the instrument panel cluster (IPC). The three season odometer programming methods in use today are listed below. In addition, this reference guide lists the component where the season odometer value is stored. The season odometer value may be stored in the IPC, the driver information center (DIC) or the integrated body control module (IBCM), also commonly called a body control module (BCM). Season Odometer Programming Methods in Use Today 1. IPC reprogramming and setup using the service programming system (SPS). 2. Odometer setup at the electronic service center (ESC) when using an exchange IPC/DIC. 3. Tech 2(R) - The Tech 2 is used to set up a replacement BCM, which includes loading the odometer value that is displayed and stored in the IPC. A replacement IPC will display the previously stored vehicle odometer value, communicated from the BCM, after cycling the ignition or driving the vehicle. *The odometer programming is integrated as part of the BCM programming procedure. It is not a stand-alone event. Page 12960 Speaker - LF Door - With RPO Code UQ3/UQ7 Wheels - Chrome Wheel Brake Dust Accumulation/Pitting Wheels: All Technical Service Bulletins Wheels - Chrome Wheel Brake Dust Accumulation/Pitting Bulletin No.: 04-03-10-012B Date: February 01, 2008 INFORMATION Subject: Pitting and Brake Dust on Chrome wheels Models: 2008 and Prior GM Passenger Cars and Trucks (including Saturn) 2008 and Prior HUMMER H2, H3 2005-2008 Saab 9-7X Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 04-03-10-012A (Section 03 - Suspension). Analysis of Returned Wheels Chrome wheels returned under the New Vehicle Limited Warranty for pitting concerns have recently been evaluated. This condition is usually most severe in the vent (or window) area of the front wheels. This "pitting" may actually be brake dust that has been allowed to accumulate on the wheel. The longer this accumulation builds up, the more difficult it is to remove. Cleaning the Wheels In all cases, the returned wheels could be cleaned to their original condition using GM Vehicle Care Cleaner Wax, P/N 12377966 (in Canada, P/N 10952905). When using this product, you should confine your treatment to the areas of the wheel that show evidence of the brake dust build-up. This product is only for use on chromed steel or chromed aluminum wheels. Parts Information Warranty Information Wheel replacement for this condition is NOT applicable under the terms of the New Vehicle Limited Warranty. Disclaimer Page 10667 *This product is currently available from 3M. To obtain information for your local retail location please call 3M at 1-888-364-3577. **This product is currently available from Meguiars (Canada). To obtain information for your local retail location please call Meguiars at 1-800-347-5700 or at www.meguiarscanada.com. ^ This product is currently available from Tri-Peek International. To obtain information for your local retail location please call Tri-Peek at 1-877-615-4272 or at www.tripeek.com. Disclaimer Page 1110 6. Remove the door module from the switch panel bezel. INSTALLATION PROCEDURE 1. Install the door module into the switch panel bezel until it snaps into place. 2. Install the switch panel bezel and module to the door panel. NOTE: Refer to Fastener Notice in Service Precautions. 3. Install the screw that retains the switch panel bezel (1) to the front door panel. Tighten Tighten the screw to 2 N.m (18 lb in). Page 14833 Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Service and Repair Parking Brake Warning Switch: Service and Repair Park Brake Warning Lamp Switch Replacement Removal Procedure 1. Caution: Refer to Battery Disconnect Caution in Service Precautions. Disconnect the negative battery cable. 2. Remove the MID-bussed electrical center from the bracket. 3. Disconnect the park brake warning lamp switch electrical connector. 4. Remove the park brake warning lamp switch mounting bolt. 5. Remove the park brake warning lamp switch. Installation Procedure Service and Repair Hazard Warning Flasher: Service and Repair HAZARD AND TURN SIGNAL FLASHER REPLACEMENT REMOVAL PROCEDURE 1. Remove the knee bolster. 2. On the back side of the fuse block release the retainer while pulling the flasher (1) outwards. 3. Remove the flasher (1) from the fuse block. INSTALLATION PROCEDURE 1. Install the flasher (1) to the fuse block until the retainer clicks into place. 2. Install the knee bolster. Page 16193 3. Prepare the surface of the used defroster tab (not required for new tabs on new-style full-size utility models) and the defroster buss bar with fine grain (500 grit) sandpaper or Emery cloth. It is not necessary to remove all of the original solder, but it should be scuffed sufficiently so that no oxidation is present. The photo above shows a close up of a properly prepared surface. Tip You may want to mask the glass around the contact area with tape. This is easy to do and will allow you to safely prepare the contact surface without the risk of scratching the glass or the black painted shading. Important Most rear glass has a black painted masking around the edge of the glass. When cleaning up the connection surface, be very careful not to damage the surface of the black shading or the surface of the glass. 4. Wipe the newly prepared contact area with Kent Automotive* Acrysol(TM) (or equivalent) to remove any residual oil or dirt. Important Page 6242 Fluid - A/T: Fluid Type Specifications Transmission Fluid Type Type ..................................................................................................................................................... ...................................... DEXRON III or Equivalent Page 6531 13. Ensure that the yellow identification band on the tube is hidden within the quick connect fitting. 14. A hidden yellow identification band indicates proper joint seating. 15. Fill the transmission to the proper level with DEXRON® III transmission fluid. Transmission Fluid Auxiliary Cooler Replacement Transmission Fluid Auxiliary Cooler Replacement Removal Procedure 1. Remove the front grill assembly. 2. Place a drain pan under the vehicle. 3. Disconnect the transmission oil cooler lines from the auxiliary cooler. 4. Remove the auxiliary oil cooler bolts (1) and push pins (2). 5. Remove the auxiliary oil cooler from the vehicle. Installation Procedure Page 2835 Tire Pressure Sensor: Technical Service Bulletins Tire Monitor System - TPM Sensor Information INFORMATION Bulletin No.: 08-03-16-003 Date: May 12, 2008 Subject: Warranty Reduction - Transfer of Tire Pressure Monitoring (TPM) Sensors to Replacement Wheels and Allowable TPM Sensor Replacements Models: 2000-2009 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2009 HUMMER H2 2006-2009 HUMMER H3 2005-2009 Saab 9-7x with On-Wheel TPM Sensors TPM Sensor / Wheel Warranty Reviews During the last warranty review period it was noted that wheels being returned under the GM New Vehicle Warranty were being shipped back to General Motors with the TPM sensor still attached to the wheel. Return rates ran as high as 60% with the TPM sensors still attached. Operational TPM sensors should not be returned to GM and are to be transferred to replacement wheels if they become necessary. Important: Operational TPM Sensors that are returned under warranty to General Motors will be charged back to the dealer.Sensors have a 10 year /150,000 mile (240,000 km) battery life, and should be transferred if one or more wheels are replaced. TPM Valve Stem / Grommet (0-ring) Replacement When the TPM sensors are transferred to new wheels you should replace the component used to seal the TPM sensor stem to the wheel. On sensors with an aluminum stem and visible nut on the outside of the wheel a replacement grommet (0-ring) should be used to assure a proper seal. The sensor retaining nut (except Aveo) should be tightened to 7 N.m (62 lb in) for all vehicles except Pontiac Vibe (4.0 N.m (35.4 lb in)). Important: ^ DO NOT overtorque the retaining nut. Notice: ^ Factory installed TPM Sensors come with plastic aluminum or nickel-plated brass stem caps. These caps should not be changed. Chrome plated steel caps may cause corrosion of aluminum valve stems due to incompatibility of the metals. On current style sensors the entire rubber stem is replaceable. The service interval on the revised TPM sensor with replaceable stem is the same as for any other traditional valve stem. Replace the stem at the time of tire replacement sensor transfer or whenever air seepage is suspected at the valve stem. When replacing the valve stem tighten the screw to 1.3 N.m (11.5 lb in). For either style of TPM sensor see the service parts guide for the correct GM part numbers to order and use. Disclaimer Page 16129 Electrical Symbols Part 4 Page 10333 2. Install the upper control arm bolts (4), the 25/35 Series for the 4WD. Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems. 3. Install the upper control arm nuts and the adjustment cams (2), the 25/35 Series for the 4WD. - Tighten the nuts to 190 Nm (140 lb ft). 4. For the 25/35 Series 4WD, install the control arm using the following procedure: 4.1. Install the upper control arm. 4.2. Install the upper control arm bolts (4). 4.3. Install the upper control arm nuts and adjuster cams (2). 5. For 15 Series 2WD/4WD and 25/35 Series 2WD, install the control arm using the following procedure: 5.1. Install the upper control arm. 5.2. Install the upper control arm bolts (4). 5.3. Install the upper control arm nuts and the adjustment cams (2). 6. Connect the upper control arm to the steering knuckle. 7. Install a new nut to the upper ball joint stud. Campaign - ECM Software Upgrade PROM - Programmable Read Only Memory: All Technical Service Bulletins Campaign - ECM Software Upgrade Bulletin No.: 06535 Date: August 09, 2006 SYSTEM SOFTWARE UPGRADE Subject: 06535-ON-BOARD DIAGNOSTIC (OBD) SYSTEM SOFTWARE UPGRADE - OBD SYSTEM IMPROVEMENTS (REPROGRAM POWERTRAIN CONTROL MODULE {PCM}) Models: 2004-05 CHEVROLET SILVERADO CHASSIS CAB, SUBURBAN, AVALANCHE 2004-05 GMC SIERRA CHASSIS CAB, YUKON XL EQUIPPED WITH DUAL FUEL TANKS Purpose This bulletin provides information about installing new Powertrain Control Module (PCM) software and calibration on certain involved 2004-05 Chevrolet Silverado chassis cab, Suburban, Avalanche; GMC Sierra chassis cab and Yukon XL model trucks, equipped with dual fuel tanks. The revised calibration includes OBD system improvements that affect the fuel level sender diagnostics that should be installed as soon as practical. Install the new calibration on all affected vehicles identified in this bulletin, including vehicles in new dealer inventory and any vehicles that return for service, for any reason, during the applicable 8 year / 80,000 mile (130,000 km) emission controller warranty coverage period. To verify if an updated calibration is required, refer to the following procedure in this bulletin. Parts Information Do not attempt to order the calibration number from GMSPO. The calibration numbers are programmed into Control Modules via a Techline Tech 2 scan tool and the Techline Information System (TIS) 2000 terminal with the calibration update. Use data version 8.0 for 2006 or later, broadcast to dealers on August 6, 2006 or TIS 2 Web version 8.0 for 2006 (website version of TIS); and on TIS DVD version 8.0 / 2006 or later, mailed to dealers beginning August 23, 2006. If you cannot access the calibration, call the Techline Customer Support Center and it will be provided. Service Procedure The "Required Field Actions" section of the GM Vehicle Inquiry System (GMVIS) must be checked to determine if a specific vehicle requires this action. If GMVIS indicates that System Software Upgrade 06535 remains 'open' and PCM reprogramming has not taken place otherwise after the TIS Broadcast or DVD availability dates identified in this bulletin, reprogram the PCM using a Tech 2 scan tool with the calibration update from Techline Information System (TIS) 2000. Tech 2(R) Remote Programming Method for PCM Note: Before reprogramming, please check the battery condition to prevent a reprogramming error of any of the modules due to battery discharge. Battery voltage must be between 12 and 16 volts during reprogramming. If the vehicle battery is not fully charged, use jumper cables from an additional battery. Be sure to turn off or disable any system that may put a load on the battery, such as automatic head lamps, daytime running lights, interior lights, heating, ventilation, and air conditioning (HVAC) system, radio, engine cooling fan, etc. A programming failure or control module damage may occur if battery voltage guidelines are not observed. The ignition switch must be in the proper position. The Tech 2(R) prompts you to turn ON the ignition, with the engine OFF. DO NOT change the position of the ignition switch during the programming procedure, unless instructed to do so. Make certain all tool connections are secure, including the following components and circuits: ^ The RS-232 communication cable port ^ The connection at the data link connector (DLC) ^ The voltage supply circuits DO NOT disturb the tool harnesses while programming. If an interruption occurs during the programming procedure, programming failure or control module damage may occur. DO NOT turn OFF the ignition if the programming procedure is interrupted or unsuccessful. Ensure that all control module and DLC connections Page 13050 8.2. Remove the console (A) together with the OnStar(R) control modules. 8.3. Remove the connectors (B). Important: The optic cable must not be bent with a radius less than 25 mm (1 in). Important: Secure the wiring harness so that there is no risk of chafing and rattling. 8.4. Fold back the wiring harness and tape over the connectors (C). Fold back the wiring harness once more and secure with cable ties (D). Page 10335 Control Arm: Service and Repair Lower Control Arm Replacement Lower Control Arm Replacement (4WD) ^ Tools Required ^ J 43631 Ball Joint Remover ^ J 45851 Ball Joint Separator Protector Adapters Removal Procedure 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Remove the tire and wheel. 3. Remove the stabilizer shaft links from the lower control arm. Refer to Stabilizer Shaft Replacement. 4. Remove the shock absorber lower nut and the bolt. Refer to Shock Absorber Replacement (4WD) Shock Absorber Replacement (RWD). 5. Remove the torsion bars. Refer to Torsion Bar Replacement. 6. Remove the wheel drive shaft. Refer to Wheel Drive Shaft Replacement in Wheel Drive Shafts. 7. Remove the lower ball joint retaining nut. 8. Disconnect the lower ball joint stud from the steering knuckle using J 43631 and J 45851. 9. Remove the lower control arm nuts and the 15-series washers. 10. Remove the lower control arm bolts. Page 16070 Electrical Symbols Part 13 Page 2646 Fuse Block - Underhood C2 Part 2 Page 10007 1. Install the relay rod (9) to the vehicle. 2. Install the relay rod (9) to the pitman arm ball stud (2). 3. Install the relay rod (9) to the idler arm ball stud (1). 4. Ensure the seal is on the stud. 5. Install the J 29193 or the J 29194. 6. Notice: Refer to Fastener Notice in Service Precautions. ^ Tighten the steering linkage installer in order to seat the tapers. ^ Tighten the steering linkage installer to 54 Nm (40 ft. lbs.). 7. Remove the J 29193 or the J 29194. 8. Install the new pitman arm prevailing torque nut. 9. Install the new idler arm prevailing torque nut. ^ Tighten the nuts to 62 Nm (46 ft. lbs.). 10. Install the tie rod ends. Refer to Tie Rod Replacement. 11. Install the steering damper to the relay rod, if equipped. Refer to Steering Damper Replacement. 12. Install the engine protection shield, if equipped. 13. Lower the vehicle. 14. Check the wheel alignment. Page 11896 Page 11031 10. Remove the condenser from the vehicle. INSTALLATION PROCEDURE IMPORTANT: If replacing the condenser, add the refrigerant oil to the condenser. Refer to Refrigerant System Capacities for system capacity information. 1. Install the condenser to the vehicle. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the upper insulator retainers and the insulator retainer bolts. Tighten Tighten the bolts to 2.4 N.m (21 lb in). 3. Connect the evaporator tube to the condenser using new sealing washers. 4. Install the evaporator tube nut to the condenser. Tighten Tighten the evaporator tube nut to 16 N.m (12 lb ft). 5. Connect the compressor discharge hose to the condenser using new sealing washers. 6. Install the compressor discharge hose nut to the condenser Tighten OnStar(R) - No Power/Inoperative/No LED Emergency Contact Module: All Technical Service Bulletins OnStar(R) - No Power/Inoperative/No LED TECHNICAL Bulletin No.: 05-08-46-001D Date: May 02, 2008 Subject: OnStar(R) Generation 5 or 6 (Digital) System Inoperative/Has No Power, LED Light Not On (Remove/Reinstall OnStar(R) Fuse and Replace VCIM or Follow SI Diagnostics) Models Supercede: This bulletin is being revised to update the information on VCIM ordering instructions in step 3 of the Correction statement. Please discard Corporate Bulletin Number 05-08-46-001C (Section 08 - Body & Accessories). Condition Some customers may comment any or all of the following conditions: ^ The OnStar(R) system may be inoperative. ^ The OnStar(R) system may have no power. ^ The OnStar(R) LED light may not be on. The technician may also not be able to communicate with the OnStar(R) Vehicle Communication Interface Module (VCIM) with a Tech 2(R). Correction Notice: On 2006 Chevrolet Impala and Monte Carlo models, make sure the ignition is OFF and the vehicle has "RAP"ed out prior to removing the OnStar(R) fuse. Disconnecting power to the OnStar(R) module while the ignition is ON may discharge and permanently damage the OnStar(R) back-up battery. Page 5242 For vehicles repaired under warranty, use the table. Disclaimer Page 13514 Electrical Symbols Part 4 Page 15439 1. Install the park brake warning lamp switch. 2. Notice: Refer to Fastener Notice in Service Precautions. Install the park brake warning lamp switch mounting bolt. ^ Tighten the bolt to 3 Nm (25 inch lbs.). 3. Connect the park brake warning lamp switch electrical connector. 4. Install the MID-bussed electrical center to the bracket. 5. Connect the negative battery cable. Page 1694 1. Lubricate a NEW O-ring seal with transmission fluid. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the VSS and bolt. ^ Tighten the bolt to 10 Nm (89 inch lbs.). 3. If equipped with the 8.1L engine, connect the VSS electrical connector (5). 4. If equipped with the 6.6L engine, connect the VSS electrical connector (4). 5. Lower the vehicle. 6. Check the transmission fluid level. Add if necessary. Page 827 Junction Block - I/P Wire Entry Part 1 Page 8805 If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Sir/SRS Wiring Repairs SIR/SRS WIRING REPAIRS TOOLS REQUIRED J 38125-D Terminal Repair Kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-D contains the following items: - Special sealed splices - in order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping tool - A heat torch - An instruction manual The sealed splices have the following 2 critical features: - A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-D also serves as a generic terminal repair kit. The kit contains the following items: - A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors Service and Repair Shackle: Service and Repair Spring Shackle Replacement Removal Procedure 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Remove the leaf spring assembly from vehicle. Refer to Leaf Spring Replacement. 3. Remove the shackle nut and the bolt from the spring. Installation Procedure 1. Install the shackle to the spring. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the shackle nut and bolt to the spring. ^ Tighten the shackle nut to 95 Nm (70 ft. lbs.). 3. Install the leaf spring assembly to the vehicle. Refer to Leaf Spring Replacement. 4. Remove the safety stands. 5. Lower the vehicle. Page 3081 Service and Repair Towing Hook / Bracket: Service and Repair Tow Hook Replacement (15 Series) Removal Procedure 1. Remove the front bumper. 2. Remove the tow hook bolts from the frame rail. 3. Remove the tow hook from the vehicle. Installation Procedure 1. Install the tow hook to the frame rail. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the bolts to the tow hook through the frame rail. Tighten the bolts to 85 N.m (63 lb ft). 3. Install the front bumper. Page 11883 Driver/Vehicle Information Display: Description and Operation DRIVER INFORMATION CENTER (DIC) DESCRIPTION AND OPERATION DRIVER INFORMATION CENTER (DIC) The driver information center (DIC) consists of a single line 22 character vacuum fluorescent (VF) display placed in the lower center area of the instrument panel cluster (IPC). The DIC will display vehicle information, configuration, and warning parameters to the driver. The display parameters are cycled, changed, and acknowledged using 4 DIC buttons. Trip Information Button representation icon appears as a road to the horizon. - Fuel Information Button representation icon appears as a gasoline pump. - Personalization Button representation icon appears as a human next to vehicle. - Select Button representation icon appears as an arrow. DIC DISPLAYS The DIC parameters are displayed by order of priority as follows (from highest to lowest) : Service Diagnostics - Driver Identifier - Feature Programming - Driver Warnings - Vehicle Information VEHICLE INFORMATION Vehicle information provides feedback to the driver on vehicle performance, mileage, maintenance, or related information. Vehicle information can only be displayed with the ignition switch in the RUN position. When the English/Metric status changes, any applicable vehicle information data values will also change. DIC TRIP INFORMATION / RESET CAPABILITIES The available DIC Trip Information and reset capabilities are as follows: Odometer - Cannot be reset - Personal Trip Odometer - Can be reset - Business Trip Odometer - Can be reset - Timer - Can be reset - Hourmeter - Cannot be reset TRIP RESET STEM The trip reset stem on the IPC operates in the following manner with the ignition switch in the RUN position: 1. Each time the trip reset stem is pushed the display will cycle to the next trip parameter. The trip parameters are as follows: - Odometer - Personal Trip odometer - Business Trip odometer - Timer - Hourmeter 2. Holding the trip reset stem for greater than 1 second or depressing the SWC Select button while either Personal Trip or Business Trip odometer is displayed will reset the displayed trip odometer and all other corresponding trip parameters to 0.0 upon release of the stem. The trip odometer will remain displayed after being reset. 3. If a trip information parameter is being displayed, pressing the DIC Trip Information button will display the next trip information parameter. 4. If the next Trip Information parameter to be displayed is Timer, Hourmeter, or blank, pressing the reset stem will return the display to the Odometer. ODOMETER The odometer is capable of displaying values from 0 - 999,999 mi or km. If the ignition is in the OFF or UNLOCK/ACC position, the odometer can be displayed by pressing the trip reset stem. The odometer will remain displayed for 5 seconds. TRIP ODOMETERS The DIC can display Personal Trip or Business Trip odometers. The trip odometers are capable of displaying values from 0 - 999999.9 mi or km. Page 6368 1. Install a NEW seal to the indicator tube. 2. Install the oil level indicator tube, if equipped with RPO HP2. 3. Install a NEW seal to the indicator tube. 4. Install the oil level indicator tube. Page 11915 Important: Secure the wiring harness so that there is no risk of chafing or rattling. 6.1. Remove the passenger seat in accordance with WIS 8. Body - Seats Adjustment/Replacement. 6.2. Remove the right-hand B-pillar trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.3. Remove the right-hand C pillar trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.4. Fold the rear seat backrest forward. 6.5. Remove the right-hand side bolster in accordance with WIS - 8. Body - Seats Adjustment/Replacement. 6.6. Remove the A-pillar's lower side piece. 6.7. Open the cover on the right-hand wiring harness channels. 6.8. Loosen the locking strip (A) on the 2-pin connector (H2-11) for the optic cable, located by the right-hand A-pillar. 6.9. Loosen the catch (B) and remove the optic cable that runs backward in the car. 6.10. Dismantle the end cap from the new optic cable (12 783 577) and connect it to the connector H2-11. Push in the optic cable and make sure the catch (B) locks and refit the locking strip (A). 6.11. Secure the connector and the old optic cable using the cable tie for the existing wiring harness (C). Page 16085 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Micro-Pack 100W Connectors MICRO-PACK 100W CONNECTORS TOOLS REQUIRED J 38125-D Terminal Repair Kit REMOVAL PROCEDURE There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2)has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. IMPORTANT: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Page 8289 8. Inspect the brake caliper mounting bracket guide surfaces for corrosion and wear. Remove and replace the brake caliper mounting bracket if needed. 9. Clean all of the residue from the brake pad guiding surfaces on the brake caliper housing and the brake caliper mounting bracket. 10. Clean all of the parts not included in the repair kit with denatured alcohol. 11. Dry all the parts with non lubricated filtered compressed air. 12. Blow out all passages in the brake caliper housing and the brake caliper bleeder valve. Assembly Procedure 1. Notice: Refer to Fastener Notice in Service Precautions. Install the brake caliper bleed screw. ^ Tighten the brake caliper bleed screw to 12 Nm (106 inch lbs.). 2. Install the brake caliper bleed screw cap. 3. Lubricate the new piston seal and the brake caliper bore seal groove with brake fluid. 4. Install the new seal into the brake caliper bore seal groove. 5. Ensure that the seal is not twisted. 6. Lubricate the brake caliper bore and the piston with brake fluid. 7. Install the boot and piston. 1. Install the boot over the end of the piston so that the fold will face toward the brake caliper housing piston bore opening. 2. Seat the boot into the brake caliper bore groove. Slide the piston into the brake caliper bore. 3. Push down the piston to the bottom of the brake caliper bore. 4. Ensure that the boot is properly seats into the piston groove and into the groove in the brake caliper bore. 8. Install the brake caliper to the vehicle. Power Window Switch Replacement - Rear Door Power Window Switch: Service and Repair Power Window Switch Replacement - Rear Door POWER WINDOW SWITCH REPLACEMENT - REAR DOOR REMOVAL PROCEDURE 1. Use a small flat-bladed tool in order to carefully pry the door power window switch from the door trim panel. 2. Disconnect the electrical connector from the switch. INSTALLATION PROCEDURE 1. Connect the electrical connector to the switch. 2. Install the switch to the door trim panel by pressing the switch into place until fully seated. Page 2419 Page 7667 1. Align the input seal evenly on the input shaft. Important: The input shaft seal should be even with the surface of the transfer case after installation. 2. Using the J 42738, install the input shaft seal. 3. Install the transfer case. 4. Check the fluid level, add fluid if necessary. Page 13893 7. Apply a small bead of urethane adhesive (2) between the windshield (1) and the pinchweld. 8. Install the upper reveal molding. 1. Start from the center and hand-press the reveal molding into place over the edge of the windshield. 2. Install both right and left sides of the reveal molding. 3. Run warm water over the reveal molding in order to speed the setup time of the urethane adhesive. Tape should be applied in order to retain the reveal molding to the windshield, this will maintain a flush fit with the body. The tape is to be removed after 6 hours. Page 4633 Electrical Symbols Part 3 Page 8151 11. Remove the 2 brake caliper mounting bolts. 12. Caution: Do not depress the brake pedal with the brake rotors/calipers and/or the brake drums removed. Damage to the brake system may result. If brake system damage occurs and is not repaired, vehicle damage and/or personal injury or death may result. Remove the brake caliper from the brake caliper mounting bracket. Installation Procedure 1. Notice: Refer to Fastener Notice in Service Precautions. Install the brake caliper to the brake caliper mounting bracket. 2. Install the 2 brake caliper mounting bolts. ^ Tighten the 2 brake caliper mounting bolts to 108 Nm (80 ft. lbs.). 3. Remove the rubber cap or plug from the exposed brake hose fitting end. 4. Important: Install 2 New copper brake hose gaskets. Assemble the 2 New copper brake hose gaskets and the brake hose to caliper bolt to the brake hose. 5. Install the brake hose to caliper bolt to the brake caliper. ^ Tighten the brake hose to caliper bolt to 40 Nm (30 ft. lbs.). 6. Bleed the hydraulic brake system. 7. Install the tire and wheel assembly. 8. Lower the vehicle. 9. Fill the master cylinder reservoir to the proper level with clean brake fluid. Refer to Master Cylinder Reservoir Filling in Hydraulic Brakes. Page 9577 Junction Block - I/P - C2 Part 1 Electrical - No Module Communication/DTCs/Warning Lamps Wiring Harness: All Technical Service Bulletins Electrical - No Module Communication/DTCs/Warning Lamps Bulletin No.: 03-08-50-014A Date: January 20, 2006 TECHNICAL Subject: No Communication with Any Modules, Memory Seat May Not Recall, Multiple U-DTCs Set or Instrument Panel Cluster (IPC) Warning Indicators, Crank No Start (Inspect/Repair Affected Wiring Harness) Models: 2003-2006 Cadillac Escalade, Escalade ESV, Escalade EXT 2003-2006 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2003-2006 GMC Sierra, Yukon, Yukon XL with Front, Individual (Non-Bkt) Seat (RPO AN3) and/or Active Brake Control (Stabilitrak(R)) (RPO JL4) Supercede: This bulletin is being revised to update the various conditions and add the 2004-2006 model years, additional diagnostic and warranty information. Please discard Corporate Bulletin Number 03-08-50-014 (Section 08 - Body & Accessories). Condition Some customers may comment on any of the following conditions: ^ Various IPC Warning indicators are coming on. ^ Driver Information Center (DIC) displays "Unknown Driver". ^ Memory seat may not recall. ^ RKE fobs may be inoperative. ^ Radio or HVAC may shut off. ^ Engine cranks but will not start. Upon investigation, the Technician may find multiple U-DTCs set. Cause On RPO AN3 equipped vehicles, a chafed or pinched seat wiring harness under the driver seat may be a cause of this condition. Because of the routing, a portion of the seat wiring harness may rest on the inboard edge of the seat track or frame. Over time, the harness may be pinched or chafed because of the seat movement. Refer to the above illustration. The illustration shows the inverted position of the seat bottom. The arrow shows the primary location Page 11933 Disclaimer Engine Oil Cooler Hose/Pipe Replacement Oil Cooler: Service and Repair Engine Oil Cooler Hose/Pipe Replacement Engine Oil Cooler Hose/Pipe Replacement Removal Procedure The optional oil cooler is either an integral part of the radiator or a separate unit placed in front of the radiator. The cooler lines and hoses are serviceable. 1. Disengage the plastic caps from the quick connect fittings. Pull the caps back along the pipe. 2. Hold one leg of the retaining clip. 3. Using a small pick-type tool or bent screwdriver, gently pry the other end of the retaining clip from the quick connect fitting. 4. Rotate the retaining clip out of the quick connect fitting. Remove the retaining clip completely. 5. Discard the OLD retaining clip. 6. If equipped with a 6.0L engine, perform the following: 1. Open the oil cooler hose clip located on the lower fan shroud. 2. Remove the oil cooler hoses from the clip. 3. Gently pull the oil cooler pipe fittings straight out from the radiator quick connect fittings. 4. Raise and suitably support the vehicle. 7. Remove the exhaust manifold pipe nuts. 8. Reposition the pipe out of the way. Page 4724 Remove all rust from the ground terminal, the cylinder head and the retaining nut or bolt. Position the main engine wiring harness ground terminal and install the nut or bolt. Tighten: Tighten the retaining nut or bolt to 16 N.m (12 lb ft). Apply some type of electrical moisture sealant to protect the harness terminal from further corrosion. Disclaimer Restraints - Seat Belt Warning Lamp On/Buckling Issues Seat Belt Buckle: Customer Interest Restraints - Seat Belt Warning Lamp On/Buckling Issues INFORMATION Bulletin No.: 09-09-40-001A Date: February 02, 2011 Subject: Seat Belt Buckle Latching Issues and/or Seat Belt Warning Lights Illuminated Models: 2011 and Prior GM Passenger Cars and Trucks (Including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7 X Supercede: This bulletin is being revised to add the 2011 model year. Please discard Corporate Bulletin Number 09-09-40-001 (Section 09 - Restraints). This bulletin is being published to advise dealers about seat belt buckles not operating and/or seat belt warning light illumination, as well as difficulty latching and unlatching the buckle or the buckle release button sticking. Analysis of warranty data has determined that this condition may be caused by sticky beverages being spilled onto or into the seat belt buckle assembly. Foreign debris from food, candy wrappers, paper and coins can also contribute to this condition. Important If foreign material (debris) or sticky liquids are the cause of the concern, show the customer the condition of the component (buckle assembly) and explain how it is affecting the function of the restraint system. Strongly recommend that the component be replaced. Point out the fact that this is not a manufacturing defect and is not covered by the new vehicle warranty. If the customer declines to have parts replaced, the service department management must make a notation on the service record that the lack of functionality of seating position with an inoperative buckle was fully explained to the customer. The service department management must advise the customer that having a non-functioning buckle in a seating position voids ability to use that seating position (no one should ride in the seat). Also make the customer aware that it may be against the law to ride in a vehicle without wearing a restraint system. Important Never insert anything other than the seat belt latch plate into the buckle assembly. Do not attempt to dig anything out of a buckle with a tool. Never try to wash out a buckle to remove a spilled liquid as this may damage the buckle. Use the following steps to determine the cause of the concern. 1. Inspect the buckle assembly with a light shining on the latch plate insertion area. Look for any debris or foreign objects in the buckle. 2. If any debris or foreign objects are observed, try to vacuum out the item. After the foreign material is removed, latch and unlatch the seat belt. If the system functions properly, do not replace the seat belt buckle assembly. 3. If the condition has not been corrected, inspect the buckle assembly for any sticky residue. If sticky residue is found, inform the customer that a substance was spilled on the seat belt buckle assembly causing the malfunction. The buckle assembly will need to be replaced at the customer's expense. 4. Refer to SI for seat belt component replacement. Important If foreign material (debris) or sticky liquids are the cause of the concern, show the customer the condition of the component (buckle assembly) and explain how it is affecting the function of the restraint system. Strongly recommend that the component be replaced at the customer's expense. Point out the fact that this is not a manufacturing defect and is not covered by the new vehicle warranty. If the customer declines to have parts replaced, the service department management must make a notation on the service record that the lack of functionality of seating position with an inoperative buckle was fully explained to the customer. The service department management must advise customer that having a non-functioning buckle in a seating position voids ability to use that seating position (no one should ride in the seat). Also make the customer aware that it may be against the law to ride in a vehicle without wearing a restraint system. 5. If further restraint diagnosis is required, refer to Seat Belt System Operational and Functional Checks in SI. Page 821 Relay Box: Diagrams Junction Block - Rear Lamps - C1 Page 13145 4.1. Unplug the SRS control module's connector (A). 4.2. Cut off the cable tie (B), detach the connector's rear end face (C), and pull out the connecting rail (D). 4.3. Extract pin 15, cut off the cable terminal and insulate the end with tape (E). Fold back the cable and secure it with tape (F). 4.4. Fit the connecting rail and end face. 4.5. Plug in the connector (A) and secure the cables with cable ties (B). 5. Remove the parcel shelf trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6. M03: Replace the optic cable on the right-hand side Page 6052 8. Remove the 1-2 accumulator piston seal (1) from the 1-2 accumulator piston. 9. Inspect the 1-2 accumulator piston for the following conditions: ^ Porosity ^ Cracks ^ Scoring ^ Nicks and scratches 10. Inspect the 1-2 accumulator cover for the following conditions: ^ Porosity ^ Cracks ^ Scoring ^ Nicks and scratches 11. Remove the spacer plate support bolts. 12. Important: Use care not to drop the following items that will be removed along with the spacer plate: ^ The number 1 checkball ^ The 3-4 accumulator spring ^ The 3-4 accumulator pin Remove the spacer plate support. Service and Repair Radiator Drain Plug: Service and Repair Drain Cock Replacement Removal Procedure 1. Drain the cooling system. 2. Remove the radiator drain cock. Installation Procedure 1. Install the radiator drain cock. 2. Fill the cooling system. Page 14299 WA8554/40 - WA8554/40 Page 14390 Driver Door Module (DDM) - C2 (With RPO Code YE9) Part 1 Page 6350 The first phase also machined a case chamfer leading into the pump bore (2). The chamfer is designed to help eliminate possible 0-ring seal damage during pump installation. Phase two modified the case casting and the chamfer into the pump bore. The casting change left additional material in the surrounding pump bore to allow deeper bore machining in order to create the necessary sealing surface for a new pump seal design. The leading surface into the pump bore was also machined with a modified chamfer (1). Page 6644 Page 15151 Audible Warning Device: Diagnostic Aids Basic Knowledge Required BASIC KNOWLEDGE REQUIRED Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the Service Data. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories CHECKING AFTERMARKET ACCESSORIES Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: - Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions INDUCING INTERMITTENT FAULT CONDITIONS In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: - Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. Page 14607 Seat Recliner Motor - Front Passenger (With RPO Code AN3) Page 8147 5. Install the caliper guide pin bolts. 6. Notice: Refer to Fastener Notice in Service Precautions. ^ Tighten the caliper guide pin bolts. ^ Tighten the caliper guide pin bolts to 42 Nm (31 ft. lbs.). 7. Remove the rubber cap or plug from the exposed brake hose fitting end. 8. Important: Install 2 new copper brake hose gaskets. Assemble the 2 new copper brake hose gaskets and the brake hose to caliper bolt to the brake hose. 9. Connect the brake hose at the caliper by installing the brake hose to caliper bolt. ^ Tighten the bolt to 40 Nm (30 ft. lbs.). 10. Bleed the hydraulic brake system. 11. Install the tire and wheel assembly. 12. Lower the vehicle. 13. Fill the master cylinder reservoir to the proper level with clean brake fluid. Refer to Master Cylinder Reservoir Filling in Hydraulic Brakes. OnStar(R) - Loss of GPS Signal/Hands Free Issues Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Loss of GPS Signal/Hands Free Issues Bulletin No.: 02-08-46-007C Date: November 19, 2007 INFORMATION Subject: Information on OnStar(R) System - Possible Loss of GPS Signal, Hands-Free Calling Minutes Expire Prematurely and/or Inability to Add Hands-Free Calling Minutes Models: 2001-2008 GM Passenger Cars and Light Duty Trucks (Including Saturn) 2003-2008 HUMMER H2 2006-2008 HUMMER H3 2005-2008 Saab 9-7X with OnStar(R) System (RPO UE1) Supercede: This bulletin is being revised to add the 2008 model year, warranty information and to provide GPS signal recovery steps (under Dealer Action heading) to do PRIOR to determining if the VIU/VCIM needs replacement. Please discard Corporate Bulletin Number 02-08-46-007B (Section 08 - Body & Accessories). If the vehicle currently has analog-upgradable OnStar(R) hardware, then the customer should be made aware of the digital upgrade program per the latest version of Service Bulletin # 05-08-46-006. Any analog OnStar system that is not upgraded prior to the end of 2007 will be deactivated due to the upcoming phase-out of the analog cellular network in the U.S. and Canada. If the vehicle has recently been upgraded or has had a service replacement unit installed, this bulletin may not be applicable. Certain 2001-2008 model year vehicles equipped with OnStar(R) may exhibit a condition with the Global Positioning System (GPS) that causes inaccuracies in the GPS clock. The GPS system is internal to the OnStar(R) Vehicle Interface Unit (VIU) or the Vehicle Communication Interface Module (VCIM). This inaccuracy can result in a symptom where the OnStar(R) Call Center is unable to obtain an accurate GPS signal, hands-Free Calling minutes expire prematurely and/or the inability to add Hands-Free calling minutes. Customer Notification OnStar(R) will notify the customer by mail with instructions to contact their dealership service department. Dealer Action Not all vehicles will require VIU/VCIM replacement. The GPS signal in some vehicles may be recoverable. To determine if the signal is recoverable, simply connect the Tech2(R) and using the GPS information data display option, observe the GPS date and time. If the date/time stamps are equal to a date approximately 19 years in the future, the GPS clock has exceeded its capacity and the VIU/VCIM will need to be replaced. If the date/time stamp is in the past or near future, the GPS clock has simply generated an inaccurate value and may be recoverable by performing the following power-up reset. To initiate a power-up reset, battery voltage (batt. +) must be removed from the VIU/VCIM. The preferred methods, in order, of initiating the reset are outlined below. Remove the fuse that supplies Battery positive (Batt. +) voltage to the module (refer to the applicable Service Information schematics for the appropriate fuse). The next preferred method is to remove the connector to the OnStar(R) unit that Batt + is contained. The least preferable method is to remove the negative terminal of the vehicle battery. This will not only initiate the power-up reset, but it may also result in the loss of radio presets and other stored personalization information/settings in other modules as well. After initiating the power-up reset, the GPS data will be set to the defaulted date and time and will require an acquisition of the GPS signal in order to gain the proper date and time. Acquiring the GPS signal requires running the vehicle in an open/unobstructed view of the sky. First, contact OnStar(R) Technical Support by pressing the blue button. Allow the OnStar(R) Technical Advisor to activate the GPS recovery process. This should take approximately 10 minutes. Continue to Page 4153 Flexible Fuel Sensor: Testing and Inspection Step 1 Steps 2 - 5 Page 2121 Spark Plug: Service and Repair SPARK PLUG REPLACEMENT REMOVAL PROCEDURE 1. Remove the spark plug wire. 2. Loosen the spark plug 1 or 2 turns. 3. Brush or using compressed air, blow away any dirt from around the spark plug. 4. Remove the spark plug. If removing more than one plug, place each plug in a tray marked with the corresponding cylinder number. INSTALLATION PROCEDURE 1. Correctly position the spark plug washer. 2. Inspect the spark plug gap. Adjust the gap as needed. Specification Spark plug gap: 1.01 mm (0.040 in) 3. Hand start the spark plug in the corresponding cylinder. NOTE: Refer to Fastener Notice in Service Precautions. 4. Tighten the spark plug. Tighten Tighten the plug to 15 N.m (11 lb ft) for used heads. - Tighten the plug to 20 N.m (15 lb ft) for NEW heads. 1. Install the spark plug wire. Page 11599 Page 5694 Torque Converter Clutch Solenoid: Service and Repair Torque Converter Clutch Pulse Width Modulation (TCC PWM) Solenoid, TCC Solenoid, and Wiring Harness ^ Tools Required J 28458 Seal Protector Retainer Installer Removal Procedure 1. Remove the transmission filter. 2. Disconnect the transmission harness 20-way connector (1) from the transmission internal harness pass-through connector. Depress both tabs on the connector and pull straight up; do not pry the connector. 3. Important: Removal of the valve body is not necessary for the following procedure. Remove the 1-2 accumulator. Do not remove the spacer plate. 4. Disconnect the internal wiring harness electrical connectors from the following components: ^ Transmission fluid pressure switch (1) ^ 1-2 shift control solenoid (2) ^ 2-3 shift control solenoid (3) ^ Pressure control solenoid (4) ^ Torque converter clutch pulse width modulation (TCC PWM) solenoid (5) ^ 3-2 control solenoid (6) 5. Remove the TCC PWM solenoid retainer. 6. Remove the TCC PWM solenoid in order to access one of the TCC solenoid bolts. Page 8287 5. Install the caliper guide pin bolts. 6. Notice: Refer to Fastener Notice in Service Precautions. ^ Tighten the caliper guide pin bolts. ^ Tighten the caliper guide pin bolts to 42 Nm (31 ft. lbs.). 7. Remove the rubber cap or plug from the exposed brake hose fitting end. 8. Important: Install 2 new copper brake hose gaskets. Assemble the 2 new copper brake hose gaskets and the brake hose to caliper bolt to the brake hose. 9. Connect the brake hose at the caliper by installing the brake hose to caliper bolt. ^ Tighten the bolt to 40 Nm (30 ft. lbs.). 10. Bleed the hydraulic brake system. 11. Install the tire and wheel assembly. 12. Lower the vehicle. 13. Fill the master cylinder reservoir to the proper level with clean brake fluid. Refer to Master Cylinder Reservoir Filling in Hydraulic Brakes. Page 12335 7. Insert the J 38125-13A (GM P/N 12031876-1) tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the Terminal Repair Kit to ensure that the correct release tool is used. 8. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. REPAIR PROCEDURE Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. A/T - 4L60-E/-4L65E No Shift/Slipping/Fluid Leaks Band Apply Servo: Customer Interest A/T - 4L60-E/-4L65E No Shift/Slipping/Fluid Leaks Bulletin No.: 04-07-30-025A Date: July 27, 2004 TECHNICAL Subject: Transmission Fluid Leak, Inoperative 2nd/3rd/4th Gears, No Movement, Case Cracked or Broken at 2-4 Servo (Repair Transmission and Install New Retaining Ring) Models: 2004 Chevrolet Corvette 2004 Pontiac GTO 2004 Light Duty Trucks with 4L60-E and 4L65-E Automatic Transmission (RPOs M30 or M32) Supercede: This bulletin is being revised to add the Corvette and GTO models and to include the 4L65-E transmission. Please discard Corporate Bulletin Number 04-07-30-025 (Section 07 Transmission/Transaxle). Condition Some customers may comment on a transmission leak, inoperative 2nd/4th gear, slipping 3rd/4th gear or no movement due to excess fluid loss. Cause This condition normally occurs at low mileage, usually under 1,600 km (1,000 mi), and investigation may show that the servo cover is loose or that the transmission case is cracked or broken at the servo bore. This condition may be caused by a servo cover retaining ring that did not retain the servo cover. The servo retaining ring design was changed for the 2004 MY from round wire to wire with two flat faces. In mid-April, 2004, the retaining ring design did revert back to a round design in production. It is possible that the transmission case may crack at the servo cover area due to the retaining ring being incorrectly seated. Correction Important: ^ In mid-April, 2004, the retaining ring design did revert back to a round design in production. ^ If the transmission fluid level has lowered due to loss of fluid, it is possible that damaged 3/4 clutches will result. ^ A cracked or broken case may usually be repaired at a significantly lower cost than transmission assembly replacement by replacing the case and any damaged clutches or bands. 1. Raise and suitably support the vehicle. 2. Inspect the transmission case around the servo cover for signs of cracks or damage to the case. ^ If the transmission case is cracked or damaged, replace the transmission case. Refer to the appropriate SI Document for Transmission Case Replacement. ^ If the servo cover is leaking and the case is not damaged, continue with the next step. 3. Remove the front exhaust pipe assembly. Refer to the appropriate SI Document. 4. Remove the heat shield if equipped. Refer to the appropriate SI Document. 5. Clean the servo cover area with Brake Clean and shop air. Page 11115 Discharge Air Temperature Sensor / Switch: Description and Operation AIR TEMPERATURE SENSORS The air temperature sensors are a 2-wire negative temperature co-efficient thermistor. The vehicle uses the following air temperature sensors: Ambient Air Temperature Sensor - Inside Air Temperature Sensor Assembly - Upper Left Air Temperature Sensor - Upper Right Air Temperature Sensor - Lower Left Air Temperature Sensor - Lower Right Air Temperature Sensor A signal and a low-reference circuit enables the sensor to operate. As the air temperature surrounding the sensor increases, the sensor resistance decreases. The sensor signal voltage decreases as the resistance decreases. The sensor operates within a temperature range between -40°C (-40°F) to 101°C (215°F). The sensor signal varies between 0.5 volts. The input of the duct air temperature sensors are different from the ambient and inside sensors. The HVAC control module converts the signal to a range between 0-255 counts. As the air temperature increases the count value will decrease. If the HVAC control module detects a malfunctioning sensor, then the control module software will use a defaulted air temperature value. The default value for the ambient and inside air temperature sensors will be displayed on the scan tool. The default value for the duct air temperature sensors will not be displayed on the scan tool. The scan tool parameter for the duct air temperature sensors are the actual state of the signal circuit. The default action ensures that the HVAC system can adjust the inside air temperature near the desired temperature until the condition is corrected. The ambient air temperature sensor mounts underhood and can be affected by city traffic, by idling, and by restarting a hot engine. Therefore, the HVAC control module filters the value of the ambient air temperature sensor for temperature display. The ambient air temperature value is updated under the above conditions. The scan tool has the ability to update the displayed ambient air temperature. To update the ambient air temperature display on the HVAC control module, perform the following procedure: Simultaneously press the MODE, FRONT DEFROST and REAR DEFROST switches. 1. Turn ON the ignition. 2. Simultaneously press the MODE, FRONT DEFROST and REAR DEFROST switches. Page 7790 5. Compress the reverse boost valve sleeve into the bore of the oil pump to expose the retaining ring slot. 6. Install the reverse boost valve retaining ring, then slowly release tension on the reverse boost valve sleeve. 7. Install the transmission filter. Page 9925 Verify Original Equipment Condition of the Vehicle - Verify that Original Equipment Tires and Wheels or Official GM Accessory Tires and Wheels are on the vehicle. - Verify that aftermarket suspension "Lift" or "Lowering" Kits or other suspension alterations have NOT been done to the vehicle. - Check for accidental damage to the vehicle; for example, severe pothole or curb impacts, collision damage that may have affected the wheel alignment of the vehicle; e.g., engine cradles, suspension control arms, axles, wheels, wheel covers, tires may show evidence of damage/impact. - Check to be sure vehicle has seen "Normal Use" rather than abuse; e.g., very aggressive driving may show up by looking at the tires and condition of the vehicle. - Check for other additional equipment items that may significantly affect vehicle mass such as large tool boxes, campers, snow plow packages (without the snowplow RPO), etc., especially in trucks and cutaway/incomplete vehicles. Significant additional mass can affect trim height and wheel alignment of the vehicle and may necessitate a customer pay wheel alignment when placed semi-permanently in the vehicle (Upfitter instructions are to realign the vehicle after placement of these types of items. (This typically applies to trucks and incomplete vehicles that can be upfit with equipment such as the above.) Customer Concerns, "Normal Operation" Conditions and "Mileage Policy" Possible Concerns The following are typical conditions that may require wheel alignment warranty service: 1. Lead/Pull: defined as "at a constant highway speed on a typical straight road, the amount of effort required at the steering wheel to maintain the vehicle's straight heading." Important Please evaluate for the condition with hands-on the steering wheel. Follow the "Vehicle Leads/Pulls" diagnostic tree located in SI to determine the cause of a lead/pull concern. Lead/Pull concerns can be due to road crown or road slope, tires, wheel alignment or even in rare circumstances a steering gear issue. Lead/pull concerns due to road crown are considered "Normal Operation" and are NOT a warrantable condition -- the customer should be advised that this is "Normal Operation." Important Some customers may comment on a "Lead/Pull" when they hold the steering wheel in a level condition. If so, this is more likely a "steering wheel angle" concern because the customer is "steering" the vehicle to obtain a "level" steering wheel. 2. Steering wheel angle to the left or right (counter-clockwise or clockwise, respectively): Defined as the steering wheel angle (clocking) deviation from "level" while maintaining a straight heading on a typical straight road. 3. Irregular or Premature tire wear: Slight to very slight "feathering" or "edge" wear on the shoulders of tires is NOT considered unusual and should even out with a tire rotation; if the customer is concerned about a "feathering" condition of the tires, the customer could be advised to rotate the tires earlier than the next scheduled mileage/maintenance interval (but no later than the next interval). Be sure to understand the customer's driving habits as this will also heavily influence the tire wear performance; tire wear from aggressive or abusive driving habits is NOT a warrantable condition. Important Slight or mild feathering, cupping, edge or heel/toe wear of tire tread shoulders is "normal" and can show up very early in a tire/vehicle service mileage; in fact, some new tires can show evidence of feathering from the factory. These issues do NOT affect the overall performance and tread life of the tire. Dealer personnel should always check the customer's maintenance records to ensure that tire inflation pressure is being maintained to placard and that the tires are being rotated (modified-X pattern) at the proper mileage intervals. Wheel alignments are NOT to be performed for the types of "Normal" Tire Feathering shown in Figures 1-4 below. Page 8213 Brake Rotor/Disc: Service and Repair Burnishing Pads and Rotors Burnishing Pads and Rotors Caution: Refer to Road Test Caution in Service Precautions. Burnishing the brake pads and brake rotors is necessary in order to ensure that the braking surfaces are properly prepared after service has been performed on the disc brake system. This procedure should be performed whenever the disc brake rotors have been refinished or replaced, and/or whenever the disc brake pads have been replaced. 1. Select a smooth road with little or no traffic. 2. Accelerate the vehicle to 48 km/h (30 mph). Important: Use care to avoid overheating the brakes while performing this step. 3. Using moderate to firm pressure, apply the brakes to bring the vehicle to a stop. Do not allow the brakes to lock. 4. Repeat steps 2 and 3 until approximately 20 stops have been completed. Allow sufficient cooling periods between stops in order to properly burnish the brake pads and rotors. Brake Rotor Replacement - Front Brake Rotor Replacement - Front ^ Tools Required J 41013 Rotor Resurfacing Kit - J 42450-A Wheel Hub Resurfacing Kit Caution: Refer to Brake Dust Caution in Service Precautions. Removal Procedure 1. Notice: Any new rotor must have the protective coating removed from the friction surfaces before being placed in service. Remove the protective coating using denatured alcohol or an equivalent, and wipe the surface clean with clean cloths. Do not use gasoline, kerosene, or other oil base solvents which may leave an oily residue. This residue is damaging to the brake lining and is flammable. Raise and support the vehicle. Refer Vehicle Lifting 2. Remove the tire and wheel assembly. 3. Remove the front wheel hub extension, dual wheel vehicles only. 1. Insert a drift or large screwdriver through the brake caliper into one of the brake rotor vanes in order to prevent the rotor from turning. Page 3277 1. Install the right engine mount to the engine. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the engine mount bolts to the engine. ^ Tighten the engine mount bolts to 50 Nm (37 ft. lbs.). 3. Install the engine mount-to-engine mount bracket bolts. 4. Lower the engine. 5. Remove the adjustable jack stands. 6. Install the engine mount heat shield, if equipped. ^ Tighten the engine mount-to-engine mount bracket bolts to 65 Nm (48 ft. lbs.). 7. Install the exhaust manifold. 8. Install the wheelhouse panel. A/C - Defaults To Defrost Mode/Poor Control Wiring Harness HVAC: All Technical Service Bulletins A/C - Defaults To Defrost Mode/Poor Control Bulletin No.: 04-01-38-008 Date: June 17, 2004 TECHNICAL Subject: HVAC System Cannot be Controlled or Defaults to Defrost Mode (Repair HVAC Actuator Harness) Models: 2003-2005 Cadillac Escalade, Escalade ESV, Escalade EXT 2003-2005 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2003-2005 GMC Sierra, Yukon, Yukon XL Condition ^ Some customers may comment that they cannot control the HVAC (heating, ventilation and air conditioning) system. Others may comment that the HVAC system defaults to the Defrost mode. ^ Technicians may find that the following diagnostic trouble codes have set: ^ B0229 Recirculation Actuator ^ B0414 Left Air Temperature Actuator ^ B0424 Right Air Temperature Actuator ^ B3770 Mode Actuator Cause The HVAC actuator harness may contact a sharp edge on the instrument panel support brace, causing a rub through condition and a ground out of the actuator control and/or feedback circuits. Correction Locate the HVAC actuator harness contact point shown by the arrow in the above illustration. The illustration is of the instrument panel with the instrument panel compartment door opened and folded downward. The actuator harness is located in the left side of the opening in the instrument panel. Page 8912 Auxiliary Power Outlet - Console (With RPO Code UQ7) Page 15156 IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections TESTING FOR INTERMITTENT AND POOR CONNECTIONS TOOLS REQUIRED - J 35616-C GM-Approved Terminal Test Kit - J 38125-D Terminal Repair Kit - J 42675 Flat-Wire Probe Adapter Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector. - Poor terminal to wire connection - Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. - Wire insulation which is rubbed through - This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. - Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. Testing For Proper Terminal Contact It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-D or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-D, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. Description and Operation Pedal Positioning Switch: Description and Operation Brake Pedal Position Sensor Calibration Description and Operation Calibration Criteria The brake pedal position (BPP) sensor receives a low reference signal and a 5-volt reference signal from the electro-hydraulic power steering (EHPS). Whenever the brake pedal is applied, the brake pedal position sensor applies a variable voltage signal to the EHPS through the BPP sensor signal circuit. Brake pedal position sensor calibration must be performed after the brake pedal position sensor or EHPS system have been serviced. The calibration procedure will set brake pedal position sensor home value. This value is used by the EHPS to determine the brake pedal position and the brake pedal rate. These two outputs are provided to the hybrid control module (HCM) via GMLAN. Calibration Procedure 1. Install a scan tool. 2. Turn ON the ignition, with the engine OFF. 3. Important: Make sure the brake pedal is not depressed before sending BPP sensor calibration command. Navigate to the Special Functions screen on the scan tool and select BPP Sensor Calibration in order to perform the brake pedal position sensor calibration. Page 5335 12. Install the harness clips to the fuel rail (1). 13. Install the CPA retainers. 14. Connect the following electrical connectors: - MAP sensor (1) - Knock sensor (2) 15. Install the knock sensor harness connector to the intake manifold. 16. Connect the EVAP purge solenoid electrical connector (1). 17. Connect the generator electrical connector (3). 18. Install the wire harness bracket nut (2). Tighten Tighten the nut to 5 N.m (44 lb in). 19. Tighten the fuel fill cap. 20. Connect the negative battery cable. 21. Use the following procedure in order to inspect for leaks: 21.1. Turn the ignition ON, with the engine OFF, for 2 seconds. 21.2. Turn the ignition OFF for 10 seconds. 21.3. Turn the ignition ON, with the engine OFF. 21.4. Inspect for fuel leaks. Page 16116 INSTALLATION PROCEDURE 1. Install the door module into the switch panel bezel until it snaps into place. 2. Install the switch panel bezel and module to the door panel. NOTE: Refer to Fastener Notice in Service Precautions. 3. Install the screw that retains the switch panel bezel (1) to the front door panel. Tighten Tighten the screw to 2 N.m (18 lb in). 4. Connect the electrical connectors. 5. Install the front door trim panel. 6. If equipped with camper mirrors program the door module. Refer to Service Programming System (SPS) in Programming. Page 3961 1. Install the CKP sensor. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the CKP sensor bolt. Tighten Tighten the bolt to 25 N.m (18 lb ft). 3. Connect the CKP sensor electrical connector. 4. Install the starter. 5. Perform the CKP system variation learn procedure. See: Testing and Inspection/Programming and Relearning Page 14664 Seat Back Frame: Service and Repair Seat Back Frame Replacement - Rear SEAT BACK FRAME REPLACEMENT - REAR REMOVAL PROCEDURE 1. Remove the seat from the vehicle. 2. Remove the armrest, if equipped. 3. Partially remove the seat-back cover in order to gain access to the retaining bolts. 4. Remove the bolts from the seat-back frame. 5. Remove the seat-back frame (4) from the seat back cushion frame. INSTALLATION PROCEDURE 1. Install the seat-back frame (4) to the seat cushion frame. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the bolts which retain the seat-back frame to the seat cushion frame. Tighten Tighten the bolts to 35 N.m (26 lb ft). 3. Install the seat-back cover. 4. Install the armrest to the seat back. 5. Install the seat to the vehicle. Door Latch Assembly (Door Jamb Switch) - Driver C2 Door Switch: Diagrams Door Latch Assembly (Door Jamb Switch) - Driver C2 Door Latch Assembly (Door Jamb Switch) - Driver C2 Page 7831 12. Inspect the TCC solenoid and wiring harness for the following defects: ^ Damage ^ Cracked connectors ^ Exposed wires ^ Loose pins Installation Procedure 1. Install the wiring harness and TCC solenoid with a new O-ring seal to the transmission. 2. Install the pass-through electrical connector to the transmission case. 3. Notice: Refer to Fastener Notice in Service Precautions. Install the valve body bolts which retain the internal wiring harness and install the TCC solenoid bolts. ^ Tighten the control valve body bolts to 11 Nm (97 inch lbs.). ^ Tighten the TCC solenoid bolts to 11 Nm (97 inch lbs.). Page 2729 5. Push on the tab (3) so that the electrical center can be rotated on the studs located at (2). 6. Remove all connectors by removing the bolt (1) for each connector. 7. Disconnect all connectors from the electrical center block. 8. Push on the tabs (2) in order to lift the electrical center (1) out of the housing. 9. To replace the engine electrical center bracket remove the 4 retaining bolts (1). 10. Remove the engine electrical center bracket assembly from the fender. INSTALLATION PROCEDURE Page 13155 1. Remove the ground cable from the battery's negative cable. 2. Remove the center console, see WIS - Body - Interior. 3. Loosen the gear shift housing (A). AUT: Disconnect the 6-pin connector (B) to improve access to the gear shift housing screws. 4. Disconnect the signal cable from the SRS control module to the OnStar(R) control module and secure the cable. 4.1. Disconnect the connector (A) from the SRS control module and cut the cable tie (B). Page 15170 circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links CIRCUIT PROTECTION - FUSIBLE LINKS Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Flat Wire Repairs FLAT WIRE REPAIRS NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Heated Oxygen Sensor (HO2S) Wiring Repairs HEATED OXYGEN SENSOR (HO2S) WIRING REPAIRS TOOLS REQUIRED J 38125-D Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: - Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-D. Repairing Damaged Wire Insulation REPAIRING DAMAGED WIRE INSULATION Page 1985 Electrical Symbols Part 12 Page 8388 8. Pull down on the park brake cable in front of the equalizer and install the left park brake cable to the equalizer bar. 9. Remove the safety stands. 10. Lower the vehicle. Page 13136 Page 1981 Electrical Symbols Part 8 Page 8154 4. Raise and support the vehicle. Refer Vehicle Lifting 5. Remove the tire and wheel assembly. 6. Install a C-clamp over the body of the brake caliper, with the C-clamp ends against the rear of the caliper body and the outboard disc brake pad. 7. Slowly tighten the C-clamp until the pistons are pushed into the caliper bores enough to remove the caliper from the pads. 8. Remove the C-clamp from the caliper. 9. Clean all dirt and foreign material from the brake hose end. 10. Important: Install a rubber cap or plug to the exposed brake pipe fitting end to prevent brake fluid loss and contamination. Remove the brake hose to caliper bolt from the brake caliper. 11. Remove the brake hose from the caliper. 12. Remove and discard the 2 copper brake hose gaskets. These gaskets may be stuck to the brake caliper housing or the brake hose end. Page 12702 Page 7726 2. Connect the speed sensor electrical connector (4). 3. Lower the vehicle. Drivetrain - Service 4WD Light/DTC C0374 Set Speed Sensor: Customer Interest Drivetrain - Service 4WD Light/DTC C0374 Set TECHNICAL Bulletin No.: 05-04-21-003C Date: April 15, 2008 Subject: Service 4WD Light Illuminated, DTC C0374 Set (Inspect Wiring Harness to Transfer Case Speed Sensors,, Replace Wiring Harness) Models: 2004-2007 Buick Rainier 2003-2006 Chevrolet Avalanche, Suburban, Tahoe 2003-2007 Chevrolet Silverado Classic, TrailBlazer, TrailBlazer EXT 2003-2006 GMC Yukon, Yukon XL 2003-2007 GMC Envoy, Envoy XL, Sierra Classic 2003-2004 Oldsmobile Bravada 2005-2007 Saab 9-7X With Four Wheel Drive or All-Wheel Drive and Active All-Wheel Drive (RPO NP4) or Active Two-Speed (RPO NP8) Transfer Case Supercede: This bulletin is being revised to update the Model and Warranty Information. Please discard Corporate Bulletin Number 05-04-21-003B (Section 04 - Driveline/Axle). Condition Some customers may comment on intermittent illumination of the Service 4WD light. Upon investigation, the technician may find DTC C0374 set. The customer may also comment on intermittent erratic operation of the 4WD or AWD system after driving through rain/snow or simply going through a car wash. Cause The speed sensor signal may have become corrupted. Possible openings in the speed sensor wire insulation (twisted pairs) can allow water intrusion. Also wire connections contaminated by water may result in short circuits and erroneous speed sensor readings. This most often occurs on the rear speed sensor circuit. Correction Inspect the wiring harness to the transfer case speed sensors. On Rainier, TrailBlazer, Envoy and 9-7X models, fabricate a replacement speed sensor harness between the C101 connector and the speed sensors. Completely inspect and test all wiring. Refer to Speed Signal Front Axle Actuator and Indicators schematic in SI. Replace the affected twisted pairs. Do not over-twist the two wires in the replacement harness. Wires should be twisted at a rate of 9 revolutions per foot. Use service connector pack, P/N 88987993 at the speed sensor end and terminal, P/N 15326267, at C101. Terminal testing tools and service terminals can be found in Terminal Repair Kit J 38125. Terminals are available from SPX/Kent-Moore. The smaller transfer case harness splices into the larger chassis harness a few inches in front of the crossmember. The chassis harness routes along the left side of the frame under the driver door area. Use nylon tie straps to secure the fabricated harness to the main chassis harness between the transfer case and C101. On the full-size pickup and full-size utility models, replace the 2.2 m (88 in) pigtail harness that runs from the C151 connector under the hood to the transfer case. Use either harness P/N 15832722 or 15224663 depending on vehicle equipment. Refer to Propshaft Speed Sensors Front Axle Actuator and Transfer Case Shift Control Switch schematic in SI. Important: Technicians should verify the integrity of the splice joints after the repair. All splice joints and connections should seal properly against water or a repeat condition can occur. Page 8212 2. Install the splash shield (15 series). 3. Install the hub and bearing assembly. 4. Install the tire and wheel assembly. 5. Remove the safety stands. 6. Lower the vehicle. Page 9245 C325 Heated Seat Jumper Harness To Seat Jumper Harness (With RPO Code KA1) NV 3500 Backup Lamp Switch: Service and Repair NV 3500 Backup Lamp Switch Replacement Removal Procedure 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. Disconnect the backup lamp switch electrical connector (3). 3. Remove the backup lamp switch. Installation Procedure 1. Notice: Refer to Fastener Notice in Service Precautions. Important: The backup lamp switch has pre-applied thread sealant on the threads. Install the backup lamp switch. ^ Tighten the switch to 37 Nm (27 ft. lbs.). Page 10971 Cut the wires back far enough from the connector to eliminate any melted insulation on the wire. Tip Use the old connector as a map for splicing the wires for the new connector. Be sure to use the correct crimping tool from the terminal repair kit J 38125. Use only Duraseal splice sleeves. Other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Install the new connector. Use the yellow splice sleeves provided with the connector. Install new blower motor resistor. Reinstall the fuse or connector block. Test the blower motor to make sure all speeds are functional. Reinstall the hush panel/close-out panel. Parts Information Warranty Information Fuel System - Cranks But No Start/Inaccurate Fuel Gauge Fuel Gauge Sender: Customer Interest Fuel System - Cranks But No Start/Inaccurate Fuel Gauge Bulletin No.: 04-08-49-018E Date: January 05, 2005 TECHNICAL Subject: Cranks But No Start, Stall, Inaccurate/Incorrect Fuel Gauge Reading, No Fuel, Vehicle is Out of Fuel and Fuel Gauge Reads Above Empty (Replace Fuel Level Sensor) Models: 2001-2004 Cadillac Trucks 1999-2004 Chevrolet and GMC Trucks with Gasoline Engine (VINs Z, X, V, T, U, N, G, 6, 8 - RPOs LU3, LR4, LM7, LQ4, LQ9, L59, L18,LK5 L52) Attention: Parts are currently available for vehicles with Variable Fuel (VIN Z - RPO L59) vehicles. Please refer to Corporate Bulletin Number 04-06-04-01 2B or newer for Variable Fuel (VIN Z - RPO L59) vehicles. Supercede: This bulletin is being revised to include information on the Chevrolet Colorado and the GMC Canyon. Please discard Corporate Bulletin Number 04-08-49-018D (Section 08 - Body and Accessories). Condition Some customers may comment on the vehicle stalling and will not restart, vehicle ran out of fuel, vehicle appears to be out of fuel but the fuel gauge reads above empty. The fuel gauge may read 1/4 tank. Cause Contamination on the fuel sending card may cause inaccurate/incorrect fuel gauge readings. Correction Follow the service procedure below for diagnosis and repair of this concern. 1. Confirm that the vehicle is actually out of fuel. ^ If the vehicle is not out of fuel but Engine Cranks but Does Not Run, refer to the appropriate Service Information. ^ If the vehicle is out of fuel and the gauge does not read empty, test the fuel gauge. Refer to the following information: - Fuel Gage Inaccurate or Inoperative Single Tank - Fuel Gage Inaccurate or Inoperative Dual Tanks - Fuel Gage Inaccurate or Inoperative Colorado and Canyon 2. If testing reveals that the fuel gauge is operating correctly, replace the fuel sensor assembly and auxiliary tank fuel level sensor if equipped. 3. Replace the fuel level sensor. Refer to the following appropriate service information: ^ Fuel Level Sensor Replacement 4.8L and 5.3L Engines ^ Fuel Level Sensor Replacement 6.0L Engine - Front Tank ^ Fuel Level Sensor Replacement 6.0L Engine - Rear Tank ^ Fuel Level Sensor Replacement 8.1L vehicles with Front Tank ^ Fuel Level Sensor Replacement 8.1 L vehicles with Rear Tank Page 11974 ^ Audio amplifier ^ Driver door module (DDM) ^ Driver door switch assembly (DDSA) ^ Front passenger door module (FPDM) ^ Left rear door module (LRDM) ^ Memory seat module (MSM) ^ Radio antenna module (listed as remote function actuation in scan tool display) ^ Rear integration module (RIM) ^ Right rear door module (RRDM) ^ Theft deterrent module (TDM) ^ TV antenna module ^ Vehicle communication interface module (VCIM) The star has 4 splice packs: ^ SP200 located in the left side of the instrument panel, near the steering column , taped to the instrument panel harness ^ SP201 located in the center of the instrument panel, near the radio ^ SP300 located in the left side middle of the passenger compartment, taped to the body harness, near the carpet seam ^ SP303 located in the right rear of the passenger compartment, taped to the body harness, approximately 24 cm (9.5 in) from the fuse block - right rear. Refer to Data Communication Schematics in SI. The following modules, components, and splice packs are connected to the ring portion of the class 2 serial data circuit: ^ Dash integration module (DIM) ^ Electronic brake control module (EBCM) ^ Engine control module (ECM) ^ Inflatable restraint sensing and diagnostic module (SDM) ^ Instrument panel cluster (IPC) ^ HVAC control module ^ Radio ^ Rear integration module (RIM) ^ Vehicle communication interface module (VCIM) OR ^ Communication interface module (CIM) ^ SP200 ^ SP201 ^ SP300 Page 1753 1. Install the knock sensors. Tighten Tighten the sensor to 20 N.m (15 lb ft). 2. Connect the knock sensor electrical connectors. 3. Push down on the rubber covers. 4. Install the intake manifold. Interior - Seat Memory Feature Appears Inoperative Memory Positioning Module: All Technical Service Bulletins Interior - Seat Memory Feature Appears Inoperative Bulletin No.: 04-08-50-003 Date: February 26, 2004 INFORMATION Subject: Enabling Memory Seat Feature via DIC If Feature Appears Inoperative Models: 2003-2004 Cadillac Escalade, Escalade ESV, Escalade EXT 2003-2004 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2003-2004 GMC Sierra, Yukon, Yukon Denali, Yukon Denali XL 2003-2004 HUMMER H2 with Steering Wheel Controls (RPO UK3) (standard on H2) If the memory seat feature appears inoperative, check the Driver Information Center (DIC). Many of the memory seat modules that were returned through the Warranty Parts Center for a condition of inoperative have shown No Trouble Found. The Driver Information Center (DIC), programmed for Seat Entry and Exit, is set to the default "Off" mode at the assembly plant. DO NOT REPLACE THE MEMORY SEAT MODULE. Perform the following procedure. Important: The following procedure will need to be completed for each Remote/Key selection. Using the DIC menu, do the following steps: 1. Set the "Seat Recall" to either "At Key In" or "On Remote" based on the customer's preference. 2. Set the "Exit Seat" to "On". 3. Adjust the following items: Memory Seat: 3.1. Driver's Seat (including the seat back, recliner, lumbar, and side wings) 3.2. Throttle and Brake Pedals (not available on H2 or Silverado and Sierra Trucks) 3.3. Outside Mirrors 3.4. Radio Station Presets 3.5. Last Chosen Climate Control System Settings (not available on Silverado or Sierra Trucks) 3.6. Press and hold the "1" or "2" (for driver 1 or 2) button of the memory control for three seconds. A double chime will sound to let you know that the position has been stored. Easy Exit Seat: 3.1. Press and release the 1 or 2 button or press the unlock button on the desired remote keyless entry transmitter. The seat will move to the stored memory position. 3.2. Adjust the seat to the desired exit position. 3.3. Press and hold the exit button of the memory control (located on the door) for three seconds. A double chime will sound to let you know that the position has been stored for the identified driver (1 or 2). Engine Mount Bracket Replacement Engine Mount: Service and Repair Engine Mount Bracket Replacement Left Engine Mount Bracket Replacement - Left Removal Procedure 1. Remove the engine mount. 2. Remove the engine mount bracket bolts. 3. Remove the engine mount bracket. Installation Procedure 1. Install the engine mount bracket. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the engine mount bracket bolts. ^ Tighten the engine mount bracket bolts to 75 Nm (55 ft. lbs.). 3. Install the engine mount. Right Engine Mount Bracket Replacement - Right Removal Procedure Page 9003 Body Harness Page 2734 Fuse Block: Service and Repair I/P Electrical Center or Junction Block Replacement - Right INSTRUMENT PANEL ELECTRICAL CENTER OR JUNCTION BLOCK REPLACEMENT - RIGHT REMOVAL PROCEDURE 1. Remove the right side end panel. 2. Push in the tabs in order to remove the fuse block. 3. Pull out the fuse block out of the I/P in order to remove the retaining bolt. 4. Loosen the bolt. 5. Insert a screw driver between the wire harness block and fuse block in order to separate. 6. Separate the fuse block from the I/P harness block. 7. Remove the I/P wiring harness block from the vehicle. INSTALLATION PROCEDURE 1. Install the fuse block to the I/P wire harness block. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the retaining bolt. Tighten Tighten the bolt to 6 N.m (53 lb in) 3. Install the fuse block to the I/P until it clicks in place. Page 978 The malfunction indicator lamp (MIL) is located in the instrument panel cluster. The MIL will display as either SERVICE ENGINE SOON or one of the following symbols when commanded ON: The MIL indicates that an emissions related fault has occurred and vehicle service is required. The following is a list of the modes of operation for the MIL: - The MIL illuminates when the ignition is turned ON, with the engine OFF. This is a bulb test to ensure the MIL is able to illuminate. - The MIL turns OFF after the engine is started if a diagnostic fault is not present. - The MIL remains illuminated after the engine is started if the control module detects a fault. A diagnostic trouble code (DTC) is stored any time the control module illuminates the MIL due to an emissions related fault. The MIL turns OFF after three consecutive ignition cycles in which a Test Passed has been reported for the diagnostic test that originally caused the MIL to illuminate. - The MIL flashes if the control module detects a misfire condition which could damage the catalytic converter. - When the MIL is illuminated and the engine stalls, the MIL will remain illuminated as long as the ignition is ON. - When the MIL is not illuminated and the engine stalls, the MIL will not illuminate until the ignition is cycled OFF and then ON. TRIP A trip is an interval of time during which the diagnostic test runs. A trip may consist of only a key cycle to power up the PCM, allow the diagnostic to run, then cycle the key off to power down the PCM. A trip may also involve a PCM power up, meeting specific conditions to run the diagnostic test, then powering down the PCM. The definition of a trip depends upon the diagnostic. Some diagnostic tests run only once per trip (i.e., catalyst monitor) while other tests run continuously during each trip (i.e. misfire). WARM-UP CYCLE The PCM uses warm-up cycles to run some diagnostics and to clear any diagnostic trouble codes (DTCs). A warm-up cycle occurs when the engine coolant temperature increases 22°C (40°F) from the start-up temperature. The engine coolant must also achieve a minimum temperature of 71°C (160°F). The PCM counts the number of warm-up cycles in order to clear the malfunction indicator lamp (MIL). The PCM will clear the DTCs when 40 consecutive warm-up cycles occur without a malfunction. DIAGNOSTIC TROUBLE CODES (DTCS) The PCM is programmed with test routines that test the operation of the various systems the PCM controls. Some tests monitor internal PCM functions. Many tests are run continuously. Other tests run only under specific conditions, referred to as Conditions for Running the DTC. When the vehicle is operating within the conditions for running a particular test, the PCM monitors certain parameters and determines if the values are within an expected range. The parameters and values considered outside the range of normal operation are listed as Conditions for Setting the DTC. When the Page 14037 2. Remove the hinge pillar panel. Installation Procedure 1. Install the hinge pillar panel. 2. Install the door-sill plate. Trim Panel Replacement - Rear Quarter (Crew Cab) Trim Panel Replacement - Rear Quarter (Crew Cab) Removal Procedure 1. Remove the coat hook, if required. 2. Remove the rear window lower molding. 3. Remove the quarter panel trim screws. 4. Remove the lower seat belt anchor bolt in order to guide the seat belt through the trim panel. 5. Remove the quarter panel. Installation Procedure 1. Install the seat belt through the trim panel. 2. Install the quarter panel. Notice: Refer to Fastener Notice in Service Precautions. 3. Install the lower seat belt anchor bolt. Tighten the bolt to 53 N.m (39 lb ft). 4. Install the quarter panel trim screws. Tighten the quarter panel trim screws to 2 N.m (18 lb in). Capacity Specifications Engine Oil: Capacity Specifications Engine Oil With Filter Change ............................................................................................................................... .............................................................. 5.7L (6.0 Qt) NOTE: ALL capacity specifications are approximate. When replacing or adding fluids, fill to the recommended level and recheck fluid level. Page 7917 Transmission Position Switch/Sensor: Service and Repair Automatic Transmission 4L80-E/4L85-E Park/Neutral Position Switch Replacement Park/Neutral Position Switch Replacement ^ Tools Required J 41364-A Park Neutral Switch Aligner Removal Procedure 1. Apply the park brake. 2. Shift the transmission into neutral. 3. If equipped with 4-wheel drive (4WD), remove the front propeller shaft. 4. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 5. Disconnect the park/neutral position (PNP) switch electrical connector (2). 6. Remove the range selector cable end (2) from the range selector lever ball stud (1). Page 12038 2. Connect the Techline Information System (TIS) terminal to the Tech2(R). 3. Scroll to the bottom of the Controller List, and select the "ONSA TIS2WEB Pass-Thru OnStar(R) Activation (Replaced/Upgraded Units Only)" option using the Service Programming System (SPS). Important: Do not use the clear DTC function. This will only temporarily turn the LED to green. 4. Upon completion of the OnStar(R) TIS2WEB step, disconnect the TIS terminal from the Tech2(R) and perform the VCIM/OnStar(R) Set-up Procedure using the Tech2(R). The set up procedure is located under the special function menu option. Important: Failure to perform the above steps will result in a red LED, DTC being set and limited or incomplete OnStar(R) services, and will require a customer return visit to the dealership. 5. The default language for the new VCIM will be English. To change to French or Spanish, access the special functions menu on the Tech 2(R), and follow the instructions accordingly. 7. Skip to the next step if the vehicle to be upgraded is not listed below: ^ 2002-2004 Cadillac DeVille ^ 2002-2004 Cadillac Seville ^ 2005 Cadillac STS Set up the Dash Integration Module (DIM) using the following procedure: 1. On the Tech2(R) select the correct Year, Make and Model. 2. Enter Dash Integration Module (DIM) > Special Functions > Set Options > Misc. Options 1 > and turn off phone (if the vehicle does not have the UV8 option). 3. Enter Nav Radio Present and set to "No Nav" (if the vehicle does not have a navigation radio). 4. Turn the ignition off and open the door to turn off the RAP. 5. Turn the ignition on and enter the Vehicle Comm. Interface Module > Special Functions > Set Up OnStar /VCIM. 6. When prompted select "No Phone" (if the vehicle does not have the UV8 phone) and "No Nav" (if the vehicle does not have a navigation radio). 7. Turn the ignition off and open the door to turn off the RAP. Important: OnStar(R) Emergency Services are immediately available after these steps, however, full configuration, including activation of Hands-Free Calling, may take up to 24 hours to complete. Processing the Module Exchange Processing the Module Exchange For this program, submitting a credit request for the removed OnStar(R) VCIM (the core) will be performed through a website. When this process is followed, the removed Analog / Digital-Ready VCIM, in most cases, will not be mailed back to the distributor, but can be scrapped by the dealership. U.S. Dealers 1. Return the removed Analog / Digital-Ready OnStar(R) VCIM to the Parts Manager. 2. The Parts Manager will log onto www.autocraft.com. 3. Select Account Maintenance. 4. Select Outstanding Cores. Page 16286 Wiper Arm: Service and Repair WIPER ARM REPLACEMENT REMOVAL PROCEDURE 1. Mark the position of the wiper blade on the windshield with a suitable marker or a piece of masking tape. 2. Disconnect the washer hose. 3. Remove the cover from the nut on the wiper arm. 4. Remove the nut from the wiper arm. IMPORTANT: Use a battery terminal puller to remove the wiper arm from the drive shaft. 5. Remove the wiper arm from the drive shaft. 6. Clean the knurls of the drive shaft with a wire brush. INSTALLATION PROCEDURE 1. Position the wiper arm so that the wiper blade aligns with the mark made on the windshield before removal. 2. Install the wiper arm onto the drive shaft. NOTE: Refer to Fastener Notice in Service Precautions. 3. Install the nut on the drive shaft. Tighten Tighten the nut to 30 N.m (22 lb ft). 4. Install the cover on the nut. 5. Connect the washer hose. 6. Clean the locating mark or masking tape from the windshield. 7. Operate the wipers and inspect for proper operation. Assist Step Pad Replacement Auxiliary Step / Running Board: Service and Repair Assist Step Pad Replacement Assist Step Pad Replacement Removal Procedure 1. Remove assist step pad bolts. 2. Remove assist step pad. Installation Procedure 1. Install assist step pad. 2. Install assist step pad bolts. Torque bolts until fully seated but not stripped. Page 2326 1. Notice: Refer to Power Steering Hose Disconnected Notice in Service Precautions. Install a drain pan under the vehicle. 2. Remove the power steering gear inlet hose (1) from the brake booster. 3. Remove the power steering gear inlet hose from the power steering gear. 4. Remove the power steering gear inlet hose from the vehicle. Installation Procedure 1. Notice: Refer to Installing Hoses Without Twists or Bends Notice in Service Precautions. Route the hose in the same position the hose occupied prior to removal. 2. Install the power steering gear inlet hose (1) to the brake booster (2). Hand tighten only. 3. Notice: Refer to Fastener Notice in Service Precautions. Install the power steering gear inlet hose to the power steering gear. ^ Tighten both power steering gear inlet hose fittings to 28 Nm (20 ft. lbs.). 4. Remove the drain pan from under the vehicle. 5. Bleed the power steering system. Refer to Bleeding the Power Steering System. (Without Hydroboost) Power Steering Gear Inlet Pipe/Hose Replacement (Without Hydroboost) Removal Procedure 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Remove the engine protection shield. Page 6057 Accumulator: Service and Repair Automatic Transmission - 4L80-E/4L85-E Accumulator Housing Replacement ^ Tools Required J 25025-5 Valve Body Align Pin Removal Procedure 1. Remove the valve body. 2. Remove the 3rd and 4th clutch accumulator housing bolts (1). 3. Remove the 3rd and 4th clutch accumulator housing (8). 4. Remove the accumulator housing gasket (6). The accumulator housing gasket may be stuck to the spacer plate (5). 5. Remove the 3rd clutch accumulator piston spring (7). 6. Remove the 4th clutch accumulator piston spring (2). 7. Remove the valve body spacer plate (5). 8. Remove the valve body to spacer plate gasket (4) from the spacer plate (5). Third and Fourth Clutch Accumulator Disassembly 1. Important: Apply low pressure compressed air to the hole at the top of the accumulator housing to assist with the piston removal. Remove the 3rd clutch accumulator piston (2). 2. Remove the 3rd clutch accumulator piston seals (1, 3). Page 8609 Use clean, new power steering fluid only. 12. Fill the pump reservoir with fluid to the FULL COLD level. 13. Attach J 43485, Power Steering Bleeder Adapter, to J 35555, Metal Mityvac, or equivalent. 14. Place J 43485 on or in the pump reservoir filler neck. 15. Apply a vacuum of 68 kpa (20 in Hg) maximum. 16. Wait 1 minute. 17. Remove 1 J43485 and J 35555. 18. Reinstall the pump reservoir cap. 19. Start the engine. Allow the engine to idle. 20. Turn the steering wheel 180-360 degrees in both directions 5 times. 21. Switch the ignition off 22. Verify the fluid level. 23. Release the park brake and unblock the wheels. Page 13106 ^ SP303 The following modules, components, and splice pack are connected to the star portion of the class 2 serial data circuit: ^ SP300 ^ Audio amplifier ^ Driver door module (DDM) ^ Driver door switch assembly (DDSA) ^ Memory seat module (MSM) ^ Left rear door module (LRDM) AND ^ SP303 ^ Antenna module ^ Front passenger door module (FPDM) ^ Rear integration module (RIM) ^ Right rear door module (RRDM) ^ Theft deterrent module (TDM) ^ Vehicle communication interface module (VCIM). Refer to Data Communication Schematics and Data Link Communications Description and Operation in SI. Part 2 Conditions for Running the DTC Voltage supplied to the module is in the normal operating voltage range of 9 - 16 volts. DTCs B1327, B1328, U1300, U1301, U1305 are not set as current. The vehicle power mode requires serial data communication to occur. Conditions for Setting the DTC A message containing a critical operating parameter has not been received within the last 5 seconds after establishing class 2 serial data communication. Action Taken When the DTC Sets The module uses a default value for the missing parameter. Conditions for Clearing the DTC A current DTC clears when the malfunction is no longer present. A history DTC clears when the module ignition cycle counter reaches the reset threshold, without a repeat of the malfunction. Diagnostic Aids When a malfunction such as an open fuse to a module occurs while modules are communicating, a DTC U1001-1254 Loss of XXX Communications is set current. When the modules stop communicating the current DTC U1001-1254 Loss of XXX Communications is cleared but the history DTC remains. When the modules begin to communicate again, the module with the open fuse will not be learned by the other modules so U1000 or U1255 is set current by the other modules. If the malfunction occurs when the modules are not communicating, only U1000 or U1255 is set. Automatic Transmission - 4L60-E/4L65-E Shift Solenoid: Diagrams Automatic Transmission - 4L60-E/4L65-E Page 16062 Electrical Symbols Part 4 A/T - Shift Lock Control Feature Function Shift Interlock: Technical Service Bulletins A/T - Shift Lock Control Feature Function Bulletin No.: 03-07-30-043A Date: May 25, 2006 INFORMATION Subject: Information Regarding Automatic Transmission Shift Lock Control Function Models: 2007 and Prior Passenger Cars and Trucks (Including Saturn) 2007 and Prior HUMMER H2, H3 2005-2007 Saab 9-7X with Automatic Transmission Supercede: This bulletin is being revised to add models and model years. Please discard Corporate Bulletin Number 03-07-30-043 (Section 07 - Transmission/Transaxle). This bulletin is being issued to better explain how the Automatic Transmission Shift Lock Control (formerly known as Brake Transmission Shift Interlock (BTSI)) feature is intended to operate. Revised wording regarding the shift lock control system began appearing in the Owner Manuals beginning with the 2004 model year. The shift lock control feature was intended to prevent drivers from shifting out of Park with the vehicle running without the brakes applied. However, if the ignition switch is in the Accessory (ACC) position, it may be possible on some vehicles to move the shift lever out of Park WITHOUT first activating the brake. The shift lock control system is ONLY active when the ignition switch is in the RUN or ON position. This means that when the ignition switch is in the RUN or ON position, the shift lever cannot be moved out of the Park position without activating the brake. Some owners may feel that the shift lock control system prevents an unattended child from moving the vehicle. Please stress to owners, as stated in the Owner Manual, that children should NEVER be left unattended in a vehicle, even if the ignition key has been removed from the vehicle. Disclaimer Page 12544 CKP System Variation Learn Procedure Crankshaft Position Sensor: Service and Repair CKP System Variation Learn Procedure CKP SYSTEM VARIATION LEARN PROCEDURE 1. Install a scan tool. 2. Monitor the powertrain control module (PCM) for DTCs with a scan tool. If other DTCs are set, except DTC P0315, refer to Diagnostic Trouble Code (DTC) List for the applicable DTC that set. 3. Select the crankshaft position (CKP) variation learn procedure with a scan tool. 4. The scan tool instructs you to perform the following: 4.1. Accelerate to wide open throttle (WOT). 4.2. Release throttle when fuel cut-off occurs. 4.3. Observe fuel cut-off for applicable engine. 4.4. Engine should not accelerate beyond calibrated RPM value. 4.5. Release throttle immediately if value is exceeded. 4.6. Block drive wheels. 4.7. Set parking brake. 4.8. DO NOT apply brake pedal. 4.9. Cycle ignition from OFF to ON. 4.10. Apply and hold brake pedal. 4.11. Start and idle engine. 4.12. Turn A/C OFF. 4.13. Vehicle must remain in Park or Neutral. 4.14. The scan tool monitors certain component signals to determine if all the conditions are met to continue with the procedure. The scan tool only displays the condition that inhibits the procedure. The scan tool monitors the following components: - CKP sensors activity-If there is a CKP sensor condition, refer to the applicable DTC that set. - Camshaft position (CMP) sensor activity-If there is a CMP sensor condition, refer to the applicable DTC that set. - Engine coolant temperature (ECT)-If the ECT is not warm enough, idle the engine until the engine coolant temperature reaches the correct temperature. 5. Enable the CKP system variation learn procedure with a scan tool. IMPORTANT: While the learn procedure is in progress, release the throttle immediately when the engine starts to decelerate. The engine control is returned to the operator and the engine responds to throttle position after the learn procedure is complete. 6. Accelerate to WOT. 7. Release when the fuel cut-off occurs. 8. Test in progress 9. The scan tool displays Learn Status: Learned this ignition. If the scan tool indicates that DTC P0315 ran and passed, the CKP variation learn procedure is complete. If the scan tool indicates DTC P0315 failed or did not run, refer to DTC P0315. If any other DTCs set, refer to Diagnostic Trouble Code (DTC) List for the applicable DTC that set. 10. Turn OFF the ignition for 30 seconds after the learn procedure is completed successfully. 11. The CKP system variation learn procedure is also required when the following service procedures have been performed, regardless of whether DTC P0315 is set: - A CKP sensor replacement - An engine replacement - A PCM replacement - A harmonic balancer replacement - A crankshaft replacement - Any engine repairs which disturb the CKP sensor relationship Diagrams Coolant Level Switch Page 9435 circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links CIRCUIT PROTECTION - FUSIBLE LINKS Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Flat Wire Repairs FLAT WIRE REPAIRS NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Heated Oxygen Sensor (HO2S) Wiring Repairs HEATED OXYGEN SENSOR (HO2S) WIRING REPAIRS TOOLS REQUIRED J 38125-D Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: - Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-D. Repairing Damaged Wire Insulation REPAIRING DAMAGED WIRE INSULATION Page 13118 Conditions for Running the DTC Ignition is in RUN or ACC position System voltage is between 9.5 - 15.5 volts. The above conditions are met for more than 1 second. Conditions for Setting the DTC The VCIM does not detect the presence of a cellular antenna for more than 1 second. Action Taken When the DTC Sets The vehicle is unable to connect to the OnStar(R) Call Center. The OnStar(R) status LED turns red. Conditions for Clearing the DTC The VCIM detects the presence of a cellular antenna. A history DTC clears after 50 malfunction-free ignition cycles. Circuit/System Testing Perform a visual inspection as shown above in order to verify that the cellular antenna and the cellular antenna coupling assembly are not damaged. If any components are damaged replace the assembly. DTC B2476 or B2482 DTC Descriptors Instruments - Service Tire Monitor Message is Displayed Fuse: All Technical Service Bulletins Instruments - Service Tire Monitor Message is Displayed Bulletin No.: 05-08-49-018A Date: May 11, 2006 ADVANCE SERVICE INFORMATION RESOLUTION Subject: EI 05065 - Service Tire Monitor Message Displayed (Pull/Reinstall IPC Fuse or Verify Correct Passenger Door Module (PDM) and Tires) Models: 2004 Chevrolet Silverado 2004 GMC Sierra Supercede: This bulletin is being revised to provide correction action. Please discard Corporate Bulletin Number 05-08-49-018 (Section 08 - Body and Accessories). Condition Some customers may comment that the "SERVICE TIRE MONITOR" message is being displayed on the DIC. Correction DO NOT REPLACE THE INSTRUMENT PANEL CLUSTER. If the DIC is displaying the SERVICE TIRE MONITOR message: 1. Verify if the vehicle has an electronic aftermarket module spliced into the ALDL Class 2 data line (purple wire). 2. If the vehicle HAS an aftermarket module spliced into the Class 2 line, pull the IPC fuse (located underhood) for 25 seconds. Important: Due to the electronic aftermarket module, the SERVICE TIRE MONITOR message may reoccur. 3. Reinstall the IPC fuse. This will clear the SERVICE TIRE MONITOR message from the display. 4. If the vehicle DOES NOT have an aftermarket module spliced into the Class 2 line, verify the vehicle is equipped with the correct PDM (Passenger Door Module) and tires. Warrant Information This repair is not covered under the vehicle warranty due to the installation of an aftermarket module. Disclaimer Page 3991 Knock Sensor: Service and Repair KNOCK SENSOR (KS) REPLACEMENT REMOVAL PROCEDURE 1. Remove the intake manifold. 2. Gently pry up the rubber covers. 3. Disconnect the knock sensor electrical connectors. 4. Remove the knock sensors. INSTALLATION PROCEDURE NOTE: Refer to Fastener Notice in Service Precautions. Page 12790 ^ Audio amplifier ^ Driver door module (DDM) ^ Driver door switch assembly (DDSA) ^ Front passenger door module (FPDM) ^ Left rear door module (LRDM) ^ Memory seat module (MSM) ^ Radio antenna module (listed as remote function actuation in scan tool display) ^ Rear integration module (RIM) ^ Right rear door module (RRDM) ^ Theft deterrent module (TDM) ^ TV antenna module ^ Vehicle communication interface module (VCIM) The star has 4 splice packs: ^ SP200 located in the left side of the instrument panel, near the steering column , taped to the instrument panel harness ^ SP201 located in the center of the instrument panel, near the radio ^ SP300 located in the left side middle of the passenger compartment, taped to the body harness, near the carpet seam ^ SP303 located in the right rear of the passenger compartment, taped to the body harness, approximately 24 cm (9.5 in) from the fuse block - right rear. Refer to Data Communication Schematics in SI. The following modules, components, and splice packs are connected to the ring portion of the class 2 serial data circuit: ^ Dash integration module (DIM) ^ Electronic brake control module (EBCM) ^ Engine control module (ECM) ^ Inflatable restraint sensing and diagnostic module (SDM) ^ Instrument panel cluster (IPC) ^ HVAC control module ^ Radio ^ Rear integration module (RIM) ^ Vehicle communication interface module (VCIM) OR ^ Communication interface module (CIM) ^ SP200 ^ SP201 ^ SP300 Locations Full Engine View Left Side Page 4236 - Worn ignition wires - Incorrect spark plug gap - Excessive idling or slow speeds under light loads can keep spark plug temperatures so low that normal combustion deposits may not burn off. - Deposit fouling - Oil, coolant, or additives that include substances such as silicone, very white coating, reduces the spark plug intensity. Most powdery deposits will not affect spark plug intensity unless they form into a glazing over the electrode. Page 15330 2. Install the fuel level sensor retaining clip. 3. Connect the fuel level sensor electrical connector. 4. Install the fuel level sensor electrical connector retaining clip. Page 11949 For vehicles repaired under warranty, use the table. Disclaimer Page 14088 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Micro-Pack 100W Connectors MICRO-PACK 100W CONNECTORS TOOLS REQUIRED J 38125-D Terminal Repair Kit REMOVAL PROCEDURE There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2)has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. IMPORTANT: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Page 13379 1. Connect the brake pedal position sensor (2) electrical connector (1). 2. Align the brake pedal position sensor (1) with the actuation arm (2) on the brake pedal and the brake pedal position sensor mounting bracket. Page 8167 3. Notice: Support the brake caliper with heavy mechanic's wire, or equivalent, whenever it is separated from its mount and the hydraulic flexible brake hose is still connected. Failure to support the caliper in this manner will cause the flexible brake hose to bear the weight of the caliper, which may cause damage to the brake hose and in turn may cause a brake fluid leak. Remove the brake caliper from the brake caliper mounting bracket and support the brake caliper with heavy mechanic's wire or equivalent. DO NOT disconnect the hydraulic brake hose from the caliper. 4. Remove the disc brake pads from the brake caliper mounting bracket. 5. Remove the disc brake pad retainers from the brake caliper mounting bracket. 6. Remove the caliper slide pins (5) from the brake caliper mounting bracket (3). 7. Remove the caliper slide pin boots (4) from the brake caliper mounting bracket. 8. Inspect the disc brake hardware. Installation Procedure 1. Lubricate the brake caliper mounting bracket bushings and the caliper slide pins with high temperature silicone brake lubricant. 2. Install the caliper slide pin boots (4) to the disc brake caliper mounting bracket. 3. Install the caliper slide pins (5) to the brake caliper mounting bracket (3). 4. Install the disc brake pad retainers to the brake caliper mounting bracket. 5. Install the disc brake pads to the brake caliper mounting bracket. 6. Install the disc brake caliper to the brake caliper mounting bracket. 7. With the engine OFF, gradually apply the brake pedal approximately 2/3 of it's travel distance. 8. Slowly release the brake pedal. 9. Wait 15 seconds, then repeat steps 7-8 until a firm brake pedal is obtained. This will properly seat the brake caliper pistons and brake pads. 10. Lower the vehicle. Page 4974 Right Side Of The Engine Page 5389 1. Remove the fuel tank. 2. Disconnect and remove the fuel feed (3) and/or fuel return (2) line from the sending unit and retaining clips. 3. Cap the fuel feed/return, and evaporative emission (EVAP) lines in order to prevent possible fuel/EVAP system contamination. INSTALLATION PROCEDURE 1. Remove the caps from the fuel feed/return, and EVAP lines. 2. Install and connect the fuel feed (3) and/or fuel return (2) line to the sending unit and retaining clips. 3. Install the fuel tank. Fuel Hose/Pipes Assembly Replacement (1500 Crew Cab) FUEL HOSE/PIPES ASSEMBLY REPLACEMENT (1500 CREW CAB) REMOVAL PROCEDURE IMPORTANT: Clean the fuel feed pipe connection and surrounding areas prior to disconnecting the fittings in order to avoid possible fuel system contamination. Locations Coolant Temperature Sensor/Switch (For Computer): Locations Full Engine View Left Side Page 2317 Hose/Line HVAC: Service and Repair Evaporator Tube Replacement (With RPO Code HP2) EVAPORATOR TUBE REPLACEMENT (W/ HP2) TOOLS REQUIRED J 39400-A Halogen Leak Detector REMOVAL PROCEDURE 1. Recover the refrigerant from the A/C system. Refer to Refrigerant Recovery and Recharging. 2. Remove the evaporator tube nut from the evaporator. 3. Remove the evaporator tube from the evaporator. 4. Loosen the nut from the evaporator tube fitting. 5. Remove the rear evaporator tube (3) from the vehicle. 6. Remove the air cleaner assembly. Page 8201 6. Slowly tighten the C-clamp until the pistons are pushed into the caliper bores enough to remove the caliper from the pads. 7. Remove the C-clamp from the caliper. 8. Notice: Support the brake caliper with heavy mechanic's wire, or equivalent, whenever it is separated from its mount and the hydraulic flexible brake hose is still connected. Failure to support the caliper in this manner will cause the flexible brake hose to bear the weight of the caliper, which may cause damage to the brake hose and in turn may cause a brake fluid leak. Remove the brake caliper and brake caliper bracket as an assembly and support with heavy mechanic's wire or equivalent. DO NOT disconnect the hydraulic brake flexible hose from the caliper. 9. Remove the rotor retaining push nuts from the wheel studs, if applicable. 10. It may be necessary to strike the end of the hub or the rotor with a dead blow hammer to separate the rotor from the hub. 11. Remove the rotor. 12. If the rotor is difficult to remove due to corrosion in the hub area use the following procedure to remove the rotor, 25 and 35 series only. 1. Clean all the surface areas and the threaded holes of contamination. 2. Generously apply penetrating oil or the equivalent to the hub/rotor area. 3. Insert two M10 x 1.5 bolts or jack screws into the threaded holes of the rotor. 4. Tighten both bolts evenly to force the rotor from the hub. Installation Procedure 1. Important: Whenever the brake rotor has been separated from the hub/axle flange, any rust or contaminants should be cleaned from the hub/axle flange and the brake rotor mating surfaces. Failure to do this may result in excessive assembled lateral runout (LRO) of the brake rotor, which could lead to brake pulsation. Use the J 42450-A to clean all rust and contaminants from the mating surface of the hub flange. Page 11803 1. Install the XM antenna cable and clips to the windshield pillar. 2. Connect the cable to the antenna connection above the headliner. 3. Install the headliner. 4. Connect the XM radio antenna cable (1) at the IP. 5. Install the windshield pillar garnish molding. A/C - Musty Odors Emitted From (HVAC) System Evaporator Core: Customer Interest A/C - Musty Odors Emitted From (HVAC) System TECHNICAL Bulletin No.: 99-01-39-004C Date: June 12, 2009 Subject: Air Conditioning Odor (Install Evaporator Core Dryer Kit and Apply Cooling Coil Coating) Models: 1993-2010 GM Passenger Cars and Trucks (Including Saturn) 2010 and Prior HUMMER H2, H3 All Equipped with Air Conditioning Supercede: This bulletin is being revised to add the 2009 and 2010 model years. Please discard Corporate Bulletin Number 99-01-39-004B (Section 01 - HVAC). Condition Some customers may comment about musty odors emitted from the Heating, Ventilation and Air Conditioning (HVAC) system at vehicle start-up in hot, humid conditions. Cause This condition may be caused by condensate build-up on the evaporator core, which does not evaporate by itself in high humidity conditions. The odor may be the result of microbial growth on the evaporator core. When the blower motor fan is turned on, the microbial growth may release an unpleasant musty odor into the passenger compartment. There are several other possible sources of a musty odor in a vehicle. A common source is a water leak into the interior of the vehicle or foreign material in the HVAC air distribution system. Follow the procedures in SI for identifying and correcting water leaks and air inlet inspection. The procedure contained in this bulletin is only applicable if the odor source has been determined to be microbial growth on the evaporator core inside the HVAC module. Correction Many vehicles currently incorporate an afterblow function within the HVAC control module software. The afterblow feature, when enabled, employs the HVAC blower fan to dry the evaporator after vehicle shut down and this function will inhibit microbial growth. Technicians are to confirm that the customer concern is evaporator core odor and that the vehicle has the imbedded afterblow feature, as defined in the SI document for that specific vehicle model, model year and specific HVAC option. Refer to SI for enabling the afterblow function. Vehicles being delivered in areas prone to high humidity conditions may benefit from having the afterblow enabled calibration installed prior to any customer comment. Important If the vehicle is not factory equipped with the imbedded afterblow enable feature, it may be added with the Electronic Evaporator Dryer Module Kit (P/N 12497910 or AC Delco 15-5876). Important When installing the Electronic Evaporator Dryer Module, you MUST use the included electrical splice connectors to ensure a proper splice. Complete detailed installation instructions and self testing procedures are supplied with the kit. If necessary, the Electronic Evaporator Dryer Module may be installed underhood if it is protected from extreme heat and water splash areas. To immediately remove the evaporator core odor on all suspect vehicles, it is necessary to eliminate the microbial growth and prevent its re-occurrence. To accomplish this, perform the following procedure: Vehicle and Applicator Tool Preparation 1. The evaporator core must be dry. This may be accomplished by disabling the compressor and running the blower fan on the recirc heat setting for an extended period of time. Note Compressor engagement will cause the evaporator core to remain wet and will prevent full adherence of the Coiling Coil Coating to the evaporator core surfaces. 2. Verify that the air conditioning drain hose is not clogged and place a drain pan beneath the vehicle. Page 4493 High Temperature Conditions Tools Required J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency MEASURING FREQUENCY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage MEASURING VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop MEASURING VOLTAGE DROP NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Page 9992 Maintain the sensor position. Do not turn the sensor. Remove the rear wheel position sensor (2) from the steering gear. Installation Procedure 1. Important: Make sure the O-ring (1) is installed. Install the rear wheel position sensor (2) to the steering gear. 2. Important: Be careful to maintain the position of the replacement sensor. Remove the pin retaining the position of the new sensor and immediately install the sensor to the steering gear. 3. Notice: Refer to Fastener Notice in Service Precautions. Install the rear wheel position sensor retaining bolts. Apply LOCTITE 242 blue. ^ Tighten the bolts to 4 Nm (35 inch lbs.). 4. Install the rear wheel position sensor cover (4). 5. Connect the electrical connector (1). 6. Install the steering gear protection shield (1) and retaining bolts (3). ^ Tighten the steering gear protection shield retaining bolts to 180 Nm (132 ft. lbs.). Transfer Case - NVG 246-NP8 Four Wheel Drive Selector Switch: Service and Repair Transfer Case - NVG 246-NP8 Transfer Case Shift Control Switch Replacement Removal Procedure 1. Remove the instrument panel (I/P) cluster bezel. 2. Using a flat-tipped screwdriver, gently pry the retaining clips open on the housing. 3. Slide out the selector switch until the electrical connector are accessible. 4. Disconnect the selector switch electrical connectors (2, 3). 5. Remove the selector switch from the housing. Installation Procedure 1. Position the selector switch close to the housing so the electrical connectors can be connected. Page 7785 Vehicle Speed Sensor (VSS) Tow/Haul Switch Location Page 10715 4. Drive the bearing cup into the wheel hub using the J 44419 (2) and the J 8092 (1). 5. Install the retaining ring into the groove. Make sure the retaining ring is fully and evenly seated in the groove. 6. Install the inner bearing cup. 7. Drive the inner bearing cup into the wheel hub using the J 24427 (2) and the J 8092 (1). Page 10303 1. Important: Make sure the shock dampener is on the rack before installing the inner tie rod. The threads must be clean prior to the Loctite® application. Check the Loctite®, or equivalent, container for expiration date. Use only enough Loctite® to evenly coat the threads. Apply Loctite® 262, or equivalent, to the inner tie rod threads (2). 2. Install the inner tie rod (3) to the rack and pinion (1). 3. Notice: Refer to Fastener Notice in Service Precautions. Install a torque wrench (5) to the J 34028 to tighten the inner tie rod (6).Hold the rack while tightening the tie rod as shown. ^ Tighten the inner tie rod to 100 Nm (74 ft. lbs.). Page 11923 Important: The optic cable must not be bent with a radius less than 25 mm (1 in). 12.5. Cars with brackets for e.g. an amplifier: Fit the cable tie (11 900 515) to the wiring harness approx. 100 mm (4 in) from H2-9, fit the cable tie (H) to the bracket. Gather the optic cable in a gentle loop (I) and then place the loop behind the bracket. Important: The optic cable must not be bent with a radius less than 25 mm (1 in). 12.6. Cars without brackets for e.g. an amplifier: Gather the optic cable in a gentle loop (J) and secure with cable tie. 13. CV: Fit the left-hand, rear side hatch trim in accordance with WIS - 8. Body - Interior equipment - Adjustment/Replacement. 14. Fit the ground cable to the battery's negative terminal. 15. Carry out procedures after disconnecting the battery, see WIS - 3. Electrical System - Charging system - Adjustment/Replacement. Important: Follow Tech 2(R) on-screen instructions. 16. Add ECU ICM, choose without OnStar(R). See WIS-General-Tech 2(R) - Description and Operation - Add/Remove. 2000-2004 Saab 9-5 2000-2004 Saab 9-5 Page 6511 Page 16152 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Micro-Pack 100W Connectors MICRO-PACK 100W CONNECTORS TOOLS REQUIRED J 38125-D Terminal Repair Kit REMOVAL PROCEDURE There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2)has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. IMPORTANT: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Page 3455 Install the oil level sensor to the oil pan. ^ Tighten the sensor to 13 Nm (115 inch lbs.). 2. Connect the oil level sensor electrical connector (3). 3. Fill the engine oil. Page 5986 1. Install the locating pins to the NEW encoder motor. 2. Position a NEW actuator insulator gasket to the transfer case. 3. Install the encoder motor. Notice: Refer to Fastener Notice in Service Precautions. 4. Install encoder motor bolts. ^ Tighten the bolts, in the sequence shown, to 20 Nm (15 ft. lbs.). 5. Connect the encoder motor electrical connector. Ensure that the retention clips activate. 6. Install the front propeller shaft. 7. Install the transfer case shield, if equipped. Service and Repair Steering Angle Sensor: Service and Repair Rear Position Sensor Replacement Removal Procedure 1. Notice: Refer vehicle Lifting. Raise the vehicle. Refer to Vehicle Lifting. 2. Remove the steering gear protection shield (1) retaining bolts (3). 3. Disconnect the electrical connector (1). 4. Notice: When removing the rear position cover from the steering gear be careful not to damage to the rear position sensor. Remove the rear wheel position sensor cover (4) from the steering gear by prying on the cover using the slot. 5. Remove the rear wheel position sensor retaining bolts (3). 6. Important: Check the inner tie rod boot for wear or damage. If the boots are damaged replace the steering gear actuator. 7. Important: Page 4737 Engine Control Module: Diagrams Powertrain Control Module (PCM) C2 Page 14254 Auto Magic(R) or Clay Magic(R) products available from: Auto Wax Company, Inc. 1275 Round Table Dr. Dallas, TX 75247 (800) 826-0828 (Toll-Free) or (214) 631-4000 (Local) Fax (214) 634-1342 www.automagic.com [email protected] E038 Fallout Gel or E038E Liquid Fallout Remover II available from: Valvoline Car Brite Company 1910 South State Avenue Indianapolis, In 46203 (800) 347-2439 (Toll Free) or (317) 788-9925 (Local) Fax (317) 788-9930 www.carbrite.com [email protected] *We believe these sources and their products to be reliable. There may be additional manufacturers of such products. General Motors does not endorse, indicate any preference for or assume any responsibility for the products from these firms or for any such items which may be available from other sources. If rail dust remover is not available in your area, call one of the numbers listed above for a distributor near your location. Warranty Information (excluding Saab U.S. Models) Important Refer to the Policy & Procedures Manual, section 1.2.1.7 for detailed information regarding warranty coverage for this condition. Important In certain cases where the vehicle finish is severely damaged and the actual repair time exceeds the published time, the additional time should be submitted in the "Other Labor Hours" field. Warranty Information (Saab U.S. Models) Disclaimer Page 13233 Test Description DTC U1001 and U1254 Circuit/System Description Modules connected to the Class 2 serial data circuit monitor for serial data communications during normal vehicle operation. Operating information and commands are exchanged among the modules. When a module receives a message for a critical operating parameter, the module records the identification number of the module which sent the message for State of Health monitoring. A critical operating parameter is one which, when not received, requires that the module use a default value for that parameter. Once an identification number is learned by a module, it will monitor for that module's Node Alive message. Each module on the class 2 serial data circuit which is powered and performing functions that require detection of a communications malfunction is required to send a Node Alive message every 2 seconds. When no message is detected from a learned identification number for 5 seconds, a DTC U1XXX where XXX is equal to the 3-digit identification number is set. Page 13168 10. Disconnect and remove the OnStar(R) jumper harness. Note: You will need to remove the short GPS cable from this jumper harness. 11. Untape the cell antenna coax from the body harness in the trunk. This will be necessary to provide adequate length to connect to the new VCIM. 12. Fasten three retainer clips (1) from the kit to the new bracket that is included in the kit, and position the VCIM to the bracket (2). 13. Install the three bolts from the kit. Tighten the bolts to 10 Nm (89 lb in). 14. Connect the new OnStar(R) jumper harness supplied in the kit to the VCIM (two white connectors on module). 15. Connect small GPS coax cable jumper harness supplied in the kit (end with blue plastic housing) to VCIM GPS connector. 16. Position the VCIM / bracket assembly to the studs. 17. Install the bracket nuts saved from the Removal Procedure above to the VCIM / bracket assembly mounting studs. Tighten the nuts to 4 Nm (35 lb in). 18. Connect the new OnStar(R) jumper harness to the body wiring harness (C410 connector). 19. Connect small coax cable jumper from VCIM to the OnStar(R) Global Positioning Satellite (GPS) antenna coaxial cable at the connector previously left in the vehicle (short jumper removed from old harness in step 5.10). 20. Connect the cellular coaxial cable previously left in vehicle to the OnStar(R) VCIM. 21. Verify that all harnesses are properly secured in vehicle. 6. After replacing the VCIM, it is essential to configure the new OnStar(R) system. Failure to configure the system will result in an additional customer visit for repair. DO NOT press and hold the white dot or phone button on the keypad as it will not reset this version of the OnStar(R) system and may result in a DTC being set. Use of the TIS2WEB and SPS applications, along with the Tech2(R), are required in order to perform the VCIM configuration and setup procedure for this vehicle. The configuration and set-up procedure is now a two-step process which enables an automated activation by the OnStar(R) Center, without a button press by the technician to the OnStar(R) Call Center. 1. Connect the Tech2(R) to the vehicle. Page 15049 The illustrations shown are typical examples of the types of fractures/damage that may occur. Parts Information Warranty Information Page 9808 Location View Page 15639 Fog/Driving Lamp Switch: Service and Repair Fog Lamp Switch Replacement - Rear FOG LAMP SWITCH REPLACEMENT - REAR REMOVAL PROCEDURE 1. Remove the instrument panel bezel. 2. Pull out the accessary switch housing. 3. Disconnect the electrical connectors. 4. Remove the fog lamp switch from the accessary switch housing. INSTALLATION PROCEDURE 1. Install the fog lamp switch into accessary switch housing. 2. Connect the electrical connectors. 3. Install the accessary switch housing. 4. Install the instrument panel bezel. Page 11331 HVAC Control Module - C2 Part 1 HVAC Control Module - C2 Part 2 Page 2705 Location View Page 9392 Disclaimer Page 16309 Wiper Motor: Service and Repair WIPER MOTOR REPLACEMENT TOOLS REQUIRED - J 39232 Wiper Transmission Separator - J 39529 Wiper Transmission Installer REMOVAL PROCEDURE 1. Remove the wiper arms. 2. Remove the air inlet grille panel. 3. Remove the 4 bolts and the reinforcement panel. 4. Disconnect the electrical connector from the wiper motor. 5. Remove the 2 bolts from the wiper transmission assembly. 6. Remove the wiper transmission assembly from the vehicle. Page 11240 9. Install the A/C refrigerant filter (3) to the evaporator tube (2) with the flow arrow pointing towards the evaporator. NOTE: Refer to Fastener Notice in Service Precautions. 10. While holding the evaporator tube in the A/C refrigerant filter (1), tighten the nuts (4) to the A/C refrigerant filter (1). Tighten Tighten the nuts to 15 N.m (11 lb ft). 11. Remove the nuts (4) from the A/C refrigerant filter (1). 12. Coat the O-rings (2) with 525 viscosity refrigerant oil. 13. Install the O-rings (2) to the evaporator tube halves. 14. Install the nuts (4) to the A/C refrigerant filter (1). Tighten Tighten the nuts to 15 N.m (11 lb ft). 15. Evacuate and recharge the system. Refer to Refrigerant Recovery and Recharging. 16. Leak test the fittings of the component using the J 39400-A. 17. Install the air cleaner. Page 10255 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves SPLICING COPPER WIRE USING SPLICE SLEEVES TOOLS REQUIRED J 38125-D Terminal Repair Kit IMPORTANT: Use only GM splice sleeves, other splice sleeves may not protect the splice from moisture or a provide good electrical connection. Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. Page 8102 Brake Bleeding: Service and Repair Master Cylinder Bench Bleeding Master Cylinder Bench Bleeding Caution: Refer to Brake Fluid Irritant Caution in Service Precautions. Notice: When adding fluid to the brake master cylinder reservoir, use only Delco Supreme 11, GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. The use of any type of fluid other than the recommended type of brake fluid, may cause contamination which could result in damage to the internal rubber seals and/or rubber linings of hydraulic brake system components. 1. Secure the mounting flange of the brake master cylinder in a bench vise so that the rear of the primary piston is accessible. 2. Remove the master cylinder reservoir cap and diaphragm. 3. Install suitable fittings to the master cylinder ports that match the type of flare seat required and also provide for hose attachment. 4. Install transparent hoses to the fittings installed to the master cylinder ports, then route the hoses into the master cylinder reservoir. 5. Fill the master cylinder reservoir to at least the half-way point with Delco Supreme 11® (GM P/N 12377967) or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. 6. Ensure that the ends of the transparent hoses running into the master cylinder reservoir are fully submerged in the brake fluid. 7. Using a smooth, round-ended tool, depress and release the primary piston as far as it will travel, a depth of about 25 mm (1 inch), several times. Observe the flow of fluid coming from the ports.As air is bled from the primary and secondary pistons, the effort required to depress the primary piston will increase and the amount of travel will decrease. 8. Continue to depress and release the primary piston until fluid flows freely from the ports with no evidence of air bubbles. 9. Remove the transparent hoses from the master cylinder reservoir. 10. Install the master cylinder reservoir cap and diaphragm. 11. Remove the fittings with the transparent hoses from the master cylinder ports. Wrap the master cylinder with a clean shop cloth to prevent brake fluid spills. 12. Remove the master cylinder from the vise. Page 1463 Turn Signal Multifunction Switch - C1 Page 14200 Switch Replacement - Door Lock and Side Window - Passenger Removal Procedure 1. Remove the front door trim panel. 2. Disconnect the electrical connectors. 3. Remove the screw that retains the switch panel bezel (1) from the front door panel. 4. Remove the switch panel bezel from the door panel using a flat-bladed tool. 5. Using a wide plastic flat-bladed tool, release the retaining clips on both sides of the door module. 6. Remove the door module from the switch panel bezel. Installation Procedure Page 11217 Refrigerant: Technical Service Bulletins A/C - Contaminated R134A Refrigerant Bulletin No.: 06-01-39-007 Date: July 25, 2006 INFORMATION Subject: Contaminated R134a Refrigerant Found on Market for Automotive Air-Conditioning Systems Models: 2007 and Prior GM Passenger Cars and Trucks (including Saturn) 2007 and Prior HUMMER H2, H3 2007 and Prior Saab 9-7X Attention: This bulletin should be directed to the Service Manager as well as the Parts Manager. Commercially Available Contaminated R134a Refrigerant Impurities have been found in new commercially available containers of R134a. High levels of contaminates may cause decreased performance, and be detrimental to some air-conditioning components. Accompanying these contaminates has been high levels of moisture. Tip: Excessive moisture may cause system concerns such as orifice tube freeze-up and reduced performance. Industry Reaction: New Industry Purity Standards Due to the potential availability of these lower quality refrigerants, the Society of Automotive Engineers (SAE), and the Air Conditioning and Refrigeration Industry (ARI) are in the process of instituting reliable standards that will be carried on the labels of future R134a refrigerant containers. This identifying symbol will be your assurance of a product that conforms to the minimum standard for OEM Automotive Air-Conditioning use. How Can You Protect Yourself Today? It is recommended to use GM or ACDelco(R) sourced refrigerants for all A/C repair work. These refrigerants meet General Motors own internal standards for quality and purity, insuring that your completed repairs are as good as the way it left the factory. Parts Information The part numbers shown are available through GMSPO or ACDelco(R). The nearest ACDelco(R) distributor in your area can be found by calling 1-800-223-3526 (U.S. Only). Page 14018 Passenger Assist Handle: Service and Repair Assist Handle Replacement - Rear Assist Handle Replacement - Rear Removal Procedure 1. Remove center pillar trim panel. 2. Remove the assist handle retraining screws. 3. Remove the assist handle from the vehicle. Installation Procedure 1. Install the assist handle to the vehicle. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the assist handle screws. Tighten the screws to 6 N.m (53 lb in). 3. Install the center pillar trim panel. Page 13015 * Dealers using WINs: Add 0.2 hours to the labor time for administrative allowance for the module exchange. Dealers using GWM: Submit 0.2 hours administrative allowance under "Administration Time" for the module exchange. ** The $25 represents the additional net amount allowed for the module exchange. *** Dealers are to claim only administrative allowance of 0.2 hours when the module is replaced by Masscomp's Mobile Unit. Dealers using WINS should submit the 0.2 hours administrative allowance in labor time. Dealer using GWM should submit the 0.2 hours administrative allowance under Administrative Time. Customer Notification OnStar will notify customers of this program on their vehicle. Dealer Program Responsibility All unsold new vehicles in dealers'/retailers' possession and subject to this program must be held and inspected/repaired per the service procedure of this program bulletin before customers take possession of these vehicles. Dealers/retailers are to service all vehicles subject to this program at no charge to customers, regardless of mileage, age of vehicle, or ownership, through April 30, 2011. Customers who have recently purchased vehicles sold from your vehicle inventory, and for which there is no customer information indicated on the dealer/retailer listing, are to be contacted by the dealer/retailer. Arrangements are to be made to make the required correction according to the instructions contained in this bulletin. A copy of the customer letter is provided in this bulletin for your use in contacting customers. Program follow-up cards should not be used for this purpose, since the customer may not as yet have received the notification letter. Page 12825 Diagnostic Tips Review # 4 - Denso legacy Navigation Radio Page 6290 Page 2402 21. With the trunnion seated in the bearing cup, press the bearing cup into the yoke until the bearing cup is flush with the yoke ear. 22. Install the opposite bearing cup part way into the yoke ear. 23. Ensure that the trunnions start straight and true into both bearing cups. 24. Press the opposite bearing cup into the yoke ear while working the cross all the time in order to inspect for free unbinding movement of the trunnions in the bearing cups. Important: If there seems to be a hang up or binding, stop pressing. Inspect the needle bearings for misalignment in the bearing cup. 25. Press the bearing cup into the yoke until the bearing cup retainer groove is visible over the top of the bearing cup. 26. Assemble the bearing retainer in the retainer groove. 27. Continue pressing until both retainers can be snapped into place. 28. If the retainer is difficult to seat, the yoke can be sprung slightly with a firm blow from a soft-faced dead blow hammer. 29. It may be necessary to lubricate the snap ring with a slight amount of chassis grease so that the snap ring seats in the bearing cup groove. 30. Install the slip yoke onto the output shaft in the transfer case. 31. Align the reference marks on the pinion flange and the propeller shaft. 32. Install the yoke retainers and bolts. Tighten Tighten the yoke retainer bolts to 25 N.m (19 lb ft). 33. Lower the vehicle. Page 1836 ^ A foam ring (3) ^ An alignment tab (2) for installing into the adapter and bearing assembly ^ A view of the inside of the connector 7. Important: If reusing the existing sensor, you must align the marks on the flush rotor flange cuff before installation. The alignment mark must stay aligned until the sensor is seated into the adapter and bearing assembly. If installing a new sensor, it will come with a pin installed in the sensor. Do not remove the pin until the sensor is seated. If the new sensor did not come with a pin installed, you must reorder a new sensor. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install into the adapter and bearing assembly. 8. Install the connector to the sensor. 9. From the technicians point of view, the FRONT of the sensor will have: ^ A pin hole (3) for the centering pin. Note location of the pin hole. ^ A raised rotor flange cuff (5) ^ An alignment mark (4) for installation 10. From the technicians point of view, the BACK of the sensor will have: ^ Double D flats (1) ^ An alignment tab (2) for installing into the adapter and bearing assembly 11. Important: If reusing the existing sensor, you must align the marks on the raised rotor flange cuff before installation. The alignment mark must stay aligned until the sensor is seated into the adapter and bearing assembly. If installing a new sensor, it will come with a pin installed in the sensor. Do not remove the pin until the sensor is seated. If the new sensor did not come with a pin installed, you must reorder a new sensor. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install into the adapter and bearing assembly. 12. Install the connector to the sensor. 13. From the technicians point of view, the FRONT of the sensor will have: ^ A pin hole (2) for the centering pin. Note the location of the pin hole. ^ A raised rotor flange cuff (4) ^ An alignment mark (3) for installation 14. From the technicians point of view, the BACK of the sensor will have an alignment tab (1) for installation. This sensor does not have double D flats. 15. Important: If reusing the existing sensor, you must align the marks on the raised rotor flange cuff before installation. The alignment mark must stay aligned Page 13960 Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 8842 Each user will be required to accept the following agreement each time the KeyCode application is used. Key Code User Agreement - Key codes are proprietary information belonging to General Motors Corporation and to the vehicle owner. - Unauthorized access to, or use of, key code information is unlawful and may subject the user to criminal and civil penalties. - This information should be treated as strictly confidential and should not be disclosed to anyone unless authorized. I will ensure that the following information is obtained prior to releasing any Key Code information: 1. Government issued picture ID (Drivers License) 2. Registration or other proof of ownership. Registration should have normal markings from the Province that issued the registration and possibly the receipt for payment recorded as well. Important - GM takes this agreement seriously. Each user must be certain of vehicle ownership before giving out key codes. - When the ownership of the vehicle is in doubt, dealership personnel should not provide the information. Key code requests should never be received via a fax or the internet and key codes should never be provided to anyone in this manner. A face to face contact with the owner of the vehicle is the expected manner that dealers will use to release a key code or as otherwise stipulated in this bulletin or other materials. - Key codes should NEVER be sent via a fax or the internet. - Each Dealership should create a permanent file to document all KeyCode Look Up transactions. Requests should be filed by VIN and in each folder retain copies of the following: - Government issued picture ID (Drivers License) - Registration or other proof of ownership. - Copy of the paid customer receipt which has the name of the employee who cut and sold the key to the customer. - Do not put yourself or your Dealership in the position of needing to "explain" a KeyCode Look Up to either GM or law enforcement officials. - Dealership Management has the ability to review all KeyCode Look-Up transactions. - Dealership KeyCode documentation must be retained for two years. Frequently Asked Questions (FAQs) for GM of Canada Dealers How do I request a KeyCode for customer owned vehicle that is not registered? Scrapped, salvaged or stored vehicles that do not have a current registration should still have the ownership verified by requesting the vehicle title, current insurance policy and / or current lien holder information from the customers financing source. If you cannot determine if the customer is the owner of the vehicle, do not provide the key code information. In these cases, a short description of the vehicle (scrapped, salvaged, etc.) and the dealership location should be kept on file. Any clarifying explanation should be entered into the comments field. How do I document a KeyCode request for a vehicle that is being repossessed? The repossessor must document ownership of the vehicle by providing a court ordered repossession order and lien-holder documents prior to providing key code information. Copies of the repossessors Drivers License and a business card should be retained by the dealership for documentation. What do I do if the registration information is locked in the vehicle? Every effort should be made to obtain complete information for each request. Each Dealership will have to decide on a case by case basis if enough information is available to verify the customer's ownership of the vehicle. Other forms of documentation include vehicle title, insurance policy, and or current lien information from the customers financing source. Dealership Management must be involved in any request without complete information. If you cannot determine if the customer is the owner of the vehicle, do not provide the key code information. Can I get a print out of the information on the screen? It is important to note that the Key Code Look Up Search Results contain sensitive and/or proprietary information. For this reason GM recommends against printing it. If the Search Results must be printed, store and/or dispose of the printed copy properly to minimize the risk of improper or illegal use. Who in the dealership has access to the KeyCode application? Dealership Parts Manager (or assigned management) will determine, and control, who is authorized to access the KeyCode Look Up application. However, we anticipate that dealership parts and service management will be the primary users of the application. The KeyCode Look Up application automatically tracks each user activity session. Information tracked by the system includes: User name, User ID, all other entered data and the date/time of access. Page 5943 Shift Interlock Solenoid: Service and Repair Automatic Transmission Shift Lock Actuator Replacement Removal Procedure 1. Caution: Refer to SIR Caution in Service Precautions. Disable the SIR system. 2. Remove the body control module (BCM). 3. Put the shift lever clevis into the neutral position. 4. Disconnect the electrical connector. 5. Using a small screwdriver, pry the automatic transmission shift lock control actuator away from the steering column jacket and the cable shift cam. 6. Remove the shift lock control actuator. Installation Procedure 1. Firmly install the shift lock control actuator onto the steering column jacket and the cable shift cam. 2. Connect the electrical connector. 3. Adjust the shift lock control actuator (with the shift lever clevis in the neutral position) in the following way: 1. Pull out the tab (1) on the adjuster block side (2) of the shift lock control actuator. 2. Press on the adjuster block (2) to compress the internal adjuster spring which disengages the adjuster teeth. Slide the adjuster block (2) as far away from the actuator as possible. 3. Lock the adjuster block (2) in place by pushing in on the tab (1). 4. Inspect the shift lock control actuator for the following items: Page 5743 Control Module: Locations NVG 263-NP1 Transfer Case Shift Control Module Transfer Case Shift Control Module 1 - I/P Harness 2 - Transfer Case Shift Control Module Connectors 3 - Transfer Case Shift Control Module 4 - Instrument Panel Page 1406 Fuel Gauge Sender: Diagrams Fuel Pump/Sender Assembly - Primary Page 4612 3. If equipped with a 6.0L engine, connect the HO2S electrical connector. 4. If equipped with a 4.8L or 5.3L engine, connect the HO2S electrical connector. 5. Install the HO2S connector clip to the frame. 6. Disconnect the CPA retainer. 7. Lower the vehicle. Page 5269 Fuel Injector 6 Page 14964 Tailgate Latch: Service and Repair Latch Replacement - Endgate Removal Procedure 1. Lower the endgate. 2. Loosen the handle bolts. 3. Raise the endgate. 4. Remove the handle bezel by prying gently on the upper retainer tabs. 5. Disengage the linkage rods (1). 6. Lower and support the endgate. 7. Remove the cables from the side panel cable retainer bolts. Page 7561 2. Connect the gear indicator switch electrical connector (2). 3. Install the transfer case shield, if equipped. Page 5591 Knock Sensor (KS) Page 12921 Audio Amplifier C2 - With RPO Code UQ7 Without RPO Code Y91 - Part 2 Page 10620 Refer to the appropriate section of SI for specifications and repair procedures that are related to the vibration concern. Disclaimer Page 3834 Door Control Module Diagram 2 Part 1 Page 518 Driver Door Module (DDM) - C4 (With RPO Code YE9) Part 2 Page 12717 ^ Pay the dealer the regular retail price (no discounts are available) for one of the following 1-year, non-refundable OnStar(R) Analog-to-Digital Transition (ADT) Service Subscription Plans: ^ 1-year Safe & Sound Subscription: $199 ($289 in Canada) ^ 1-year Directions & Connections Subscription: $399 ($579 in Canada) ^ Pay the dealer the applicable state and local sales taxes on the subscription: ^ U.S. Dealers: Taxes only apply in these states: CT, DC, FL, HI, ND, NJ, NM, NY, SC, SD, TX, and WV ^ Canadian Dealers: All applicable taxes ^ Pay the dealer a one-time charge of $15 for the upgrade: ^ U.S. Dealers: Do not collect taxes on the $15 ^ Canadian Dealers: Collect all applicable taxes on the $15 Note: Dealers should NOT remit OnStar(R) ADT-related taxes to their taxing authority as OnStar(R) is responsible for tax remittance. Please Be Sure To Read these Important Points: ^ The 1-year OnStar(R) subscription is not refundable or transferable to another person. Upgraders can apply unused subscription months to a new or Certified Pre-Owned digital OnStar-equipped GM vehicle purchase or lease. As noted above, the digital upgrade program requires the subscriber to purchase a one-year prepaid OnStar(R) subscription. Assuming the subscriber intends to keep their vehicle, but subsequently purchases or leases a 2006 model year or newer OnStar(R)-equipped new or certified used GM vehicle, in the interest of subscriber satisfaction, they may apply remaining unused whole months of the subscription to the new vehicle. The subscription may not be applied to another person's vehicle. Important: This is a customer satisfaction measure that would usually occur several months after an upgrade. It is not intended to be leveraged as part of a new/used vehicle purchase or lease transaction. ^ The $15 charge is not refundable. ^ Dealer ADT kit orders are VIN specific. Dealer kit orders require a VIN and must be exchanged with the OnStar(R) unit in the vehicle with that VIN. Proper activation and enrollment depends on this step. ^ You must put the actual miles on the Repair Order. Do not estimate. ^ Customers will receive a Hands-Free Calling number once the digital hardware is installed and configured. ^ Any nametags that were stored in the old system will need to be re-set by the subscriber once the new hardware is installed. ^ Customers are responsible for the charges described above regardless of whether their vehicle is in or out of the New Vehicle Warranty period. In addition, customers should not be charged labor costs. Dealers can charge GM the labor for the upgrade as specified at the end of this bulletin using the listed labor operation. ^ Vehicles eligible for an OnStar(R) hardware upgrade are listed in this bulletin. Vehicle upgradeability can also be determined by typing the VIN into the field entitled "Determine VIN Hardware Functionality" on the OnStar(R) Online Enrollment website, located in the sales or service workbench tab of GM GlobalConnect. Canadian Dealers can use a similar tool that is available within InfoNET. ^ Access to the sales and/or service workbench in the GM GlobalConnect website can be granted by the dealership's Partner Security Coordinator (PSC). If you are unsure who the PSC is, check with the Sales Manager. Ordering the Upgrade Kit/Upgrade kit Installation Ordering the Upgrade Kit 1. To order a kit, you will need to access the OnStar(R) Online Enrollment webpage, located under the sales or service workbench of GM GlobalConnect (infoNET for Canadian upgrade orders). These kits cannot be ordered from GMSPO. Page 15448 Door Latch Assembly (Door Jamb Switch) - Driver - C2 Page 11095 Control Module HVAC: Service and Repair HVAC System - Manual HVAC CONTROL MODULE REPLACEMENT REMOVAL PROCEDURE 1. Remove the instrument cluster trim plate bezel. 2. Remove the instrument panel storage tray. 3. Remove the accessory switch assembly from the instrument panel. 4. Remove the screws from the HVAC control assembly. 5. Remove the HVAC control assembly, with the following procedure: 5.1. Release the retaining tabs. 5.2. Pull the control head out of the instrument panel carrier. 6. Disconnect the electrical connectors from the HVAC control assembly. INSTALLATION PROCEDURE IMPORTANT: The Key should be in the off position when connecting the electrical connectors to ensure proper calibration. 1. Connect the electrical connectors to the HVAC control assembly. 2. Install the HVAC control assembly. 3. Install the accessory switch assembly to the instrument panel. NOTE: Refer to Fastener Notice in Service Precautions. 4. Install the screws from the HVAC control assembly. Tighten Tighten the screws to 1.9 N.m (17 lb in). Page 16262 7. Apply a small bead of urethane adhesive (2) between the windshield (1) and the pinchweld. 8. Install the upper reveal molding. 1. Start from the center and hand-press the reveal molding into place over the edge of the windshield. 2. Install both right and left sides of the reveal molding. 3. Run warm water over the reveal molding in order to speed the setup time of the urethane adhesive. Tape should be applied in order to retain the reveal molding to the windshield, this will maintain a flush fit with the body. The tape is to be removed after 6 hours. Page 15782 Door Latch Assembly (Door Jamb Switch) - RR - C2 (Crew Cab Only) Page 11598 Page 3740 3. if equipped with a 6 1/2 ft box, install the exhaust heat shield. 4. Install the exhaust heat shield bolts. Tighten the exhaust heat shield bolts to 9 Nm (80 inch lbs.). 5. Install the spare tire hoist. 6. Install the exhaust muffler. Page 13117 DTC B2483: Global Positioning System (GPS) Antenna Malfunction Short to Ground DTC B2484: Global Positioning System (GPS) Antenna Malfunction Open Circuit Conditions for Running the DTCs The ignition is in RUN or ACC position System voltage is between 9.5 - 15.5 volts. The above conditions are met for more than 1 second. Conditions for Setting the DTCs B2462 02: The CIM detects a short to ground on the navigation antenna signal circuit. B2462 04: The CIM detects an open/high resistance on the navigation antenna signal circuit. B2483: The CIM detects a short to ground on the navigation antenna signal circuit. B2484: The CIM detects an open/high resistance on the navigation antenna signal circuit. Action Taken When the DTCs Set The OnStar(R) status LED turns red. The OnStar(R) Call Center cannot locate the vehicle. Conditions for Clearing the DTCs The condition responsible for setting the DTC no longer exists. A history DTC will clear once 50 consecutive malfunction-free ignition cycles have occurred. Circuit/System Testing Turn OFF the ignition. 1. Disconnect the navigation antenna coax cable from the VCIM. 2. Ignition ON, test for 4.5-5.5 volts between the VCIM coax cable center conductor terminal at the VCIM and ground. ^ If not within the specified range, replace the VCIM. Refer to the appropriate vehicle in SI. 3. Reconnect the coax cable to the VCIM. 4. Disconnect the coax cable from the navigation antenna. 5. Test for 4.55.5 volts between the coax cable center conductor and the outer shield. ^ If not within the specified range, replace the coax cable. 6. If all circuits test normal, replace the navigation antenna. Refer to the appropriate vehicle in SI. DTC B2470 DTC Descriptor DTC B2470 04: Cellular Phone Antenna Circuit Malfunction Open Circuit Circuit/System Description The cellular antenna is connected to the vehicle communication interface module (VCIM) with an RG-58 coax cable. The VCIM collects the data from the cellular antenna once every second. Page 14363 Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA and/or the secondary locks. Micro .64 Connectors MICRO .64 CONNECTORS TOOLS REQUIRED J 38125-D Terminal Repair Kit REMOVAL PROCEDURE Follow the steps below in order to remove terminals from Micro 64 connectors. 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. 2. Disconnect the connector from the component. Page 10151 ^ A foam ring (3) ^ An alignment tab (2) for installing into the adapter and bearing assembly ^ A view of the inside of the connector 7. Important: If reusing the existing sensor, you must align the marks on the flush rotor flange cuff before installation. The alignment mark must stay aligned until the sensor is seated into the adapter and bearing assembly. If installing a new sensor, it will come with a pin installed in the sensor. Do not remove the pin until the sensor is seated. If the new sensor did not come with a pin installed, you must reorder a new sensor. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install into the adapter and bearing assembly. 8. Install the connector to the sensor. 9. From the technicians point of view, the FRONT of the sensor will have: ^ A pin hole (3) for the centering pin. Note location of the pin hole. ^ A raised rotor flange cuff (5) ^ An alignment mark (4) for installation 10. From the technicians point of view, the BACK of the sensor will have: ^ Double D flats (1) ^ An alignment tab (2) for installing into the adapter and bearing assembly 11. Important: If reusing the existing sensor, you must align the marks on the raised rotor flange cuff before installation. The alignment mark must stay aligned until the sensor is seated into the adapter and bearing assembly. If installing a new sensor, it will come with a pin installed in the sensor. Do not remove the pin until the sensor is seated. If the new sensor did not come with a pin installed, you must reorder a new sensor. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install into the adapter and bearing assembly. 12. Install the connector to the sensor. 13. From the technicians point of view, the FRONT of the sensor will have: ^ A pin hole (2) for the centering pin. Note the location of the pin hole. ^ A raised rotor flange cuff (4) ^ An alignment mark (3) for installation 14. From the technicians point of view, the BACK of the sensor will have an alignment tab (1) for installation. This sensor does not have double D flats. 15. Important: If reusing the existing sensor, you must align the marks on the raised rotor flange cuff before installation. The alignment mark must stay aligned Page 14591 Memory Seat Module - C2 Page 2018 Control Module References Part 3 Drivetrain - Service 4WD Light/DTC C0374 Set Speed Sensor: Customer Interest Drivetrain - Service 4WD Light/DTC C0374 Set TECHNICAL Bulletin No.: 05-04-21-003C Date: April 15, 2008 Subject: Service 4WD Light Illuminated, DTC C0374 Set (Inspect Wiring Harness to Transfer Case Speed Sensors,, Replace Wiring Harness) Models: 2004-2007 Buick Rainier 2003-2006 Chevrolet Avalanche, Suburban, Tahoe 2003-2007 Chevrolet Silverado Classic, TrailBlazer, TrailBlazer EXT 2003-2006 GMC Yukon, Yukon XL 2003-2007 GMC Envoy, Envoy XL, Sierra Classic 2003-2004 Oldsmobile Bravada 2005-2007 Saab 9-7X With Four Wheel Drive or All-Wheel Drive and Active All-Wheel Drive (RPO NP4) or Active Two-Speed (RPO NP8) Transfer Case Supercede: This bulletin is being revised to update the Model and Warranty Information. Please discard Corporate Bulletin Number 05-04-21-003B (Section 04 - Driveline/Axle). Condition Some customers may comment on intermittent illumination of the Service 4WD light. Upon investigation, the technician may find DTC C0374 set. The customer may also comment on intermittent erratic operation of the 4WD or AWD system after driving through rain/snow or simply going through a car wash. Cause The speed sensor signal may have become corrupted. Possible openings in the speed sensor wire insulation (twisted pairs) can allow water intrusion. Also wire connections contaminated by water may result in short circuits and erroneous speed sensor readings. This most often occurs on the rear speed sensor circuit. Correction Inspect the wiring harness to the transfer case speed sensors. On Rainier, TrailBlazer, Envoy and 9-7X models, fabricate a replacement speed sensor harness between the C101 connector and the speed sensors. Completely inspect and test all wiring. Refer to Speed Signal Front Axle Actuator and Indicators schematic in SI. Replace the affected twisted pairs. Do not over-twist the two wires in the replacement harness. Wires should be twisted at a rate of 9 revolutions per foot. Use service connector pack, P/N 88987993 at the speed sensor end and terminal, P/N 15326267, at C101. Terminal testing tools and service terminals can be found in Terminal Repair Kit J 38125. Terminals are available from SPX/Kent-Moore. The smaller transfer case harness splices into the larger chassis harness a few inches in front of the crossmember. The chassis harness routes along the left side of the frame under the driver door area. Use nylon tie straps to secure the fabricated harness to the main chassis harness between the transfer case and C101. On the full-size pickup and full-size utility models, replace the 2.2 m (88 in) pigtail harness that runs from the C151 connector under the hood to the transfer case. Use either harness P/N 15832722 or 15224663 depending on vehicle equipment. Refer to Propshaft Speed Sensors Front Axle Actuator and Transfer Case Shift Control Switch schematic in SI. Important: Technicians should verify the integrity of the splice joints after the repair. All splice joints and connections should seal properly against water or a repeat condition can occur. Page 958 Remove all rust from the ground terminal, the cylinder head and the retaining nut or bolt. Position the main engine wiring harness ground terminal and install the nut or bolt. Tighten: Tighten the retaining nut or bolt to 16 N.m (12 lb ft). Apply some type of electrical moisture sealant to protect the harness terminal from further corrosion. Disclaimer Service and Repair Power Steering Bleeding: Service and Repair Power Steering System Bleeding Important: - Use clean, new power steering fluid type only. See: Maintenance - Hoses touching the frame, body or engine may cause system noise. Verify that the hoses do not touch any other part of the vehicle. - Loose connections may not leak, but could allow air into the steering system. Verify that all hose connections are tight. - Power steering fluid level must be maintained throughout bleed procedure. 1. Fill pump reservoir with fluid to minimum system level, FULL COLD level, or middle of hash mark on cap stick fluid level indicator. Important: With hydro-boost only, the oil level will appear falsely high if the hydro-boost accumulator is not fully charged. Do not apply the brake pedal with the engine OFF. This will discharge the hydro-boost accumulator. 2. If equipped with hydro-boost, fully charge the hydro-boost accumulator using the following procedure: 2.1 Start the engine. 2.2 Firmly apply the brake pedal 10-15 times. 2.3 Turn the engine OFF. 3. Raise the vehicle until the front wheels are off the ground. 4. Key on engine OFF, turn the steering wheel from stop to stop 12 times. - Vehicle equipped with hydro-boost systems or longer length power steering hoses may require turns up to 15 to 20 stop to stops. 5. Verify power steering fluid level per operation specification. See: Power Steering Fluid 6. Start the engine. Rotate steering wheel from left to right. Check for sign of cavitation or fluid aeration (pump noise/whining). 7. Verify the fluid level. Repeat the bleed procedure, if necessary. Page 14276 Paint: Vehicle Damage Warnings Basecoat/Clearcoat Paint Systems CAUTION: - Exposure to isocyanates during paint preparation and application processes can cause severe breathing problems. Read and follow all of the instructions from the manufacturers of painting materials, equipment, and protective gear. - Approved safety glasses and gloves should be worn when performing this procedure to reduce the chance of personal injury. All paint finish repairs of rigid exterior surfaces must meet GM standards. The GM Approved Refinish Materials book GM P/N GM4901M-D identifies the paint systems you may use. Always refer to the latest revision of the 4901M-D book. All approved products, including volatile organic compound (VOC) compliant regulations are listed in the system approach recommended by the individual manufacturer. Refer to the manufacturer's instructions for the detailed procedures for materials used in the paint system in the painting repairs of rigid exterior surfaces. All components of an approved paint system have been engineered in order to ensure proper adhesion between layers.If necessary, spot repairs or color blending in an open panel can be done. However, do not blend clear coat in an open panel. Always apply clearcoat to the next break point (body side molding, feature line, or the next panel) Do not mix paint systems or substitute a product of one manufacturer for another manufacturer's product. If incompatible products are used together the following problems may occur: - Lifting of primer coats caused by overly aggressive solvents in subsequent layers - Loss of adhesion between layers due to incompatibility of resin systems - Solvent popping or pin holing due to inappropriate solvent selection - Poor through-curing due to incompatible hardener resins or insufficient reactivity - Gloss reduction due to incompatible resins and/or solvents - Poor color accuracy due to pigment interactions with incompatible resins and/or solvents - Film defects (craters, blisters, orange peel loss of gloss) due to the use of inferior quality raw materials in incompatible products. Page 752 HVAC Control Module - C2 Part 1 HVAC Control Module - C2 Part 2 Page 13480 The information shown is for the 1999-2002 wiring harnesses and for the 2003-05 wiring harness. To modify a 12171982, 15366255 or 15086884 harness for use in a 2003-05 vehicle, switch the wires in cavities "A" and "D". To modify a 15085418 harness for use in a 1999-2002 vehicle (see model list at the front of this bulletin for applicable models), switch the wires in cavities "A" and "D". Warranty Information When the correct wiring harness P/N is matched to the specific model year of the vehicle, everything works properly. Therefore, conversion of an incorrect wiring jumper to match the vehicle would not be considered a warrantable repair. Disclaimer Electrical - Trailer Brakes Apply With Headlamps ON Trailer Lighting Module: All Technical Service Bulletins Electrical - Trailer Brakes Apply With Headlamps ON Bulletin No.: 02-05-22-004C Date: April 05, 2005 TECHNICAL Subject: Trailer Brakes Applied When Headlights/Park Lamps Are On, Brake Controller Illumination (Modify Brake Controller Wiring Harness) Models: 2002-2005 Cadillac Escalade, Escalade EXT 1999-2005 Chevrolet Silverado 2000-2005 Chevrolet Suburban, Tahoe 2002-2005 Chevrolet Avalanche 1999-2005 GMC Sierra 2000-2005 GMC Yukon, Yukon XL 2003-2005 HUMMER H2 Supercede: This bulletin is being revised to add additional model years. Please discard Corporate Bulletin Number 02-05-22-004B (Section 05 - Brakes). Condition Some customers may comment that when the headlamps or park lamps are on, the brakes on the trailer are always applied, or that the back lighting for the trailer brake controller only illuminates when the brakes are applied. Cause The cause of this condition may be due to wiring changes within the vehicle electrical system for the 2003 model year. Correction Inspect the brake controller wiring harness jumper that is plugged into the vehicle relay block-body. The relay block-body is located under the left side of the instrument panel near the left kick panel, behind a plastic cover. Page 9448 Control Module References Part 5 Page 11577 Page 10091 Power Steering Pump: Diagrams Disassembled View Power Steering Pump Disassembled View (Regular) Page 14344 Electrical Symbols Part 4 Page 4446 5. Remove the PCM cover. 6. Loosen the PCM electrical connector bolts (2). NOTE: Refer to PCM and ESD Notice in Service Precautions. - In order to prevent internal damage to the PCM, the ignition must be OFF when disconnecting or reconnecting the PCM connector. 7. Disconnect the PCM electrical connectors. 8. Release the spring latch from the PCM. 9. Release the PCM mounting tabs from the PCM. 10. Remove the PCM. INSTALLATION PROCEDURE Page 15885 4. Close the endgate. 5. Inspect the operation. Page 14333 8. Install the front end diagonal brace. 9. Install the front end diagonal brace bolts. Tighten the front end diagonal brace bolts to 25 N.m (18 lb ft). 10. Install the upper condenser mounting bolts. Tighten the upper condenser mounting bolts to 9 N.m (80 lb in). 11. Install the headlamps. 12. Install the upper radiator baffle. 13. Connect the negative battery cable. Locations Engine Oil Pressure (EOP) Sensor And CMP Sensor Page 9066 Relay Block - I/P C10 Part 2 Page 1770 Inflatable Restraint Side Impact Sensor (SIS) - Right (With RPO Code HP2) Page 13295 ^ For U.S. Saturn retailer claim submission, use Net Item code "M" and Case Type VW. Page 3810 Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips SPLICING COPPER WIRE USING SPLICE CLIPS IMPORTANT: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. TOOLS REQUIRED J 38125-D Terminal Repair Kit 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-D in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. Page 14886 Power Seat Switch: Locations Driver Seat (1 Of 2) Page 9201 C201 Steering Column Harness To I/P Harness Part 3 Page 15961 circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links CIRCUIT PROTECTION - FUSIBLE LINKS Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Flat Wire Repairs FLAT WIRE REPAIRS NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Heated Oxygen Sensor (HO2S) Wiring Repairs HEATED OXYGEN SENSOR (HO2S) WIRING REPAIRS TOOLS REQUIRED J 38125-D Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: - Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-D. Repairing Damaged Wire Insulation REPAIRING DAMAGED WIRE INSULATION Page 1123 Seat Front Vertical Position Sensor - Driver (With RPO Code AN3) Page 14092 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. REPLACEMENT PROCEDURE After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Insure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the Terminal Removal Procedure. Repairing Connector Terminals REPAIRING CONNECTOR TERMINALS TOOLS REQUIRED J 38125-D Terminal Repair Kit Use the following repair procedures in order to repair the following: - Push to Seat terminals - Pull to Seat terminals - Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-D contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100 World terminals. Soldering Micro-Pack 100 World terminals may damage the terminal. Circuit Protection - Circuit Breakers CIRCUIT PROTECTION - CIRCUIT BREAKERS A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Page 6134 Remove all rust from the ground terminal, the cylinder head and the retaining nut or bolt. Position the main engine wiring harness ground terminal and install the nut or bolt. Tighten: Tighten the retaining nut or bolt to 16 N.m (12 lb ft). Apply some type of electrical moisture sealant to protect the harness terminal from further corrosion. Disclaimer Page 12780 If you are unsure who the PSC is, check with the Sales Manager. General Information 1. The first step is to verify if the OnStar(R) account is active or not. This can be done by pressing the blue OnStar(R) button and connecting to the OnStar(R) call center. Analog only accounts are no longer active. Only digital upgraded accounts will be active. On Gen 6 digital systems, a clear, or "dark" LED may indicate that the OnStar(R) system has been deactivated or may possibly have a no power/no communication condition. 2. If the account isn't active, the next step is to verify what version of OnStar(R) module is in the vehicle. This can be done via the Tech 2 (Body>VCIM>Module ID Information>Module Information 2) or by using www.onstarenrollment.com. 3. A Generation 5 or older analog module can be diagnosed by following the original electronic Service Information developed for the model year of the vehicle. Note: If the customer has an old analog module, the vehicle can be repaired by replacing the module, but the customer cannot have an active account without upgrading to a digital module. 4. Modules, antennas, brackets, and other equipment are in the same location, whether original analog production or digital upgrade. 5. An upgraded vehicle may also have a new vehicle communication interface module (VCIM) bracket. If it does, order the new bracket when replacing the bracket. Don't order the original bracket. The kit may also include a small wiring jumper cable. If it does, this jumper will be required for a new module replacement. Do not discard. 6. After replacing the VCIM, it is essential to configure the new OnStar(R) system. Failure to configure the system will result in an additional customer visit for repair. DO NOT press and hold the white dot or phone button on the keypad as it will not reset this version of the OnStar(R) system and may result in a DTC being set. Use of the TIS2WEB and SPS applications, along with the Tech2(R), are required in order to perform the VCIM configuration and setup procedure for this vehicle. The configuration and set-up procedure is now a two-step process which enables an automated activation by the OnStar(R) Center, without a button press by the technician to the OnStar(R) Call Center. Service and Repair Air Bag(s) Arming and Disarming: Service and Repair SIR Disabling and Enabling The SIR Identification Views shown below illustrate the approximate location of all SIR components available for the vehicle. This will assist in determining the appropriate SIR Disabling and Enabling for a given service procedure. Refer to See: Restraint Systems/Air Bag Systems/Locations/SIR Zone Identification Views There are several reasons for disabling the SIR system, such as repairs to the SIR system or servicing a component near or attached to an SIR component. There are several ways to disable the SIR system depending on what type of service is being performed. The following information covers the proper procedures for disabling/enabling the SIR system. SIR Service Precautions Caution: When performing service on or near the SIR components or the SIR wiring, the SIR system must be disabled. Failure to observe the correct procedure could cause deployment of the SIR components. Serious injury can occur. Failure to observe the correct procedure could also result in unnecessary SIR system repairs. The inflatable restraint sensing and diagnostic module (SDM) maintains a reserved energy supply. The reserved energy supply provides deployment power for the air bags if the SDM loses battery power during a collision. Deployment power is available for as much as 1 minute after disconnecting the vehicle power. Waiting 1 minute before working on the system after disabling the SIR system prevents deployment of the air bags from the reserved energy supply. General Service Instructions The following are general service instructions which must be followed in order to properly repair the vehicle and return it to its original integrity: - Do not expose inflator modules to temperatures above 65°C (150°F). - Verify the correct replacement part number. Do not substitute a component from a different vehicle. - Use only original GM replacement parts available from your authorized GM dealer. Do not use salvaged parts for repairs to the SIR system. Discard any of the following components if it has been dropped from a height of 91 cm (3 feet) or greater: - Inflatable restraint sensing and diagnostic module (SDM) - Any Inflatable restraint air bag module - Inflatable restraint steering wheel module coil - Any Inflatable restraint sensor - Inflatable restraint seat belt pretensioners - Inflatable restraint Passenger Presence System (PPS) module or sensor Disabling Procedure - Air Bag Fuse 1. Turn the steering wheel so that the vehicles wheels are pointing straight ahead. 2. Place the ignition in the OFF position. Important: The SDM may have more than one fused power input. To ensure there is no unwanted SIR deployment, personal injury, or unnecessary SIR system repairs, remove all fuses supplying power to the SDM. With all SDM fuses removed and the ignition switch in the ON position, the AIR BAG warning indicator illuminates. This is normal operation, and does not indicate a SIR system malfunction. 3. Locate and remove the fuse(s) supplying power to the SDM. Page 5097 1. Install the EVAP CVS valve line to the CVS, if necessary. 2. Install the CVS valve and line. NOTE: Refer to Fastener Notice in Service Precautions. 3. Install the EVAP CVS valve bracket bolt (1). Tighten Tighten the bolt to 12 N.m (106 lb in). 4. Install the EVAP CVS line to the clips on the fuel tank. 5. Connect the EVAP CVS electrical connector (1). Page 916 Body Control Module (BCM) - C2 Part 3 Page 9074 Application Table Part 1 Page 3585 Coolant: Technical Service Bulletins Cooling System - Coolant Recycling Information Bulletin No.: 00-06-02-006D Date: August 15, 2006 INFORMATION Subject: Engine Coolant Recycling and Warranty Information Models: 2007 and Prior GM Passenger Cars and Trucks (Including Saturn) 2007 and Prior HUMMER Vehicles 2005-2007 Saab 9-7X Attention: Please address this bulletin to the Warranty Claims Administrator and the Service Manager. Supercede: This bulletin is being revised to adjust the title and Include Warranty Information. Please discard Corporate Bulletin Number 00-06-02-006C (Section 06 - Engine/Propulsion System). Coolant Reimbursement Policy General Motors supports the use of recycled engine coolant for warranty repairs/service, providing a GM approved engine coolant recycling system is used. Recycled coolant will be reimbursed at the GMSPO dealer price for new coolant plus the appropriate mark-up. When coolant replacement is required during a warranty repair, it is crucial that only the relative amount of engine coolant concentrate be charged, not the total diluted volume. In other words: if you are using two gallons of pre-diluted (50:50) recycled engine coolant to service a vehicle, you may request reimbursement for one gallon of GM Goodwrench engine coolant concentrate at the dealer price plus the appropriate warranty parts handling allowance. Licensed Approved DEX-COOL(R) Providers Important: USE OF NON-APPROVED VIRGIN OR RECYCLED DEX-COOL(R) OR DEVIATIONS IN THE FORM OF ALTERNATE CHEMICALS OR ALTERATION OF EQUIPMENT, WILL VOID THE GM ENDORSEMENT, MAY DEGRADE COOLANT SYSTEM INTEGRITY AND PLACE THE COOLING SYSTEM WARRANTY UNDER JEOPARDY. Shown in Table 1 are the only current licensed and approved providers of DEX-COOL(R). Products that are advertised as "COMPATIBLE" or "RECOMMENDED" for use with DEX-COOL(R) have not been tested or approved by General Motors. Non-approved coolants may degrade the Page 16195 For vehicles repaired under warranty, use the table. Disclaimer Page 15931 Electrical Symbols Part 3 Page 1608 2. Connect the MAP sensor electrical connector (1). 3. Install the engine sight shield. Page 1207 Driver Door Module (DDM) - C5 (Memory/Heated Seat Switch) Part 2 Interior - Front Heated Seat(s) Inoperative Seat Heater Switch: Customer Interest Interior - Front Heated Seat(s) Inoperative Bulletin No.: 04-08-50-007 Date: March 12, 2004 INFORMATION Subject: Service Information for Front Heated Seat Inoperative/Cold Models: 2003-2004 Cadillac Escalade/ESV/EXT 2003-2004 Chevrolet Avalanch/Silverado/Suburban/Tahoe 2003-2004 GMC Denali/Sierra/Yukon/Yukon XL 2003-2004 Hummer H2 The purpose of this bulletin is to provide the technician with the following service information: ^ Heated Seats Switch Operation ^ Heated Seats Switch Diagnostics ^ Heated Seats Switch Customer Information Switch Operation 1. The engine must be running for the heated seat feature to work. The heated seats will shut off automatically when the ignition is turned off. 2. Two buttons, located on the door, are used to control the heated seat. ^ Press the horizontal (RH) button to heat the entire seat, back and cushion. ^ Press the vertical (LH) button to heat ONLY the seat back. ^ The three light bars are an indicator of the level of heat selected for either the entire seat (horizontal button) or ONLY the seat back (vertical button). 3. To heat both the seat back and seat cushion at the same time, press the horizontal (RH) button with the heated seat symbol one time. ^ All 3 light bars will glow indicating the HIGH temperature setting. ^ The horizontal (RH) button does NOT have an ON/OFF indicator light. Page 8554 of failure to repair within a reasonable time. If the condition is not adequately repaired within a reasonable time, the customer may be entitled to an identical or reasonably equivalent vehicle at no charge or to a refund of the purchase price less a reasonable allowance for depreciation. To avoid having to provide these burdensome remedies, every effort must be made to promptly schedule an appointment with each customer and to repair their vehicle as soon as possible. In the recall notification letters, customers are told how to contact the US National Highway Traffic Safety Administration if the recall is not completed within a reasonable time. Dealer Recall Responsibility -- All All unsold new vehicles in dealers' possession and subject to this recall MUST be held and inspected/repaired per the service procedure of this recall bulletin BEFORE customers take possession of these vehicles. Dealers are to service all vehicles subject to this recall at no charge to customers, regardless of mileage, age of vehicle, or ownership, from this time forward. Customers who have recently purchased vehicles sold from your vehicle inventory, and for which there is no customer information indicated on the dealer listing, are to be contacted by the dealer. Arrangements are to be made to make the required correction according to the instructions contained in this bulletin. A copy of the customer letter is shown in this bulletin for your use in contacting customers. Recall follow-up cards should not be used for this purpose, since the customer may not as yet have received the notification letter. In summary, whenever a vehicle subject to this recall enters your vehicle inventory, or is in your dealership for service in the future, please take the steps necessary to be sure the recall correction has been made before selling or releasing the vehicle. Disclaimer Service Procedure Inspection Tools Required CH 47950 Hydro-Boost Checking Tool 1. With the vehicle transmission in PARK or NEUTRAL, set the park brake. 2. With the engine OFF, make a minimum of five (5) high effort brake applies until the pedal feels hard. 3. Start the engine. Important: DO NOT depress the brake pedal until instructed. 4. Turn the steering wheel to the "steering lock" (fully turned) position. Hold at the steering lock position for 1 to 2 seconds and then release the steering wheel. Repeat a total of 3 times. 5. Turn the vehicle off being careful not to step on the brake pedal. 6. For Express/Savana only: A. Remove the remote power steering reservoir mounting nuts. B. Disconnect the reservoir outlet hose from the booster unit. Keeping the hose end higher than the reservoir, reposition the reservoir forward and down out of the way. 7. Using a clean, lint-free shop cloth, wipe any dirt away from the steering pump supply hose/tube connection area on the hydro-boost (this is the center hose/tube of the three). 8. Disconnect the power steering supply hose/tube from the hydro-boost unit and wrap a clean lint-free shop cloth around the end of the hose and secure it in the engine compartment. 9. Using a clean lint-free shop cloth, clean any dirt off of the inlet port adapter valve assembly. Before installing the inlet port adapter, place a shop Garnish Molding Replacement - Center Pillar Trim Panel: Service and Repair Garnish Molding Replacement - Center Pillar Garnish Molding Replacement - Center Pillar Removal Procedure 1. Remove the door sill plates. 2. Remove the pillar moldings by holding the moldings firmly while pulling out. Installation Procedure 1. Install the pillar moldings by pushing until the molding locks into place. 2. Install the door sill trim plates. Page 5380 14. Install the fuel line clip(s) to the bracket(s) on the transmission. 15. Install the HO2S sensor connector to the bracket. 16. Install the fuel pipe bracket to the bellhousing stud. 17. Install the fuel pipe bracket nut. Tighten Tighten the nut to 10 N.m (89 lb in). 18. Lower the vehicle. 19. Remove the caps from the fuel rail and EVAP lines. 20. Connect the EVAP canister purge tube (2) fitting. 21. Connect the fuel feed line (1) fitting at the engine. 22. Install the fuel fill cap. 23. Connect the negative battery cable. 24. Use the following procedure in order to inspect for leaks: 24.1. Turn the ignition ON, with the engine OFF, for 2 seconds. 24.2. Turn the ignition OFF for 10 seconds. 24.3. Turn the ignition ON, with the engine OFF. 24.4. Inspect for fuel leaks. Fuel Hose/Pipes Replacement - Chassis (Cab/Chassis-Front) FUEL HOSE/PIPES REPLACEMENT - CHASSIS (CAB/CHASSIS - FRONT) REMOVAL PROCEDURE IMPORTANT: Clean the fuel and evaporative emission (EVAP) connections and surrounding areas prior to disconnecting the lines in order to avoid possible system contamination. Page 2553 Refrigerant Oil: Fluid Type Specifications REFRIGERANT OIL PAG Oil GM P/N 12378526 (Canadian P/N 88900060) Page 6272 1. Install the transmission fluid cooler hoses to the vehicle. 2. Install the transmission fluid cooler hoses to the transmission. 3. Install the transmission fluid cooler hoses to the retainer on the engine. 4. Install the engine protection shield. 5. Lower the vehicle. 6. Install the transmission fluid cooler hose to the radiator. 7. Install the transmission fluid cooler hose from the Auxiliary oil cooler. 8. Install the grille assembly. Page 9594 Relay Block - I/P C1 Part 5 Page 999 Steps 4 - 5 Page 873 Electrical Symbols Part 10 Page 12873 6. See wiring diagram shown above for details. 5. Replace the OnStar(R) Vehicle Communication Interface Module (VCIM) in the vehicle with the provided Digitally-Capable VCIM. Refer to the Communication Interface Module Replacement procedure in the Cellular Communication section of SI. This kit may include a new VCIM bracket. If it does, use this new bracket on the vehicle and discard the original bracket. The kit may also include a small wiring jumper cable. If it does, plug the wiring jumper cable into the connector on the VCIM and the other end to the corresponding vehicle wiring harness connector. ^ For 2001, 2002 and 2003 Chevrolet Impala and Monte Carlo, do not reinstall the black plastic OnStar(R) module cover onto the vehicle after the VCIM and module bracket have been installed. This black plastic cover will no longer fit on the vehicle. ^ The upgrade kit for 2002 Sevilles and DeVilles, and some 2003 Sevilles and DeVilles, will contain a large bracket. To install the new VCIM into this bracket you'll need to carefully line up the notch in the VCIM with the tab in the bracket. Tire/Wheel - Spare Tire Is Non-Matching To Other Tires Spare Tire: All Technical Service Bulletins Tire/Wheel - Spare Tire Is Non-Matching To Other Tires INFORMATION Bulletin No.: 02-03-10-001E Date: November 01, 2010 Subject: Spare Tire is a Different Size than Other Tires Models: 2002-2011 Cadillac Escalade Models 1999-2007 Chevrolet Silverado (Classic) 2000-2011 Chevrolet Suburban, Tahoe 2002-2011 Chevrolet Avalanche 1999-2007 GMC Sierra (Classic) 2001 GMC Sierra C3 2001-2011 GMC Yukon Models 2002-2011 GMC Sierra Denali Supercede: This bulletin is being revised to update the model years. Please discard Corporate Bulletin Number 02-03-10-001D (Section 03 - Suspension). This bulletin is being issued to supply additional information concerning the spare tire on the above vehicles. You or your customers may have noticed that the spare tire has a 16-inch diameter steel wheel or 17-inch diameter aluminum wheel while the road tires have a 17-inch, 18-inch, 20-inch or 22-inch diameter aluminum wheel. Although the spare tire has a different wheel diameter and may be a different brand, the rolling circumference is nearly identical to the road tires. The size difference will not cause a concern because the spare and the other tires will travel the same distance in one revolution. This combination of non-matching tires is used most often on full-size trucks. These vehicles use a road tire and wheel combination that may be too large to conveniently fit the storage compartment space of the vehicle. The customer may not be able to easily remove the spare tire/wheel from the storage area because of its size and/or weight. A steel spare wheel, rather than an aluminum one, may be used since the spare is stowed under the vehicle where it is exposed to road and weather elements. A steel wheel is less likely to incur cosmetic damage while in the stowed position for long periods of time. Please provide this information to your customers. Also, remind your customers of the importance of following the tire maintenance schedule as listed in their Owner Manual. Additional tire care information can be found by visiting www.gmtiresafety.com or contacting GM toll-free. Disclaimer Page 4538 Information Bus: Symptom Related Diagnostic Procedures A Symptoms - Data Link Communications SYMPTOMS - DATA LINK COMMUNICATIONS IMPORTANT: The following steps must be completed before using the symptom tables. 1. Perform the applicable diagnostic system check before using the symptom tables in order to verify that there are no DTCs set. 2. Review the system operation in order to familiarize yourself with the system functions. Refer to Data Link Communications Description and Operation. Visual/Physical Inspection Inspect for aftermarket devices which could affect the operation of the systems. - Inspect the easily accessible or visible system components for obvious damage or conditions which could cause the symptom. Intermittent Faulty electrical connections or wiring may be the cause of intermittent conditions. Symptom List Refer to a symptom diagnostic procedure from the following list in order to diagnose the symptom: Scan Tool Does Not Power Up - Scan Tool Does Not Communicate with Class 2 Device - Scan Tool Does Not Communicate with High Speed GMLAN Device Scan Tool Does Not Communicate With Class 2 Device SCAN TOOL DOES NOT COMMUNICATE WITH CLASS 2 DEVICE CIRCUIT DESCRIPTION Modules connected to the class 2 serial data circuit monitor for serial data communications during normal vehicle operation. Operating information and commands are exchanged among the modules. Connecting a scan tool to the data link connector (DLC) allows communication with the modules for diagnostic purposes. DIAGNOSTIC AIDS The engine will not start when there is a total loss of class 2 serial data communication while the ignition is OFF. The following conditions will cause a total loss of class 2 serial data communication: A class 2 serial data circuit shorted to ground. - A class 2 serial data circuit shorted to voltage. - An internal condition within a module or connector on the class 2 serial data circuit, that causes a short to voltage or ground to the class 2 serial data circuit. TEST DESCRIPTION Steps 1 - 2 Powertrain Control Module (PCM) C1 Engine Control Module: Diagrams Powertrain Control Module (PCM) C1 Page 8304 1. Install the anti-rattle clips to the brake caliper mounting bracket. 2. Install the disc brake pads to the brake caliper mounting bracket. 3. Perform the following procedure before installing the 2 brake caliper mounting bracket bolts. 1. Remove all traces of the original adhesive patch. 2. Clean the threads of the bolts with brake parts cleaner or the equivalent and allow to dry. 3. Apply Threadlocker GM P/N 2345493 (Canadian P/N 10953488) to the threads of the bolts. 4. Notice: Refer to Fastener Notice in Service Precautions. Install the brake caliper mounting bracket and the 2 brake caliper mounting bracket bolts. ^ Tighten the 2 brake caliper mounting bracket bolts to 200 Nm (148 ft. lbs.). 5. Perform the following procedure before installing the 2 brake caliper mounting bolts. Page 2337 2. Remove the brake booster inlet hose (1) from the brake booster (2). 3. Remove the brake booster inlet hose from the power steering pump. 4. Remove the brake booster inlet hose from the vehicle. Installation Procedure 1. Notice: Refer to Installing Hoses Without Twists or Bends Notice in Service Precautions. Route the hose in the same position the hose occupied prior to removal. 2. Install the brake booster inlet hose (1) to the brake booster (2). Hand tighten only. 3. Notice: Refer to Fastener Notice in Service Precautions. Install the brake booster inlet hose to the power steering pump. ^ Tighten the brake booster inlet hose fittings to 28 Nm (20 ft. lbs.). 4. Remove the drain pan from under the vehicle. 5. Bleed the power steering system. Refer to Bleeding the Power Steering System. Power Brake Booster Outlet Hose Replacement Power Brake Booster Outlet Hose Replacement Removal Procedure 1. Notice: Refer to Power Steering Hose Disconnected Notice in Service Precautions. Install a drain pan under the vehicle. 2. Remove the brake booster outlet hose (1) from the brake booster (2). 3. Remove the clamp retaining the brake booster outlet hose to the power steering pump. 4. Remove the brake booster outlet hose from the vehicle. Installation Procedure Page 9576 Fuse Block- I/P C3 Part 3 Page 8001 Speed Sensor: Service and Repair Transfer Case - NVG 263-NP1 Transfer Case Speed Sensor Replacement Removal Procedure 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. Disconnect the speed sensor electrical connector. 3. Remove the speed sensor. Installation Procedure 1. Notice: Refer to Fastener Notice in Service Precautions. Install the speed sensor. ^ Tighten the sensor to 15 Nm (11 ft. lbs.). Page 12611 5. Choose the outstanding core you wish to process, by selecting the Virtual Core Button on the far right side of the screen. 6. Enter the information in the required fields and select the submit button. Record the confirmation number. Canadian Dealers 1. Return the removed Analog / Digital-Ready OnStar(R) VCIM to the Parts Manager. 2. The Parts Manager will log onto https://adt.onstar.gm.mass.ca and enter information as prompted. All Dealers If the website indicates that the VCIM needs to be physically returned to the distributor, please use the pre-paid shipping label that was included in the kit to return the removed VCIM. Important: To avoid a $250 core non-return charge, you must do one of the following within 30 days of kit shipment: 1. Submit the necessary VCIM data through the website, as indicated above. 2. Mail the removed core from the customer's vehicle back to the distributor. 3. Return the unused digital upgrade kit back to the distributor using the pre-paid shipping label that is included in the kit box. Returning the Upgraded Vehicle to the Customer Returning the Upgraded Vehicle to the Customer 1. Place the new OnStar Subscriber Information (Owner's Manual kit) in the customer's vehicle where they can review some of the new features of the Digital-Capable system. The continuous digit dialing feature should be highlighted to the customer to avoid a return to the dealership for dialing instructions. Advise the customer to discard any existing OnStar(R) Owner's Manuals that may be in the vehicle. 2. Have the Service Advisor, Service Manager or Sales Consultant review the new OnStar(R) Hands-Free Calling procedure with the customer. The customer is uses to their analog OnStar(R) Hands-Free Calling system, which uses individual digit dial to make a call. The Generation 6 Digital-Capable system uses continuous digit dial, and the customer needs to be made aware of this change. 3. U.S. Dealers Only: Staple the "Tip Sheet - OnStar(R) Generation 6 Digitally-Capable System", that was included in the kit, to the customer's copy of the repair order. This tip sheet will help your customer better understand their new OnStar(R) system. 4. Canadian Dealers Only: Refer the customer to the Hands-Free Calling Quick Review Card from the new OnStar(R) Owner's Manual kit for help with the new dialing procedure. 5. Fill out the form entitled "GM Limited Warranty for Upgraded OnStar(R) Digital Equipment Program Participants" and staple a copy of this to the customer's repair order. You may want to keep a copy for your records. 6. Encourage your customer to press their blue OnStar(R) button the next day. The OnStar(R) Advisor will be able to review some of the new features of their digital OnStar(R) system. Closing the Onstar(R) Upgrade Exchange Closing the OnStar(R) Upgrade Exchange 1. Collect payment from the customer. Your dealership's open account (sales) will be charged for the cost of the chosen subscription plan, any applicable subscription taxes, and the $15 upgrade charge after the vehicle has been configured through the TIS2WEB process. 2. None of the costs associated with the OnStar Digital Upgrade program may be claimed as a GM goodwill event. These costs must be paid by the customer, and may not be included in any goodwill offered to the customer. GM employees or representatives or field personnel are not able to offer goodwill for this program. If the dealership decides to pay for the upgrade for their customer, be aware that your GM or OnStar(R) contact will not be able to reimburse you for this cost. 3. Use labor code Z2096 to submit your claim for the labor time published below plus 0.2 hr Administrative Allowance and an additional $20.00 Net Amount. ^ For all dealer claim submissions (excluding U.S. Saturn), use Complaint Code MH - Technical Bulletin, and Failure Code 93 - Technical Service Bulletin. Page 9240 C321 Seat Jumper Harness To Seat Harness (With RPO Code AN3) Part 2 Page 8376 7. For 25/35 series vehicles, enable the park brake cable automatic adjuster. Refer to Enabling the Park Brake Cable Automatic Adjuster. 8. For all 15 series vehicles, pull down on the park brake cable in front of the equalizer and install the left park brake cable to the equalizer bar. 9. Remove the safety stands. 10. Remove the safety stands and lower the vehicle. 11. Adjust the park brake cable. (W/NYS) Park Brake Cable Replacement - Left Rear (w/NYS) Removal Procedure 1. Release the park brake. 2. Raise and support the vehicle. Refer Vehicle Lifting Page 13045 4.1. Unplug the SRS control module's connector (A). 4.2. Cut off the cable tie (B), detach the connector's rear end face (C), and pull out the connecting rail (D). 4.3. Extract pin 15, cut off the cable terminal and insulate the end with tape (E). Fold back the cable and secure it with tape (F). 4.4. Fit the connecting rail and end face. 4.5. Plug in the connector (A) and secure the cables with cable ties (B). 5. Remove the parcel shelf trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6. M03: Replace the optic cable on the right-hand side Page 8458 1. Install the gasket. 2. Install the booster assembly. 3. Install the 4 booster to bulkhead nuts. Tighten Tighten the nuts to 36 N.m (26 lb-ft). 4. Snap the stop lamp switch onto the pushrod to the power brake booster. 5. Install the stop lamp switch with the pushrod on the brake pedal pin. 6. Install the brake switch retainer. 7. Connect the electrical connector to the stop lamp switch. 8. Install the master cylinder to the booster. 9. Install the master cylinder mounting nuts. Tighten Tighten the nuts to 36 N.m (27 lb-ft). 10. Connect the power brake booster outlet hose, the steering gear inlet hose, and the power brake booster inlet hose. Tighten ^ Tighten the power brake booster inlet hose to 28 N.m (20 lb-ft). ^ Tighten the steering gear inlet hose to 28 N.m (20 lb-ft). Important: Maintain the fluid level throughout the bleed procedure. 11. Remove the pump reservoir cap. Important: Page 13903 7. Remove the lower bolts from the rear of the fender. 8. Disconnect the electrical connectors from the running lights, if equipped. 9. Remove the screws from the wheelwell. 10. Remove the bolts from the bottom of the fender. 11. With an assistant, pivot the fender from the bottom to approximately 90 degrees in order to remove the fender. Installation Procedure 1. With an assistant, install the fender to the pickup box at a 90 degree angle and lower gently. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the bolts to the bottom of the fender. Tighten the bolts to 25 N.m (18 lb ft). 3. Install the screws to the wheelwell area. Tighten the screws to 2 N.m (18 lb in). 4. Connect the electrical connectors to the running lamps, if equipped. Page 6643 A cracked 1-2 accumulator piston (56) that is allowing fluid to leak by. Mislocated/Missing valve body-to-spacer plate check balls (61). When attempting to correct a consistent harsh 1-2 shift, the four conditions listed above should be inspected as possible causes. It is important to also refer to the appropriate Service Manual for further possible causes of this condition. Page 12295 DVD Player: Description and Operation DVD PLAYER DVD Player The DVD player and the video display screen are located in the overhead console. The DVD player can be controlled by both the buttons on the DVD player and by the buttons on the remote control. The DVD player power may be turned on when the ignition is in the run, accessory, or retained accessory power (RAP) power modes. DVDs are manufactured with different region codes based on the country in which they are sold. Therefore, the RSE system DVD player is only compatible with the region code where the vehicle is sold. The DVD region code is printed on the jacket of most DVDs. The DVD player will also play audio CDs. Home recorded CDs, CD-R or CD-RW formats, will not play in this DVD player. Page 6940 18. Remove the inner race (1) from the cage (2) by rotating the inner race (1) upward. 19. Clean the following items thoroughly with cleaning solvent. Remove all traces of old grease and any contaminates. 19.1. The inner and outer race assemblies 19.2. The CV joint cage 19.3. The chrome alloy balls. 20. Dry all the parts. 21. Check the CV joint assembly for unusual wear, cracks, or other damage. 22. Replace any damaged parts. 23. Clean the halfshaft bar. Use a wire brush to remove any rust in the seal mounting area (grooves). Installation Page 13278 Important: The optic cable must not be bent with a radius less than 25 mm (1 in). 12.5. Cars with brackets for e.g. an amplifier: Fit the cable tie (11 900 515) to the wiring harness approx. 100 mm (4 in) from H2-9, fit the cable tie (H) to the bracket. Gather the optic cable in a gentle loop (I) and then place the loop behind the bracket. Important: The optic cable must not be bent with a radius less than 25 mm (1 in). 12.6. Cars without brackets for e.g. an amplifier: Gather the optic cable in a gentle loop (J) and secure with cable tie. 13. CV: Fit the left-hand, rear side hatch trim in accordance with WIS - 8. Body - Interior equipment - Adjustment/Replacement. 14. Fit the ground cable to the battery's negative terminal. 15. Carry out procedures after disconnecting the battery, see WIS - 3. Electrical System - Charging system - Adjustment/Replacement. Important: Follow Tech 2(R) on-screen instructions. 16. Add ECU ICM, choose without OnStar(R). See WIS-General-Tech 2(R) - Description and Operation - Add/Remove. 2000-2004 Saab 9-5 2000-2004 Saab 9-5 Locations Oil Pressure Sender: Locations Engine Oil Pressure (EOP) Sensor And CMP Sensor Page 4433 Page 3816 Control Module References Part 2 Page 9869 Important The following information MUST be documented on the repair order. Failure to do so may result in a chargeback. - Customer vehicle condition. - Was a Service Lamp or Service Message illuminated? If yes, specify which Service Lamp or Service Message. - Was a DTC(s) set? If yes, specify which DTC(s) were set. - After following the procedure contained within this bulletin, could the condition be duplicated? ‹› If the condition was not duplicated, then document the affected module/component connector name and number on the repair order. - If the condition was duplicated after the procedure contained within this bulletin was followed, and additional diagnosis led to the replacement of a module or component, the SI Document ID Number MUST be written on the repair order. Parts Information Alternate Distributor For All of North America Note NyoGel(R) 760G Lubricant* is equivalent to GMSPO P/N 12377900, and P/N 10953529 (Canada), specified for use to correct the condition in this bulletin. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to: Warranty Information (Saab Models) Steering/Suspension - Wheel Alignment Specifications Alignment: Technical Service Bulletins Steering/Suspension - Wheel Alignment Specifications WARRANTY ADMINISTRATION Bulletin No.: 05-03-07-009C Date: December 09, 2010 Subject: Wheel Alignment Specifications, Requirements and Recommendations for GM Vehicles Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks Supercede: This bulletin is being extensively revised to provide technicians and warranty administrators with an all inclusive guide for wheel alignments. PLEASE FAMILIARIZE YOURSELF WITH THESE UPDATES BEFORE PERFORMING YOUR NEXT GM WHEEL ALIGNMENT SERVICE. Please discard Corporate Bulletin Number 05-03-07-009B (Section 03 - Suspension). Purpose The purpose of this bulletin is to provide retail, wholesale and fleet personnel with General Motors' warranty service requirements and recommendations for customer concerns related to wheel alignment. For your convenience, this bulletin updates and centralizes all of GM's Standard Wheel Alignment Service Procedures, Policy Guidelines and bulletins on wheel alignment warranty service. Important PLEASE FAMILIARIZE YOURSELF WITH THESE UPDATES BEFORE PERFORMING YOUR NEXT GM WHEEL ALIGNMENT SERVICE. The following five (5) key steps are a summary of this bulletin and are REQUIRED in completing a successful wheel alignment service. 1. Verify the vehicle is in an Original Equipment condition for curb weight, tires, wheels, suspension and steering configurations. Vehicles modified in any of these areas are not covered for wheel alignment warranty. 2. Review the customer concern relative to "Normal Operation" definitions. 3. Verify that vehicle is within the "Mileage Policy" range. 4. Document wheel alignment warranty claims appropriately for labor operations E2000 and E2020. The following information must be documented or attached to the repair order: - Customer concern in detail - What corrected the customer concern? - If a wheel alignment is performed: - Consult SI for proper specifications. - Document the "Before" AND "After" wheel alignment measurements/settings. - Completed "Wheel Alignment Repair Order Questionnaire" (form attached to this bulletin) 5. Use the proper wheel alignment equipment (preferred with print-out capability), process and the appropriate calibration maintenance schedules. Important If it is determined that a wheel alignment is necessary under warranty, use the proper labor code for the repair. E2000 for Steering Wheel Angle and/or Front Toe set or E2020 for Wheel Alignment Check/Adjust includes Caster, Camber and Toe set (Wheel alignment labor time for other component repairs is to be charged to the component that causes a wheel alignment operation.). The following flowchart is to help summarize the information detailed in this bulletin and should be used whenever a wheel alignment is performed. Page 12590 7.1. Remove the console (A) together with the OnStar(R) control modules. 7.2. Remove the connectors (B). Important: The optic cable must not be bent with a radius less than 25 mm (1 in). Important: Secure the wiring harness so that there is no risk of chafing and rattling. 7.3. Fold back the wiring harness and tape over the connectors (C). Fold back the wiring harness once more and secure with cable ties (D). 7.4. Fit the parcel shelf trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 8. CV: Removing the OnStar(R) control modules and securing the wiring: Adjustment/Replacement. 8.1. Open the luggage compartment floor. Page 1366 Door Latch Assembly (Door Jamb Switch) - RR - C2 (Crew Cab Only) Page 10873 Ambient Temperature Sensor / Switch HVAC: Service and Repair AMBIENT AIR TEMPERATURE SENSOR REPLACEMENT REMOVAL PROCEDURE 1. Remove the Park/Turn Signal. 2. Disconnect the electrical connector from the ambient air temperature sensor (3). 3. Remove the ambient air temperature sensor (3). INSTALLATION PROCEDURE 1. Install the ambient air temperature sensor (3). 2. Connect the electrical connector to the ambient air temperature sensor (3). 3. Install the Park/Turn Signal. Page 12451 Page 11657 3. Fold the rear seat down. 4. Pull the seat belt buckles through the seat cushion. Page 1899 Interior - Intermittent Seat Heater Operation Seat Heater: All Technical Service Bulletins Interior - Intermittent Seat Heater Operation Bulletin No.: 05-08-50-008 Date: August 19, 2005 TECHNICAL Subject: Intermittent Heated Seats Inoperative, DTC B3941 Set (Reprogram Driver Seat Module) Models: 2003-2005 Cadillac Escalade, Escalade ESV, Escalade EXT 2003-2005 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2003-2005 GMC Sierra, Yukon, Yukon XL, Yukon Denali All with Seat FRT, Individual (Non BKT) (RPO AN3) 2003-2005 HUMMER H2 with Seat, Front Bucket Deluxe (RPO AR9) Condition Some customers may comment that occasionally the seat heater will not operate when activated. If the ignition key is cycled OFF and back ON again, the heated seat will operate correctly. Also, on some LB7 diesel engine vehicles, the seat heater may turn itself off during the first 10 minutes of operation. This occurs only with the first activation for the day and works correctly with subsequent activations immediately after the event. These conditions are intermiffent and DTC B3941 may be set. Correction Technicians are to reprogram the driver seat module with an updated software calibration. This new service calibration was released with TIS satellite data update version 6.5 available June 13, 2005. As always, make sure your Tech 2(R) is updated with the latest software version. Warranty Information Page 9755 C305 Body Harness To Drivers Seat Harness (With RPO Code AG1) Part 2 Page 12538 DTC B2476 04: Cellular Phone Select Service Switch Open Circuit DTC B2476 59: Cellular Phone Select Service Switch Stuck Button DTC B2482 00: Cellular Phone Select Service Switch Range/Performance Circuit Short to Ground Open / High Resistance Short to Voltage Signal Performance Circuit/System Description The OnStar(R) button assembly consists of 3 buttons, Call/Answer, OnStar(R) Call Center, and OnStar(R) Emergency. The vehicle communication interface module (VCIM) supplies the OnStar(R) button assembly with 10 volts via the keypad supply voltage circuit. Each of the buttons, when pressed, completes the circuit across a resistor allowing a specific voltage to be returned to the VCIM over the keypad signal circuit. Depending upon the voltage range returned, the VCIM is able to identify which button has been activated. Conditions for Running the DTCs The ignition is ON. System voltage is between 9 - 16 volts. Conditions for Setting the DTCs B2476 04: The VCIM detects an open/high resistance on the keypad supply voltage circuit. B2482 and B2476 59: The VCIM detects a valid signal on the keypad signal circuit for more than 15 seconds. If one of the OnStar(R) buttons is held or stuck for 15 seconds or more, the VCIM will set these DTCs. Action Taken When the DTCs Set The OnStar(R) status LED turns red. No calls can be placed. The VCIM will ignore all inputs from the OnStar® button assembly. Conditions for Clearing the DTCs The condition responsible for setting the DTC no longer exists. A history DTC will clear once 100 consecutive malfunction-free ignition cycles have occurred. Page 377 9. Erase the diagnostic trouble codes. 10. Set the date and time, see WIS - 3. Electrical system - Information display (SID) - Technical description. Page 12021 10.4. Remove the end cap from the new optic cable, connect to the connector and refit the secondary catch (D). Fit the terminal housing (C) to the connector and refit the locking strip (B). 10.5. Secure the old optic cable together with the new one (E). Important: The optic cable must not be bent with a radius less than 25 mm (1 in). Important: Secure the wiring harness so that there is no risk of chafing and rattling. 11. CV: Remove the rear seat in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. The O-bus connector H2-9 is located behind the left speaker. 12. M04-05: Disconnect the optic cables on the OnStar(R) control modules and join the cables: 12.1. Cut off the cable tie holding the connector (H2-9) against REC. Page 4309 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Weather Pack Connectors WEATHER PACK CONNECTORS The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. Page 5783 7. Remove the control lever to the manual shaft nut. 8. Remove the control lever from the manual shaft. 9. Remove the PNP switch bolts. 10. Remove the PNP switch from the manual shaft. If the PNP switch does not slide off the manual shaft, file the outer edge of the manual shaft in order to remove any burrs. Installation Procedure 1. Install the PNP switch to the manual shaft by aligning the switch hub flats with the manual shaft flats. 2. Slide the PNP switch onto the manual shaft until the switch mounting bracket contacts the mounting bosses on the transmission. 3. Important: If a new PNP switch is being installed, the switch will come with a positive assurance bracket. The positive assurance bracket aligns the new switch in its proper position for installation and the use of the park neutral switch aligner will not be necessary. Install the PNP switch bolts finger tight. Specifications Page 10817 Air Temperature Sensors - Lower Right Page 15138 Electrical Symbols ELECTRICAL SYMBOLS Electrical Symbols Part 1 Page 3114 Jump Starting: Service and Repair JUMP STARTING IN CASE OF EMERGENCY (NON HP2) CAUTION: Batteries produce explosive gases. Batteries contain corrosive acid. Batteries supply levels of electrical current high enough to cause burns. Therefore, in order to reduce the risk of personal injury while working near a battery, observe the following guidelines: - Always shield your eyes. - Avoid leaning over the battery whenever possible. - Do not expose the battery to open flames or sparks. - Do not allow battery acid to contact the eyes or the skin. - Flush any contacted areas with water immediately and thoroughly. - Get medical help. NOTE: This vehicle has a 12 volt, negative ground electrical system. Make sure the vehicle or equipment being used to jump start the engine is also 12 volt, negative ground. Use of any other type of system will damage the vehicle's electrical components. This vehicle has a 12-volt positive, negative ground electrical system. Do not try to jump start a vehicle, if you are unsure of the other vehicle's positive voltage or ground position. The booster battery and the discharged battery should be treated carefully when using jumper cables. 1. Position the vehicle with the booster battery so that the jumper cables will comfortably reach the battery of the other vehicle. - Do not let the 2 vehicles touch. - Make sure that the jumper cables do not have loose clamps or missing insulation. 2. Perform the following steps on both vehicles: 2.1. Place the automatic transmission in PARK. 2.2. Block the wheels. 2.3. Set the parking brake. 2.4. Turn off all electrical loads that are not needed-Leave the hazard flashers ON. 2.5. Turn OFF the ignition switch. IMPORTANT: Some vehicles have a battery remote positive stud-ALWAYS use the battery remote positive stud in order to give or to receive a jump start-Consult the vehicle's owner's manual for proper connections. 3. Attach the end of one jumper cable to the positive terminal of the discharged battery. 4. Attach the other end of the first cable to the positive terminal of the booster battery. 5. Attach one end of the remaining jumper cable to the negative terminal of the booster battery. NOTE: Do not connect the negative charger lead to the housings of other vehicle electrical accessories or equipment. The action of the battery charger may damage such equipment. 6. Make the final connection of the negative jumper cable to the block or suitable bracket connected directly to the block, away from the battery. 7. Start the engine of the vehicle that is providing the jump start and turn off all electrical accessories. Raise the engine RPM to approximately 1,500 RPM. 8. Crank the engine of the vehicle with the weak battery. If the engine does not crank or cranks too slowly, perform the following steps: 8.1. Turn the ignition OFF. 8.2. Allow the booster vehicle engine to run at approximately 1,500 RPM for 5 minutes. Page 15031 Tailgate Shock / Support: Service and Repair Support Cable Anchor Bolt Replacement - Endgate Support Cable Anchor Bolt Replacement - Endgate Removal Procedure 1. Lower the endgate. 2. Remove the cable from the Anchor Bolt. 3. Remove the Anchor Bolt. Installation Procedure Notice: Refer to Fastener Notice in Service Precautions. 1. Install the Anchor Bolt. Tighten the bolt to 25 N.m(18 lb ft) Page 15616 Door Latch Assembly (Door Jamb Switch) - Front Passenger - C2 Page 10823 Air Temperature Actuator - Left Page 7430 Speed Sensor: Service and Repair Transfer Case - NVG 261-NP2 Transfer Case Speed Sensor Replacement Removal Procedure 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. Disconnect the speed sensor electrical connector (4). 3. Remove the speed sensor. Installation Procedure 1. Notice: Refer to Fastener Notice in Service Precautions. Install the speed sensor. ^ Tighten the sensor to 15 Nm (11 ft. lbs.). Page 3932 Mass Air Flow (MAF) Sensor: Service and Repair MASS AIR FLOW (MAF)/INTAKE AIR TEMPERATURE (IAT) SENSOR REPLACEMENT REMOVAL PROCEDURE IMPORTANT: Use care when handling the mass air flow/intake air temperature (MAF/IAT) sensor. Do not dent, puncture, or otherwise damage the honeycell located at the air inlet end of the MAF/IAT. Do not touch the sensing elements or allow anything including cleaning solvents and lubricants to come in contact with them. Use a small amount of a non-silicone based lubricant, on the air duct only, to aid in installation. 1. Remove the air cleaner outlet duct. 2. Pull out the gray connector position assurance (CPA) retainer. 3. Push down on the black clip in order to disconnect the MAF/IAT sensor electrical connector (4). 4. Loosen the MAF/IAT clamp. 5. Remove the MAF/IAT sensor from the air cleaner assembly. INSTALLATION PROCEDURE IMPORTANT: The embossed arrow on the MAF/IAT sensor indicates the proper air flow direction. The arrow must point toward the engine. Page 3250 Diagnostic Aids Vibration from the engine operating may cause a body component or another part of the vehicle to make rumbling noise. The drive belt(s) may have a condition that can not be seen or felt. Sometimes replacing the drive belt(s) may be the only repair for the symptom. If after replacing the drive belt(s) and completing the diagnostic table, the rumbling is only heard with the drive belt(s) installed, there might be an accessory drive component failure. Varying the load on the accessory drive component(s) may aid in identifying which component is causing the rumbling noise. Test Description Steps 1 - 8 The number(s) below refer to the step(s) in the diagnostic table. 2. This test is to verify that the symptom is present during diagnosing. Other vehicle components may cause a similar symptom. 3. This test is to verify that the drive belt(s) is causing the rumbling. Rumbling may be confused with an internal engine noise due to the similarity in the description. Remove only one drive belt at a time if the vehicle has multiple drive belts. Operate the engine for a few seconds, this will verify if the rumbling noise is related to the drive belt(s) or not. With the drive belt(s) removed the water pump will not operate and the engine may overheat. Also diagnostic trouble codes (DTCs) may set when the engine is operated with the drive belt(s) removed. 4. Inspect the drive belt(s) to ensure that the drive belt(s) is not the cause of the noise. Small cracks across the ribs of the drive belt(s) will not cause Page 5123 1. Relieve the fuel system pressure. Refer to Fuel Pressure Relief Procedure. 2. Disconnect the fuel feed and pressure balance lines from the front tank. 3. Cap the fuel and balance lines at the fuel tank in order to avoid possible system contamination. 4. Disconnect the fuel feed and pressure balance lines from the rear tank. 5. Cap the fuel and balance lines at the fuel tank in order to avoid possible system contamination. 6. Remove the rear fuel line bundle clip nuts. 7. Remove the rear fuel line bundle. INSTALLATION PROCEDURE Page 1912 Park Neutral Position (PNP) Switch C175 Page 6035 Page 3842 1. Slide the BCM onto the bracket. 2. Connect all the connectors (1) except the brown connector. 3. Connect the brown connector. 4. Install the knee bolster. 5. Connect the negative battery cable(s). 6. Reprogram the BCM. Refer to Body Control Module (BCM) Programming/RPO Configuration. 7. Perform the Passlock Learn Procedure. See: Testing and Inspection/Programming and Relearning Page 6466 Shift Cable: Service and Repair Automatic Transmission - 4L80-E/4L85-E Range Selector Cable Replacement Automatic Transmission Range Selector Cable Replacement Removal Procedure 1. Position the steering column shift lever to the park position. 2. Remove the instrument panel knee bolster. 3. Remove the driver's seat. 4. Pull back the carpet and insulation around the driver's area. 5. Remove the retainer securing the cable to the steering column. 6. Remove the cable end from the steering column ball stud. 7. Depress the tangs and remove the cable from the steering column bracket. 8. Remove the bolt securing the cable support to the brace. Page 1229 Parts Information Place unused material on dealer shelf for future use. Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Page 363 Important: Secure the wiring harness so that there is no risk of chafing and rattling. 9.4. Fold back the wiring harness and tape over the connectors (C). Fold back the wiring harness once more and secure with cable ties (D). 9.5. Install the right-hand rear luggage compartment in accordance with WIS - 8. Body - Interior equipment - Adjustment/Replacement. 10. Install the ground cable to the battery's negative terminal. 11. Clear the diagnostic trouble codes. 12. Set the date and time, see WIS - 3. Electrical system - Information display (SID_ - Technical description. 2003-2005 Saab 9-3 (9400) 4D/5D; 2004-2005 Saab 9-3 (9400) CV 2003-2005 Saab 9-3 (9440) 4D/5D; 2004-2005 Saab 9-3 (9440) CV Notice: Handle the fiber optic cables with care or the signal may be distorted. ^ It is very important that the two leads in the connector are not confused with one another. ^ Do not splice the cables. ^ Do not bend the cable in a radius smaller than 25 mm (1 in). ^ Do not expose the cable to temperatures exceeding 185°F (85°C). ^ Keep the cable ends free from dirt and grime. ^ Do not expose the cable to impact as this may cause the transparent plastic to whiten, thereby reducing the intensity of the light and causing possible communication interruptions. ^ The cable should not lie against any sharp edges as this may cause increased signal attenuation. 1. Remove the ECU CU with a Tech 2(R) according to the following: Fault diagnosis - Select model year - Select Saab 9-3 Sport (9440) - All - Add/Remove - Control Module - CU/PU - Remove. 2. Remove the ground cable from the battery's negative terminal. 3. Remove the floor console in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 4. Pry out the signal line from the SRS control module to the OnStar(R) control module and secure it: Page 6562 Transmission Position Switch/Sensor: Service and Repair Automatic Transmission 4L80-E/4L85-E Park/Neutral Position Switch Replacement Park/Neutral Position Switch Replacement ^ Tools Required J 41364-A Park Neutral Switch Aligner Removal Procedure 1. Apply the park brake. 2. Shift the transmission into neutral. 3. If equipped with 4-wheel drive (4WD), remove the front propeller shaft. 4. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 5. Disconnect the park/neutral position (PNP) switch electrical connector (2). 6. Remove the range selector cable end (2) from the range selector lever ball stud (1). Page 596 Memory Seat Module - C2 ABS Automated Bleed Procedure Brake Bleeding: Service and Repair ABS Automated Bleed Procedure ABS Automated Bleed Procedure Notice: When adding fluid to the brake master cylinder reservoir, use only Delco Supreme 11®, GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. The use of any type of fluid other than the recommended type of brake fluid, may cause contamination which could result in damage to the internal rubber seals and/or rubber linings of hydraulic brake system components. Notice: Refer to Brake Fluid Effects on Paint and Electrical Components Notice in Service Precautions. Important: This procedure may be performed on all vehicles EXCEPT those equipped with option code JL4, Vehicle Stability Enhancement System (VSES). Important: The base hydraulic brake system must be bled before performing this automated bleeding procedure. If you have not yet performed the base hydraulic brake system bleeding procedure, refer to Hydraulic Brake System Bleeding (Manual) Hydraulic Brake System Bleeding (Pressure) in Hydraulic Brakes before proceeding. 1. Install a scan tool to the vehicle. 2. Start the engine and allow the engine to idle. 3. Depress the brake pedal firmly and maintain steady pressure on the pedal. 4. Using the scan tool, begin the automated bleed procedure. 5. Follow the instructions on the scan tool to complete the automated bleed procedure. Release the brake pedal between each test sequence. 6. Turn the ignition OFF. 7. Remove the scan tool from the vehicle. 8. Fill the brake master cylinder reservoir to the maximum-fill level with Delco Supreme 11® GM P/N 12377967 (Canadian P/N 992667) or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. 9. Bleed the hydraulic brake system. Refer to Hydraulic Brake System Bleeding (Manual) Hydraulic Brake System Bleeding (Pressure) in Hydraulic brakes. 10. With the ignition OFF, apply the brakes 3-5 times, or until the brake pedal becomes firm, in order to deplete the brake booster power reserve. 11. Slowly depress and release the brake pedal. Observe the feel of the brake pedal. 12. If the brake pedal feels spongy, repeat the automated bleeding procedure. If the brake pedal still feels spongy after repeating the automated bleeding procedure inspect the brake system for external leaks. Refer to Brake System External Leak Inspection in Hydraulic Brakes. 13. Turn the ignition key ON, with the engine OFF; check to see if the brake system warning lamp remains illuminated. 14. If the brake system warning lamp remains illuminated, DO NOT allow the vehicle to be driven until it is diagnosed and repaired. Refer to Symptoms - Hydraulic Brakes. 15. Drive the vehicle to exceed 13 kph (8 mph) to allow ABS initialization to occur. Observe brake pedal feel. 16. If the brake pedal feels spongy, repeat the automated bleeding procedure until a firm brake pedal is obtained. Page 13340 Important The following information MUST be documented on the repair order. Failure to do so may result in a chargeback. - Customer vehicle condition. - Was a Service Lamp or Service Message illuminated? If yes, specify which Service Lamp or Service Message. - Was a DTC(s) set? If yes, specify which DTC(s) were set. - After following the procedure contained within this bulletin, could the condition be duplicated? ‹› If the condition was not duplicated, then document the affected module/component connector name and number on the repair order. - If the condition was duplicated after the procedure contained within this bulletin was followed, and additional diagnosis led to the replacement of a module or component, the SI Document ID Number MUST be written on the repair order. Parts Information Alternate Distributor For All of North America Note NyoGel(R) 760G Lubricant* is equivalent to GMSPO P/N 12377900, and P/N 10953529 (Canada), specified for use to correct the condition in this bulletin. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to: Warranty Information (Saab Models) Page 7013 Axle Nut: Specifications Axle Shaft Nut ...................................................................................................................................... ................................................ 240 Nm (177 ft. lbs.) Page 8909 Control Module References Part 6 Page 3613 Left Side Of Engine Page 14695 Vehicles Involved For dealers with involved vehicles, a listing with involved vehicles containing the complete vehicle identification number, customer name, and address information has been prepared and will be provided through the GM DealerWorld Recall Information system. Dealers will not have a report available if they have no involved vehicles currently assigned. The listing may contain customer names and addresses obtained from Motor Vehicle Registration Records. The use of such motor vehicle registration data for any purpose other than follow-up necessary to complete this recall is a violation of law in several states/provinces/countries. Accordingly, you are urged to limit the use of this report to the follow-up necessary to complete this recall. Parts Information No parts are required for this recall. Service Procedure General Motors will work with the customer to reach an agreement on the purchase of the vehicle. Dealers will be asked by General Motors to assist in the removal of any aftermarket accessories, inspection of the vehicle, obtaining titles and other documentation required to transfer ownership to General Motors, presenting the customer with a check for the repurchase, and taking possession of the vehicle. General Motors will arrange for transportation of the vehicle from the dealer. Front Suspension Wheel Fastener: Service and Repair Front Suspension Wheel Stud Replacement ^ Tools Required J 43631 Ball Joint Remover Removal Procedure 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Remove the tire and wheel. 3. Remove the brake rotor. Refer to Brake Rotor Replacement - Front in Disc Brakes. 4. Remove the wheel stud from the hub flange using the J 43631. 5. Remove the wheel stud from the hub flange. Installation Procedure 1. Install the new stud into the hub flange hole using firm hand pressure. 2. Install 4 washers to the new wheel stud. 3. Thread a wheel nut onto the new stud with the flat side facing the front hub flange. 4. Tighten the lug nut until the stud contacts the back of the hub flange. 5. Remove the wheel nut. 6. Remove the washers. 7. Install the brake rotor. Refer to Brake Rotor Replacement Front in Disc Brakes. 8. Install the tire and wheel. 9. Remove the safety stands. 10. Lower the vehicle. Page 12269 analyzed. Therefore, technicians should be checking for loose connections and installing cable connector clamps to ensure a positive and robust connection. Technicians are to install a video cable connector clamp on each cable connector located under each front seat. A total of four cable connector clamps, P/N 19159659, are required for each vehicle. The illustration above shows a pair of display monitor cable connectors without the cable clamps installed. The illustration above shows the display monitor cable connectors with the cable connector clamps. The lower cable connector clamp is installed but not locked together. The upper cable connector clamp is closed and locked. The cable connector clamps have now been added as a permanent component to all GM Accessories Headrest DVD Systems installation kits. Parts Information Warranty Information (excluding Saab U.S. Models) Page 1367 Door Switch: Description and Operation DOOR LATCH (DOOR JAMB) SWITCHES The theft deterrent system uses the door key switch as one method in order to activate the alarm. If the BCM detects any door opening before the BCM receives a disarm input, the alarm mode activates. DOOR KEY SWITCH The BCM monitors the door key switches in order to disarm the CTD system. When the lock cylinder turns in order to unlock the door, the switch grounds the disarm input to the BCM. Page 3790 Refer to the table as a guide in selecting the correct test adapter for frontprobing connectors: Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure SCAN TOOL SNAPSHOT PROCEDURE Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: - Snapshot - taken from the Snapshot menu choice - Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information Inflatable Restraint I/P Module Disable Switch (HD Model) Air Bag Deactivation Switch: Description and Operation Inflatable Restraint I/P Module Disable Switch (HD Model) INFLATABLE RESTRAINT I/P MODULE DISABLE SWITCH (HD MODEL PICKUPS) The instrument panel (I/P) module disable switch is a manual 2-position key switch. The I/P module disable switch allows the vehicle operator the ability to enable or disable the I/P module (passenger frontal air bag). The I/P module disable switch interfaces with the inflatable restraint sensing and diagnostic module (SDM) to request the enabling or disabling of the I/P module. The occupants are notified of the enabling or disabling of the I/P module via the I/P module disable switch ON/OFF indicators located on the I/P module disable switch. Page 3100 Wheel Nut Torque Sequence Page 8187 When using the On-Car lathe on vehicles equipped with limited slip (or posi-trac) rear system, it is critical that the rear drive shaft is disconnected/disengaged prior to operation of the On-Car lathe. Remember to mark and re-index the drive shaft correctly on re-assembly to prevent creating driveline vibration. Whenever the lathe drive motor is being switched on, the operator MUST keep their body out of the wheel well area until the machine has reached its normal operating RPM. 2. Refinish the existing rotor on an approved, well-maintained lathe to guarantee smooth, flat and parallel surfaces. Important When raising the vehicle on the lift, be sure to have it at a good working height (waist high is average) to accommodate mounting the On-Car lathe. Optimally, the center piston on the lathe trolley will be mid-travel. If the lathe trolley center piston is completely compressed (bottoming out) or inversely fully extended and hanging off the vehicle hub, this could affect the calibration time of the lathe. 3. Select the correct adapter for the vehicle you're working on and mount it to the hub with the vehicle lug nuts. Hand tighten 34-41 Nm (25-30 lb ft) the nuts using equal torque. DO NOT use impact wrenches, excessive torque will damage the adapter. Important Ensure the adapter sits flush on the rotor hat surface. Be sure to remove any rust, rotor retaining clips, etc. that may preclude the adapter from sitting flat on the mounting surface. 4. Connect the lathe to the adapter, turn on the lathe and activate the computer to compensate for run-out in the hub. 5. Once the computer indicates the compensation process was successful, on the outboard area of the rotor, position the cutting tools one eighth of an inch into the brake pad area of the rotor. Feed the cutting tools into the rotor until they cut the rotor to new metal, a full 360 degrees. Zero each dial and back off a full turn. 6. Move the cutting bits to the middle of the rotor and do the same procedure. If zero is passed during the process, reset zero. Back off a full turn. 7. Position the cutting bits one eighth of an inch inside the inboard (closest to the hub) edge of the brake pad contact area. Do the same procedure. If zero is passed during the process, reset zero. 8. Back off a full turn and position the cutting bits all the way inboard in preparation to refinish the full rotor surface. Advance both tool cutters to the zero setting plus just enough to clean up the entire rotor surface. 9. After completing the refinish, sand both sides of the rotor for approximately one minute per side using a sanding block and 130-150 grit sandpaper to obtain a non-directional finish. 10. Dismount the lathe, but leave the lathe adapter attached to the vehicle. 6. Once the rotor has been properly machined, wash the rotor with soap and water (use a mild dish washing soap) or wipe it clean with GM approved brake cleaner, P/N 88862650 (Canadian P/N 88901247). Important Thoroughly cleaning the rotor will prevent the possible transfer of finite metal dust left as a by-product of machining to the pad material during the seating process, thus reducing the opportunity for squeaks or other noises to occur. 7. ***Record the REFINISHED rotor thickness measurement on the repair order hard copy. Refer to the "Repair Order Documentation - Rotor Refinish" section of this bulletin. 8. Setting up to measure for Lateral Run Out (LRO): Important Measuring for Lateral Run Out (LRO) (steps 8 - 15) is no longer required however, these steps are being left in the overall procedure as a good check to be performed in the case of a repeat pulsation complaint. If you are not checking for LRO, go to step 16. Bench-Type Lathe 1. Ensure that the mating surfaces of the rotor hat section and the hub mating surface are clean and free of debris. 2. Mount the new, original or refinished rotor onto the vehicle hub. Important Always hold the rotor on the bottom half so any debris that may be dislodged from the vents will fall out instead of falling into the mounting area. Any movement or jarring from the rotor falling over on the studs can release rust from the vents on the rotor. 3. Tilt the top of the rotor in towards the vehicle so you can see the studs and ease the rotor onto the studs. A/T - MIL ON/DTC P0757/Harsh or Slipping 2-3 Shift Clutch: All Technical Service Bulletins A/T - MIL ON/DTC P0757/Harsh or Slipping 2-3 Shift INFORMATION Bulletin No.: 08-07-30-015 Date: March 27, 2008 Subject: Diagnostic Information on MN8, MT1 SES/MIL Illuminated, DTC P0757, Harsh Shift, Delayed 2-3 Shift, 2-3 Shift Flare, No Third Gear, Slips in Third Gear or Reverse Models: 2002-2007 Chevrolet Avalanche 2500 Series, Silverado Classic, Suburban 2500 Series 2002-2008 Chevrolet Express 2002-2007 GMC Sierra Classic, Yukon XL 2500 Series 2002-2008 GMC Savana with HYDRA‐MATIC(R)4L80‐E (RPO MT1) or4L85‐E (RPO MN8) Automatic Transmission The purpose of this bulletin is to provide technicians with additional diagnostic information on DTC P0757. Refer to Service Information (SI) for DTC P0757, 2-3 Shift Solenoid Valve Performance No Third or Fourth Gear. Additional 4L80‐E or 4L85‐E transmission symptoms may be a harsh shift, delayed 2-3 shift, no third gear or slip in third or reverse, or a 2-3 shift flare. The transmission fluid inspection may or may not indicate distressed clutches. On all 2002-2006 vehicles and certain 2007-2008 vehicles, check for any debris caught in the # 11 check ball. If debris is found, repair per Service Bulletin 08-07-30-001. Also inspect the direct clutch for damage that may have been caused by a leak in the oil circuit that may be a result of the debris. If no debris is found, and no other cause is found when referring to Service Information (SI) for DTC P0757, valve body replacement may be indicated. Also check the 2-3 shift valve for debris or leakage. If none of these items seem to have a concern, replace the 2-3 shift solenoid due to a possible sticking pintle. Disclaimer Page 10304 4. Slide the shock dampener (2) over the inner tie rod housing (3) until the front lip of the shock dampener bottoms out against the inner tie rod housing. 5. Install the rack and pinion boot. Refer to Rack and Pinion Boot Replacement - On Vehicle. 6. Install the tire and wheel assembly to the vehicle. 7. Remove the safety stands. 8. Lower the vehicle. 9. Check the wheel alignment. Page 7020 The wheel hubs illustrated above are intended to provide enough visual details to identify subtle differences between the Gen II and Gen III replacement hubs. The various colors used in the graphics are not indicative of any difference or feature, but are used to increase the detail and clarity of the assembly. The associated part number is listed with each illustration. Please refer to the chart above for the specific application for each hub. Page 11444 ^ C222 (4 Cavities) (w/HP2) - Behind the left side I/P access panel ^ Refer to the Master Electrical Component List for additional location information. 1. Remove the appropriate side door sill plate. 2. Remove the appropriate side hinge pillar panel. 3. Locate the IP harness to inflatable restraint module yellow 4-way connector C221 or C222. 4. Inspect the IP harness to inflatable restraint module connector C221 or C222 for proper connection. 5. Disconnect and reconnect the IP harness to inflatable restraint module connector C221 or C222 THREE times. 6. Clear the DTC and road test the vehicle. ^ If DTCs B0013, B0014, B0017, B0018, B0024, B0026, B0043, B0044 DOES NOT reset, no additional repairs are necessary. Continue with step 10. ^ If DTCs B0013, B0014, B0017, B0018, B0024, B0026, B0043, B0044 DOES reset, the most likely cause is high resistance in the IP harness to inflatable restraint module connector C221 or C222. Continue with the next step. 7. Replace the appropriate connector C221 and/or C222, P/N's 15306186 and 88987998. Refer to SIR/SRS Wiring Repairs (SI Document ID #325229). 8. Road test the vehicle and confirm that the repair is complete. 9. Install the driver's side hinge pillar panel. 10. Install the driver's side door sill plate. Parts Information Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Page 1586 Fuel Tank Pressure (FTP) Sensor Page 4318 SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-D. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: - The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair Tools Required J 38125-D Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-D. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Page 14674 If any of the involved vehicles are in the used car inventory of your dealership or were recently sold by you or a customer brings in an involved vehicle for service, please contact the GM Reacquired Vehicle Disclosure Center (RVDC). Claim Information Submit a Product Recall Claim with the information shown. Refer to the General Motors WINS Claims Processing Manual for details on Product Recall Claim Submission. Customer Notification General Motors will notify customers of this recall on their vehicle (see copy of customer letter shown in this bulletin). Dealer Recall Responsibility The customer will contact General Motors to begin the repurchase process. General Motors will work with the customer to reach an agreement on the purchase of the vehicle. Dealers will be contacted by General Motors to assist in the removal of any aftermarket accessories, inspection of the vehicle, obtaining titles and other documentation required to transfer ownership to General Motors, presenting the customer with a check for the purchase, and taking possession of the vehicle. General Motors will arrange for transportation of the vehicle from the dealer. Whenever a vehicle subject to this recall enters your vehicle inventory, or is in your dealership for service in the future, you must contact the GM Reacquired Vehicle Disclosure Center (RVDC). Disclaimer Page 4393 Throttle Actuator Control (TAC) Module C2 Part 1 Page 8452 Yukon XL vehicles built within the VIN breakpoints shown. Important: Dealers should confirm vehicle eligibility through GMVIS (GM Vehicle Inquiry System) before beginning recall repairs. [Not all vehicles within the above breakpoints may be involved.] For US For dealers with involved vehicles, a Campaign Initiation Detail Report containing the complete Vehicle Identification Number, customer name and address data has been prepared and will be loaded to the GM DealerWorld, Recall Information website. Dealers that have no involved vehicles currently assigned will not have a report available in GM DealerWorld. For Canada For dealers with involved vehicles, a Campaign Initiation Detail Report containing the complete Vehicle Identification Number, customer name and address data has been prepared and is being furnished to involved dealers. Dealers that have no involved vehicles currently assigned will not receive a report with the recall bulletin. For Export For dealers with involved vehicles, a Campaign Initiation Detail Report containing the complete Vehicle Identification Number, customer name and address data has been prepared and is being furnished to involved dealers. Dealers that have no involved vehicles currently assigned will not receive a report with the recall bulletin. The Campaign Initiation Detail Report may contain customer names and addresses obtained from Motor Vehicle Registration Records. The use of such motor vehicle registration data for any other purpose other than follow-up necessary to complete this recall is a violation of law in several states/provinces/countries. Accordingly, you are urged to limit the use of this report to the follow-up necessary to complete this program. Parts Information A very small number of vehicles (less than 90 world-wide) will require the replacement of the hydraulic brake booster. Do not order boosters for shelf stock. When a replacement is required, order the appropriate booster from GMSPO. All replaced boosters (excluding Export) must be returned to the Warranty Parts Center. Hold the booster until you receive the request for return. Special Tool Beginning February 18, 2005, each dealer was shipped a Hydro-Boost Checking Tool, CH 47950, for use in this recall. This tool is being furnished at no charge. Additional tools, if required, may be purchased by contacting SPX Kent-Moore at 1-800-468-6657. Courtesy Transportation The General Motors Courtesy Transportation program is intended to minimize customer inconvenience when a vehicle requires a repair that is covered by the New Vehicle Limited Warranty. The availability of courtesy transportation to customers whose vehicles are within the warranty coverage period and involved in a product recall is very important in maintaining customer satisfaction. Dealers are to ensure that these customers understand that shuttle service or some other form of courtesy transportation is available and will be provided at no charge. Dealers should refer to the General Motors Service Policies and Procedures Manual for Courtesy Transportation guidelines. Page 11564 4. Wait 1 minute before working on the system. Enabling Procedure - Air Bag Fuse 1. Place the ignition in the OFF position. 2. Install the fuse(s) supplying power to the SDM. 3. Turn the ignition switch to the ON position. The AIR BAG indicator will flash then turn OFF. 4. Perform the Diagnostic System Check - Vehicle if the AIR BAG warning indicator does not operate as described. Disabling Procedure - Negative Battery Cable 1. Turn the steering wheel so that the vehicles wheels are pointing straight ahead. 2. Place the ignition in the OFF position. 3. Disconnect the negative battery cable from the battery. 4. Wait 1 minute before working on system. Enabling Procedure - Negative Battery Cable 1. Place the ignition in the OFF position. 2. Connect the negative battery cable to the battery. 3. Turn the ignition switch to the ON position. The AIR BAG indicator will flash then turn OFF. 4. Perform the Diagnostic System Check - Vehicle if the AIR BAG warning indicator does not operate as described. Page 8868 Electrical Symbols Part 6 Page 763 1. Remove the instrument panel accessory trim plate. 2. Remove the screws from the HVAC control module. 3. Depress the control assembly retaining tabs and remove the HVAC control module from the instrument panel. 4. Disconnect the electrical connectors from the HVAC control module. INSTALLATION PROCEDURE IMPORTANT: The Key should be in the off position when connecting the electrical connectors to ensure proper calibration. 1. Connect the electrical connectors to the HVAC control module. 2. Install the HVAC control module into the instrument panel, ensuring that the HVAC control module retaining tabs lock into place. NOTE: Refer to Fastener Notice in Service Precautions. 3. Install the screws from the HVAC control module. Tighten Tighten the screws to 1.9 N.m (17 lb in). 4. Install the instrument panel accessory trim plate IMPORTANT: Do not adjust any controls on the HVAC control module while the HVAC control module is calibrating. If interrupted improper HVAC performance will result. 5. Start the vehicle and let run for one minute. Page 8555 cloth below the booster supply port in order to capture any fluid exiting the hydro-boost unit. 10. Install the inlet port adapter, CH 47950-2 (2) into the booster supply port. 11. Using a torque wrench, slowly tighten the inlet port adapter to 16 N.m (12 lb-ft). If the clear tube was removed from the inlet port adapter assembly, be sure it is reinstalled. 12. Before each use of the accumulator pressure clamp, CH 47950-1, be sure to grease the clamp bolt and anti rotation washer with wheel bearing grease. 13. Install the accumulator pressure clamp, CH 47950-1 (1), by sliding it over the accumulator and straddling the hydro-boost housing. 14. Confirm that the accumulator pressure clamp is squarely seated onto the booster housing and accumulator, and place the 3/4 inch containment bolt into the fixture. Install the nut hand-tight onto the containment bolt. 15. Check and make sure that the fixture washer is correctly positioned between the end of the accumulator, and that the pin is engaged in the end of the bolt. The tab on the washer should be rotated clockwise so it is located below the master cylinder mounting flange ear. Caution: Incorrect installation of the washer will result in damage to the accumulator end. 16. Hand-tighten the accumulator pressure clamp bolt. Make sure the clamp is level and the tube is square to the end of the accumulator. 17. Place a shop cloth next to the opening of the inlet port adapter in order to capture any fluid exiting the hydro-boost unit. Important: Do not exceed 65 N.m (48 lb-ft) torque. Important: A torque wrench must be used to tighten the fixture clamp bolt 18. Slowly tighten the fixture clamp bolt while monitoring the inlet port adapter tube for signs of power steering fluid. Stop tightening of the bolt when either fluid is observed (below the maximum 65 N.m (48 lb-ft) torque) OR The 65 N.m (48 lb-ft) maximum bolt torque is achieved (with no fluid Page 3933 1. Locate the air flow direction arrow (2) on the MAF/IAT sensor. 2. Install the MAF/IAT sensor to the air cleaner assembly. NOTE: Refer to Fastener Notice in Service Precautions. 3. Tighten the MAF/IAT clamp. Tighten Tighten the clamp to 7 N.m (62 lb in). 4. Connect the MAF/IAT sensor electrical connector (4). 5. Push in the gray CPA retainer. 6. Install the air cleaner outlet duct. Page 9523 Application Tabel Part 1 Page 10895 Refer to the table as a guide in selecting the correct test adapter for frontprobing connectors: Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure SCAN TOOL SNAPSHOT PROCEDURE Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: - Snapshot - taken from the Snapshot menu choice - Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information Wheels/Tires - Refinishing Aluminum Wheels Wheels: All Technical Service Bulletins Wheels/Tires - Refinishing Aluminum Wheels INFORMATION Bulletin No.: 99-08-51-007E Date: March 17, 2011 Subject: Refinishing Aluminum Wheels Models: 2012 and Prior GM Passenger Cars and Trucks Supercede: This bulletin is being revised to add additional model years. Please discard Corporate Bulletin Number 99-08-51-007D (Section 08 - Body and Accessories). This bulletin updates General Motor's position on refinishing aluminum wheels. GM does not endorse any repairs that involve welding, bending, straightening or re-machining. Only cosmetic refinishing of the wheel's coatings, using recommended procedures, is allowed. Evaluating Damage In evaluating damage, it is the GM Dealer's responsibility to inspect the wheel for corrosion, scrapes, gouges, etc. The Dealer must insure that such damage is not deeper than what can be sanded or polished off. The wheel must be inspected for cracks. If cracks are found, discard the wheel. Any wheels with bent rim flanges must not be repaired or refinished. Wheels that have been refinished by an outside company must be returned to the same vehicle. The Dealer must record the wheel ID stamp or the cast date on the wheel in order to assure this requirement. Refer to Refinisher's Responsibility - Outside Company later in this bulletin. Aluminum Wheel Refinishing Recommendations - Chrome-plated aluminum wheels Re-plating these wheels is not recommended. - Polished aluminum wheels These wheels have a polyester or acrylic clearcoat on them. If the clearcoat is damaged, refinishing is possible. However, the required refinishing process cannot be performed in the dealer environment. Refer to Refinisher's Responsibility - Outside Company later in this bulletin. - Painted aluminum wheels These wheels are painted using a primer, color coat, and clearcoat procedure. If the paint is damaged, refinishing is possible. As with polished wheels, all original coatings must be removed first. Media blasting is recommended. Refer to GM Aluminum Refinishing Bulletin #53-17-03A for the re-painting of this type of wheel. - Bright, machined aluminum wheels These wheels have a polyester or acrylic clearcoat on them. In some cases, the recessed "pocket" areas of the wheel may be painted. Surface refinishing is possible. The wheel must be totally stripped by media blasting or other suitable means. The wheel should be resurfaced by using a sanding process rather than a machining process. This allows the least amount of material to be removed. Important Do not use any re-machining process that removes aluminum. This could affect the dimensions and function of the wheel. Painting is an option to re-clearcoating polished and bright machined aluminum wheels. Paint will better mask any surface imperfections and is somewhat more durable than clearcoat alone. GM recommends using Corsican SILVER WAEQ9283 for a fine "aluminum-like" look or Sparkle SILVER WA9967 for a very bright look. As an option, the body color may also be used. When using any of the painting options, it is recommended that all four wheels be refinished in order to maintain color uniformity. Refer to GM Aluminum Refinishing Bulletin #53-17-03A for specific procedures and product recommendations. Refinisher's Responsibility - Outside Company Important Some outside companies are offering wheel refinishing services. Such refinished wheels will be permanently marked by the refinisher and are warranted by the refinisher. Any process that re-machines or otherwise re-manufactures the wheel should not be used. A refinisher's responsibility includes inspecting for cracks using the Zyglo system or the equivalent. Any cracked wheels must not be refinished. No welding, hammering or reforming of any kind is allowed. The wheel ID must be recorded and follow the wheel throughout the process in order to assure that the same wheel is returned. A plastic media blast may be used for clean up of the wheel. Hand and/or lathe sanding of the machined surface and the wheel window is allowed. Material removal, though, must be kept to a minimum. Re-machining of the wheel is not allowed. Paint and/or clear coat must not be present on the following surfaces: the nut chamfers, the wheel mounting surfaces and the wheel pilot hole. The refinisher must permanently ID stamp the wheel and warrant the painted/clearcoated surfaces for a minimum of one year or the remainder of the new vehicle warranty, whichever is Page 5428 Fuel Pump And Sender Assembly Components Brakes - Wheel Cylinder Inspection Guidelines Wheel Cylinder: Technical Service Bulletins Brakes - Wheel Cylinder Inspection Guidelines Bulletin No.: 03-05-24-001A Date: March 21, 2005 INFORMATION Subject: Service Information Regarding Rear Brake Drum Wheel Cylinder Inspections Models: 2005 and Prior GM Passenger Cars and Trucks 2005 and Prior Saturn Vehicles with Rear Drum Brakes Supercede: This bulletin is being revised add model years and include all GM vehicles. Please discard Corporate Bulletin Number 03-05-24-001 (Section 03 - Suspension). This bulletin provides information on proper inspection of rear drum brake wheel cylinders. Important: It is not recommended that dust boots be removed during inspection processes as dirt and debris could contaminate the wheel cylinder bore causing premature wear of the wheel cylinder. In addition, most bores should look damp and some lubricant may drip out from under the boot as a result of lubricant being present. All rear drum brake wheel cylinders are assembled with a lubricant to aid in assembly, provide an anti-corrosion coating to the cylinder bore, and lubricate internal rubber components. As a result of this lubrication process, it is not uncommon for some amount of lubricant to accumulate at the ends of the cylinder under the dust boot. Over time, the lubricant may work its way to the outside of the boot and cause an area of the boot to look damp. Evidence of a damp area on the boot does not indicate a leak in the cylinder. However, if there is excessive wetness (i.e. drips) coming from the boot area of the wheel cylinder, it could indicate a brake hydraulic fluid leak requiring wheel cylinder replacement. (Refer to the Wheel Cylinder Replacement procedures in the appropriate Service Manual.) Disclaimer Page 8887 7. Insert the J 38125-13A (GM P/N 12031876-1) tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the Terminal Repair Kit to ensure that the correct release tool is used. 8. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. REPAIR PROCEDURE Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. Page 9081 Application Table Page 8782 Electrical Symbols Part 12 Page 12230 9. Erase the diagnostic trouble codes. 10. Set the date and time, see WIS - 3. Electrical system - Information display (SID) - Technical description. Page 12685 High OR Low The above conditions are met for more than 3 seconds. Circuit/System Verification These DTCs cannot be retrieved with a current status. To diagnose use the Scan Tool Does Not Communicate with a Class 2 Device. Refer to SI. An intermittent condition is likely to be caused by a short on the Class 2 serial data circuit. To diagnose use the Scan Tool Does Not Communicate with a Class 2 Device. Refer to SI. DTC B2455 DTC Descriptors DTC B2455 01: Cellular Phone Microphone Circuit Short to Battery DTC B2455 02: Cellular Phone Microphone Circuit Short to Ground DTC B2455 04: Cellular Phone Microphone Circuit Open Circuit Circuit/System Description Without RPO UAV The vehicle communication interface module (VCIM) uses the cellular phone microphone to allow driver communication with OnStar(R). With RPO UAV The vehicle communication interface module (VCIM) and navigation radio use the cellular phone microphone to allow driver communication with OnStar(R), as well as to operate the voice recognition/voice guidance feature of the navigation radio. Conditions for Running the DTC The ignition is in RUN or ACC position. System voltage is between 9.5 - 15.5 volts. The above conditions are met for more than 10 seconds. Conditions for Setting the DTC B2455 01: A short to battery is detected on the cellular microphone signal circuit. B2455 02: A short to ground is detected on the cellular microphone signal circuit. B2455 04: An open circuit is detected on the cellular microphone signal circuit. Action Taken When the DTC Sets The VCIM and/or navigation radio (RPO UAV) will not receive any signal from the microphone. The OnStar(R) status LED turns red. Voice recognition will not function. Conditions for Clearing the DTC Page 14684 - Wear/cracking/peeling - Discoloration/dye transfer from customer clothing (if discoloration/dye transfer is not removed after using GM Leather and Vinyl Plastic Cleaner, P/N 88861401 (in Canada, P/N 88861409), replace the covers.) Disclaimer Page 6322 Park Neutral Position (PNP) Switch C175 Locations Fuel Composition Sensor Page 13454 The 1999 though early 2003 wiring harness jumper that plugs into the relay block will have a reddish/brown 6-way connector and a tag with the last four digits of the wiring harness part number. Second design 2003-05 may have a white plastic connector with part number 5418 as well. ^ The 1999 jumper is/was P/N 12171982 with a pink/purple tag identifier of 1982. This number has been superseded to 15366255, with a pink/purple tag identifier of 6255. ^ The 2000 jumper harness is P/N 15366255. The pink/purple tag identifier is 6255. ^ The 2001-2002 jumper is P/N 15086884. The orange tag identifier is 6884. ^ The 2003-05 jumper is P/N 15085418. The orange tag identifier is 5418. When transferring the brake controller with the wiring jumper attached from a 2001-2002 vehicle to a 2003-05 vehicle, a change to the jumper harness connector must be performed. Page 6899 Axle Shaft: Service and Repair Rear Axle Shaft and/or Gasket Replacement Rear Axle Shaft and/or Gasket Replacement Removal Procedure 1. Remove the flange bolts. 2. Lightly tap the axle shaft with a soft-faced hammer in order to loosen the shaft. 3. Grip the rib on the axle shaft flange with a locking pliers. Twist the axle shaft flange in order to start the axle shaft removal. 4. Remove the axle shaft from the tube. 5. Remove the gasket. 6. Clean the axle shaft flange and the outside face of the hub assembly. Installation Procedure 1. Install the gasket onto the axle shaft. 2. Install the gasket and the axle shaft into the axle tube. 1. Ensure the shaft splines mesh into the differential side gear. 2. Align the holes in the axle flange and the gasket with the holes in the hub. 3. Notice: Refer to Fastener Notice in Service Precautions. Install the axle flange bolts. ^ For the 10.5 inch axle, tighten the rear axle flange bolts to 156 Nm (115 ft. lbs.). ^ For the 11.5 inch axle, tighten the rear axle flange bolts to 200 Nm (148 ft. lbs.). 4. Inspect and add axle lubricant to the axle housing, if necessary. Page 3333 Oil Filter: Service and Repair Engine Oil and Oil Filter Replacement Removal Procedure Important: In order to completely drain the oil from the oil pan internal baffling, the bottom of the oil pan must be level during the oil drain procedure. 1. Open the hood. 2. Remove the oil fill cap. 3. Raise and suitably support the vehicle. 4. Place a oil drain pan under the oil pan drain plug. 5. Remove the oil pan drain plug. 6. Drain the engine oil. 7. Wipe the excess oil from the drain plug hole and plug. 8. Remove the oil filter from the engine block. Important: Check the old oil filter to ensure that the filter seal is not left on the engine block. 9. Wipe the excess oil from the oil filter mounting. Installation Procedure 1. Lubricate the oil filter seal with clean engine oil. Page 6797 Fluid - Differential: Fluid Type Specifications Differential Fluid Type Differential Fluid Type Front 4WD Grade ................................................................................................................................ ............................................................................................. GL-5 Viscosity ....................................... .............................................................................................................................................................. .............. 80W-90 Front AWD Grade ................................................................................................... .................................................................................................................... Synthetic Viscosity .......... .............................................................................................................................................................. ........................................... 75W-90 Rear Grade ................................................................................ ....................................................................................................................................... Synthetic Viscosity .............................................................................................................................................. ..................................................................... 75W-90 Rear (Steerable) Grade ................................... .............................................................................................................................................................. ...................... Synthetic Viscosity ........................................................................................................ ........................................................................................................... 75W-90 Front Differential Differential Fluid Type The content of this article reflects the changes identified in TSB number 05-00-90-010 dated December 07, 2005. 1999-2004 7.25 Inch (Blazer, Jimmy, S-10, Sonoma, Astro, Safari) Grade ........................................ .............................................................................................................................................................. ....................... GL-5 Viscosity ............................................................................................................. ...................................................................................................... 80W-90 2002-2005 7.25 Inch (Trailblazer, Envoy, Bravada, Rainier Grade ....................................................................................... ................................................................................................................................ Synthetic Viscosity .............................................................................................................................................. ..................................................................... 75W-90 8.25 Inch With Selectable 4WD Grade ............ .............................................................................................................................................................. ................................................... GL-5 Viscosity ................................................................................. .................................................................................................................................. 80W-90 8.25 Inch With AWD Grade ......................................................................................................................... .............................................................................................. Synthetic Viscosity ................................ .............................................................................................................................................................. ..................... 75W-90 1999-2001 9.25 Inch Grade ............................................................................. ................................................................................................................................................ GL-5 Viscosity .............................................................................................................................................. ..................................................................... 80W-90 2002-2005 9.25 Inch Grade ............................. .............................................................................................................................................................. ............................ Synthetic Viscosity .................................................................................................. ................................................................................................................. 75W-90 Front Drive Axle Differential Fluid Type The content of this article reflects the changes identified in TSB number 05-00-90-010 dated December 07, 2005. 1999-2004 7.25 Inch (Blazer, Jimmy, S-10, Sonoma, Astro, Safari) Grade ........................................ .............................................................................................................................................................. ....................... GL-5 Viscosity ............................................................................................................. ...................................................................................................... 80W-90 2002-2005 7.25 Inch (Trailblazer, Envoy, Bravada, Rainier Grade ....................................................................................... ................................................................................................................................ Synthetic Viscosity .............................................................................................................................................. ..................................................................... 75W-90 8.25 Inch With Selectable 4WD Grade ............ .............................................................................................................................................................. ................................................... GL-5 Viscosity ................................................................................. .................................................................................................................................. 80W-90 8.25 Inch With AWD Grade ......................................................................................................................... .............................................................................................. Synthetic Viscosity ................................ .............................................................................................................................................................. ..................... 75W-90 1999-2001 9.25 Inch Grade ............................................................................. ................................................................................................................................................ GL-5 Viscosity .............................................................................................................................................. ..................................................................... 80W-90 2002-2005 9.25 Inch Electrical - Trailer Brakes Apply With Headlamps ON Trailer Lighting Module: All Technical Service Bulletins Electrical - Trailer Brakes Apply With Headlamps ON Bulletin No.: 02-05-22-004C Date: April 05, 2005 TECHNICAL Subject: Trailer Brakes Applied When Headlights/Park Lamps Are On, Brake Controller Illumination (Modify Brake Controller Wiring Harness) Models: 2002-2005 Cadillac Escalade, Escalade EXT 1999-2005 Chevrolet Silverado 2000-2005 Chevrolet Suburban, Tahoe 2002-2005 Chevrolet Avalanche 1999-2005 GMC Sierra 2000-2005 GMC Yukon, Yukon XL 2003-2005 HUMMER H2 Supercede: This bulletin is being revised to add additional model years. Please discard Corporate Bulletin Number 02-05-22-004B (Section 05 - Brakes). Condition Some customers may comment that when the headlamps or park lamps are on, the brakes on the trailer are always applied, or that the back lighting for the trailer brake controller only illuminates when the brakes are applied. Cause The cause of this condition may be due to wiring changes within the vehicle electrical system for the 2003 model year. Correction Inspect the brake controller wiring harness jumper that is plugged into the vehicle relay block-body. The relay block-body is located under the left side of the instrument panel near the left kick panel, behind a plastic cover. Page 16269 Washer Fluid Level Switch: Service and Repair WASHER SOLVENT CONTAINER LEVEL SENSOR REPLACEMENT REMOVAL PROCEDURE 1. Remove the washer solvent container. 2. Using a small flat-bladed tool, remove the washer solvent container level sensor (1) and seal (2) from the container. INSTALLATION PROCEDURE 1. Position the washer solvent container level sensor (1) and the seal (2) to the container by pressing in until fully seated. 2. Install the washer solvent container. Page 3801 Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. 1. Disconnect the connector from the component. 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. Page 16069 Electrical Symbols Part 12 Page 7922 Install the parking lock bracket bolts. ^ Tighten the bolts to 24 Nm (18 ft. lbs.). 13. Install the PNP switch. 14. Install the transmission filter. 15. Fill the transmission to the proper level with Dexron® III transmission fluid. Page 15771 Turn Signal Multifunction Switch - C4 (With RPO Code K34) Page 3824 Body Control Module (BCM) - C2 Part 2 Page 9474 Auxiliary Power Outlet: Service and Repair Accessory Power Receptacle Replacement - 12 Volt ACCESSORY POWER RECEPTACLE REPLACEMENT - 12 VOLT TOOLS REQUIRED J 42059 Cigar Lighter Socket Remover REMOVAL PROCEDURE 1. Remove the power supply fuse. 2. Lift up the front cover of the receptacle. 3. Insert the J 42059 into the receptacle sleeve. Tilt the tool so that the tool fits into the slots on the sides of the receptacle sleeve. 4. Hold the plastic ring in place. Pull the receptacle out of the assembly in order to remove the outlet. Page 12953 Speaker: Diagrams Speaker - LF Tweeter Speaker - LF - Tweeter - With RPO Code UQ3 Page 8601 of failure to repair within a reasonable time. If the condition is not adequately repaired within a reasonable time, the customer may be entitled to an identical or reasonably equivalent vehicle at no charge or to a refund of the purchase price less a reasonable allowance for depreciation. To avoid having to provide these burdensome remedies, every effort must be made to promptly schedule an appointment with each customer and to repair their vehicle as soon as possible. In the recall notification letters, customers are told how to contact the US National Highway Traffic Safety Administration if the recall is not completed within a reasonable time. Dealer Recall Responsibility -- All All unsold new vehicles in dealers' possession and subject to this recall MUST be held and inspected/repaired per the service procedure of this recall bulletin BEFORE customers take possession of these vehicles. Dealers are to service all vehicles subject to this recall at no charge to customers, regardless of mileage, age of vehicle, or ownership, from this time forward. Customers who have recently purchased vehicles sold from your vehicle inventory, and for which there is no customer information indicated on the dealer listing, are to be contacted by the dealer. Arrangements are to be made to make the required correction according to the instructions contained in this bulletin. A copy of the customer letter is shown in this bulletin for your use in contacting customers. Recall follow-up cards should not be used for this purpose, since the customer may not as yet have received the notification letter. In summary, whenever a vehicle subject to this recall enters your vehicle inventory, or is in your dealership for service in the future, please take the steps necessary to be sure the recall correction has been made before selling or releasing the vehicle. Disclaimer Service Procedure Inspection Tools Required CH 47950 Hydro-Boost Checking Tool 1. With the vehicle transmission in PARK or NEUTRAL, set the park brake. 2. With the engine OFF, make a minimum of five (5) high effort brake applies until the pedal feels hard. 3. Start the engine. Important: DO NOT depress the brake pedal until instructed. 4. Turn the steering wheel to the "steering lock" (fully turned) position. Hold at the steering lock position for 1 to 2 seconds and then release the steering wheel. Repeat a total of 3 times. 5. Turn the vehicle off being careful not to step on the brake pedal. 6. For Express/Savana only: A. Remove the remote power steering reservoir mounting nuts. B. Disconnect the reservoir outlet hose from the booster unit. Keeping the hose end higher than the reservoir, reposition the reservoir forward and down out of the way. 7. Using a clean, lint-free shop cloth, wipe any dirt away from the steering pump supply hose/tube connection area on the hydro-boost (this is the center hose/tube of the three). 8. Disconnect the power steering supply hose/tube from the hydro-boost unit and wrap a clean lint-free shop cloth around the end of the hose and secure it in the engine compartment. 9. Using a clean lint-free shop cloth, clean any dirt off of the inlet port adapter valve assembly. Before installing the inlet port adapter, place a shop Page 14610 Power Seat Motor: Diagrams Seat Front Vertical Motor Seat Front Vertical Motor - Driver Page 11846 2.2. Press together the top and the bottom covers. 2.3. Inspect the operation of the transmitter. 3. Synchronize the transmitter. Refer to Transmitter Synchronization. Diagrams Page 9432 9. Use J 38125-12A to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. REPAIR PROCEDURE The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. 1. Cut the wire as close to the terminal as possible. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. Page 11523 Disclaimer Page 14240 Seat Memory Switch: Diagrams Driver Door Module (DDM) - C5 (Memory/Heated Seat Switch) Part 1 Page 1983 Electrical Symbols Part 10 Page 6757 Extended Cab Short Box Shown Below, Other Configurations Similar 6. Install the new canister vent valve solenoid to the fuel tank clip or mounting bracket as shown above. The valve port closest to the electrical connector must point towards the canister. 7. Cut bulk 5/8" heater hose to a length of approximately 76 mm (3 in). Install the hose between the solenoid and the canister pipe and secure using clamps. 8. Attach bulk 5/8" heater hose to the vent port and secure using a clamp. Run a length as needed along the frame rail routing to the area above the transmission. 9. Cut the hose to determined length and install the supplied filter box. Secure using a clamp. 10. Remove the transmission support and lower the transmission assembly as necessary to allow for access to the new filter box location. 11. Secure the filter box to the transmission vent hose just forward of the hose tee-section using a tie strap. DO NOT pinch or restrict the transmission vent hose. The filter box opening should be pointing downward. 12. Raise the transmission and reinstall the transmission support. 13. Connect the EVAP canister vent valve electrical connector. 14. Tie strap the hose as needed along the frame rail in order to keep the hose away from pinch-points and heat sources. 15. Lower the vehicle. Correction (2007-2010 New Style Models) After following the published SI diagnostics and determining that the EVAP canister vent valve is the cause of the MIL light, replace the EVAP canister vent valve assembly and relocate the remote filter box. To ensure correct installation, follow the procedures below. Important DO NOT replace the EVAP canister assembly for this concern unless it fails the leak test. Use Service Kit P/N 19207763 1. Raise the vehicle. Suitably support the vehicle. 2. Disconnect the EVAP canister vent valve electrical connector. Page 4794 Crankshaft Position Sensor: Service and Repair Crankshaft Position (CKP) Sensor Replacement CRANKSHAFT POSITION (CKP) SENSOR REPLACEMENT REMOVAL PROCEDURE IMPORTANT: Perform the CKP System Variation Learn Procedure whenever the crankshaft position sensor is removed or replaced. 1. Remove the starter. 2. Disconnect the crankshaft position (CKP) sensor electrical connector. 3. Clean the area around the CKP sensor before removal in order to avoid debris from entering the engine. 4. Remove the CKP sensor bolt. 5. Remove the CKP sensor. INSTALLATION PROCEDURE Locations Crankshaft Position (CKP) Sensor Location Page 15328 Fuel Gauge Sender: Service and Repair Fuel Level Sensor Replacement - 2 FUEL LEVEL SENSOR REPLACEMENT REMOVAL PROCEDURE 1. Remove the sending unit. 2. Disconnect the fuel pump electrical connector. 3. Remove the fuel level sensor electrical connector retaining clip. 4. Disconnect the fuel level sensor electrical connector. Page 14159 Keyless Entry Receiver: Service and Repair REMOTE CONTROL DOOR LOCK RECEIVER REPLACEMENT The remote control door lock module is incorporated into the passenger side window switch module. Page 9520 Fuse Block - Underhood - Secondary Wire Entry (With RPO Code HP2) Part 3 Page 16148 Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA and/or the secondary locks. Micro .64 Connectors MICRO .64 CONNECTORS TOOLS REQUIRED J 38125-D Terminal Repair Kit REMOVAL PROCEDURE Follow the steps below in order to remove terminals from Micro 64 connectors. 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. 2. Disconnect the connector from the component. Burnishing Pads and Rotors Brake Rotor/Disc: Service and Repair Burnishing Pads and Rotors Burnishing Pads and Rotors Caution: Refer to Road Test Caution in Service Precautions. Burnishing the brake pads and brake rotors is necessary in order to ensure that the braking surfaces are properly prepared after service has been performed on the disc brake system. This procedure should be performed whenever the disc brake rotors have been refinished or replaced, and/or whenever the disc brake pads have been replaced. 1. Select a smooth road with little or no traffic. 2. Accelerate the vehicle to 48 km/h (30 mph). Important: Use care to avoid overheating the brakes while performing this step. 3. Using moderate to firm pressure, apply the brakes to bring the vehicle to a stop. Do not allow the brakes to lock. 4. Repeat steps 2 and 3 until approximately 20 stops have been completed. Allow sufficient cooling periods between stops in order to properly burnish the brake pads and rotors. Locations Chassis And License Lamp Harnesses Page 16203 For vehicles repaired under warranty, use the table. Disclaimer A/T - 4T80E, Slips in Gear/L/H Axle Seal Leaks Seals and Gaskets: All Technical Service Bulletins A/T - 4T80E, Slips in Gear/L/H Axle Seal Leaks TECHNICAL Bulletin No.: 08-07-30-009B Date: May 01, 2008 Subject: HYDRA-MATIC(R) Front Wheel Drive 4T80-E (MH1) Left Front Axle Seal Leak, Transmission Slips in Gear (Replace Third Clutch Housing with Revised Service Part) Models: 2001-2008 GM Passenger Cars with HYDRA-MATIC(R) Front Wheel Drive 4T80-E Automatic Transmission (RPO - MH1) Supercede: This bulletin is being updated to revise the Warranty Information. Please discard Corporate Bulletin Number 08-07-30-009A (Section 07 - Transmission/Transaxle). Condition Some customers may comment on a transmission oil leak and/or that the transmission slips in gear. Cause An oil leak may be caused by bushing wear in the third clutch housing, causing excessive fluid build-up at axe sea. Correction Important: DO NOT replace the transmission for above concerns. Replace the third clutch housing with service P/N 8682114, which has revised bushing material to extend life and reduce left front axle seal leaks. Refer to Automatic/Transaxle - 4T80-E Transmission Off-Vehicle Repair Instructions for the replacement of the third clutch housing in SI. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 12318 Electrical Symbols Part 9 Page 3570 16. Install the radiator inlet hose clip to the outlet duct. 17. Tighten the air cleaner outlet duct clamps at the following locations: ^ Throttle body ^ MAF/IAT sensor Tighten the clamps to 7 Nm (62 inch lbs.). 18. Fill the cooling system. Page 3696 16. Install the radiator inlet hose clip to the outlet duct. 17. Tighten the air cleaner outlet duct clamps at the following locations: ^ Throttle body ^ MAF/IAT sensor Tighten the clamps to 7 Nm (62 inch lbs.). 18. Fill the cooling system. Page 7824 Park Neutral Position (PNP) Switch C175 HVAC System - Automatic Control Module HVAC: Service and Repair HVAC System - Automatic Blower Motor Control Processor Replacement BLOWER MOTOR CONTROL PROCESSOR REPLACEMENT REMOVAL PROCEDURE 1. If equipped, remove the sound insulator panel. 2. Disconnect the electrical connector at the blower motor. 3. Disconnect the electrical connector (4) from the blower motor control processor (2). 4. Remove the blower motor control processor retaining screws (3) from the HVAC module (1). 5. Remove the blower motor control processor (2) from the HVAC module (1). INSTALLATION PROCEDURE Page 2016 Control Module References Part 1 Page 8131 13. If necessary, lower the vehicle. 14. Using a scan tool, clear the DTCs. 15. Start the vehicle and inspect for leaks. Important: Advise the customer that a similar condition may occur if the vehicle is fueled with the engine running AND the rear tank is fueled first. The engine must be shut off (as required by law) during vehicle refueling. Parts Information Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 1057 Pay particular attention to the terminal connections at the module. Spread or open terminal connections may create an intermittent contact. Do a pin drag test. Refer to the terminal testing information in the table shown. ^ After repairs are complete, ALWAYS clear DTCs from the module prior to a system function test. If codes are not cleared first, the system will not function after repair. The technician may erroneously think that the system is still down and that further repairs are needed. Warranty Dealers who unnecessarily replace the TCCM that are found to have No Trouble Found (NTF) at the WPC will be returned to the AVM (Area Service Manager), or the DSM (District Service Manager) in Canada, through the Regional Feedback Process and may be charged back for the repair through the WINS system. Disclaimer Page 8411 5. For 25/35 series vehicles, disable the park brake cable automatic adjuster. Refer to Disabling the Park Brake Cable Automatic Adjuster. 6. For 25/35 series vehicles, disconnect the cable at the equalizer. Installation Procedure 1. For 25/35 series vehicles, connect the cable at the equalizer. 2. For 25/35 series vehicles, enable the park brake cable automatic adjuster. Refer to Enabling the Park Brake Cable Automatic Adjuster. 3. For the 15 series vehicles, connect the rear park brake cables to the equalizer. Page 5499 Accelerator Pedal Position Sensor: Diagrams Accelerator Pedal Position (APP) Sensor Part 1 Page 14737 1. Remove the seat cushion trim cover (8) and the pad (7). 2. Remove the bolts from the hinge assembly, if equipped with folding seats. 3. Remove the seat cushion frame (5). Installation Procedure 1. Install the seat cushion frame (5). Notice: Refer to Fastener Notice in Service Precautions. 2. Install the bolts to the hinge assembly, if removed. Tighten the bolts to 35 N.m (26 lb ft). 3. Install the seat cushion trim cover (8) and the pad (7). Seat Cushion Trim Cover and Pad Replacement Seat Cushion Trim Cover and Pad Replacement Removal Procedure Page 6371 15. Install the transmission mount nut. ^ Tighten the nut to 50 Nm (37 ft. lbs.). 16. Remove the support from the transmission. 17. Lower the vehicle. 18. Install the transmission oil level indicator. 19. Lock the transmission oil level indicator. Manual Shift Shaft Seal Replacement Manual Shift Shaft Seal Replacement ^ Tools Required J 43911 Selector Shaft Seal Remover - J 43909 Selector Shaft Seal Installer Removal Procedure 1. Remove the park/neutral position (PNP) switch. 2. Ensure that the jackscrew for J 43911 is backed off and will not interfere with installation of the removal tool. Slide the seal remover tool over the selector shaft (2) with the threaded end of the tool towards the seal. 3. Rotate the removal tool so that the threads on the end of the tool engage the steel shell (1) of the seal. Use a wrench to ensure that the removal tool is firmly attached to the seal shell. 4. Rotate the jackscrew in the clockwise direction to remove the seal from the bore. Discard the seal that was removed. Installation Procedure 1. Carefully slide a new selector shaft seal (1) over the selector shaft (2) with the wide face of the steel case facing outward. Position the seal so that it is starting to enter the seal bore. 2. Obtain J 43909 and remove the inner sleeve so that the tool will slide over the selector shaft. 3. Slide the J 43909 into position so that the end of the tool contacts the seal being installed. Use a mallet to strike the J 43909 and drive the new seal Page 8934 Auxiliary Power Outlet: Service and Repair Accessory Power Receptacle Replacement - 12 Volt ACCESSORY POWER RECEPTACLE REPLACEMENT - 12 VOLT TOOLS REQUIRED J 42059 Cigar Lighter Socket Remover REMOVAL PROCEDURE 1. Remove the power supply fuse. 2. Lift up the front cover of the receptacle. 3. Insert the J 42059 into the receptacle sleeve. Tilt the tool so that the tool fits into the slots on the sides of the receptacle sleeve. 4. Hold the plastic ring in place. Pull the receptacle out of the assembly in order to remove the outlet. Page 14455 1. Position the module into the vehicle. 2. Connect the lower electrical harness connectors (2). 3. Slide the module (2) to the left to engage the lower retainers. NOTE: Refer to Fastener Notice in Service Precautions. 4. Install the module retaining screws (3). Tighten Tighten the screws to 3 N.m (26 lb in). 5. Connect the upper electrical harness connectors (3). 6. Install the seat cushion. 7. If a new memory seat module was installed, calibrate the seat. Refer to Memory Seat Calibration Procedure. Page 11639 Seat Belt Buckle: Service and Repair Center Rear SEAT BELT BUCKLE REPLACEMENT - CENTER REAR CAUTION: To avoid personal injury to the occupants of the vehicle, observe the following precautions: - More than one supplier's seat belts are used, therefore, install ONLY the seat belt components specified in the GM parts catalog. - To verify that the correct seat belt components were installed, insert the seat belt latch in the seat belt buckle. The latch must be fully seated and be retained in the buckle until purposely released. REMOVAL PROCEDURE 1. Fold the rear seat to the open position. 2. Remove the two bolts that retain the buckle assembly to the back of the seat frame. 3. Remove the nut that retains the buckle assembly to the floor stud. 4. Remove the buckle assembly from the rear seat. INSTALLATION PROCEDURE 1. Install the buckle assembly to the rear seat. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the nut that retains the buckle assembly to the floor stud. Tighten Tighten the nut to 52 N.m (38 lb ft). 3. Install the two bolts that retain the buckle assembly to the back of the seat frame. Page 9242 C322 Seat Motor Jumper Harness To Seat Jumper Harness (With RPO Code AN3) Part 2 Page 4683 Body Control Module (BCM) - C3 Part 1 OnStar(R) - Number Incorrect/Incorrectly Assigned Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Number Incorrect/Incorrectly Assigned INFORMATION Bulletin No.: 05-08-46-004C Date: December 23, 2010 Subject: OnStar(R) Phone Number Concerns (Phone Number Incorrect/Assigned to Another Vehicle/Phone) That Occur During Diagnosis of OnStar(R) System Models: 2000-2011 GM Passenger Cars and Trucks Equipped with OnStar(R) (RPO UE1) Supercede: This bulletin is being revised to update model years up to 2011. Please discard Corporate Bulletin Number 05-08-46-004B (Section 08 - Body and Accessories). During diagnosis of an OnStar(R) concern, the technician may be told that the OnStar(R) phone number is incorrect or tied to another vehicle and/or phone of some kind. To resolve these concerns, the Tech 2(R) with software version 22.005 (or higher), has the capability to change the OnStar(R) phone number. Service Procedure 1. With the Tech 2(R), build the vehicle to specifications within the Diagnostics area of the Tech 2(R). 2. For vehicles with physical-based diagnostics - under Body, go to the OnStar(R) section. Then select the Special Functions menu. For vehicles with functional-based diagnostics - under Body and Accessories, go to the Cellular Communication section. Select Module Setup and then Vehicle Communication Interface Module. 3. Locate the Program Phone Number prompt and select it. The original phone number will be displayed on the Tech 2(R) screen. 4. Contact the OnStar(R) team at the GM Technical Assistance Center (TAC) to obtain a new phone number. 5. Highlight the digits of the phone number one at a time and enter the new phone number using the number keys on the Tech 2(R). 6. Press the Soft key at the base of the screen for Done once these numbers have been changed on the screen. 7. Press the Soft key for Done again. The area code or new phone number has now been programmed into the phone. 8. Cycle the ignition to Off and open the driver's door. 9. Press the blue OnStar(R) button to make sure that a normal connection can be made to the OnStar(R) call center. If applicable, make sure the Hands-Free Calling (HFC) works properly by making a phone call. 10. If the system is working properly, fax or voicemail a case closing into the OnStar(R) team at TAC with the results. Dealers in Canada should submit case closing information through the GM infoNET. Please follow this diagnostic process thoroughly and complete each step. If the condition exhibited is resolved WITHOUT completing every step, the remaining steps do not need to be performed. If the procedure above does not resolve the condition, you must contact TAC for further assistance. This diagnostic approach was developed specifically for this condition and should not automatically be used for other vehicles with similar symptoms. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use: Warranty Information (Saab Models) For vehicles repaired under warranty, use the table. Page 13259 Involved are certain vehicles within the VIN breakpoints shown above. PARTS INFORMATION -- Saab US Only Customer Notification General Motors will notify customers of this special coverage on their vehicles (see copy of typical customer letter shown in this bulletin - actual divisional letter may vary slightly). Locations Manifold Pressure/Vacuum Sensor: Locations Full Engine View Left Side Page 6870 8. Remove the pinion gear bearing retainer bolts. 9. Remove the pinion gear bearing retainer and the pinion. 10. Remove the selective shim. 11. Measure the amount of torque required to rotate the pinion. Use an inch-pound torque wrench. Record this measurement for reassembly. 12. Install the J 8614-01 as shown. 13. Remove the pinion nut while holding the J 8614-01. 14. Remove the washer. 15. Install the J 8614-2 (2) and the J 8614-3 (1) into the J 8614-01 (3) as shown. 16. Remove the pinion yoke by turning the J 8614-3 (1) clockwise while holding the J 8614-01 (3). 17. Remove the pinion oil seal. Use a suitable seal removal tool. Do not damage the housing. 18. Remove the outer pinion bearing. 19. Remove the pinion. Page 4348 Body Control Module: Description and Operation BODY CONTROL MODULE (BCM) The body control module (BCM) monitors several inputs in order to arm and disarm the CTD system. The BCM controls the alarm function outputs. When the BCM detects an unauthorized entry (any door opened), the BCM applies ground to the horn, the park lamp and the headlamp relays. The BCM will send messages to the security telltale in the instrument cluster through the Class 2 serial data link. The BCM has the following 8 basic modes for operating the CTD system. The more detailed descriptions are below. - Off state - Idle state - Disarmed state - Ready-to-arm state - Arm initiated state - Arm delay state - Armed state - Alarm state The BCM has the following 6 discrete inputs in order to monitor the CTD system: - Ignition 1 - Driver door latch (door jamb) switch - Passenger door latch (door jamb) switch - Door lock relay - Door key switch - Passenger door unlock relay The BCM applies ground once per second for approximately 2 minutes, or until a valid input to disarm the system is received by the BCM. The Body Control Module (BCM) contains the theft deterrent system logic. The BCM reads the Passlock(TM) data from the Passlock(TM) sensor. If the Passlock(TM) data is correct, the BCM will pass theft. The BCM will then transmit the fuel continue password to the VCM/PCM. During the tamper mode the vehicle may start. The vehicle will then stall. If the BCM receives the wrong Passlock(TM) data, the VTD will immediately go into the tamper mode. The tamper mode will lock-out the vehicle fuel injectors for 10 minutes. The SECURITY indicator will flash while the VTD is in the tamper mode. If the Passlock(TM) sensor sends a correct password to the BCM when the ignition is in the ON position, the BCM will send a fuel enable signal to the VCM/PCM. The VCM/PCM will not disable the fuel due to any BCM message for the remainder of the ignition cycle. Page 4569 Manifold Absolute Pressure (MAP) Sensor Page 4530 Data Link Connector (DLC) Diagram 2 Part 2 Page 9937 Alignment: Description and Operation Caster Description Caster is the tilting of the uppermost point of the steering axis either forward or backward, when viewed from the side of the vehicle. A backward tilt is positive (+) and a forward tilt is negative (-). Caster influences directional control of the steering but does not affect the tire wear. Caster is affected by the vehicle height, therefore it is important to keep the body at its designed height. Overloading the vehicle or a weak or sagging rear spring will affect caster. When the rear of the vehicle is lower than its designated trim height, the front suspension moves to a more positive caster. If the rear of the vehicle is higher than its designated trim height, the front suspension moves to a less positive caster. With too little positive caster, steering may be touchy at high speed and wheel returnability may be diminished when coming out of a turn. If one wheel has more positive caster than the other, that wheel will pull toward the center of the vehicle. This condition will cause the vehicle to pull or lead to the side with the least amount of positive caster. Camber Description Camber is the tilting of the wheels from the vertical when viewed from the front of the vehicle. When the wheels tilt outward at the top, the camber is positive (+). When the wheel tilts inward at the top, the camber is negative (-). The amount of tilt is measured in degrees from the vertical. Camber settings influence the directional control and the tire wear. Too much positive camber will result in premature wear on the outside of the tire and cause excessive wear on the suspension parts. Too much negative camber will result in premature wear on the inside of the tire and cause excessive wear on the suspension parts. Unequal side-to-side camber of 1 degree or more will cause the vehicle to pull or lead to the side with the most positive camber. Toe Description Page 9449 Control Module References Part 6 Automatic Transmission Input Shaft Speed (AT ISS) Sensor Connector Page 3901 Fuel Pump Relay: Locations Fuel Pump Relay Secondary - With Dual Tanks FUEL PUMP RELAY - SECONDARY (Vehicles with Dual Tanks Only) Fuel Pump Relay-Secondary-With Dual Tanks The Fuel Pump Relay - Secondary is attached to the Underhood Fuse Block Bracket. The Underhood Fuse Block is located at the left side of the engine compartment, to the rear of the battery. Page 14529 1. Raise the head restraint (1) to the full up position. 2. Insert a paper clip or a similar tool in the hole at the side edges of the head restraint retainers. 3. Press in on the tool in order to release the retainer clips (2). 4. Lift the head restraint from the retainers. INSTALLATION PROCEDURE 1. Install the head restraint (1) into the retainers. 2. Push the head restraint to the full down position. 3. Pull up in order to ensure that the head restraint engages with the head restraint retainers (2). Page 2217 Extended Cab Short Box Shown Below, Other Configurations Similar 6. Install the new canister vent valve solenoid to the fuel tank clip or mounting bracket as shown above. The valve port closest to the electrical connector must point towards the canister. 7. Cut bulk 5/8" heater hose to a length of approximately 76 mm (3 in). Install the hose between the solenoid and the canister pipe and secure using clamps. 8. Attach bulk 5/8" heater hose to the vent port and secure using a clamp. Run a length as needed along the frame rail routing to the area above the transmission. 9. Cut the hose to determined length and install the supplied filter box. Secure using a clamp. 10. Remove the transmission support and lower the transmission assembly as necessary to allow for access to the new filter box location. 11. Secure the filter box to the transmission vent hose just forward of the hose tee-section using a tie strap. DO NOT pinch or restrict the transmission vent hose. The filter box opening should be pointing downward. 12. Raise the transmission and reinstall the transmission support. 13. Connect the EVAP canister vent valve electrical connector. 14. Tie strap the hose as needed along the frame rail in order to keep the hose away from pinch-points and heat sources. 15. Lower the vehicle. Correction (2007-2010 New Style Models) After following the published SI diagnostics and determining that the EVAP canister vent valve is the cause of the MIL light, replace the EVAP canister vent valve assembly and relocate the remote filter box. To ensure correct installation, follow the procedures below. Important DO NOT replace the EVAP canister assembly for this concern unless it fails the leak test. Use Service Kit P/N 19207763 1. Raise the vehicle. Suitably support the vehicle. 2. Disconnect the EVAP canister vent valve electrical connector. Page 8317 Brake Hose/Line: Service and Repair Brake Hose Replacement - Front Brake Hose Replacement - Front Removal Procedure Caution: Refer to Brake Fluid Irritant Caution in Service Precautions. Notice: Refer to Brake Fluid Effects on Paint and Electrical Components Notice in Service Precautions. 1. Raise and suitably support the vehicle. 2. Remove the tire and wheel assembly. 3. Clean all dirt and foreign material from the brake hose and brake pipe fittings. 4. Important: Install a rubber cap or plug to the exposed brake pipe fitting ends in order to prevent brake fluid loss and contamination. Use a backup wrench on the hose fitting, disconnect the brake pipe fitting from the brake hose, then cap or plug the brake pipe fitting end. 5. Remove the brake hose retaining clip from the hose mounting bracket. 6. Remove the brake hose bolt and the bracket from the upper control arm. 7. Remove the brake hose bolt and the bracket from the steering knuckle. 8. Remove the brake hose to caliper bolt from the brake caliper. 9. Remove the brake hose from the brake caliper. 10. Remove and discard the 2 copper brake hose gaskets. These gaskets may be stuck to the brake caliper housing or the brake hose end. Installation Procedure Page 12036 ^ On 2002 Sevilles and DeVilles, the GPS jumper cable MUST be unclipped from the back seat cross brace, or unplugged from the VCIM first. DO NOT pull back on the mounting bracket until the GPS antenna jumper cable is unclipped from the back seat cross brace or unplugged from the VCIM. The short length of jumper cable does not allow the VCIM mounting bracket to be pulled back very far, and could lead to a break at the VCIM connector. ^ On 2000-2002 Bonnevilles and LeSabres and 2001-2002 Auroras you will need to follow these steps: 1. Remove the 4 nuts that secure the VCU/VIU bracket assembly to the rear seat back brace. Note: Save these nuts for later use. 2. Remove and discard the plastic VCU/VIU bracket assembly from the vehicle. 3. Remove the upper right stud (1) from the rear seat back brace and re-install in the middle lower slot (2) on the brace. Tighten the fastener to 4 Nm (36 lb in). 4. Position the new VCIM in the vehicle over the studs on the rear seat back brace. 5. Install two of the nuts saved from step (1). Tighten the nuts to 4 Nm (36 lb in). 6. Connect the new OnStar jumper harness supplied in the kit to the VCIM (two white connectors) and the body wiring harness (C345 connector). 7. Connect the small coaxial jumper cable supplied in the kit, to the VCIM, with the end that has a blue plastic housing connector. Plug the other end of this coaxial jumper cable to the OnStar Global Positioning Satellite (GPS) antenna coaxial cable at the right angle connector. Note: The GPS cable in the new OnStar jumper harness is not utilized. 8. Connect the cellular coaxial cable to the OnStar VCIM. On 2001 Impala and Monte Carlos you will need to follow these steps: 9. Remove the Vehicle Communications Unit (VCU) and Vehicle Interface Unit (VIU) following the procedures listed in SI. Save the bracket nuts for later use. Page 11980 The module uses a default value for the missing parameter. Conditions for Clearing the DTC A current DTC clears when the malfunction is no longer present. A history DTC clears when the module ignition cycle counter reaches the reset threshold, without a repeat of the malfunction. Diagnostic Aids When multiple Loss of Communication DTCs are set concurrently, the cause is likely to be 2 opens in the ring portion of the class 2 serial data circuit. Use the Control Modules and Devices ‐ Description and Identification Number table in order to determine which modules are not communicating. Use the class 2 serial data circuit schematic in order to determine the location of the opens. Test Description Page 13046 Important: Secure the wiring harness so that there is no risk of chafing or rattling. 6.1. Remove the passenger seat in accordance with WIS 8. Body - Seats Adjustment/Replacement. 6.2. Remove the right-hand B-pillar trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.3. Remove the right-hand C pillar trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.4. Fold the rear seat backrest forward. 6.5. Remove the right-hand side bolster in accordance with WIS - 8. Body - Seats Adjustment/Replacement. 6.6. Remove the A-pillar's lower side piece. 6.7. Open the cover on the right-hand wiring harness channels. 6.8. Loosen the locking strip (A) on the 2-pin connector (H2-11) for the optic cable, located by the right-hand A-pillar. 6.9. Loosen the catch (B) and remove the optic cable that runs backward in the car. 6.10. Dismantle the end cap from the new optic cable (12 783 577) and connect it to the connector H2-11. Push in the optic cable and make sure the catch (B) locks and refit the locking strip (A). 6.11. Secure the connector and the old optic cable using the cable tie for the existing wiring harness (C). Page 2693 Relay Block - I/P C5 Part 1 Page 6129 results from the alteration or modification of a vehicle using non-GM approved parts or accessories. Dealers should be especially cautious of accessory companies that claim the installation of their product will not void the factory warranty. Many times these companies have even given direction on how to quickly disassemble the accessory in an attempt to preclude the manufacturer from finding out that is has been installed. Any suspect repairs should be reviewed by the Fixed Operations Manager (FOM), and in Canada by the Warranty Manager (WM) for appropriate repair direction. If it is decided that a goodwill repair is to be made on the vehicle, even with the installation of such non-GM approved components, the customer is to be made aware of General Motors position on this issue and is to sign the appropriate goodwill documentation required by General Motors. It is imperative for dealers to understand that by installing such devices, they are jeopardizing not only the warranty coverage, but also the performance and reliability of the customer's vehicle. Disclaimer Page 15596 1. Install the bulb (1) into the socket. 2. Connect the electrical connector. 3. Install the switch until the tabs (1) click in place. 4. Close the compartment door. Page 8272 Disclaimer Page 10925 Control Module References Part 6 Page 11707 Impact Sensor: Service and Repair Side INFLATABLE RESTRAINT SIDE IMPACT SENSOR REPLACEMENT REMOVAL PROCEDURE CAUTION: - Refer to SIR Inflator Module Handling and Storage Caution in Service Precautions. - When carrying an undeployed inflatable restraint seat belt pretensioner: - Do not carry the seat belt pretensioner by the wires or connector. - Carry the seat belt pretensioner by the piston tube, keeping hands and fingers away from the cable. - Make sure the open end of the seat belt pretensioner piston tube points away from you and other people. - Do not cover the seat belt pretensioner piston tube opening with your hand. Failure to observe these guidelines may result in personal injury. 1. Disable the SIR system. Refer to SIR Disabling and Enabling Zone 6. 2. Remove the front door trim panel. 3. Loosen the 2 inflatable restraint side impact sensor fasteners (2). 4. Remove the inflatable restraint side impact sensor (1) from the door (4). 5. Remove the connector position assurance (CPA) (3), and disconnect the inflatable restraint side impact sensor yellow 2-way harness connector (5). INSTALLATION PROCEDURE 1. Connect the inflatable restraint side impact sensor yellow 2-way harness connector (5) to the inflatable restraint side impact sensor (1). 2. Install the CPA (3) to the inflatable restraint side impact sensor yellow 2-way connector (5). 3. Install the inflatable restraint side impact sensor (1) to the door (4). Page 7098 2. Assemble 1 bearing cup part way into 1 side of the yoke. Turn the yoke ear toward the bottom. 3. Assemble the cross into the yoke so that the trunnion seats freely into the bearing cup. 4. With the trunnion seated in the bearing cup, press the bearing cup into the yoke until the bearing cup is flush with the yoke ear. 5. Install the opposite bearing cup part way into the yoke ear. 6. Ensure that the trunnions start straight and true into both bearing cups. 7. Press the opposite bearing cup into the yoke ear while working the cross all the time in order to inspect for free unbinding movement of the trunnions in the bearing cups. 8. Press the bearing cup into the yoke until the bearing cup retainer groove is visible over the top of the bearing cup. Important: If there seems to be a hang up or binding, stop pressing. Inspect the needle bearings for misalignment in the bearing cup. 9. Assemble the bearing retainer in the retainer groove. 10. Continue pressing until both retainers can be snapped into place. Page 8799 Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. 1. Disconnect the connector from the component. 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. Page 509 Control Module References Part 5 Page 1679 7. Use the modified screw extractor in order to remove the plug. 8. Remove the parking pawl shaft retainer, shaft and pawl. 9. Important: If the manual shaft binds in the case during removal, file or sand the shaft in the area adjacent to the detent lever. Remove the manual shaft. 10. Remove the manual shaft seal. Installation Procedure 1. Install the pawl shaft. 2. Install the parking pawl. 3. Install the plug using a 8 mm or (5/16 inch) rod with Loctite® or equivalent. 4. Install the retainer. 5. Install the pawl return spring. 6. Install the detent lever to the actuator. 7. Install the actuator over the parking pawl. 8. Install the manual shaft seal. 9. Lubricate the manual shaft with transmission oil and install the manual shaft into the case. 10. Install the nut on the shaft. 11. Install the roll pin. 12. Notice: Refer to Fastener Notice in Service Precautions. Page 4934 Vehicle Speed Sensor: Service and Repair Manual Transmission - ZF S6-650 Vehicle Speed Sensor (VSS) Replacement Removal Procedure 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. If equipped with the 6.6L engine, disconnect the vehicle speed sensor (VSS) electrical connector (4). 3. If equipped with the 8.1L engine, disconnect the VSS electrical connector (5). 4. Remove the VSS bolt, sensor and seal. Installation Procedure Page 8904 Control Module References Part 1 Page 14898 1. Remove the power seat switch bezel from the seat. 2. Remove the power seat switch to bezel screws. 3. Remove the power seat switch. INSTALLATION PROCEDURE NOTE: Refer to Fastener Notice in Service Precautions. 1. Install the power seat switch to bezel screws. Tighten Tighten the screws to 2 N.m (18 lb in). Page 16045 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-8 (12085115) crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-8 (12085115) until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes SPLICING INLINE HARNESS DIODES Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate Service Data wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. 9. Tape the diode to the harness or connector using electrical tape. Page 10120 2. Snap the locking tabs together on the rack and pinion boot protector. 3. Lower the vehicle. Page 8783 Electrical Symbols Part 13 Page 10256 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-8 (12085115) crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-8 (12085115) until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes SPLICING INLINE HARNESS DIODES Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate Service Data wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. 9. Tape the diode to the harness or connector using electrical tape. Page 1270 10. Install the brake rotor (2) shown on the 1500 series. Refer to Brake Rotor Replacement - Front in Disc Brakes. 11. Install the tire and wheel. 12. Perform the Diagnostic System Check - ABS. Heated Oxygen Sensor (HO2S) Bank 1 Sensor 1 Heated Oxygen Sensor (HO2S) Bank 1 Sensor 1 A/C - Blower Motor Runs After Vehicle Is Shut OFF Blower Motor Relay: All Technical Service Bulletins A/C - Blower Motor Runs After Vehicle Is Shut OFF TECHNICAL Bulletin No.: 03-01-38-015A Date: October 27, 2008 Subject: HVAC Blower Motor May Run Continuously After Vehicle is Turned Off (Replace Blower Resistor Relay) Models: 2004 Chevrolet Avalanche, Silverado, Suburban, Tahoe, TrailBlazer, TrailBlazer EXT 2004 GMC Envoy, Envoy XL, Sierra, Yukon, Yukon XL with Manual Control HVAC (RPO CJ3) Built Prior to August, 2003 Supercede: This bulletin is being revised to update the parts information. Please discard Corporate Bulletin Number 03-01-38-015 (Section 01 - HVAC). Condition Some customers may comment on the HVAC blower motor running after the vehicle has been turned off. The blower may run for just a few minutes or continuously until the battery is discharged. Cause A new style HVAC blower relay/resistor may stick in the "on" position. When the HVAC fan blower relay has been energized, the contacts may "micro-weld" together. After this occurrence, the HVAC blower may not respond to the HVAC controller commands. Correction Replace the HVAC blower resistor/relay with the type used previous to the 2004 model year. The appropriate part numbers are listed in the table below. For specific repair procedures, refer to the 2004 Service Information (SI) under Blower Motor Resistor Assembly Replacement (SI Document ID # 526350 (C/K) or # 729996 (S/T). Parts Information Warranty Information Disclaimer Fuel Pressure Gage Installation and Removal Fuel Pressure Release: Service and Repair Fuel Pressure Gage Installation and Removal FUEL PRESSURE GAGE INSTALLATION AND REMOVAL INSTALLATION PROCEDURE TOOLS REQUIRED J 34730-1A Fuel Pressure Gage CAUTION: - Refer to Gasoline/Gasoline Vapors Caution in Service Precautions. - Refer to Fuel Gage Leak Caution in Service Precautions. 1. Remove the engine sight shield. 2. Remove the fuel rail pressure fitting cap. 3. Connect the J 34730-1A to the fuel pressure valve. Wrap a shop towel around the fitting while connecting the gage in order to avoid spillage. 4. Install the bleed hose on J 34730-1A into an approved container. REMOVAL PROCEDURE 1. Remove the bleed hose on the J 34730-1A from the approved container. 2. Remove the shop towel from around the fitting and discard into an approved container. 3. Disconnect the J 34730-1A from the fuel pressure valve. 4. Install the fuel rail pressure fitting cap. 5. Install the engine sight shield. Page 13833 Body Emblem: Service and Repair Emblem/Nameplate Replacement - Endgate (W/O SS) Emblem/Nameplate Replacement - Endgate (W/O SS) Tools Required J 25070 Heat Gun Removal Procedure Important: Use the tape for protection and alignment marks for alignment of the new emblem. 1. Apply tape to the area around the endgate emblem. 2. Heat the emblem/nameplate, using a heat gun J 25070 152 mm (6.0 in) from the surface. 3. Apply the heat using a circular motion for about 30 seconds. Notice: Refer to Exterior Trim Emblem Removal Notice in Service Precautions. 4. Remove the emblem/nameplate from the endgate surface using a plastic, flat-bladed tool. 5. Remove all adhesive from the endgate panel surface and the back of the emblem/nameplate using 3M(TM) scotch brite molding adhesive remover disk 3M(TM) P/N 07501 or equivalent. 6. Clean the endgate surface using varnish makers and painters (VMP) naptha. Installation Procedure 1. If the location of the emblem/nameplate has not been marked apply tape. 2. Warm the endgate surface with a heat gun J 25070 152 mm (6.0 in) from the surface to a minimum of 21°C (70°F). Important: Do not touch the adhesive backing of the emblem/nameplate. 3. Remove the backing from the front end of the emblem/nameplate. 4. Press the emblem/nameplate to the endgate panel surface while continuing to remove the backing. 5. Hand roll the emblem/nameplate to the endgate panel to ensure proper adhesion. 6. Inspect the emblem/nameplate for bonding. 7. Remove the tape from the area around the endgate emblem. Automatic Transmission - 4L60-E/4L65-E Shift Solenoid: Locations Automatic Transmission - 4L60-E/4L65-E Automatic Transmission Electronic Component Views (M30/M32) Automatic Transmission Electronic Component Views (M30/M32) Electronic Components Page 7451 Case Adapter: Service and Repair Transfer Case - NVG 263-NP1 Transfer Case Adapter Replacement Removal Procedure 1. Remove the transfer case. 2. Remove the transfer case adapter bolts. 3. Remove the transfer case adapter. 4. Remove the transfer case adapter seal. 5. Remove the transfer case gasket, if necessary. Installation Procedure Important: If the gasket or the seal becomes damaged, replace it. DO NOT use any type of silicone sealer or liquid gasket maker in place of the seal or gasket. 1. Install a NEW transfer case adapter seal. 2. Install the transfer case adapter. Notice: Refer to Fastener Notice in Service Precautions. 3. Install the transfer case adapter bolts. ^ Tighten the bolts to 50 Nm (37 ft. lbs.). 4. Install the transfer case. Page 15733 The information shown is for the 1999-2002 wiring harnesses and for the 2003-05 wiring harness. To modify a 12171982, 15366255 or 15086884 harness for use in a 2003-05 vehicle, switch the wires in cavities "A" and "D". To modify a 15085418 harness for use in a 1999-2002 vehicle (see model list at the front of this bulletin for applicable models), switch the wires in cavities "A" and "D". Warranty Information When the correct wiring harness P/N is matched to the specific model year of the vehicle, everything works properly. Therefore, conversion of an incorrect wiring jumper to match the vehicle would not be considered a warrantable repair. Disclaimer Drivetrain - Front Drive Axle Lubrication Update Fluid - Differential: Technical Service Bulletins Drivetrain - Front Drive Axle Lubrication Update Bulletin No.: 05-00-90-010 Date: December 07, 2005 SERVICE MANUAL UPDATE Subject: Revised Front Drive Axle Carrier Lubricant Information Models: 1999-2005 Light Duty Trucks 2003-2005 HUMMER H2 2005 Saab 9-7X with Four-Wheel or All-Wheel Drive and Separate Front Drive Axle Carriers This bulletin is being issued to revise the front drive axle carrier lubricant specification in the Maintenance and Lubrication and the Front Drive Axle sub-sections of the Service Manual. Please replace the current information in the Service Manual with the following information. The information has been updated within SI. If you are using a paper version of this Service Manual, please make a reference to this bulletin on the affected page. This information also updates the information found in the Owner Manual. Important: Front drive axle carriers do not require periodic lubricant replacement. Page 14729 6. Lift the seat cushion up off the rear plastic holders (1) on the underside of the seat cushion, and pull forward. 7. Remove the seat switch bezel. 8. Remove the lumbar actuator (5). 9. Unclip the seat trim cover from the seat cushion frame. Page 11008 2. Install the inside air temperature sensor to the headliner and sensor grille. 3. Connect the electrical connector to the inside air temperature sensor. 4. Install the left sunshade. 5. Install the left center pillar garnish molding. 6. Install the left center assist handle. 7. Install the left windshield garnish molding. Locations Accelerator Pedal Position (APP) Sensor Connector Locations Center of the I/P - Accessory Switches Page 3616 1. If installing the old sensor, coat the threads with sealant GM P/N 12346004 (Canadian P/N 10953480) or equivalent. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the ECT sensor. Tighten Tighten the sensor to 20 N.m (15 lb ft). 3. Connect the ECT sensor electrical connector (5). 4. Refill the cooling. Refer to Draining and Filling Cooling System in Cooling System. Locations Ambient Air Temperature Sensor Page 7766 2. Connect the speed sensor electrical connector. 3. Lower the vehicle. Page 5354 Fuel Supply Line: Service and Repair Fuel Hose/Pipes Replacement - Chassis (1500 Crew Cab) FUEL HOSE/PIPES REPLACEMENT - CHASSIS (1500 CREW CAB) REMOVAL PROCEDURE IMPORTANT: Clean the fuel and evaporative emission (EVAP) connections and surrounding areas prior to disconnecting the fittings in order to avoid possible system contamination. 1. Relieve the fuel system pressure. Refer to Fuel Pressure Relief Procedure. 2. Disconnect the fuel feed line (1) fitting at the engine. 3. Disconnect the EVAP canister purge tube (2) fitting. 4. Cap the fuel rail and EVAP lines in order to avoid possible system contamination. 5. Raise and support the vehicle. Refer to Vehicle Lifting and. 6. Remove the fuel pipe bracket nut. 7. Remove the fuel pipe bracket from the bellhousing stud. 8. Remove the heated oxygen (HO2S) sensor connector from the bracket. Recall 04V225000: Child Seat Anchorage Non-Compliance Child Seat: All Technical Service Bulletins Recall 04V225000: Child Seat Anchorage Non-Compliance Make / Models : Model/Build Years: Chevrolet / Express 2003 Chevrolet / Silverado 2003-2004 GMC / Savana 2003 GMC / Sierra 2003-2004 MANUFACTURER: General Motors Corp. NHTSA CAMPAIGN ID Number : 04V225000 Recall Date : MAY 10, 2004 COMPONENT: Seat Belts: Front: Anchorage Potential Number Of Units Affected : 736 SUMMARY: certain extended and regular cab pickup trucks and cargo vans converted to compressed natural gas (CNG) fail to conform to the requirements of Federal Motor Vehicle Safety Standard NO. 225, "Child Restraint Anchorage Systems." These vehicles have one seating position, the center rear seat, equipped with child restraint lower anchorages. CONSEQUENCE: The standard requires child seat lower anchorages in two seating positions for vehicles with three rear seating positions. The standard cab and cargo van vehicles, which only have front seating positions, have an air bag off switch to disable the front passenger air bag and do not have child restraint lower anchorages in the passenger seat. The standard requires passenger seat child seat lower anchorages in vehicles with an air bag off switch. however, the standard does not require vehicles with only front seating positions to have lower anchorage provisions if the vehicle is not equipped with an air bag off switch. REMEDY: To bring the standard cab and cargo van vehicles into compliance, dealers will inject epoxy into the air bag off switch to prevent air bag activation, relocate the switch behind the instrument panel and then install a cover over the resulting opening. The sun visor label and owner's manual will also be changed. the correction for the extended cab vehicle will consist of changing the front passenger seat to a seat that has child restraint lower anchorages. The recall began on September 9, 2004. Owners should contact Chevrolet at 1-800-630-2438 OR GMC AT 1-866-996-9463. NOTES: GM Recall NO. 04038. Customers can also contact The National Highway Traffic Safety Administration's Auto Safety Hotline at 1-888-DASH-2-DOT (1-888-327-4236). Page 9870 For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to refer to the table above. Disclaimer Page 269 10. Disconnect and remove the OnStar(R) jumper harness. Note: You will need to remove the short GPS cable from this jumper harness. 11. Untape the cell antenna coax from the body harness in the trunk. This will be necessary to provide adequate length to connect to the new VCIM. 12. Fasten three retainer clips (1) from the kit to the new bracket that is included in the kit, and position the VCIM to the bracket (2). 13. Install the three bolts from the kit. Tighten the bolts to 10 Nm (89 lb in). 14. Connect the new OnStar(R) jumper harness supplied in the kit to the VCIM (two white connectors on module). 15. Connect small GPS coax cable jumper harness supplied in the kit (end with blue plastic housing) to VCIM GPS connector. 16. Position the VCIM / bracket assembly to the studs. 17. Install the bracket nuts saved from the Removal Procedure above to the VCIM / bracket assembly mounting studs. Tighten the nuts to 4 Nm (35 lb in). 18. Connect the new OnStar(R) jumper harness to the body wiring harness (C410 connector). 19. Connect small coax cable jumper from VCIM to the OnStar(R) Global Positioning Satellite (GPS) antenna coaxial cable at the connector previously left in the vehicle (short jumper removed from old harness in step 5.10). 20. Connect the cellular coaxial cable previously left in vehicle to the OnStar(R) VCIM. 21. Verify that all harnesses are properly secured in vehicle. 6. After replacing the VCIM, it is essential to configure the new OnStar(R) system. Failure to configure the system will result in an additional customer visit for repair. DO NOT press and hold the white dot or phone button on the keypad as it will not reset this version of the OnStar(R) system and may result in a DTC being set. Use of the TIS2WEB and SPS applications, along with the Tech2(R), are required in order to perform the VCIM configuration and setup procedure for this vehicle. The configuration and set-up procedure is now a two-step process which enables an automated activation by the OnStar(R) Center, without a button press by the technician to the OnStar(R) Call Center. 1. Connect the Tech2(R) to the vehicle. Page 1478 Door Switch: Description and Operation DOOR LATCH (DOOR JAMB) SWITCHES The theft deterrent system uses the door key switch as one method in order to activate the alarm. If the BCM detects any door opening before the BCM receives a disarm input, the alarm mode activates. DOOR KEY SWITCH The BCM monitors the door key switches in order to disarm the CTD system. When the lock cylinder turns in order to unlock the door, the switch grounds the disarm input to the BCM. Page 8381 Parking Brake Cable: Service and Repair Park Brake Cable Replacement - Right Rear (W/O NYS) Park Brake Cable Replacement - Right Rear (w/o NYS) Removal Procedure 1. Release the park brake. 2. Raise and support the vehicle. Refer Vehicle Lifting 3. For all 15 series vehicles, relieve the tension from the park brake cable by pulling down on the park brake cable in front of the equalizer and removing the right park brake cable from the equalizer bar. 4. For 25/35 series vehicles, disable the park brake cable automatic adjuster. Refer to Disabling the Park Brake Cable Automatic Adjuster. 5. For 25/35 series vehicles, disconnect the cable at the equalizer. Page 5938 Pressure Regulating Solenoid: Service and Repair Automatic Transmission - 4L80-E/4L85-E Pressure Regulator Replacement ^ Tools Required J 36850 Transjel Removal Procedure 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. Remove the transmission filter. 3. Caution: Valve springs can be tightly compressed. Use care when removing retainers and plugs. Personal injury could result. Remove the reverse boost valve bushing retainer ring (2). 4. Remove the following from the reverse boost valve cylinder: ^ The reverse boost valve bushing ^ The reverse boost valve ^ The pressure regulator spring retainer ^ The pressure regulator spring ^ The pressure regulator valve ^ The reverse boost valve bushing Installation Procedure 1. Install the pressure regulator valve using J 36850. 2. Pre-assemble the following parts: Page 1122 Seat Lumbar Motor/Position Sensor - Driver (With RPO Code AN3) Page 5859 2. Connect the speed sensor electrical connector (4). 3. Lower the vehicle. Page 7040 Description and Operation Voltage Regulator: Description and Operation REGULATOR The voltage regulator controls the field current of the rotor in order to limit system voltage. The regulator switches the current on and off at a rate of 400 cycles per second in order to perform the following functions: Radio noise control - Obtain the correct average current needed for proper system voltage control At high speeds, the on-time may be 10 percent with the off-time at 90 percent. At low speeds, the on-time may be 90 percent and the off-time 10 percent. Page 814 Junction Block - I/P Wire Entry Part 2 Universal Joint Replacement - Nylon Injected Ring Universal Joint: Service and Repair Universal Joint Replacement - Nylon Injected Ring Universal Joint Replacement - Nylon Injected Ring ^ Tools Required J 9522-3 U Joint Bearing Separator - J 9522-5 U Joint Bearing Spacer Remover Disassembly Procedure 1. Support the propeller shaft in a line horizontal with the table of a press. Notice: Never clamp propeller shaft tubing in a vise. Clamping could dent or deform the tube causing an imbalance or unsafe condition. Always clamp on one of the yokes and support the shaft horizontally. Avoid damaging the slip yoke sealing surface. Nicks may damage the bushing or cut the lip seal. 2. Mark the propeller shaft as to which end is the transmission end and which end goes to the rear axle. 3. Place the universal joint so that the lower ear of the yoke is supported on a 30 mm (1 1/8 inch) socket. 4. In order to shear the plastic retaining ring on the bearing cup, place J 9522-3 on the open horizontal bearing cups. Press the lower bearing cup out of the yoke ear. 5. If you do not completely remove the bearing cup, lift the cross and insert J 9522-5 between the seal and the bearing cup you are removing. Continue to press the bearing cup out of the yoke. 6. Rotate the propeller shaft. Press the opposite bearing cup out of the yoke. 7. Mark the orientation of the slip yoke to the tube for proper reassembly. 8. Remove the cross from the yoke. 9. Remove the remaining universal joint parts from the yoke. If you are replacing the front universal joint, remove the bearing cups in the slip yoke in the same manner. 10. Inspect the retaining ring grooves for plastic. 11. Inspect the bearing cup bores in the yoke ears for burrs or imperfections. 12. Clean the remains of the sheared plastic bearing retainers from the grooves in the yoke. 13. The sheared plastic may prevent the bearing cups from pressing into place and thus prevent the bearing retainers from properly seating. Assembly Procedure 1. Remove the bearing cups from the universal joint. Page 3838 Body Control Module: Description and Operation BODY CONTROL MODULE (BCM) The body control module (BCM) monitors several inputs in order to arm and disarm the CTD system. The BCM controls the alarm function outputs. When the BCM detects an unauthorized entry (any door opened), the BCM applies ground to the horn, the park lamp and the headlamp relays. The BCM will send messages to the security telltale in the instrument cluster through the Class 2 serial data link. The BCM has the following 8 basic modes for operating the CTD system. The more detailed descriptions are below. - Off state - Idle state - Disarmed state - Ready-to-arm state - Arm initiated state - Arm delay state - Armed state - Alarm state The BCM has the following 6 discrete inputs in order to monitor the CTD system: - Ignition 1 - Driver door latch (door jamb) switch - Passenger door latch (door jamb) switch - Door lock relay - Door key switch - Passenger door unlock relay The BCM applies ground once per second for approximately 2 minutes, or until a valid input to disarm the system is received by the BCM. The Body Control Module (BCM) contains the theft deterrent system logic. The BCM reads the Passlock(TM) data from the Passlock(TM) sensor. If the Passlock(TM) data is correct, the BCM will pass theft. The BCM will then transmit the fuel continue password to the VCM/PCM. During the tamper mode the vehicle may start. The vehicle will then stall. If the BCM receives the wrong Passlock(TM) data, the VTD will immediately go into the tamper mode. The tamper mode will lock-out the vehicle fuel injectors for 10 minutes. The SECURITY indicator will flash while the VTD is in the tamper mode. If the Passlock(TM) sensor sends a correct password to the BCM when the ignition is in the ON position, the BCM will send a fuel enable signal to the VCM/PCM. The VCM/PCM will not disable the fuel due to any BCM message for the remainder of the ignition cycle. Campaign - Unwanted Repeat Calls to OnStar(R) Technical Service Bulletin # 10037 Date: 100420 Campaign - Unwanted Repeat Calls to OnStar(R) CUSTOMER SATISFACTION Bulletin No.: 10037 Date: April 20, 2010 Subject: 10037 - Unwanted Repeat Calls to OnStar(R) Models: 2003 Buick LeSabre 2004-2006 Buick Rendezvous 2005 Buick LeSabre, Terraza 2005-2006 Buick LaCrosse/Allure 2006-2008 Buick Lucerne 2008 Buick LaCrosse/Allure 2008-2009 Buick Enclave 2003 Cadillac CTS 2004 Cadillac Escalade 2004-2005 Cadillac CTS-V, Deville 2005 Cadillac Escalade ESV, SRX 2005-2006 Cadillac STS 2005-2008 Cadillac CTS 2006-2008 Cadillac DTS 2007 Cadillac Escalade, Escalade EXT 2007-2008 Cadillac Escalade ESV 2008 Cadillac SRX, STS 2002 Chevrolet Impala 2003-2008 Chevrolet Suburban 2003-2009 Chevrolet Silverado 2004-2008 Chevrolet Impala 2005 Chevrolet Colorado, Corvette, Malibu 2005-2006 Chevrolet Uplander 2005-2008 Chevrolet Avalanche, Tahoe, TrailBlazer 2006 Chevrolet HHR, Monte Carlo 2006-2008 Chevrolet Equinox 2007-2008 Chevrolet Corvette 2008 Chevrolet HHR 2008-2009 Chevrolet Cobalt, Colorado, Malibu, Uplander 2003 GMC Envoy XL, Sierra, Yukon XL 2004-2008 GMC Yukon 2005-2009 GMC Sierra 2005-2008 GMC Yukon XL 2006-2008 GMC Envoy 2007 GMC Canyon 2007-2009 GMC Acadia 2006 HUMMER H2 2006-2008 HUMMER H3 2008 HUMMER H2 2003 Oldsmobile Silhouette 2005 Montana SV6 2005-2008 Pontiac Grand Prix 2006 Pontiac G6, Vibe 2007 Pontiac Montana SV6 2007-2008 Pontiac Solstice 2008 Pontiac G6, Torrent 2008-2009 Pontiac G5, G8 2009 Pontiac G3, Montana SV6 2005-2007 Saturn ION 2006-2009Saturn VUE 2007-2008 Saturn AURA, OUTLOOK, SKY Equipped with OnStar(R) (RPO UE1) Page 6375 3. Slide the J 43909 into position so that the end of the tool contacts the seal being installed. Use a mallet to strike the J 43909 and drive the new seal into the seal bore until it is seated at the bottom of the bore. 4. Install the PNP switch. 5. Fill the transmission to the proper level with DEXRON® III transmission fluid. Transmission Extension Housing Rear Oil Seal Replacement Transmission Extension Housing Rear Oil Seal Replacement ^ Tools Required J 41505 Output Shaft Seal Installer - J 6125-1BSlide Hammer - J 23129 Universal Seal Remover - J 36850 Transmission Assembly Lubricant Removal Procedure 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Place a drain pan under the vehicle. 3. Remove the propeller shaft. 4. Using the J 6125-1B (1) and the J 23129 (2), remove the output shaft seal (3) from the extension housing (4). 5. Inspect the case extension housing for damage. Replace the extension housing if necessary. Installation Procedure 1. Lubricate the inside diameter of the new seal with J 36850. 2. Use the J 41505 (1) with a soft faced mallet to install the seal (2). 3. Install the seal (2) to the extension housing (3). 4. Install the propeller shaft. 5. Remove the drain pan and lower the vehicle. 6. Fill the transmission to the proper level with Dexron® III transmission fluid. Page 2751 Junction Block - Rear Lamps - C2 Junction Block - I/P Relay Box: Locations Junction Block - I/P Location View Location View Specifications Wheel Bearing: Specifications Front Hub and Bearing Assembly to Steering Knuckle Bolts ............................................................................................................... 180 Nm (133 ft. lbs.) Page 10433 4. Remove the upper insulator (1). Do not discard the plastic pilot ring (2). 5. Remove the shock absorber mounting bolt at the lower control arm, the 15 series. 6. The lower shock mounting bushing is serviceable by driving the bushing out with the appropriate tool. 7. Remove the shock absorber mounting bolt (2) at the lower control arm, the 25 series. 8. Remove the shock absorber. Installation Procedure 1. Install the shock absorber. Insert the stem through the hole in the shock bracket on the frame. 2. Align the shock absorber with the mounting holes in the lower control arm, the 15 series. 3. Align the shock absorber with the mounting holes in the lower control arm, the 25 series. Page 8524 Page 7796 Shift Interlock Solenoid: Service and Repair Automatic Transmission Shift Lock Actuator Replacement Removal Procedure 1. Caution: Refer to SIR Caution in Service Precautions. Disable the SIR system. 2. Remove the body control module (BCM). 3. Put the shift lever clevis into the neutral position. 4. Disconnect the electrical connector. 5. Using a small screwdriver, pry the automatic transmission shift lock control actuator away from the steering column jacket and the cable shift cam. 6. Remove the shift lock control actuator. Installation Procedure 1. Firmly install the shift lock control actuator onto the steering column jacket and the cable shift cam. 2. Connect the electrical connector. 3. Adjust the shift lock control actuator (with the shift lever clevis in the neutral position) in the following way: 1. Pull out the tab (1) on the adjuster block side (2) of the shift lock control actuator. 2. Press on the adjuster block (2) to compress the internal adjuster spring which disengages the adjuster teeth. Slide the adjuster block (2) as far away from the actuator as possible. 3. Lock the adjuster block (2) in place by pushing in on the tab (1). 4. Inspect the shift lock control actuator for the following items: Page 10456 Wheel Bearing: Testing and Inspection Wheel Bearings Diagnosis Test 1-7 Page 2629 Junction Block - I/P Wire Entry Part 3 Page 6512 Torque Converter Clutch Solenoid: Service and Repair Torque Converter Clutch Pulse Width Modulation (TCC PWM) Solenoid, TCC Solenoid, and Wiring Harness ^ Tools Required J 28458 Seal Protector Retainer Installer Removal Procedure 1. Remove the transmission filter. 2. Disconnect the transmission harness 20-way connector (1) from the transmission internal harness pass-through connector. Depress both tabs on the connector and pull straight up; do not pry the connector. 3. Important: Removal of the valve body is not necessary for the following procedure. Remove the 1-2 accumulator. Do not remove the spacer plate. 4. Disconnect the internal wiring harness electrical connectors from the following components: ^ Transmission fluid pressure switch (1) ^ 1-2 shift control solenoid (2) ^ 2-3 shift control solenoid (3) ^ Pressure control solenoid (4) ^ Torque converter clutch pulse width modulation (TCC PWM) solenoid (5) ^ 3-2 control solenoid (6) 5. Remove the TCC PWM solenoid retainer. 6. Remove the TCC PWM solenoid in order to access one of the TCC solenoid bolts. Page 3115 8.3. Attempt to start the engine of the vehicle with the discharged battery. 9. Reverse the steps exactly when removing the jumper cables. The negative battery cable must first be disconnected from the engine that was jump started. Page 11512 31. Install the ring gear onto the differential case. 32. Install the ring gear bolts. Hand start each bolt to ensure that the ring gear is properly seated to the differential case. 33. Tighten the ring gear bolts. Tighten the ring gear bolts alternately and in stages, gradually pulling the ring gear onto the differential case. Tighten Tighten the ring gear bolts in sequence to 120 N.m (88 lb ft). 34. Install the differential side bearings by performing the following steps: 34.1. In order to protect the differential case, install the J 8107-2 in the case on the side opposite the bearing installation. 34.2. Install the J 22761(2) and the J 8092 (1) onto the differential case bearing as shown. 34.3. Drive the differential case bearing onto the case using the J 22761 and the J 8092. 35. Install the new differential case assembly into the carrier. 36. Clean the sealing surface of each half of the differential carrier case and the inner axle housing to differential carrier assembly. The surfaces must be clean of all grease and oil. 37. Apply a bead of sealer, P/N 1052942 (Canadian P/N 10953466), or equivalent, to one differential carrier case half sealing surface. 38. Install the right differential carrier case half. 39. Install the differential carrier case bolts Tighten Tighten the differential carrier case bolts to 47 N.m (35 lb ft). 40. Install the front drive axle clutch shaft to the differential carrier. 41. Install the left side inner axle shaft by doing the following steps: 41.1. Install the left side inner shaft into the differential carrier assembly until the inner shaft is seated against the differential side gear. 41.2. While holding the inner shaft against the differential side gear, turn the inner shaft in order to align the splines of the inner shaft with the splines on the differential side gear. 41.3. Drive the inner into the differential case side gear using a soft-faced mallet until the retaining ring on the inner shaft is fully seated within the groove in the differential case side gear. Pull back on the inner shaft to ensure that the inner shaft is properly retained in the differential case side gear. 42. Apply sealant, P/N 1052942 (Canadian P/N 10953466), or equivalent, to the inner axle housing to differential carrier sealing surface. Page 10326 7. Install the new nut to the upper ball joint stud. Tighten Tighten the nut to 50 N.m (37 lb ft). 8. Install the retaining bolts for the brake hose and wheel speed sensor brackets. Tighten Tighten the bolts to 9 N.m (80 lb in). 9. Connect the ESC link rod to the sensor, if equipped. Refer to Front Position Sensor Link Assembly Replacement - Electronic Suspension in Electronic Suspension Control. 10. Install the tire and wheel. Refer to Tire and Wheel Removal and Installation in Tires and Wheels. 11. Remove the safety stands. 12. Lower the vehicle. 13. Verify the wheel alignment. Refer to Measuring Wheel Alignment in Wheel Alignment. Upper Control Arm Replacement (H2) Tools Required J 42188-B Ball Joint Separator Removal Procedure 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information. 2. Remove the tire and wheel. Refer to Tire and Wheel Removal and Installation in Tires and Wheels. Page 1390 Important The new canister vent valve will be installed in a new location, outside of the frame. 7. Position and secure the new valve assembly to the frame bracket on the outside of the frame using the existing hole and mounting bolt. Tighten Tighten the bracket mounting bolt to 12 Nm (106 lb in). 8. Connect the vent valve pipe to the EVAP canister. 9. Install the two vent valve pipe clips into the existing underbody holes. 10. Connect the EVAP canister vent valve electrical connector, if equipped. 11. Attach bulk 5/8" heater hose to the vent valve port and secure using a clamp. Run a length as needed along the frame rail routing to the area above the transmission. 12. Cut the hose to determined length and install the supplied filter box. Secure using a clamp. 13. Remove the transmission support and lower the transmission assembly as necessary to allow for access to the new filter box location. 14. Secure the filter box to the transmission vent hose just forward of the hose tee-section using a tie strap. DO NOT pinch or restrict the transmission vent hose. The filter box opening should be pointing downward. 15. Raise the transmission and reinstall the transmission support. 16. Tie strap the hose as needed along the frame rail in order to keep the hose away from pinch-points and heat sources. 17. Lower the vehicle. 2004-2007 Model Year (Use Service Kit P/N 19152349) 1. Raise the vehicle. Suitably support the vehicle. 2. Disconnect the EVAP canister vent valve electrical connector. 3. Disconnect the canister pipe from the vent valve. 4. Push in the retainer and remove the existing canister vent valve from the fuel tank clip or mounting bracket. Discard the old valve. 5. Cut back the existing canister pipe approximately 51 mm (2 in) to remove the quick connect end. Crew Cab Short Box Shown Below, Other Configurations Similar Page 6904 6. Using side cutters, remove the small boot retaining clamp. 7. Remove the following items from the halfshaft bar: 1. The spacer ring (1) 2. The tripot spider assembly (2) 3. The tripot boot (3) 8. Clean the halfshaft bar (4). Use a wire brush in order to remove any rust in the seal mounting area (grooves). 9. Inspect the needle rollers, needle bearings, and trunnion. Inspect the tripot housing for unusual wear, cracks, or other damage. Replace any damaged parts with the appropriate service kit. Assembly Procedure Page 13531 TOOLS REQUIRED J 34142-B 12 V Unpowered Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. When testing for voltage: 1. Attach 1 lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach 1 lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Using Connector Test Adapters USING CONNECTOR TEST ADAPTERS NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-B Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires USING FUSED JUMPER WIRES TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Connector Position Assurance Locks CONNECTOR POSITION ASSURANCE LOCKS The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Terminal Position Assurance Locks TERMINAL POSITION ASSURANCE LOCKS The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Push to Seat Connectors PUSH TO SEAT CONNECTORS TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Page 5320 Location View The Fuel Pump Relay is located in the Underhood Fuse Block. The Underhood Fuse Block is located in the left side of the engine compartment to the rear of the battery. Page 10487 The wheel hubs illustrated above are intended to provide enough visual details to identify subtle differences between the Gen II and Gen III replacement hubs. The various colors used in the graphics are not indicative of any difference or feature, but are used to increase the detail and clarity of the assembly. The associated part number is listed with each illustration. Please refer to the chart above for the specific application for each hub. Page 8602 cloth below the booster supply port in order to capture any fluid exiting the hydro-boost unit. 10. Install the inlet port adapter, CH 47950-2 (2) into the booster supply port. 11. Using a torque wrench, slowly tighten the inlet port adapter to 16 N.m (12 lb-ft). If the clear tube was removed from the inlet port adapter assembly, be sure it is reinstalled. 12. Before each use of the accumulator pressure clamp, CH 47950-1, be sure to grease the clamp bolt and anti rotation washer with wheel bearing grease. 13. Install the accumulator pressure clamp, CH 47950-1 (1), by sliding it over the accumulator and straddling the hydro-boost housing. 14. Confirm that the accumulator pressure clamp is squarely seated onto the booster housing and accumulator, and place the 3/4 inch containment bolt into the fixture. Install the nut hand-tight onto the containment bolt. 15. Check and make sure that the fixture washer is correctly positioned between the end of the accumulator, and that the pin is engaged in the end of the bolt. The tab on the washer should be rotated clockwise so it is located below the master cylinder mounting flange ear. Caution: Incorrect installation of the washer will result in damage to the accumulator end. 16. Hand-tighten the accumulator pressure clamp bolt. Make sure the clamp is level and the tube is square to the end of the accumulator. 17. Place a shop cloth next to the opening of the inlet port adapter in order to capture any fluid exiting the hydro-boost unit. Important: Do not exceed 65 N.m (48 lb-ft) torque. Important: A torque wrench must be used to tighten the fixture clamp bolt 18. Slowly tighten the fixture clamp bolt while monitoring the inlet port adapter tube for signs of power steering fluid. Stop tightening of the bolt when either fluid is observed (below the maximum 65 N.m (48 lb-ft) torque) OR The 65 N.m (48 lb-ft) maximum bolt torque is achieved (with no fluid Fuel Level Sensor Fuel Gauge Sender: Description and Operation Fuel Level Sensor FUEL LEVEL SENSOR The fuel level sensor consists of a float, a wire float arm, and a ceramic resistor cord. The position of the float arm indicates the fuel level. The fuel level sensor contains a variable resistor, which changes resistance in correspondence to the amount of fuel in the fuel tank. The powertrain control module (PCM) sends the fuel level information via the class 2 circuit to the instrument panel (I/P) cluster. This information is used for the I/P fuel gage and the low fuel warning indicator, if applicable. The PCM also monitors the fuel level input for various diagnostics. Page 2912 of vibration is normally felt more in the "seat of the pants" than the steering wheel. 5. Next, record the Hertz (Hz) reading as displayed by the EVA onto the tire data worksheet found at the end of this bulletin. This should be done after a tire break-in period of at least 16 km (10 mi) at 72 km/h (45 mph) or greater, in order to eliminate any possible tire flat-spotting. This reading confirms what the vehicle vibration frequency is prior to vehicle service and documents the amount of improvement occurring as the result of the various steps taken to repair. Completing the Steering Wheel Shake Worksheet below is required. A copy of the completed worksheet must be saved with the R.O. and a copy included with any parts returned to the Warranty Parts Center for analysis. A reading of 35 to 50 Hz typically indicates a first order propshaft vibration. If this is the situation, refer to Corporate Bulletin Number 08-07-30-044D. Generally, a reading between 10 and 20 Hz indicates a tire/wheel vibration and if this is the reading obtained, continue using this bulletin. If the tire 1st order vibration goes away and stays away during this evaluation, the cause is likely tire flat-spotting. Tire flat-spotting vibration may come and go at any speed over 72 km/h (45 mph) during the first 10 minutes of operation, if vibration continues after 10 minutes of driving at speeds greater than 72 km/h (45 mph), tire flat-spotting can be ruled out as the cause for vibration. 6. If flat-spotting is the cause, provide the explanation that this has occurred due to the vehicle being parked for long periods of time and that the nature of the tire is to take a set. Refer to Corporate Bulletin Number 03-03-10-007E: Information on Tire/Wheel Characteristics (Vibration, Balance, Shake, Flat Spotting) of GM Original Equipment Tires. 7. If the road test indicates a shake/vibration exists, check the imbalance of each tire/wheel assembly on a known, calibrated, off-car dynamic balancer.Make sure the mounting surface of the wheel and the surface of the balancer are absolutely clean and free of debris. Be sure to chose the proper cone/collet for the wheel, and always use the pilot bore for centering. Never center the wheel using the hub-cap bore since it is not a precision machined surface. If any assembly calls for more than 1/4 ounce on either rim flange, remove all balance weights and rebalance to as close to zero as possible. If you can see the vibration (along with feeling it) in the steering wheel (driving straight without your hands on the wheel), it is very likely to be a tire/wheel first order (one pulse per revolution) disturbance. First order disturbances can be caused by imbalance as well as non-uniformities in tires, wheels or hubs. This first order frequency is too low for a human to hear, but if the amplitude is high enough, it can be seen. If a vibration or shake still exists after balancing, any out of round conditions, of the wheel, and force variation conditions of the tire, must be addressed. Equipment such as the Hunter GSP9700 can address both (it is also a wheel balancer). Tire radial force vibration (RFV) can be defined as the amount of stiffness variation the tire will produce in one revolution under a constant load. Radial force variation is what the vehicle feels because the load (weight) of the vehicle is always on the tires. Although free runout of tires (not under load) is not always a good indicator of a smooth ride, it is critical that total tire/wheel assembly runout be within specification. Equipment such as the Hunter GSP9700 loads the tire, similar to on the vehicle, and measures radial force variation of the tire/wheel assembly. Note that the wheel is affecting the tire's RFV measurement at this point. To isolate the wheel, its runout must be measured. This can be easily done on the Hunter, without the need to set up dial indicators. If the wheel meets the runout specification, the tire's RFV can then be addressed. After measuring the tire/wheel assembly under load, and the wheel alone, the machine then calculates (predicts) the radial force variation of the tire. However, because this is a prediction that can include mounting inaccuracies, and the load wheel is much smaller in diameter than used in tire production, this type of service equipment should NOT be used to audit new tires. Rather, it should be used as a service diagnostic tool to minimize radial force variation of the tire/wheel assembly. Equipment such as the Hunter GSP9700 does an excellent job of measuring wheel runout, and of finding the low point of the wheel (for runout) and the high point of the tire (for radial force variation). This allows the tire to be matched mounted to the wheel for lowest tire/wheel assembly force variation. The machine will simplify this process into easy steps. The following assembly radial force variation numbers should be used as a guide: When measuring RFV and match mounting tires perform the following steps. Measuring Wheel Runout and Assembly Radial Force Variation Important The completed worksheet at the end of this bulletin must be attached to the hard copy of the repair order. - Measure radial force variation and radial runout. - If a road force/balancing machine is used, record the radial force variation (RFV) on the worksheet at the end of this bulletin. It may be of benefit to have the lowest RFV assembly to the front left corner. If the machine is not available and the EVA data suggests there is an issue, swap the tire and wheel assemblies from the front to the back. Re-check on the EVA and if the problem still exists, test another vehicle to find tires that do not exhibit the same frequency and swap those tires onto the subject vehicle. - If a runout/balancing machine is used, record the radial runout of the tire/wheel assemblies on the worksheet at the end of this bulletin. If one or more of the tire/wheel assemblies are more than.040 in (1.02 mm), match mount the tire to the wheel to get below.040 in (1.02 mm). For sensitive customers, readings of 0.030 inch (0.76 mm) or less are preferable, it may also be of benefit to have the lowest runout assembly to the front left corner. If the machine is not available and the EVA data suggests there is an issue, swap the tire and wheel assemblies from the front to the back. Re-check on the EVA and if the problem still exists, test another vehicle to find tires that do not exhibit the same frequency and swap those tires Page 3791 When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage TESTING FOR A SHORT TO VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity TESTING FOR CONTINUITY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents TESTING FOR ELECTRICAL INTERMITTENTS Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground - Testing for Continuity - Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 msRECORD and emits an audible tone (beep). Page 15880 Park/Turn Signal Lamp - RF Page 13426 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Page 11160 1. Install the heater core (2) to the HVAC module assembly (3). 2. Install the heater core cowl gasket (1) to the heater core (2). 3. Install the heater core cover (1) to the HVAC module assembly (2). NOTE: Refer to Fastener Notice in Service Precautions. 4. Install the screws to the heater core cover (1). Tighten Tighten the screws to 2 N.m (18 lb in). 5. Install the HVAC module assembly. Page 1998 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the cover up until the dress cover releases. Repeat this procedure for the other locking tab. 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. 5. If the connector has a nose piece, use a small flat-blade tool to remove the nose piece by inserting the blade into the slot on the front of the connector and prying up on the nose piece. IMPORTANT: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 6. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. IMPORTANT: Be careful not to angle or rock the J 38125-13A tool when inserting it into the connector or the tool may break. Page 6140 results from the alteration or modification of a vehicle using non-GM approved parts or accessories. Dealers should be especially cautious of accessory companies that claim the installation of their product will not void the factory warranty. Many times these companies have even given direction on how to quickly disassemble the accessory in an attempt to preclude the manufacturer from finding out that is has been installed. Any suspect repairs should be reviewed by the Fixed Operations Manager (FOM), and in Canada by the Warranty Manager (WM) for appropriate repair direction. If it is decided that a goodwill repair is to be made on the vehicle, even with the installation of such non-GM approved components, the customer is to be made aware of General Motors position on this issue and is to sign the appropriate goodwill documentation required by General Motors. It is imperative for dealers to understand that by installing such devices, they are jeopardizing not only the warranty coverage, but also the performance and reliability of the customer's vehicle. Disclaimer Locations Oil Pressure Sender: Locations Engine Oil Pressure (EOP) Sensor And CMP Sensor Page 11210 1. Install the heater/vent module assembly to the vehicle. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the heater/vent module mounting nuts. Tighten Tighten the nuts to 9 N.m (80 lb in). 3. Install the heater/vent module mounting screws. Tighten Tighten the screws to 4 N.m (35 lb in). 4. Connect the electrical harnesses and the ground connections. 5. Install the heater/vent module drain hose. 6. Install the I/P carrier. 7. Install the outlet heater hose to the heater core. 8. Reposition the outlet heater hose clamp to the heater core. 9. Install the inlet heater hose to the heater core. 10. Reposition the inlet heater hose clamp to the heater core. 11. Fill the cooling system. Blower Motor Resistor Replacement Blower Motor Resistor: Service and Repair Blower Motor Resistor Replacement BLOWER MOTOR RESISTOR REPLACEMENT REMOVAL PROCEDURE 1. If equipped, remove the IP sound insulator. 2. Disconnect the electrical connection from the blower motor. 3. Disconnect the electrical connection from the blower motor resistor. 4. Remove the blower motor resistor retaining screws. 5. Remove the blower motor resistor. INSTALLATION PROCEDURE Page 1653 Oxygen Sensor: Service and Repair Heated Oxygen Sensor (HO2S) Replacement Bank 1 Sensor 2 HEATED OXYGEN SENSOR (HO2S) REPLACEMENT BANK 1 SENSOR 2 REMOVAL PROCEDURE 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. If equipped, disconnect the fuel composition sensor electrical connector. 3. Disconnect the connector position assurance (CPA) retainer. NOTE: Refer to Heated Oxygen and Oxygen Sensor Notice in Service Precautions. 4. If equipped with a fuel composition sensor, remove the heated oxygen sensor (HO2S) electrical connector from the fuel line clip. 5. If equipped with a 4.8L or 5.3L engine, disconnect the HO2S electrical connector (2). 6. If equipped with a 6.0L engine, disconnect the HO2S electrical connector (2). Page 7343 Transmission Position Switch/Sensor: Adjustments Automatic Transmission - 4L80-E/4L85-E Park/Neutral Position Switch Adjustment Important: ^ The following procedure is for vehicles that have not had the park/neutral position (PNP) switch removed or replaced. If the switch has been removed or replaced, refer to Park/Neutral Position Switch Replacement for the proper adjustment procedure. ^ Apply the park brake. ^ The engine must start in the park (P) or neutral (N) positions only. ^ Check the PNP switch for proper operation. If adjustment is required, proceed as follows: 1. Place the shift lever in the neutral (N) position. 2. With an assistant in the drivers seat, raise and suitably support the vehicle. Refer to Vehicle Lifting. 3. Loosen the PNP switch bolts. 4. With the vehicle in neutral (N), rotate the PNP switch while the assistant attempts to start the engine. 5. Following a successful start, turn the engine off. 6. Notice: Refer to Fastener Notice in Service Precautions. Tighten the PNP switch bolts. ^ Tighten the bolts to 25 Nm (18 ft. lbs.). 7. Lower the vehicle. 8. Check the PNP switch for proper operation. The engine must start in the park (P) or neutral (N) positions only. 9. Replace the PNP switch if proper operation can not be achieved. Page 12325 High Temperature Conditions Tools Required J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency MEASURING FREQUENCY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage MEASURING VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop MEASURING VOLTAGE DROP NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Page 674 Disclaimer Page 5112 8. Install the fuel pipe bracket to the bellhousing stud. 9. Install the fuel pipe bracket nut. Tighten Tighten the nut to 10 N.m (89 lb in). 10. Lower the vehicle. 11. Remove the cap from the fuel rail. 12. Connect the fuel feed line (1) at the engine. 13. Connect the EVAP canister purge tube line (2). 14. Install the fuel fill cap. 15. Connect the negative battery cable. 16. Use the following procedure in order to inspect for leaks: 16.1. Turn the ignition ON, with the engine OFF, for 2 seconds. 16.2. Turn the ignition OFF for 10 seconds. 16.3. Turn the ignition ON, with the engine OFF. 16.4. Inspect for fuel leaks. Evaporative Emission (EVAP) Hoses/Pipes Replacement - Chassis 2 EVAPORATIVE EMISSION (EVAP) HOSES/PIPES REPLACEMENT - CHASSIS REMOVAL PROCEDURE IMPORTANT: Clean all fuel pipe connections and surrounding areas before disconnecting the pipes in order to avoid possible fuel system contamination. Page 511 Control Module References Part 7 Page 3402 8. Rotate the handle of the tool (1) clockwise until the seal enters the rear cover and bottoms into the cover bore. 9. Remove the J 41479. 10. Install the engine flywheel. Page 1152 7. From inside the vehicle remove the upper bolt from the upper intermediate steering shaft (1) to the steering column connection. 8. Remove the upper intermediate steering shaft assembly. 1. From inside the vehicle slide the shaft down and off the steering column. 2. From inside the vehicle slide the upper intermediate shaft through the dash boot seal and remove the shaft from the vehicle. 9. Replace the upper intermediate shaft. 10. Install the upper intermediate steering shaft through the dash boot seal and slide the lower end into the steering gear coupling shaft. 11. Raise the upper end of the intermediate steering shaft and install into the steering column shaft. 12. Install the upper bolt and nut. Tighten Tighten the bolt to 47 N.m (35 lb ft). 13. Install the lower bolt and nut. Tighten Tighten the bolt to 50 N.m (37 lb ft). 14. For vehicles equipped with adjustable foot pedals perform the following steps: 1. Reposition the accelerator pedals into position on the bulkhead. 2. Install the two retaining nuts. Tighten Tighten the nuts to 20 N.m (15 lb ft). 3. Reposition the carpet into place. Parts Information Warranty Information For vehicles repaired under warranty use, the table. Page 8100 Brake Bleeding: Service and Repair Hydraulic Brake System Bleeding (Pressure) Hydraulic Brake System Bleeding (Pressure) ^ Tools Required J 29532 Diaphragm Type Brake Pressure Bleeder, or equivalent - J 35589-A Brake Pressure Bleeder Adapter Caution: Refer to Brake Fluid Irritant Caution in Service Precautions. Notice: Refer to Brake Fluid Effects on Paint and Electrical Components Notice in Service Precautions. Notice: When adding fluid to the brake master cylinder reservoir, use only Delco Supreme 11®, GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. The use of any type of fluid other than the recommended type of brake fluid, may cause contamination which could result in damage to the internal rubber seals and/or rubber linings of hydraulic brake system components. 1. Place a clean shop cloth beneath the brake master cylinder to prevent brake fluid spills. 2. With the ignition OFF and the brakes cool, apply the brakes 3-5 times, or until the brake pedal effort increases significantly, in order to deplete the brake booster power reserve. 3. If you have performed a brake master cylinder bench bleeding on this vehicle, or if you disconnected the brake pipes from the master cylinder, you must perform the following steps: 1. Ensure that the brake master cylinder reservoir is full to the maximum-fill level. If necessary add Delco Supreme 11®, GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container.If removal of the reservoir cap and diaphragm is necessary, clean the outside of the reservoir on and around the cap prior to removal. 2. With the rear brake pipe installed securely to the master cylinder, loosen and separate the front brake pipe from the front port of the brake master cylinder. 3. Allow a small amount of brake fluid to gravity bleed from the open port of the master cylinder. 4. Reconnect the brake pipe to the master cylinder port and tighten securely. 5. Have an assistant slowly depress the brake pedal fully and maintain steady pressure on the pedal. 6. Loosen the same brake pipe to purge air from the open port of the master cylinder. 7. Tighten the brake pipe, then have the assistant slowly release the brake pedal. 8. Wait 15 seconds, then repeat steps 3.3-3.7 until all air is purged from the same port of the master cylinder. 9. With the front brake pipe installed securely to the master cylinder - after all air has been purged from the front port of the master cylinder loosen and separate the rear brake pipe from the master cylinder, then repeat steps 3.3-3.8. 10. After completing the final master cylinder port bleeding procedure, ensure that both of the brake pipe-to-master cylinder fittings are properly tightened. 4. Fill the brake master cylinder reservoir to the maximum-fill level with Delco Supreme 11®, GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container.Clean the outside of the reservoir on and around the reservoir cap prior to removing the cap and diaphragm. 5. Install the J 35589-A to the brake master cylinder reservoir. 6. Check the brake fluid level in the J 29532 , or equivalent. Add Delco Supreme 11®, GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container as necessary to bring the level to approximately the half-full point. 7. Connect the J 29532 , or equivalent, to the J 35589-A. 8. Charge the J 29532 , or equivalent, air tank to 175-205 kPa (25-30 psi). 9. Open the J 29532 , or equivalent, fluid tank valve to allow pressurized brake fluid to enter the brake system. 10. Wait approximately 30 seconds, then inspect the entire hydraulic brake system in order to ensure that there are no existing external brake fluid leaks. Any brake fluid leaks identified require repair prior to completing this procedure. 11. Install a proper box-end wrench onto the RIGHT REAR wheel hydraulic circuit bleeder valve. 12. Install a transparent hose over the end of the bleeder valve. 13. Submerge the open end of the transparent hose into a transparent container partially filled with Delco Supreme 11®, GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. 14. Loosen the bleeder valve to purge air from the wheel hydraulic circuit. Allow fluid to flow until air bubbles stop flowing from the bleeder, then tighten the bleeder valve. 15. With the right rear wheel hydraulic circuit bleeder valve tightened securely - after all air has been purged from the right rear hydraulic circuit install a proper box-end wrench onto the LEFT REAR wheel hydraulic circuit bleeder valve. 16. Install a transparent hose over the end of the bleeder valve, then repeat steps 13-14. 17. With the left rear wheel hydraulic circuit bleeder valve tightened securely - after all air has been purged from the left rear hydraulic circuit - install a proper box-end wrench onto the RIGHT FRONT wheel hydraulic circuit bleeder valve. 18. Install a transparent hose over the end of the bleeder valve, then repeat steps 13-14. 19. With the right front wheel hydraulic circuit bleeder valve tightened securely - after all air has been purged from the right front hydraulic circuit install a proper box-end wrench onto the LEFT FRONT wheel hydraulic circuit bleeder valve. 20. Install a transparent hose over the end of the bleeder valve, then repeat steps 13-14. 21. After completing the final wheel hydraulic circuit bleeding procedure, ensure that each of the 4 wheel hydraulic circuit bleeder valves are properly tightened. 22. Close the J 29532 , or equivalent, fluid tank valve, then disconnect the J 29532 , or equivalent, from the J 35589-A. 23. Remove the J 35589-A from the brake master cylinder reservoir. Page 9774 C329 Lumbar Bolster Harness To Passenger Seat Harness (With RPO Code AG2) Page 6794 Disclaimer Page 9084 Fuse Block - Underhood - Secondary Wire Entry (With RPO Code HP2) Part 1 Page 1343 A/C Low Pressure Switch And A/C Accumulator Page 2355 10. Reposition the inlet hose clamp at the water pump. 11. Remove the inlet hose from the water pump. Installation Procedure 1. Install the inlet hose to the water pump. 2. Position the inlet hose clamp at the water pump. 3. Install the inlet hose to the radiator. 4. Position the inlet hose clamp at the radiator. 5. Install the inlet hose clip to the fan shroud. 6. Install the radiator vent inlet hose to the radiator inlet hose clips. 7. If necessary, install the engine sight shield. Page 9816 4. Connect the wire connectors to the lower portion of the electrical center block. 5. Connect the wire connectors with the bolts to the electrical center block. Tighten Tighten all connector bolts (1) to 9 N.m (80 lb in). 6. Ensure all wire connectors are securely connected. 7. Set the electrical center block in its resting position till the tabs (3) locks in place. 8. Install the lower part of the cover (1). 9. With the cover (2) off, use the fuse location information to install all fuses and relays. 10. Install the cover. 11. Install the fender upper brace. 12. Install the 4 fender upper brace bolts. Tighten Tighten the 4 retaining bolts to 25 N.m (18 lb ft). 13. Connect the negative battery cable. 14. Start vehicle and ensure all components function properly. Page 982 Engine Control Module: Service and Repair POWERTRAIN CONTROL MODULE (PCM) REPLACEMENT Service of the powertrain control module (PCM) should consist of either replacement of the PCM or programming of the electrically erasable programmable read only memory (EEPROM). If the diagnostic procedures call for the PCM to be replaced, the replacement PCM should be checked to ensure that the correct part is being used. If the correct part is being used, remove the faulty PCM and install the new service PCM. REMOVAL PROCEDURE IMPORTANT: To prevent internal PCM damage, the ignition switch must be OFF when disconnecting or connecting power to the PCM. - Remove any debris from around the PCM connector surfaces before servicing the PCM. Inspect the PCM module connector gaskets when diagnosing or replacing the PCM. Ensure that the gaskets are installed correctly. The gaskets prevent contaminant intrusion into the PCM. - The replacement PCM must be programmed. 1. Disconnect the negative battery cable. 2. If equipped with regular production option (RPO) NYS, remove the harness ground clip from the PCM cover. 3. Release the PCM cover mounting tabs. 4. Release the PCM cover from the mounting bracket. Page 15971 Control Module References Part 2 Page 11709 Impact Sensor: Service and Repair Sensor Replacement Guidelines SENSOR REPLACEMENT GUIDELINES The SIR sensor replacement policy requires replacing sensors in the area of accident damage. The area of accident damage is defined as the portion of the vehicle which is crushed, bent, or damaged due to a collision. For example, a moderate collision where the front of the vehicle impacts a tree. If the vehicle has an SIR sensor mounted forward of the radiator, it must be replaced. - Replace the sensor whether or not the air bags have deployed. - Replace the sensor even if it appears to be undamaged. Sensor damage which is not visible, such as slight bending of the mounting bracket or cuts in the wire insulation, can cause improper operation of the SIR sensing system. Do not try to determine whether the sensor is undamaged, replace the sensor. Also, if you follow a Diagnostic Trouble Code (DTC) table and a malfunctioning sensor is indicated, replace the sensor. Page 7018 Page 12090 Vehicles Built with Upgradeable OnStar(R) System Analog Modules Note: Page 9530 Application Table Part 4 Page 9203 C202 I/P Harness To Brake/Clutch Harness Part 1 Page 5313 Steps 4 - 6 Page 15755 Stop Lamp Switch Part 2 Page 12365 Steps 4-11 Diagram Information and Instructions Body Control Module: Diagram Information and Instructions Truck Zoning TRUCK ZONING Truck Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that corresponds to where they are located in the vehicle. The table explains the numbering system. Page 3600 Notice: Refer to Fastener Notice in Service Precautions. 2. Install the bolt to the surge tank. Tighten the bolt to 9 Nm (80 inch lbs.). 3. Install the nut to the surge tank. Tighten the nut to 9 Nm (80 inch lbs.). 4. Install the surge tank outlet hose (2) to the surge tank. 5. Position the surge tank outlet hose clamp to the surge tank. 6. Install the surge tank inlet hose (1) to the surge tank. 7. Position the surge tank inlet hose clamp to the surge tank. 8. Connect the coolant level sensor electrical connector (3). Page 1069 Page 5183 Intake Air Temperature (IAT)/Mass Air Flow (MAF) Sensor Page 14648 Seat Adjuster Switch- Front Passenger (With RPO Code AN3) Part 1 Page 8395 7. For 25/35 series vehicles, enable the park brake cable automatic adjuster. Refer to Enabling the Park Brake Cable Automatic Adjuster. 8. For all 15 series vehicles, pull down on the park brake cable in front of the equalizer and install the left park brake cable to the equalizer bar. 9. Remove the safety stands. 10. Remove the safety stands and lower the vehicle. 11. Adjust the park brake cable. (W/NYS) Park Brake Cable Replacement - Left Rear (w/NYS) Removal Procedure 1. Release the park brake. 2. Raise and support the vehicle. Refer Vehicle Lifting Page 4605 7. Remove the HO2S. INSTALLATION PROCEDURE IMPORTANT: A special anti-seize compound is used on the HO2S threads. The compound consists of liquid graphite and glass beads. The graphite tends to burn away, but the glass beads remain, making the sensor easier to remove. New, or service replacement sensors already have the compound applied to the threads. If the sensor is removed from an exhaust component and if for any reason the sensor is to be reinstalled, the threads must have anti-seize compound applied before the reinstallation. 1. If reinstalling the old sensor, coat the threads with anti-seize compound GM P/N 12377953, or equivalent. NOTE: Refer to Component Fastener Tightening Notice in Service Precautions. 2. Install the HO2S. Page 8803 Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses CIRCUIT PROTECTION - FUSES The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the Diagram Information and Instructions Door Module: Diagram Information and Instructions Truck Zoning TRUCK ZONING Truck Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that corresponds to where they are located in the vehicle. The table explains the numbering system. Coaxial Cable - Navigation and Cellular Telephone Antenna Global Positioning System Antenna: Service and Repair Coaxial Cable - Navigation and Cellular Telephone Antenna COAXIAL CABLE REPLACEMENT - NAVIGATION AND CELLULAR TELEPHONE ANTENNA REMOVAL PROCEDURE 1. Remove the I/P trim panel. 2. Lower the headliner. 3. Disconnect the cables from the antenna base. IMPORTANT: Observe the routing of the cables. 4. Remove the cable retainers from the roof and pillar. 5. Disconnect the cable (3) from the module. INSTALLATION PROCEDURE Service and Repair Leaf Spring Bushing: Service and Repair Spring Bushing Replacement Removal Procedure 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Remove the leaf spring assembly from vehicle. Refer to Leaf Spring Replacement. 3. Remove the bushing from the leaf spring using the following procedure: 1. Place the leaf spring in a press. 2. Press the bushing out. 3. Clean the spring bushing bore of any foreign or old bushing material. Installation Procedure 1. Apply rubber lubricant to the bushing (1) and spring eye (2). 2. Install the bushing to the leaf spring. 1. Place the leaf spring in a press. 2. Press the bushing into the spring. 3. Install the leaf spring assembly to the vehicle. Refer to Leaf Spring Replacement. 4. Remove the safety stands. 5. Lower the vehicle. Page 7269 Power Take-Off: Symptom Related Diagnostic Procedures - Symptoms - Power Take-Off (PTO) SYMPTOMS - POWER TAKE-OFF (PTO) IMPORTANT: The following steps must be completed before using the symptom tables. 1. Perform the Diagnostic System Check - Power Take-Off (PTO) before using the Symptom Tables in order to verify that all of the following are true: There are no PCM or TAC module DTCs set. - The PCM and TAC module can communicate to each other via the serial data links. 2. Review the system operation in order to familiarize yourself with the system functions. Refer to Power Take-Off (PTO) Description and Operation. VISUAL/PHYSICAL INSPECTION - Inspect the upfitter connections of the PTO system. - Inspect the easily accessible, or the visible system components for obvious damage or conditions which could cause the symptom. - Inspect the transmission and the hydraulic pump for the proper fluid level. INTERMITTENT Faulty electrical connections or wiring may be the cause of intermittent conditions. SYMPTOM LIST Refer to a symptom diagnostic procedure from the following list in order to diagnose the symptom: Power Take-Off (PTO) Does Not Engage - Engine RPM Does Not Increase with Power Take-Off Engaged - Power Take-Off (PTO) Indicator Inoperative Engine RPM Does Not Increase With Power Take-Off Engaged ENGINE RPM DOES NOT INCREASE WITH POWER TAKE-OFF ENGAGED CIRCUIT DESCRIPTION When the Power Take-Off (PTO) switch is turned to the ON position and all PTO engage conditions are met, the engine RPM should increase to the standby speed. When the Powertrain Control Module (PCM) receives the signal from the PTO switch the PCM will send a signal to the Throttle Actuator Control Module (TAC). The TAC module controls the TAC motor which changes the position of the throttle. Communications between the two modules is monitored and checked for accuracy by the PCM. DTCs may be recorded in the event of the failure. The 6.6L diesel engine does not have a TAC system and the engine RPM is strictly controlled by the ECM and the Fuel Injection Control Module. TEST DESCRIPTION Steps 1-2 Page 12610 2. Connect the Techline Information System (TIS) terminal to the Tech2(R). 3. Scroll to the bottom of the Controller List, and select the "ONSA TIS2WEB Pass-Thru OnStar(R) Activation (Replaced/Upgraded Units Only)" option using the Service Programming System (SPS). Important: Do not use the clear DTC function. This will only temporarily turn the LED to green. 4. Upon completion of the OnStar(R) TIS2WEB step, disconnect the TIS terminal from the Tech2(R) and perform the VCIM/OnStar(R) Set-up Procedure using the Tech2(R). The set up procedure is located under the special function menu option. Important: Failure to perform the above steps will result in a red LED, DTC being set and limited or incomplete OnStar(R) services, and will require a customer return visit to the dealership. 5. The default language for the new VCIM will be English. To change to French or Spanish, access the special functions menu on the Tech 2(R), and follow the instructions accordingly. 7. Skip to the next step if the vehicle to be upgraded is not listed below: ^ 2002-2004 Cadillac DeVille ^ 2002-2004 Cadillac Seville ^ 2005 Cadillac STS Set up the Dash Integration Module (DIM) using the following procedure: 1. On the Tech2(R) select the correct Year, Make and Model. 2. Enter Dash Integration Module (DIM) > Special Functions > Set Options > Misc. Options 1 > and turn off phone (if the vehicle does not have the UV8 option). 3. Enter Nav Radio Present and set to "No Nav" (if the vehicle does not have a navigation radio). 4. Turn the ignition off and open the door to turn off the RAP. 5. Turn the ignition on and enter the Vehicle Comm. Interface Module > Special Functions > Set Up OnStar /VCIM. 6. When prompted select "No Phone" (if the vehicle does not have the UV8 phone) and "No Nav" (if the vehicle does not have a navigation radio). 7. Turn the ignition off and open the door to turn off the RAP. Important: OnStar(R) Emergency Services are immediately available after these steps, however, full configuration, including activation of Hands-Free Calling, may take up to 24 hours to complete. Processing the Module Exchange Processing the Module Exchange For this program, submitting a credit request for the removed OnStar(R) VCIM (the core) will be performed through a website. When this process is followed, the removed Analog / Digital-Ready VCIM, in most cases, will not be mailed back to the distributor, but can be scrapped by the dealership. U.S. Dealers 1. Return the removed Analog / Digital-Ready OnStar(R) VCIM to the Parts Manager. 2. The Parts Manager will log onto www.autocraft.com. 3. Select Account Maintenance. 4. Select Outstanding Cores. Page 10450 Notice: Refer to Fastener Notice in Service Precautions. 4. Install the upper link mounting nuts and the bolts (3). ^ Tighten the nut to 95 Nm (70 ft. lbs.). 5. While supporting the adjustment arm, slide the torsion bar rearward until the torsion bar fully engages the adjustment arm. 6. Install the J 36202 to the adjustment arm and the crossmember. 7. Increase the tension on the adjustment arm in order to load the torsion bar. 8. Install the adjustment bolt (3) and the adjuster nut (4). Important: Install the adjustment bolt the same amount of turns that were required to remove the bolt during removal. Page 14182 7. Disconnect the cylinder lock rod (1). 8. Remove the bolts (2) which retain the door lock actuator to the door. 9. Remove the door lock actuator and control rods as an assembly. 10. Disconnect the electrical connector from the door lock actuator, if equipped. 11. Remove the control rods as necessary. INSTALLATION PROCEDURE 1. Install the control rods to the assembly. 2. Connect the electrical connectors to the door lock actuator, if equipped. 3. Install the door lock actuator to the door. 4. Connect the outside door handle control rod. 5. Connect the cylinder lock rod. NOTE: Refer to Fastener Notice in Service Precautions. 6. Install the bolts which retain the door lock actuator to the door. Tighten Tighten the screws to 9 N.m (80 lb in). 7. Connect the manual door lock to the door retainer clips. Page 337 Conditions for Running the DTC Ignition is in RUN or ACC position System voltage is between 9.5 - 15.5 volts. The above conditions are met for more than 1 second. Conditions for Setting the DTC The VCIM does not detect the presence of a cellular antenna for more than 1 second. Action Taken When the DTC Sets The vehicle is unable to connect to the OnStar(R) Call Center. The OnStar(R) status LED turns red. Conditions for Clearing the DTC The VCIM detects the presence of a cellular antenna. A history DTC clears after 50 malfunction-free ignition cycles. Circuit/System Testing Perform a visual inspection as shown above in order to verify that the cellular antenna and the cellular antenna coupling assembly are not damaged. If any components are damaged replace the assembly. DTC B2476 or B2482 DTC Descriptors Drivetrain - Front Drive Axle Lubrication Update Fluid - Differential: Technical Service Bulletins Drivetrain - Front Drive Axle Lubrication Update Bulletin No.: 05-00-90-010 Date: December 07, 2005 SERVICE MANUAL UPDATE Subject: Revised Front Drive Axle Carrier Lubricant Information Models: 1999-2005 Light Duty Trucks 2003-2005 HUMMER H2 2005 Saab 9-7X with Four-Wheel or All-Wheel Drive and Separate Front Drive Axle Carriers This bulletin is being issued to revise the front drive axle carrier lubricant specification in the Maintenance and Lubrication and the Front Drive Axle sub-sections of the Service Manual. Please replace the current information in the Service Manual with the following information. The information has been updated within SI. If you are using a paper version of this Service Manual, please make a reference to this bulletin on the affected page. This information also updates the information found in the Owner Manual. Important: Front drive axle carriers do not require periodic lubricant replacement. Page 8801 9. Use J 38125-12A to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. REPAIR PROCEDURE The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. 1. Cut the wire as close to the terminal as possible. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. Page 4527 Data Link Connector (DLC) Page 5818 Four Wheel Drive Selector Switch: Diagrams Page 5510 1. Locate the air flow direction arrow (2) on the MAF/IAT sensor. 2. Install the MAF/IAT sensor to the air cleaner assembly. NOTE: Refer to Fastener Notice in Service Precautions. 3. Tighten the MAF/IAT clamp. Tighten Tighten the clamp to 7 N.m (62 lb in). 4. Connect the MAF/IAT sensor electrical connector (4). 5. Push in the gray CPA retainer. 6. Install the air cleaner outlet duct. Page 4544 Steps 21 - 23 Tires/Wheels - Low Tire/Leaking Cast Aluminum Wheels Wheels: Customer Interest Tires/Wheels - Low Tire/Leaking Cast Aluminum Wheels TECHNICAL Bulletin No.: 05-03-10-003F Date: April 27, 2010 Subject: Low Tire Pressure, Leaking Cast Aluminum Wheels (Repair with Adhesive Sealant) Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks (Including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X with Cast Aluminum Wheels Supercede: This bulletin is being revised to update the model years and the bulletin reference information. Please discard Corporate Bulletin Number 05-03-10-003E (Section 03 - Suspension). Condition Some customers may comment on a low tire pressure condition. Diagnosis of the low tire pressure condition indicates an air leak through the cast aluminum wheel. Cause Porosity in the cast aluminum wheel may be the cause. Notice This bulletin specifically addresses issues related to the wheel casting that may result in an air leak. For issues related to corrosion of the wheel in service, please refer to Corporate Bulletin Number 08-03-10-006C - Tire Slowly Goes Flat, Tire Air Loss, Low Tire Pressure Warning Light Illuminated, Aluminum Wheel Bead Seat Corrosion (Clean and Resurface Wheel Bead Seat). Correction 1. Remove the tire and wheel assembly from the vehicle. Refer to the appropriate service procedure in SI. 2. Locate the leaking area by inflating the tire to 276 kPa (40 psi) and dipping the tire/wheel assembly in a water bath, or use a spray bottle with soap and water to locate the specific leak location. Important - If the porosity leak is located in the bead area of the aluminum rim (where the tire meets the rim), the wheel should be replaced. - If two or more leaks are located on one wheel, the wheel should be replaced. 3. If air bubbles are observed, mark the location. - If the leak location is on the tire/rubber area, refer to Corporate Bulletin Number 04-03-10-001F Tire Puncture Repair Procedures for All Cars and Light Duty Trucks. - If the leak is located on the aluminum wheel area, continue with the next step. 4. Inscribe a mark on the tire at the valve stem in order to indicate the orientation of the tire to the wheel. 5. Dismount the tire from the wheel. Refer to Tire Mounting and Dismounting. 6. Remove the tire pressure sensor. Refer to Tire Pressure Sensor removal procedure in SI. 7. Scuff the INSIDE rim surface at the leak area with #80 grit paper and clean the area with general purpose cleaner, such as 3M(R) General Purpose Adhesive Cleaner, P/N 08984, or equivalent. 8. Apply a 3 mm (0.12 in) thick layer of Silicone - Adhesive/Sealant, P/N 12378478 (in Canada, use 88900041), or equivalent, to the leak area. 9. Allow for the adhesive/sealant to dry. Notice Caution must be used when mounting the tire so as not to damage the sealer. Damaging the repair area may result in an air leak. Page 8806 SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-D. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: - The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair Tools Required J 38125-D Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-D. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Specifications Fuel Pressure: Specifications Fuel Pressure (Key ON Engine OFF) .............................................................................................................................................. 385-425 kPa (55-62 psi) Page 1264 Wheel Speed Sensor: Locations ABS Component Views Wheel Speed Sensor (WSS) - RF and LF Page 7274 Steps 11-18 Step 19 The numbers below refer to the step numbers on the diagnostic table. 2. This step tests for an open fog lamp fuse. Page 5190 Flexible Fuel Sensor: Description and Operation FUEL COMPOSITION SENSOR DESCRIPTION The fuel composition sensor (FCS), or flex fuel sensor (service parts term), measures the ethanol-gasoline ratio of the fuel being used in a flexible fuel vehicle. Flexible fuel vehicles can be operated with a blend of ethanol and gasoline, up to 85 percent ethanol. In order to adjust the ignition timing and the fuel quantity to be injected, the engine management system requires information about the percentage of ethanol in the fuel. The FCS uses quick-connect style fuel connections, an incoming fuel connection, and an outgoing fuel connection. The two connections have different diameters, to prevent incorrect attachment of the fuel lines. All fuel passes through the fuel composition sensor before continuing on to the fuel rail. The fuel composition sensor measures two different fuel related parameters, and sends an electrical signal to the powertrain control module (PCM) to indicate ethanol percentage, and fuel temperature. The fuel composition sensor has a three-wire electrical harness connector. The three wires provide a ground circuit, a power source, and a signal output to the PCM. The power source is vehicle system voltage, +12 volts), and the ground circuit connects to chassis ground. The signal circuit carries both the ethanol percentage and fuel temperature within the same signal, on the same wire. The FCS uses a microprocessor inside the sensor to measure the ethanol percentage and fuel temp, and change an output signal accordingly. The electrical characteristic of the FCS signal is a square-wave digital signal. The signal is both variable frequency and variable pulse width. The frequency of the signal indicates the ethanol percentage, and the pulse width indicates the fuel temperature. The PCM provides an internal pull-up to five volts on the signal circuit, and the FCS pulls the 5 volts to ground in pulses. The output frequency is linear to the percentage of ethanol content in the fuel. The normal range of operating frequency is between 50 and 150 Hertz, with 50 Hertz representing 0 percent ethanol, and 150 Hertz representing 100 percent ethanol. The normal pulse width range of the digital pulses is between 1 and 5 milliseconds, with 1 millisecond representing -40°C (-40°F), and 5 milliseconds representing 125°C (257°F). The microprocessor inside the sensor is capable of a certain amount of self-diagnosis. An output frequency of 170 Hertz indicates either that the fuel is contaminated or contains methanol (it should not), or that an internal sensor electrical fault has been detected. Certain substances dissolved in the fuel can cause the fuel to be contaminated, raising the output frequency to be higher than the actual ethanol percentage should indicate. Examples of these substances include water, sodium chloride (salt), and methanol. It should be noted that it is likely that the FCS will indicate a slightly lower ethanol percentage than what is advertised at the fueling station. This is not a fault of the sensor. The reason has to do with government requirements for alcohol-based motor fuels. Government regulations require that alcohol intended for use as motor fuel be DENATURED. This means that 100 percent pure ethanol is first denatured with approximately 41/2 percent gasoline, before being mixed with anything else. When an ethanol gasoline mixture is advertised as E85, the 85 percent ethanol was denatured before being blended with gasoline, meaning an advertised E85 fuel contains only about 81 percent ethanol. The FCS measures the actual percentage of ethanol in the fuel. Steering Wheel Position Sensor or Steering Shaft Lower Bearing Replacement Steering Column Position Sensor: Service and Repair Steering Wheel Position Sensor or Steering Shaft Lower Bearing Replacement Steering Wheel Position Sensor or Steering Shaft Lower Bearing Replacement (Centering Required) ^ Tools Required J 42640 Steering Column Anti-Rotation Pin Removal Procedure 1. Set the front wheels in the straight-ahead position. 2. Install J 42640 or set the steering wheel in the LOCKED position. 3. Caution: Refer to SIR Caution in Service Precautions. Disconnect the negative battery cable. 4. Disable the SIR. 5. Important: You MUST make an alignment mark on the upper intermediate shaft to the steering column shaft, where they connect. You will need the alignment marks for installation. Make an alignment mark on the upper intermediate shaft and the steering column shaft, where they connect, before removal. 6. Remove the nut and the bolt from the upper to the lower steering shaft connection. Slide the lower shaft down. 7. Remove the steering wheel position sensor connector by using a suitable tool in order to pull the connector down around the right side of the steering column for accessibility. 8. Important: Do not apply force to the steering wheel position sensor and the adapter and bearing assembly in a sideways direction. If reusing the existing steering wheel position sensor, it MUST be centered before removal. Verify the type of steering wheel position sensor before removal. Refer to Steering Wheel Position Sensor Centering. 9. Remove the steering wheel position sensor and adapter and bearing assembly from the steering column jacket by pulling the assembly straight out. 10. Remove the steering wheel position sensor from the clips in the adapter and bearing assembly. Installation Procedure 1. Important: A new sensor MUST come with a pin installed. If pin is not installed, return and reorder sensor. Verify the following before installing the steering wheel position sensor: ^ The front wheels are in the straight-ahead position. ^ That J 42640 is installed or the steering wheel is in the LOCKED position. 2. If reusing the existing steering wheel position sensor, verify the type of sensor you have before installing. Refer to Steering Wheel Position Sensor Centering. 3. Install the steering wheel position sensor into the adapter and bearing assembly. 4. Install the adapter and bearing assembly into the steering column jacket. 1. Align the notches on the adapter and bearing assembly and the steering column jacket. 2. Important: Drivetrain - Transfer Case Control Module Replacement Control Module: All Technical Service Bulletins Drivetrain - Transfer Case Control Module Replacement Bulletin No.: 05-04-21-002 Date: March 10, 2005 INFORMATION Subject: Guidelines for Replacement of Transfer Case Control Module (TCCM) Models: 2005 and Prior Light Duty Trucks with New Venture Gear (NVG) Transfer Case (RPOs NP1, NP4, NP8) Dealers are replacing the TCCM unnecessarily. Dealers are replacing the TCCM with codes stored in HISTORY only. The TCCM does not have a current fault condition when tested. Parts reviewed at the Warranty Parts Center (WPC) have a 75% No Trouble Found (NTF) rate. The only two legitimate reasons to replace the TCCM are: ^ Diagnostic Trouble Code (DTC) C0550 ^ NO Communication with a scan tool. DTC C0550 This DTC indicates that the module has an internal fault and should be replaced. No Communication ^ The no communication conditions referenced here are also caused by a module internal fault to a point where the module physically will not talk. A technician cannot pull DTCs from the module because it will not communicate. The module is electrically dead. ^ No communication is not to be confused with a U1026 code. This code tells the technician that the module may still be functioning but is temporarily off line. This code may be set by the Instrument Panel (IP) or the Powertrain Control Module (PCM) against the TCCM. The technician needs to figure out why the module went off line. These are typically caused by connection concerns. There is no need to replace a TCCM for a U1026 DTC. Diagnostic Aids ^ When diagnosing a transfer case electrical control system, ALWAYS check power and ground wiring first. ^ Test the connections for intermittent or poor connections, complete plug insertion, bent pins, pushed out terminals and water contamination. Engine - GM dexos 1 and dexos 2(R) Oil Specifications Engine Oil: Technical Service Bulletins Engine - GM dexos 1 and dexos 2(R) Oil Specifications INFORMATION Bulletin No.: 11-00-90-001 Date: March 14, 2011 Subject: Global Information for GM dexos1(TM) and GM dexos2(TM) Engine Oil Specifications for Spark Ignited and Diesel Engines, Available Licensed Brands, and Service Fill for Adding or Complete Oil Change Models: 2012 and Prior GM Passenger Cars and Trucks Excluding All Vehicles Equipped with Duramax(TM) Diesel Engines GM dexos 1(TM) Information Center Website Refer to the following General Motors website for dexos 1(TM) information about the different licensed brands that are currently available: http://www.gmdexos.com GM dexos 1(TM) Engine Oil Trademark and Icons The dexos(TM) specification and trademarks are exclusive to General Motors, LLC. Only those oils displaying the dexos‹›(TM) trademark and icon on the front label meet the demanding performance requirements and stringent quality standards set forth in the dexos‹›(TM) specification. Look on the front label for any of the logos shown above to identify an authorized, licensed dexos 1(TM) engine oil. GM dexos 1(TM) Engine Oil Specification Important General Motors dexos 1(TM) engine oil specification replaces the previous General Motors specifications GM6094M, GM4718M and GM-LL-A-025 for most GM gasoline engines. The oil specified for use in GM passenger cars and trucks, PRIOR to the 2011 model year remains acceptable for those previous vehicles. However, dexos 1(TM) is backward compatible and can be used in those older vehicles. In North America, starting with the 2011 model year, GM introduced dexos 1(TM) certified engine oil as a factory fill and service fill for gasoline engines. The reasons for the new engine oil specification are as follows: - To meet environmental goals such as increasing fuel efficiency and reducing engine emissions. - To promote long engine life. - To minimize the number of engine oil changes in order to help meet the goal of lessening the industry's overall dependence on crude oil. dexos 1(TM) is a GM-developed engine oil specification that has been designed to provide the following benefits: - Further improve fuel economy, to meet future corporate average fuel economy (CAFE) requirements and fuel economy retention by allowing the oil to maintain its fuel economy benefits throughout the life of the oil. - More robust formulations for added engine protection and aeration performance. Page 8811 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-8 (12085115) crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-8 (12085115) until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes SPLICING INLINE HARNESS DIODES Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate Service Data wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. 9. Tape the diode to the harness or connector using electrical tape. Page 2047 available, measurements may also be clearly and legibly handwritten into the Wheel Alignment Repair Order Questionnaire attached to this bulletin. 4. Attach the Wheel Alignment Repair Order Questionnaire below along with the print-out of "Before" and "After" wheel alignment measurements to the Repair Order and retain for use by GM. Wheel Alignment Equipment and Process Wheel alignments must be performed with a quality machine that will give accurate results when performing checks. "External Reference" (image-based camera technology) is preferred. Please refer to Corporate Bulletin Number 05-00-89-029B: General Motors Dealership Critical Equipment Requirements and Recommendations. Requirements: - Computerized four wheel alignment system. - Computer capable of printing before and after alignment reports. - Computer capable of time and date stamp printout. - Racking system must have jacking capability - Racking system must be capable of level to 1.6 mm (1/16 in) - Appropriate wheel stops and safety certification - Built-in turn plates and slip plates - Wheel clamps capable of attaching to 20" or larger wheels - Racking capable of accepting any GM passenger car or light duty truck - Operator properly trained and ASE-certified (U.S. only) in wheel alignment Recommendations: Racking should have front and rear jacking capability. Equipment Maintenance and Calibration: Alignment machines must be regularly calibrated in order to give correct information. Most manufacturers recommend the following: - Alignment machines with "internal reference" sensors should be checked (and calibrated, if necessary) every six months. - Alignment machines with "external reference" (image-based camera technology) should be checked (and calibrated, if necessary) once a year. - Racks must be kept level to within 1.6 mm (1/16 in). - If any instrument that is part of the alignment machine is dropped or damaged in some way, check the calibration immediately. Check with the manufacturer of your specific equipment for their recommended service/calibration schedule. Wheel Alignment Process When performing wheel alignment measurement and/or adjustment, the following steps should be taken: Preliminary Steps: 1. Verify that the vehicle has a full tank of fuel (compensate as necessary). 2. Inspect the wheels and the tires for damage. 3. Inspect the tires for the proper inflation and irregular tire wear. 4. Inspect the wheel bearings for excessive play. 5. Inspect all suspension and steering parts for looseness, wear, or damage. 6. Inspect the steering wheel for excessive drag or poor return due to stiff or rusted linkage or suspension components. 7. Inspect the vehicle trim height. 8. Compensate for frame angle on targeted vehicles (refer to Wheel Alignment Specifications in SI). Satisfactory vehicle operation may occur over a wide range of alignment angles. However, if the wheel alignment angles are not within the range of specifications, adjust the wheel alignment to the specifications. Refer to Wheel Alignment Specifications in SI. Give consideration to excess loads, such as tool boxes, sample cases, etc. Follow the wheel alignment equipment manufacturer's instructions. Measure/Adjust: Important Prior to making any adjustments to wheel alignment on a vehicle, technicians must verify that the wheel alignment specifications loaded into their wheel alignment machine are up-to-date by comparing these to the wheel alignment specifications for the appropriate model and model year in SI. Using incorrect and/or outdated specifications may result in unnecessary adjustments, irregular and/or premature tire wear and repeat customer concerns Page 3154 Connecting Rod: Specifications Connecting Rod Bolts - First Pass ............................................................................................................................................................ 20 Nm (15 ft. lbs.) Connecting Rod Bolts - Final Pass ........................................................................ ................................................................................................ 85 degrees Connecting Rod Bore Diameter - Bearing End ......................................................................................................... 56.505-56.525 mm (2.224-2.225 inch) Connecting Rod Bore Out-of-Round - Bearing End Production ........................................................................... 0.004-0.008 mm (0.00015-0.0003 inch) Connecting Rod Bore Out-of-Round - Bearing End -Service ................................................................................. 0.004-0.008 mm (0.00015-0.0003 inch) Connecting Rod Side Clearance ...................................................................................................................................... 0.11-0.51 mm (0.00433-0.02 inch) Page 841 4. Push on the top part until it clicks in place. 5. Connect the harness to the front of the junction block. 6. Install the cover to the junction block until it clicks in place. 7. Hand tighten the retaining nut until seated. Page 2256 11. If the vehicle is a 2003 model year Chevrolet Express or GMC Savana van, the vehicle may require a new accumulator. Refer to Corporate Bulletin Number 03-01-38-016 for more information. This bulletin refers to an updated design accumulator that may improve the performance of the A/C system. 12. Install a new serpentine belt tensioner and serpentine belt if they have been damaged due to A/C system slugging or an A/C compressor seizure. The serpentine belt tensioner may have broken stop tabs and/or a missing front cap. 13. Verify proper operation of the A/C system. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer TPMS System - Service And Re-Learning Sensor IDs Tire Pressure Module: Technical Service Bulletins TPMS System - Service And Re-Learning Sensor IDs INFORMATION Bulletin No.: 10-03-16-001 Date: July 19, 2010 Subject: TPMS System Service and Re-Learning Sensor IDs Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks 2010 and Prior HUMMER H2 2009 and Prior HUMMER H3 2010 and Prior Saturn Models 2009 and Prior Saab 9-7X with Wheel-Mounted Tire Pressure Sensors In the event that the spare tire, which is normally not equipped with a tire pressure monitor (TPM) sensor, is installed in place of one of the road tires and the vehicle is driven above 40 km/h (25 mph) for 20 minutes or more, the TPM indicator icon on the instrument panel cluster (IPC) will flash for approximately one minute and then remain on steady each time the ignition is turned ON, indicating a diagnostic trouble code (DTC) has been set. The driver information center (DIC), if equipped, will also display a SERVICE TIRE MONITOR type message. When the road tire is repaired and reinstalled in the original location, the TPM indicator icon illumination and DIC message may remain displayed until the DTC is cleared. To ensure that the TPM indicator and the DIC message are cleared after service, it is necessary to clear any TPM DTCs using a scan tool. If a scan tool is unavailable, performing the TPM relearn procedure using a TPM diagnostic tool will provide the same results. It is advised to perform the relearn procedure away from other vehicles to prevent picking up a stray sensor signal. If one or more of the TPM sensors are missing or damaged and have been replaced, then the relearn procedure must be performed. Disclaimer Page 2516 3. Install the fill plug. ^ Tighten the plug to 20 Nm (15 ft. lbs.). 4. Install the transfer case shield, if equipped. 5. Lower the vehicle. Capacity Specifications Power Steering Fluid: Capacity Specifications Power Steering ............................................................................................................................................................. 0.77 - 1.25 liters (0.81 - 1.32 quarts) NOTE: ALL capacity specifications are approximate. When replacing or adding fluids, fill to the recommended level and recheck fluid level. Page 1909 Page 497 If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Sir/SRS Wiring Repairs SIR/SRS WIRING REPAIRS TOOLS REQUIRED J 38125-D Terminal Repair Kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-D contains the following items: - Special sealed splices - in order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping tool - A heat torch - An instruction manual The sealed splices have the following 2 critical features: - A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-D also serves as a generic terminal repair kit. The kit contains the following items: - A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors Page 5315 Steps 10 - 13 Page 12592 8.5. Close the luggage compartment floor. 9. Fold down the left-hand rear side hatch in the luggage compartment. 10. M03: Replace the optic cable on the left-hand rear side: 10.1. Place the optic cable so that it is positioned behind the terminal housing on top of REC (A). 10.2. Remove the locking strip (B) on the 2-pin connector (H2-9) for the optic cable. 10.3. Open the terminal housing (C) with a screwdriver. Remove the secondary catch (D) on the connector and disconnect the optic cable coming from the OnStar(R) control modules. With Full Floating 10.5 8. Install the inner bearing. 9. Important: Each time you replace the wheel hub bearings, install a new oil seal in order to prevent the wheel hub from leaking. Install the new oil seal using the J 44420 (2) and the J 8092 (1). 10. Install the rotor, if necessary. 11. Apply a light coat of high melting point EP bearing lubricant to the axle housing spindle. 12. Install the wheel hub to the axle housing. 13. Install the adjusting nut to the hub using the J 2222-C. 14. Adjust the wheel bearings. 15. Install the axle shaft. 16. Install the brake caliper. 17. Install the tire and wheel assembly. Page 508 Control Module References Part 4 Page 1449 Brake Light Switch: Diagrams Stop Lamp Switch Part 1 Page 14108 Control Module References Part 6 Page 13266 5.2 Cut off the cable tie (B), detach the connector's rear end face (C) and pull out the connecting rail (D). 5.3. Remove pin 39, cut off the cable terminal and insulate the end with tape (E). Fold back the cable and secure it with tape (F). 5.4. Fit the connecting rail and end face. 5.5. Plug in the connector (A) and secure the cables with cable ties (B). 6. Install the floor console over the handbrake. Do not press the console down into place, but instead allow it to fit loosely. 7. Install the switch: 7.1. Install the switch for the roof lighting (B) and plug in its connector. 7.2. Guide the connectors for the window lift module and rear seat heater, if equipped, through the hole for each respective unit. Plug in the window lift module's connector and install the module (A). Locations Crankshaft Position (CKP) Sensor Location Page 13130 Page 14470 Disclaimer Page 12785 OnStar(R) Microphone The OnStar(R), or cellular microphone, can be a part of the rearview mirror assembly, or on some vehicle lines, a separate, stand alone unit. In either case, the VCIM supplies approximately 10 volts to the microphone on the cellular microphone signal circuit, and voice data from the user is sent back to the VCIM over the same circuit. A cellular microphone low reference circuit or a drain wire provides a ground for the microphone. Cellular and GPS Antennas The vehicle will be equipped with one of the following types of antennas: ^ Separate, stand-alone cellular and navigation (GPS) antennas. ^ A combination cellular and navigation (GPS) antenna, which brings the functions of both into a single part. ^ A cellular, GPS, and digital radio receiver (DRR) antenna, which also incorporates the functionality of the DRR satellite antenna (XM). The cellular antenna is the component that allows the OnStar(R) system to send and receive data using electromagnetic waves by means of cellular technology. The antenna is connected at the base to a coax cable that plugs directly into the VCIM. The GPS antenna is used to collect the signals of the orbiting GPS satellites. Within the antenna is housed a low noise amplifier that allows for a more broad and precise reception of this data. The antenna is connected at the base to a coax cable that plugs directly into the VCIM. The cable also provides a path for DC current for powering the antenna. The OnStar(R) Call Center also has the capability of communicating with the vehicle during an OnStar(R) call to retrieve the latest GPS location and transmit it to the OnStar(R) Call Center. A history location of the last recorded position of the vehicle is stored in the module and marked as aged, for as long as the module power is not removed. Actual GPS location may take up to 10 minutes to register in the event of a loss of power. Audio System Interface When the OnStar(R) requires audio output, a serial data message is sent to the audio system to mute all radio functions and transmit OnStar(R) originated audio. The OnStar(R) audio is transmitted to the vehicle audio system by a dedicated signal circuit and a low reference circuit. The audio system will mute and an audible ring will be heard though the speakers if the vehicle receives a call with the radio ON. On some vehicles, the HVAC blower speed may be reduced when the OnStar(R) system is active to aid in reducing interior noise. When the system is no longer active, the blower speed will return to its previous setting. OnStar(R) Steering Wheel Controls Some vehicles may have a button on the steering wheel, that when pushed can engage the OnStar(R) system. The button may be a symbol of a face with sound waves, or may say MUTE, or be a symbol of a radio speaker with a slash through it. By engaging the OnStar(R) system with this feature, the user can interact with the system by use of voice commands. A complete list of these commands is supplied in the information provided to the customer. If the information is not available for reference, at any command prompt, the user can say "HELP" and the VCIM will return an audible list of available commands. The steering wheel controls consist of multiple momentary contact switches and a resistor network. The switches and resistor network are arranged so that each switch has a different resistance value. When a switch is pressed, a voltage drop occurs in the resistor network. This produces a specific voltage value unique to the switch selected, to be interpreted by the radio or the body control module (BCM). OnStar(R) Power Moding (DRX or Sleep Cycle) The OnStar(R) system uses a unique sleep cycle to allow the system to receive cellular calls while the ignition is in the OFF position and retained accessory power (RAP) mode has ended. A green status LED on the OnStar(R) keypad normally indicates an active OnStar(R) account. The OnStar(R) system will stay powered up after ignition off for an extended time in order to allow for remote services like door unlock, horn honk, light flash, etcetera to take place as requested by the customer. Power cycle (also referred to as DRX) times vary depending on the generation of the OnStar(R) system. Technicians may identify the OnStar(R) system generation by using a Tech 2 and following this menu path: (Body>VCIM>Module ID Information>Module Information 2) or by accessing www.onstarenrollment.com All Generation 6 digital systems are powered up continuously for 48 hours from ignition OFF. After 48 hours, the Generation 6 systems will enter a 9 minute OFF, 1 minute ON power cycle for an additional 72 hours. At the beginning and end of the 1 minute ON stage, you may or may not experience a short spike of current at the beginning and at the end. This allows for calls from OnStar to be received by the system. After 120 hours from ignition OFF, Page 3257 7. Inspect the drive belt (1) for proper installation and alignment. 8. Align the arrow (2) at the throttle body end of the duct with the throttle body attaching stud (1). 9. Install the air cleaner outlet duct. 10. Connect the radiator inlet hose clip to the outlet duct. Notice: Refer to Fastener Notice in Service Precautions. 11. Tighten the air cleaner outlet duct clamp screws at the following locations: ^ The throttle body ^ The MAF/IAT sensor ^ Tighten the screws to 7 Nm (62 inch lbs.). Page 5514 Fuel Composition Sensor Page 2349 3. Notice: Refer to Power Steering Hose Disconnected Notice in Service Precautions. Place a drain pan under the vehicle. 4. Siphon the fluid from the reservoir to prevent excess spillage. 5. Remove the clamp retaining the power steering cooler inlet hose (3) to the power steering gear. 6. Remove the clamp retaining power steering cooler outlet hose (2) to the power steering pump (1). 7. Remove the bolts (2) retaining the power steering cooler from the radiator support. 8. Remove the power steering cooler from the vehicle. Installation Procedure 1. Notice: Page 10771 Wheel Nut Torque Sequence Page 1990 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors USING CONNECTOR TEST ADAPTERS IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-B Connector Test Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Page 4671 IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. Splicing Twisted or Shielded Cable SPLICING TWISTED OR SHIELDED CABLE Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. - Rewrap the conductors with the mylar tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with mylar tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Control Module References Page 2331 Power Steering Line/Hose: Service and Repair Power Brake Booster Outlet Hose Replacement Power Brake Booster Outlet Hose Replacement Removal Procedure 1. Notice: Refer to Power Steering Hose Disconnected Notice in Service Precautions. Install a drain pan under the vehicle. 2. Remove the brake booster outlet hose (1) from the brake booster (2). 3. Remove the clamp retaining the brake booster outlet hose to the power steering pump. 4. Remove the brake booster outlet hose from the vehicle. Installation Procedure 1. Notice: The inlet and outlet hoses must not be twisted during installation. Do not bend or distort the inlet or outlet hoses to make installation easier. Failure to follow these procedures could result in component damage. Route the hose in the same position the hose occupied prior to removal. 2. Install the brake booster outlet hose (1) to the brake booster (2).Position the clamp at the end of the hose. 3. Install the brake booster outlet hose to the power steering pump (4).Position the clamp at the end of the hose. 4. Remove the drain pan from under the vehicle. 5. Bleed the power steering system. Refer to Bleeding the Power Steering System. Vehicle Speed Sensor (VSS) Vehicle Speed Sensor: Diagrams Vehicle Speed Sensor (VSS) Page 2714 Application Table Page 11387 A/C Low Pressure Switch Page 11024 1. Install the clutch coil (6) to the A/C compressor (7). 2. Install the snap ring (5) to the clutch coil (6). 3. Install the clutch hub/bearing assembly (4). 4. Install the clutch hub/bearing snap ring (3). 5. Install the clutch plate assembly (2). NOTE: Refer to Fastener Notice in Service Precautions. 6. Install the clutch plate retaining bolt (1). Tighten Tighten the bolt to 18 N.m (13 lb ft). 7. Install a ratchet into the A/C belt tensioner adapter opening. 8. Rotate the A/C belt tensioner clockwise in order to relieve the tension on the belt. 9. Install the A/C belt to the A/C compressor. 10. Slowly release the tension on the A/C belt tensioner. 11. Remove the ratchet from the A/C belt tensioner. 12. Install the engine protection shield. 13. Lower the vehicle. Page 3972 2. Install the fuel level sensor retaining clip. 3. Connect the fuel level sensor electrical connector. 4. Install the fuel level sensor electrical connector retaining clip. Emissions - MIL ON/DTC P0446 Stored In ECM Canister Purge Control Valve: All Technical Service Bulletins Emissions - MIL ON/DTC P0446 Stored In ECM TECHNICAL Bulletin No.: 02-06-04-037I Date: September 16, 2010 Subject: Check Engine Light On, Fuel Tank Hard to Fill, DTCs P0442, P0446, P0455 or P0449 Set (Replace Evaporative Emission (EVAP) Vent Valve Solenoid Assembly and Add/Relocate Filter Box Using Service Kit) Models: 1999-2007 Chevrolet Silverado (Classic) Models 1999-2007 GMC Sierra (Classic) Models 2007-2010 Chevrolet Silverado Models (Including Hybrid) 2007-2010 GMC Sierra Models (Including Hybrid) Supercede: This bulletin is being revised to add the 2010 model year and to include the Hybrid models. Please discard Corporate Bulletin Number 02-06-04-037H (Section 06 - Engine/Propulsion System). Condition Some customers may comment about the check engine light being illuminated. They may also comment that their vehicle is difficult to fill with fuel or when filling, the pump continuously shuts off before the tank is full. When checking the vehicle for DTCs, the ECM may report one or more of the following DTCs set as current or in history: P0442, P0446, P0449 or P0455. Cause The EVAP canister vent solenoid (CVS) valve draws fresh air into the system through a vent. Under certain operating conditions, dirt and dust intrusion into the EVAP CVS fresh air intake/venting system, may result in restricted air flow. Under certain operating conditions, water, if ingested into the EVAP CVS fresh air intake/venting system, may reach the CVS valve causing corrosion in the CVS valve, and may cause restrictions in the fresh air intake path, when the valve is in the closed position. Correction (1999-2007 Classic/Old Style Models) After following the published SI diagnostics and determining that the EVAP canister vent valve is the cause of the MIL light, replace the existing EVAP canister vent valve assembly with a new assembly. This new assembly is a sealed unit that is designed to be vented through a remote filter box. To ensure correct installation, follow the procedures below. Important DO NOT replace the EVAP canister assembly for this concern unless it fails the leak test. 1999-2003 Model Year (Use Service Kit P/N 19207762) 1. Raise the vehicle. Suitably support the vehicle. 2. Disconnect the EVAP canister vent valve electrical connector, if equipped. 3. Disengage the two vent valve pipe clips securing the pipe to the underbody. Remove the clips from the underbody and discard. 4. Disconnect the vent valve pipe at the EVAP canister. 5. Remove and retain the EVAP canister vent valve bracket mounting bolt. 6. Remove the complete EVAP canister vent valve assembly with bracket attached and discard. A/T - MIL ON/DTC P0757/Harsh or Slipping 2-3 Shift Valve Body: All Technical Service Bulletins A/T - MIL ON/DTC P0757/Harsh or Slipping 2-3 Shift INFORMATION Bulletin No.: 08-07-30-015 Date: March 27, 2008 Subject: Diagnostic Information on MN8, MT1 SES/MIL Illuminated, DTC P0757, Harsh Shift, Delayed 2-3 Shift, 2-3 Shift Flare, No Third Gear, Slips in Third Gear or Reverse Models: 2002-2007 Chevrolet Avalanche 2500 Series, Silverado Classic, Suburban 2500 Series 2002-2008 Chevrolet Express 2002-2007 GMC Sierra Classic, Yukon XL 2500 Series 2002-2008 GMC Savana with HYDRA‐MATIC(R)4L80‐E (RPO MT1) or4L85‐E (RPO MN8) Automatic Transmission The purpose of this bulletin is to provide technicians with additional diagnostic information on DTC P0757. Refer to Service Information (SI) for DTC P0757, 2-3 Shift Solenoid Valve Performance No Third or Fourth Gear. Additional 4L80‐E or 4L85‐E transmission symptoms may be a harsh shift, delayed 2-3 shift, no third gear or slip in third or reverse, or a 2-3 shift flare. The transmission fluid inspection may or may not indicate distressed clutches. On all 2002-2006 vehicles and certain 2007-2008 vehicles, check for any debris caught in the # 11 check ball. If debris is found, repair per Service Bulletin 08-07-30-001. Also inspect the direct clutch for damage that may have been caused by a leak in the oil circuit that may be a result of the debris. If no debris is found, and no other cause is found when referring to Service Information (SI) for DTC P0757, valve body replacement may be indicated. Also check the 2-3 shift valve for debris or leakage. If none of these items seem to have a concern, replace the 2-3 shift solenoid due to a possible sticking pintle. Disclaimer Brake Caliper Replacement - Front Brake Caliper: Service and Repair Brake Caliper Replacement - Front Brake Caliper Replacement - Front Caution: Refer to Brake Dust Caution in Service Precautions. Caution: Refer to Brake Fluid Irritant Caution in Service Precautions. Removal Procedure 1. Inspect the fluid level in the brake master cylinder reservoir. 2. If the brake fluid level is midway between the maximum-full point and the minimum allowable level, no brake fluid needs to be removed from the reservoir before proceeding. 3. If the brake fluid level is higher than midway between the maximum-full point and the minimum allowable level, remove brake fluid to the midway point before proceeding. 4. Raise and support the vehicle. Refer Vehicle Lifting 5. Remove the tire and wheel assembly. 6. Compress the brake caliper pistons. ^ Install a large C-clamp over the top of the caliper housing and against the back of the outboard pad. ^ Slowly tighten the C-clamp until the pistons are pushed completely into the caliper bores. ^ Remove the C-clamp from the caliper. 7. Clean all dirt and foreign material from the brake hose end. 8. Important: Install a rubber cap or plug to the exposed brake pipe fitting end to prevent brake fluid loss and contamination. Remove the brake hose to caliper bolt from the brake caliper. 9. Remove and discard the 2 copper brake hose gaskets. These gaskets may be stuck to the brake caliper housing or the brake hose end. 10. Remove the brake hose from the caliper. Instruments - Service Tire Monitor Message is Displayed Low Tire Pressure Indicator: Customer Interest Instruments - Service Tire Monitor Message is Displayed Bulletin No.: 05-08-49-018A Date: May 11, 2006 ADVANCE SERVICE INFORMATION RESOLUTION Subject: EI 05065 - Service Tire Monitor Message Displayed (Pull/Reinstall IPC Fuse or Verify Correct Passenger Door Module (PDM) and Tires) Models: 2004 Chevrolet Silverado 2004 GMC Sierra Supercede: This bulletin is being revised to provide correction action. Please discard Corporate Bulletin Number 05-08-49-018 (Section 08 - Body and Accessories). Condition Some customers may comment that the "SERVICE TIRE MONITOR" message is being displayed on the DIC. Correction DO NOT REPLACE THE INSTRUMENT PANEL CLUSTER. If the DIC is displaying the SERVICE TIRE MONITOR message: 1. Verify if the vehicle has an electronic aftermarket module spliced into the ALDL Class 2 data line (purple wire). 2. If the vehicle HAS an aftermarket module spliced into the Class 2 line, pull the IPC fuse (located underhood) for 25 seconds. Important: Due to the electronic aftermarket module, the SERVICE TIRE MONITOR message may reoccur. 3. Reinstall the IPC fuse. This will clear the SERVICE TIRE MONITOR message from the display. 4. If the vehicle DOES NOT have an aftermarket module spliced into the Class 2 line, verify the vehicle is equipped with the correct PDM (Passenger Door Module) and tires. Warrant Information This repair is not covered under the vehicle warranty due to the installation of an aftermarket module. Disclaimer Page 12037 10. Disconnect and remove the OnStar(R) jumper harness. Note: You will need to remove the short GPS cable from this jumper harness. 11. Untape the cell antenna coax from the body harness in the trunk. This will be necessary to provide adequate length to connect to the new VCIM. 12. Fasten three retainer clips (1) from the kit to the new bracket that is included in the kit, and position the VCIM to the bracket (2). 13. Install the three bolts from the kit. Tighten the bolts to 10 Nm (89 lb in). 14. Connect the new OnStar(R) jumper harness supplied in the kit to the VCIM (two white connectors on module). 15. Connect small GPS coax cable jumper harness supplied in the kit (end with blue plastic housing) to VCIM GPS connector. 16. Position the VCIM / bracket assembly to the studs. 17. Install the bracket nuts saved from the Removal Procedure above to the VCIM / bracket assembly mounting studs. Tighten the nuts to 4 Nm (35 lb in). 18. Connect the new OnStar(R) jumper harness to the body wiring harness (C410 connector). 19. Connect small coax cable jumper from VCIM to the OnStar(R) Global Positioning Satellite (GPS) antenna coaxial cable at the connector previously left in the vehicle (short jumper removed from old harness in step 5.10). 20. Connect the cellular coaxial cable previously left in vehicle to the OnStar(R) VCIM. 21. Verify that all harnesses are properly secured in vehicle. 6. After replacing the VCIM, it is essential to configure the new OnStar(R) system. Failure to configure the system will result in an additional customer visit for repair. DO NOT press and hold the white dot or phone button on the keypad as it will not reset this version of the OnStar(R) system and may result in a DTC being set. Use of the TIS2WEB and SPS applications, along with the Tech2(R), are required in order to perform the VCIM configuration and setup procedure for this vehicle. The configuration and set-up procedure is now a two-step process which enables an automated activation by the OnStar(R) Center, without a button press by the technician to the OnStar(R) Call Center. 1. Connect the Tech2(R) to the vehicle. Locations Cabin Air Filter: Locations This vehicle does not have a factory installed Cabin Air Filter. Locations Combination Switch: Locations Steering Wheel and Column Sub-System Components Rear Window Defogger Heated Glass Element: Description and Operation Rear Window Defogger REAR WINDOW DEFOGGER DESCRIPTION AND OPERATION REAR WINDOW DEFOGGER SYSTEM COMPONENTS The rear window defogger system consist of the following components: HVAC control module - Body control module (BCM) - DEFOG relay - Rear window defogger grid REAR WINDOW DEFOGGER OPERATION When you turn the ignition to the ON position, ignition voltage is supplied to the DEFOG relay coil. Battery positive voltage is supplied at all times to the DEFOG relay switched input. When the rear window defogger switch is depressed, the HVAC control module illuminates the rear window defogger indicator and sends a class 2 message to the BCM. The BCM energizes the DEFOG relay by grounding the control circuit of the relay. This allows battery positive voltage from the relay switched input through the switch contacts and out the relay switched output to the rear window defogger. Ground for the rear window defogger is provided by G306 or G390 (crew cab). When you turn ON the ignition and press the rear window defogger switch for the first time, the defogger cycle lasts 10 minutes. Further operation results in 5 minute defogger cycles. Page 4035 15. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 16. Install the electrical ground wire terminal to the rivet stud. 17. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 18. Install the M6 conductive nut to the rivet stud and: Tighten Tighten to 8 Nm (71 lb in). 19. Verify proper system operation. M6 Weld Nut Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M6 weld nut at the electrical ground location is damaged or stripped, a M7 conductive self-threading bolt may be used to secure the ground wire terminal. 2. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the weld nut and allow to dry. 3. Remove any loose metal particles from the damaged or stripped weld nut with a stiff brush. 4. Select a M7 conductive self-threading bolt. Refer to the Parts Information section of this bulletin 5. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M7 conductive self-threading bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 6. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 7. Install the electrical ground wire terminal to the M7 conductive self-threading bolt. 8. Install the M7 conductive self-threading bolt and: Tighten Tighten to 9 Nm (80 lb in). 9. Verify proper system operation. M6 Weld Nut Alternative Repair Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the electrical ground location is accessible from both sides of the panel, a M6 conductive bolt and a M6 conductive nut may be used to secure the electrical ground wire terminal. Refer to the Parts Information section of this bulletin. 2. Select a location adjacent the damaged M6 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the new electrical ground site. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the ground location and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 8.5 mm (0.33 in) diameter hole through the panel. 5. Remove paint and primer from the area surrounding the 8.5 mm (0.33 in) hole until bare metal is visible. 6. Select a M6 conductive bolt. Refer to the Parts Information section of this bulletin. 7. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 8. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 9. Install the electrical ground wire terminal and the M6 conductive bolt to the ground location. 10. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 11. Install the M6 conductive nut to the bolt and: Page 461 Front Passenger Door Page 7596 Page 12795 The control module ID number list above provides a method for determining which module is not communicating. A module with a class 2 serial data circuit malfunction or which loses power during the current ignition cycle will have a Loss of Communication DTC set by other modules that depend on information from that failed module. The modules that can communicate will set a DTC indicating the module that cannot communicate. Diagnostic Order When more than one Loss of Communication DTC is set in either one module or in several modules, diagnose the DTCs in the following order: 1. Current DTCs before history DTCs unless told otherwise in the diagnostic table. 2. The DTC which is reported the most times. 3. From the lowest number DTC to the highest number DTC. Conditions for Running the DTC The following DTCs do not have a current status: ^ B1327 ^ B1328 ^ U1300 ^ U1301 ^ U1305 AND ^ The vehicle power mode requires serial data communication to occur. Conditions for Setting the DTC A node alive message has not been received from a module with a learned identification number within the last 5 seconds. Action Taken When the DTC Sets Campaign - HVAC Blower Not Functional Runs Continuously Control Module HVAC: Recalls Campaign - HVAC Blower Not Functional Runs Continuously SPECIAL COVERAGE Bulletin No.: 11046 Date: April 07, 2011 Subject: 11046 - Special Coverage Adjustment - Heating, Ventilation, and Air Conditioning Blower Not Fully Functional on All Blower Speeds, Inoperative, or Runs Continuously with the Ignition Off Models: 2003-2006 Chevrolet Avalanche, Suburban, Tahoe 2003-2007 Chevrolet Silverado 2003-2006 GMC Yukon, Yukon XL 2003-2007 GMC Sierra Equipped with Manual HVAC (CJ3) or Heavy Duty Heater (C42) Due to part availability, owner letters will be released in phases starting with older model year first. Owners for model year vehicles not included in first phase owner mailing will receive an owner advisory letter. The letter will inform the customer that parts are not yet available and that another letter will be sent to them when parts become available. A copy of this letter will be attached to the dealer message announcing this bulletin. In the meantime, if a customer brings their vehicle to the dealership with the condition described in this bulletin, repair the vehicle using the parts called out in this bulletin. Condition On some 2003-2006 model year Chevrolet Avalanche, Suburban, Tahoe; GMC Yukon, Yukon XL; and 2003-2007 model year Chevrolet Silverado and GMC Sierra vehicles equipped with a manual heating, ventilation, and air conditioning (HVAC) system (CJ3) or heavy duty heater (C42), the interface between the electrical terminals of the relay resistor module and the wiring connector that powers the module may be incapable of conducting higher current levels for sustained periods of blower motor operation. In addition, moisture and other contaminants may enter the fresh air intake plenum and contact the internal circuit of the module or corrode the terminals. Either of the above may cause the relay resistor module or wiring connector to overheat, resulting in one or more of the following symptoms: - The HVAC blower may not function on certain or all blower speed settings - A burning plastic smell or smoke may be present in the vehicle - The HVAC blower may run continually with the ignition in the OFF position In very rare events, if the above symptoms are ignored, a fire could occur. Special Coverage Adjustment This special coverage covers the condition described above for a period of 10 years or 240,000 km, whichever occurs first, from the date the vehicle was originally placed in service, regardless of ownership. Dealers are to install a new blower motor resistor and resistor module connector. The repairs will be made at no charge to the customer. For vehicles covered by Vehicle Service Contracts, all eligible claims with repair orders on or after April 8, 2011 are covered by this special coverage and must be submitted using the labor operation codes provided with this bulletin. Claims with repair orders prior to April 8, 2011 must be submitted to the Service Contract provider. Vehicles Involved Involved are certain 2003-2006 model year Chevrolet Avalanche, Suburban, Tahoe; GMC Yukon, Yukon XL; and 2003-2007 model year Chevrolet Silverado and GMC Sierra vehicles equipped with a manual HVAC (CJ3) or heavy duty heater (C42). Important Dealers are to confirm vehicle eligibility prior to beginning repairs by using the Applicable Warranties section in the Global Warranty Management system. Parts Information Page 6668 8. Remove the lube oil pipe bolt (6) and retainer (7). 9. Remove the lube oil pipe (5). 10. Remove the manual shaft detent spring bolt and spring (3). Important: Keep the control valve body level when lowering it from the vehicle. This will prevent the loss of checkballs located in the valve body passages. 11. Remove the remaining valve body bolts. 12. Carefully lower the valve body from the transmission. Use care not to drop the manual shaft valve. 13. Remove the valve body (2) which includes the following: ^ The accumulator housing (1) ^ The valve body to the spacer plate gasket ^ The spacer plate 14. Remove the manual valve (1) from the valve body. 15. Inspect the manual valve for nicks and burrs. 16. Remove the spacer plate to case gasket (2) from the case. The gasket may stick to the spacer plate. 17. Remove the PWM screen (1) from the case passage. Page 6735 Replace the side bearing adjuster lock ring and refer to SI for adjustment. When replacing the side bearing adjuster lock ring, inspect the old locking ring and make sure there are vertical lines in the outer and inner diameter of the ring (1). Next inspect and make sure there is tension when the locking rings are installed. If the locking ring rotates freely around the adjuster, do not use the locking ring. Replace with a new locking ring and make the same inspection. Oversize Lock Rings-Do Not Use The new lock rings will not have any vertical lines (inner or outer). They are imprinted during install. If vertical lines are shown (1), DO NOT USE. Parts Information Refer to GM Parts Catalog. Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Page 12228 4.2. Release the back end of the connector (C) and remove from the contact rail (D). 4.3. M00-01: Disconnect pin 39, cut off the cable terminal and insulate the end using tape (E). Fold back the cable and secure using tape (F). 4.4. M02-04: Disconnect pin 58, cut off the cable terminal and insulate the end using tape (E). Fold back the cable and secure using tape (F). 4.5. Assemble the contact rail and end. 4.6. Connect connector (A) and secure the cable using a cable tie (B). 5. Assemble the gear shift housing (A). AUT: Connect connector (B). 6. Assemble the center console, see WIS - Body - Interior. 7. Remove the OnStar(R) control module and secure the cable harness: 7.1. 5D: Remove the right-hand cover from the luggage compartment floor. Capacity Specifications Brake Fluid: Capacity Specifications Information not supplied by the manufacturer. Page 9692 Important The M6 conductive rivet stud as shown, can accommodate a panel thickness range of 0.7-4.2 mm (0.03-0.17 in). If there are layers of sheet metal, they should be touching without any air gaps to ensure a good ground. 5. Select a M6 conductive rivet stud. Refer to the Parts Information section of this bulletin. Note Use the GE-50317 rivet stud tool kit. 6. Place the M6 conductive rivet stud (1) in the 10 mm (0.40 in) hole. Assemble the rivet stud tool (2) with the groove and flare side facing the rivet stud, then the washer and the M6 nut (3). 7. Using a wrench on the rivet stud tool, and a socket on the M6 nut, secure the M6 conductive rivet stud. 8. Ensure the rivet stud is securely fastened, WITHOUT ANY detectable movement. 9. Completely wrap the threads of the rivet stud with painters tape or equivalent. Note The rivet stud and surrounding panel area MUST BE properly refinished PRIOR to the installation of the ground wire terminal and conductive nut to maintain a secure, stable and corrosion-free electrical ground. 10. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 11. Allow the refinished repair area to cure sufficiently before removing the protective material applied to the rivet stud threads. 12. Remove the painters tape or equivalent from the rivet stud threads. 13. Using GM approved residue-free solvent or equivalent, thoroughly clean the rivet stud threads to remove any adhesive and allow to dry. 14. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive rivet stud. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. Page 5107 1. Remove the fuel tank. 2. Disconnect and remove the EVAP rear line (2) from the sending unit and retaining clips. 3. Disconnect and remove the EVAP line (3) from the sending unit and retaining clips. 4. Cap the fuel feed/return, and EVAP lines in order to prevent possible fuel/EVAP system contamination. INSTALLATION PROCEDURE 1. Remove the caps from the fuel feed/return, and EVAP lines. 2. Install and connect the EVAP line (3) to the sending unit and retaining clips. 3. Install and connect the EVAP rear line (2) to the sending unit and retaining clips. 4. Install the fuel tank. EVAP Hoses/Pipes Replacement - Engine EVAPORATIVE EMISSION (EVAP) HOSES/PIPES REPLACEMENT - ENGINE REMOVAL PROCEDURE IMPORTANT: Clean the evaporative emission (EVAP) line connections and surrounding areas prior to disconnecting the fittings in order to avoid possible system contamination. 1. Remove the engine sight shield. Page 9845 Location View Page 1549 Camshaft Position (CMP) Sensor Page 11894 Models The service procedure in this bulletin has been revised. Step 11 in the procedure for the 2004-2005 Saab 9-3 (9440) Convertible has been revised. Discard all copies of bulletin 08089B, issued September 2008. Condition In November 2002, the U.S. Federal Commissions (FCC) ruled that wireless carriers would no longer be required to support the analog wireless network beginning in 2008. As a result, On Star(R) is unable to continue analog service. OnStar(R) has deactivated most of the systems operating in the analog mode; however, there are some vehicles that OnStar(R) could not deactivate. Although the analog OnStar(R) hardware in these vehicles can no longer communicate with OnStar(R), the hardware in the vehicle is still active. If the OnStar(R) emergency button is pressed, or in the case of an airbag deployment, or near deployment, the customer may hear a recording that OnStar(R) is being contacted. However, since analog service is no longer available, the call will not connect to OnStar(R). To end the call, the customer must press the white phone or white dot button. If the call is not ended, the system will continue to try to connect to OnStar(R) until the vehicle battery is drained. Special Policy Adjustment At the customer's request, dealers/retailers are to deactivate the OnStar(R) system. The service will be made at no charge to the customer. This special coverage covers the condition described above until December 31, 2008 for all non-Saab vehicles; April 30, 2009 for all Saab vehicles. Vehicles Involved Page 9579 Junction Block - I/P - C4 Part 1 Page 11914 4.1. Unplug the SRS control module's connector (A). 4.2. Cut off the cable tie (B), detach the connector's rear end face (C), and pull out the connecting rail (D). 4.3. Extract pin 15, cut off the cable terminal and insulate the end with tape (E). Fold back the cable and secure it with tape (F). 4.4. Fit the connecting rail and end face. 4.5. Plug in the connector (A) and secure the cables with cable ties (B). 5. Remove the parcel shelf trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6. M03: Replace the optic cable on the right-hand side Page 8117 9.1. Push the mud flap to make contact with the front side of the underbody cross sill and mark location of the hole (5) of the mud flap. 9.2. Center punch the marked location and drill a 5.159 mm (13/64 in) hole. 9.3. Install the screw. Tighten Tighten the screw to 4 N.m (35 lb in). 9.4. Repeat the above steps for hole location 6. 10. Repeat the above steps for the opposite side. Parts Information Parts are expected to be available from GMSPO on June 30, 2004. Warranty Information Please advise the customer that the mud flaps can be purchased as an accessory. Installation and/or cost of the mud flaps will not be covered under the vehicle's warranty. Disclaimer Page 12852 4.1. Unplug the SRS control module's connector (A). 4.2. Cut off the cable tie (B), detach the connector's rear end face (C), and pull out the connecting rail (D). 4.3. Extract pin 15, cut off the cable terminal and insulate the end with tape (E). Fold back the cable and secure it with tape (F). 4.4. Fit the connecting rail and end face. 4.5. Plug in the connector (A) and secure the cables with cable ties (B). 5. Remove the parcel shelf trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6. M03: Replace the optic cable on the right-hand side Page 1894 Park Neutral Position (PNP) Switch C175 NV 3500 Transmission Mount: Service and Repair NV 3500 Transmission Mount Replacement Removal Procedure Notice: Broken or deteriorated mounts can cause misalignment and destruction of certain drive train components. When a single mount breaks, the remaining mounts are subjected to abnormally high stresses. 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. Remove the transmission mount to crossmember nut. 3. Remove the transmission mount to transmission bolts. 4. Raise the transmission just enough in order to permit removal of the mount using a suitable transmission jack. 5. Remove the transmission mount. Installation Procedure 1. Position the transmission mount. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the transmission mount to transmission bolts. ^ Tighten the transmission mount bolts to 50 Nm (37 ft. lbs.). 3. Lower the transmission and remove the transmission jack. Electrical - MIL ON/DTC's Set By Various Control Modules Relay Module: Customer Interest Electrical - MIL ON/DTC's Set By Various Control Modules TECHNICAL Bulletin No.: 09-06-03-004D Date: December 08, 2010 Subject: Intermittent No Crank/No Start, No Module Communication, MIL, Warning Lights, Vehicle Messages or DTCs Set by Various Control Modules - Diagnosing and Repairing Fretting Corrosion (Disconnect Affected Connector and Apply Dielectric Lubricant) Models: 2011 and Prior GM Passenger Cars and Trucks Attention: This repair can be applied to ANY electrical connection including, but not limited to: lighting, body electrical, in-line connections, powertrain control sensors, etc. DO NOT over apply lubricant to the point where it prevents the full engagement of sealed connectors. A light coating on the terminal surfaces is sufficient to correct the condition. Supercede: This bulletin is being revised to update the Attention statement and add the 2011 model year. Please discard Corporate Bulletin Number 09-06-03-004C (Section 06 Engine/Propulsion System). Condition Some customers may comment on any of the following conditions: - An intermittent no crank/no start - Intermittent malfunction indicator lamp (MIL) illumination - Intermittent service lamp illumination - Intermittent service message(s) being displayed The technician may determine that he is unable to duplicate the intermittent condition. Cause This condition may be caused by a buildup of nonconductive insulating oxidized debris known as fretting corrosion, occurring between two electrical contact surfaces of the connection or connector. This may be caused by any of the following conditions: - Vibration - Thermal cycling - Poor connection/terminal retention - Micro motion - A connector, component or wiring harness not properly secured resulting in movement On low current signal circuits this condition may cause high resistance, resulting in intermittent connections. On high current power circuits this condition may cause permanent increases in the resistance and may cause a device to become inoperative. Representative List of Control Modules and Components The following is only a representative list of control modules and components that may be affected by this connection or connector condition and DOES NOT include every possible module or component for every vehicle. - Blower Control Module - Body Control Module (BCM) - Communication Interface Module (CIM) - Cooling Fan Control Module - Electronic Brake Control Module (EBCM) - Electronic Brake and Traction Control Module (EBTCM) - Electronic Suspension Control (ESC) Module - Engine Control Module (ECM) - Heating, Ventilation and Air Conditioning (HVAC) Control Module Page 10241 7. Insert the J 38125-13A (GM P/N 12031876-1) tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the Terminal Repair Kit to ensure that the correct release tool is used. 8. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. REPAIR PROCEDURE Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. Instruments - GPS System Performance Degradation Antenna, Navigation: All Technical Service Bulletins Instruments - GPS System Performance Degradation Info - Global Position Sensor (GPS) Performance Degradation # 00-08-46-003B - (Feb 9, 2005) Models: 1996-2005 Passenger Cars and Trucks 2002-2005 Saturn Vehicles with Navigation Systems and/or OnStar(R) This bulletin is being revised to include additional information. Please discard Corporate Bulletin Number 00-08-46-003A (Section 08 - Body and Accessories). Navigation and OnStar(R) systems require a GPS antenna in order to function properly. This antenna may be located inside the vehicle. If the GPS antenna is located inside the vehicle, performance of the system may be compromised by window tinting film. If the GPS system performance is in question and the vehicle has window tinting, a quick diagnostic check can be made by temporarily moving the GPS antenna to an external vehicle surface, such as the decklid or roof. If the GPS function of the navigation or On Star(R) system operates normally with the antenna relocated the repair would not be considered a warranty repair. The subsequent repair procedure or GPS placement would be up to the customer. Some vehicles have the GPS antenna located on the rear window shelf Objects placed on the rear window shelf such as tissue boxes, books, dolls, etc,, also have the potential to interfere with GPS performance. Warranty Information Repairs made to the vehicle navigation and/or OnStar(R) system, which are the result of window tinting, are not considered warranty repairs. Disclaimer Page 531 Door Control Module Diagram 2 Part 2 Specifications Wheel Bearing: Specifications Front Hub and Bearing Assembly to Steering Knuckle Bolts ............................................................................................................... 180 Nm (133 ft. lbs.) Page 2669 Fuse Block- I/P C3 Part 3 Page 12613 Page 15453 Door Switch: Diagrams Door Latch Assembly (Door Jamb Switch) - RR C2 (Crew Cab Only) Door Latch Assembly (Door Jamb Switch) - RR C2 (Crew Cab Only) Page 15268 Door Latch Assembly (Door Jamb Switch) - Driver - C2 Page 3665 8. Important: Align the arrow at the throttle body end of the duct with the throttle body attaching stud. Install the air cleaner outlet duct. 9. Install the radiator inlet hose clip to the outlet duct. 10. Tighten the air cleaner outlet duct clamps at the following locations: ^ Throttle body ^ MAF/IAT sensor Tighten the air cleaner outlet duct clamp screws to 7 Nm (62 inch lbs.). 11. Fill the cooling system. Page 4401 1. Install the TAC module. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the TAC module nuts. Tighten Tighten the nuts to 9 N.m (80 lb in). 3. Connect the engine wiring harness electrical connector (1). 4. Install the red CPA retainer. 5. Connect the I/P harness electrical connector (2). Page 8873 Electrical Symbols Part 12 Page 8582 Use clean, new power steering fluid only. 12. Fill the pump reservoir with fluid to the FULL COLD level. 13. Attach J 43485, Power Steering Bleeder Adapter, to J 35555, Metal Mityvac, or equivalent. 14. Place J 43485 on or in the pump reservoir filler neck. 15. Apply a vacuum of 68 kPa (20 in Hg) maximum. 16. Wait 1 minute. 17. Remove J 43485 and J 35555. 18. Reinstall the pump reservoir cap. 19. Start the engine. Allow the engine to idle. 20. Turn the steering wheel 180-360 degrees in both directions 5 times. 21. Switch the ignition off 22. Verify the fluid level. 23. Release the park brake and unblock the wheels. Hydro-Boost(R) Replacement -- Kodiak, TopKick Tools Required ^ J 35555 Metal Mityvac ^ J 43485 Power Steering Bleeder Adapter Removal 1. Block the wheels. 2. Disconnect the electrical connectors from the electrohydraulic pump and the flow switch. Page 10226 Electrical Symbols Part 11 Page 12245 Parts Information Page 12875 10. Disconnect and remove the OnStar(R) jumper harness. Note: You will need to remove the short GPS cable from this jumper harness. 11. Untape the cell antenna coax from the body harness in the trunk. This will be necessary to provide adequate length to connect to the new VCIM. 12. Fasten three retainer clips (1) from the kit to the new bracket that is included in the kit, and position the VCIM to the bracket (2). 13. Install the three bolts from the kit. Tighten the bolts to 10 Nm (89 lb in). 14. Connect the new OnStar(R) jumper harness supplied in the kit to the VCIM (two white connectors on module). 15. Connect small GPS coax cable jumper harness supplied in the kit (end with blue plastic housing) to VCIM GPS connector. 16. Position the VCIM / bracket assembly to the studs. 17. Install the bracket nuts saved from the Removal Procedure above to the VCIM / bracket assembly mounting studs. Tighten the nuts to 4 Nm (35 lb in). 18. Connect the new OnStar(R) jumper harness to the body wiring harness (C410 connector). 19. Connect small coax cable jumper from VCIM to the OnStar(R) Global Positioning Satellite (GPS) antenna coaxial cable at the connector previously left in the vehicle (short jumper removed from old harness in step 5.10). 20. Connect the cellular coaxial cable previously left in vehicle to the OnStar(R) VCIM. 21. Verify that all harnesses are properly secured in vehicle. 6. After replacing the VCIM, it is essential to configure the new OnStar(R) system. Failure to configure the system will result in an additional customer visit for repair. DO NOT press and hold the white dot or phone button on the keypad as it will not reset this version of the OnStar(R) system and may result in a DTC being set. Use of the TIS2WEB and SPS applications, along with the Tech2(R), are required in order to perform the VCIM configuration and setup procedure for this vehicle. The configuration and set-up procedure is now a two-step process which enables an automated activation by the OnStar(R) Center, without a button press by the technician to the OnStar(R) Call Center. 1. Connect the Tech2(R) to the vehicle. Page 12721 ^ On 2002 Sevilles and DeVilles, the GPS jumper cable MUST be unclipped from the back seat cross brace, or unplugged from the VCIM first. DO NOT pull back on the mounting bracket until the GPS antenna jumper cable is unclipped from the back seat cross brace or unplugged from the VCIM. The short length of jumper cable does not allow the VCIM mounting bracket to be pulled back very far, and could lead to a break at the VCIM connector. ^ On 2000-2002 Bonnevilles and LeSabres and 2001-2002 Auroras you will need to follow these steps: 1. Remove the 4 nuts that secure the VCU/VIU bracket assembly to the rear seat back brace. Note: Save these nuts for later use. 2. Remove and discard the plastic VCU/VIU bracket assembly from the vehicle. 3. Remove the upper right stud (1) from the rear seat back brace and re-install in the middle lower slot (2) on the brace. Tighten the fastener to 4 Nm (36 lb in). 4. Position the new VCIM in the vehicle over the studs on the rear seat back brace. 5. Install two of the nuts saved from step (1). Tighten the nuts to 4 Nm (36 lb in). 6. Connect the new OnStar jumper harness supplied in the kit to the VCIM (two white connectors) and the body wiring harness (C345 connector). 7. Connect the small coaxial jumper cable supplied in the kit, to the VCIM, with the end that has a blue plastic housing connector. Plug the other end of this coaxial jumper cable to the OnStar Global Positioning Satellite (GPS) antenna coaxial cable at the right angle connector. Note: The GPS cable in the new OnStar jumper harness is not utilized. 8. Connect the cellular coaxial cable to the OnStar VCIM. On 2001 Impala and Monte Carlos you will need to follow these steps: 9. Remove the Vehicle Communications Unit (VCU) and Vehicle Interface Unit (VIU) following the procedures listed in SI. Save the bracket nuts for later use. Exhaust System - Popping/Snapping Noise When Hot/Idling Heat Shield: All Technical Service Bulletins Exhaust System - Popping/Snapping Noise When Hot/Idling Bulletin No.: 03-06-05-008D Date: March 05, 2007 TECHNICAL Subject: Exhaust Popping/Snapping Noise When Vehicle is Hot, at Idle, or Immediately After Vehicle is Shut Off (Replace Muffler Heat Shield) Models: 2002-2006 Cadillac Escalade, Escalade EXT 2003-2006 Cadillac Escalade ESV 2002-2006 Chevrolet Avalanche, Suburban, Tahoe, Silverado, Silverado HD 2007 Chevrolet Silverado Classic, Silverado HD Classic 2002-2006 GMC Sierra, Sierra HD , Yukon, Yukon Denali, Yukon Denali XL 2007 GMC Sierra Classic, Sierra HD Classic 2003-2006 HUMMER H2 with 4.8L, 5.3L, 6.0L or 8.1L Gasoline Engine (VINs V, B, T, Z, N, V, G - RPOs LR4, L33, LM7, L59, LQ9, LQ4, L18) Supercede: This bulletin is being revised to add the 2006 and 2007 (Classic Only) model years and the 5.3L (L33) engine. Please discard Corporate Bulletin Number 03-06-05-008C (Section 06 Engine/Propulsion System). Condition Some customers may comment on a popping/snapping noise from underneath the vehicle at idle or immediately after the vehicle is shut off. Some popping/snapping noise from the exhaust system during cool down is a normal condition. The noise may be intermittent depending on the outside temperature and or temperature of the exhaust system at the time of testing. Cause As the exhaust system warms and cools, the muffler and the muffler heat shield expand and contract at different rates and may cause a popping and/or snapping noise. Some popping/snapping noise from the exhaust system during cool down is a normal condition. The customer should be made aware that this service procedure is designed to reduce but not eliminate all exhaust system popping and snapping during cool down. Correction Follow the service procedure below to correct this condition. Some popping/snapping noise from the exhaust system during cool down is a normal condition. The customer should be made aware that this service procedure is designed to reduce but not eliminate all exhaust system popping and snapping during cool down. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information. In order to avoid being burned, do not service the exhaust system while it is still hot. Service the system when it is cool. Always wear protective goggles and gloves when removing exhaust parts as falling rust and sharp edges could result in serious personal injury. Diagrams Clutch Start Switch (M/T) Page 3910 Steps 7 - 9 Page 5681 Shift Solenoid: Service and Repair Control and Shift Solenoids Replacement Removal Procedure 1. Remove the transmission filter. 2. Important: Removal of the 1-2 accumulator is necessary only if servicing the pressure control solenoid. Remove the 1-2 accumulator, if necessary. 3. Disconnect the internal wiring harness electrical connectors from the following components: ^ Transmission fluid pressure switch (1) ^ 1-2 shift control solenoid (2) ^ 2-3 shift control solenoid (3) ^ Pressure control solenoid (4) ^ torque converter clutch pulse width modulation (TCC PWM) solenoid (5) ^ 3-2 control solenoid (6) 4. Remove the pressure control solenoid retainer bolt (364A) and retainer (378). 5. Remove the pressure control solenoid (377). 4L60-E/4L65-E Fluid Filter - A/T: Service and Repair 4L60-E/4L65-E Automatic Transmission Fluid/Filter Replacement Removal Procedure Caution: When the transmission is at operating temperatures, take necessary precautions when removing the drain plug, to avoid being burned by draining fluid. 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. Place a drain pan under the transmission oil pan. 3. Remove the oil pan drain plug, if equipped. 4. If necessary, remove the bolts and position aside the range selector cable bracket for clearance while lowering the pan. It is not necessary to remove the cable from the lever or bracket. 5. Remove the oil pan bolts from the front and sides of the pan only. 6. Loosen the rear oil pan bolts approximately 4 turns. 7. Lightly tap the oil pan with a rubber mallet in order to loosen the pan to allow the fluid to drain. 8. Remove the remaining oil pan bolts. 9. Remove the oil pan and the gasket. Page 321 ^ An OnStar(R) Call Center button press WILL NOT connect the vehicle with OnStar(R). The vehicle must be upgraded to reactivate the account. The customer will hear a demo message stating that there is not a current OnStar(R) subscription for the vehicle. The message will also instruct the customer how to upgrade and reactivate services. ^ OnStar(R) personal calling (OPC) will not be available, as this feature requires the customer to have a current OnStar(R) account. Attempts to use this feature will result in cellular connection failure messages and the inability to connect to the number dialed. Note For deactivated vehicles, a no connect response should be considered normal system operation. Further diagnosis and subsequent repair is only necessary should the customer elect to become an active OnStar(R) subscriber and upgrade the account subscription. OnStar(R) Cellular, GPS, and Diagnostic Limitations The proper operation of the OnStar(R) System is dependent on several elements outside the components integrated into the vehicle. These include the National Cellular Network Infrastructure, the cellular telephone carriers within the network, and the GPS. The cellular operation of the OnStar(R) system may be inhibited by factors such as the users range from a digital cellular tower, the state of the cellular carrier's equipment, and the location where the call is placed. Making an OnStar(R) key press in areas that lack sufficient cellular coverage or have a temporary equipment failure will result in either the inability of a call to complete with a data transfer or the complete inability to connect to the OnStar(R) Call Center. The OnStar(R) system may also experience connection issues if the identification numbers for the module, station identification number (STID), electronic serial number (ESN) or manufacturers electronic ID (MEID), are not recognized by the cellular carriers local signal receiving towers. The satellites that orbit earth providing the OnStar system with GPS data have almost no failures associated with them. In the event of a no GPS concern, the failure will likely lie with the inability of the system to gain GPS signals because of its location, i.e. in a parking structure, hardware failure, or being mistaken with an OnStar(R) call which has reached the Call Center without vehicle data. During diagnostic testing of the OnStar(R) system, the technician should ensure the vehicle is located in an area that has a clear unobstructed view of the open sky, and preferably, an area where digital cellular calls have been successfully placed. These areas can be found by successfully making an OnStar(R) keypress in a known good OnStar(R) equipped vehicle and confirming success with the OnStar(R) Call Center advisor. Such places can be used as a permanent reference for future OnStar(R) testing. Mobile Identification Number and Mobile Directory Number The vehicle communication interface module (VCIM) utilizes 2 numbers for cellular device identification, call routing and connection. They are: ^ A mobile identification number (MIN) ^ A mobile directory number (MDN) Note The MIN represents the number used by the cellular carrier for call routing purposes. The MDN represents the number dialed to reach the cellular device. Diagnostic Information Symptoms - Cellular Communication The following steps must be completed before using the symptom table. 1. Perform the Diagnostic System Check - Vehicle, before using the Symptom Tables in order to verify that the following are true: ^ There are no DTCs set. ^ The control modules can communicate via the serial data link. 2. Review the system operation in order to familiarize yourself with the system functions. Refer to Radio/Audio System Description and Operation in SI. Diagnostic Starting Point - Displays and Gages Begin the displays and gages system diagnosis with Diagnostic System Check - Vehicle or the audible warning system diagnosis with Diagnostic System Page 1004 Steps 19 - 23 Page 7231 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly, Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Pull to Seat Connectors PULL TO SEAT CONNECTORS TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Page 16034 6. Use fingers to squeeze the 2 locking legs of the cover. 7. Apply pressure and gently rock the cover until one locking leg is unseated. 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. Page 6412 Page 12533 ^ I/O check Any faults detected during the initialization self-test shall generate a DTC. All nodes also continuously perform a self-test while in an active state. DTCs and their associated telltales will set as a result of unprogrammed or unlearned information. DTCs, which are defined for system configuration (e.g. Vehicle Option Content not programmed) do not support the history status bit (set =0). Warning indicator bit is also set, when applicable, while this DTC is present. Action Taken When the DTCs Sets The module suspends all message transmission. The module uses default values for all parameters received on the serial data circuits. The module inhibits the setting of all other communication DTCs. Conditions for Clearing the DTC A current DTC clears when the malfunction is no longer present. A history DTC clears when the module ignition cycle counter reaches the reset threshold of 50, without a repeat of the malfunction. Circuit/System Verification Refer to Data Link References to determine which serial data system is used for a specific module. The DTCs cannot be retrieved with a current status. Diagnosis is accomplished using the following symptom procedures: Scan Tool Does Not Communicate with High Speed GMLAN Device in SI. OR Scan Tool Does Not Communicate with Low Speed GMLAN Device in SI. DTC U1300, U1301, or U1305 Circuit Description Modules connected to the Class 2 serial data circuit monitor for serial data communications during normal vehicle operation. Operating information and commands are exchanged among the modules. In addition to this, Node Alive messages are transmitted by each module on the Class 2 serial data circuit about once every 2 seconds. When the module detects one of the following conditions on the Class 2 serial data circuit for approximately 3 seconds, the setting of all other Class 2 serial communication DTCs is inhibited and a DTC will set. Conditions for Running the DTCs Voltage supplied to the module is in the normal operating voltage range. The vehicle power mode requires serial data communication to occur. Conditions for Setting the DTCs No valid messages are detected on the Class 2 serial data circuit. The voltage level detected on the Class 2 serial data circuit is in one of the following conditions: Campaign - Deactivation Of Analog OnStar(R) Technical Service Bulletin # 08089C Date: 081118 Campaign - Deactivation Of Analog OnStar(R) # 08089C: Special Coverage Adjustment - Analog OnStar Deactivation (Nov 18, 2008) Subject: 08089C -- SPECIAL COVERAGE ADJUSTMENT - ANALOG ONSTAR(R) DEACTIVATION Page 16006 Electrical Symbols ELECTRICAL SYMBOLS Electrical Symbols Part 1 Page 7792 ^ The reverse boost valve bushing ^ A new reverse boost valve ^ A new pressure regulator spring retainer ^ The added isolator pressure regulator spring ^ The pressure regulator spring 3. Install the pre-assembled parts into the pump bore. 4. Install the reverse boost valve bushing retainer ring while holding the reverse boost valve bushing in place. Ensure the retainer ring (2) is in the groove. 5. Install the transmission filter. 6. Fill the transmission to the proper level with Dexron® III transmission fluid. Page 8368 Parking Brake Cable: Adjustments Enabling the Park Brake Cable Automatic Adjuster Enabling the Park Brake Cable Automatic Adjuster If the park brake automatic adjuster has been disabled, the following two person procedure must be performed. 1. Hold the park brake pedal in the FULL upward position. 2. Pull rearward on the front park brake cable until the tension is released from the scribe or nail (1) installed through the holes in the pedal assembly. 3. Remove the scribe or screwdriver (1). 4. Slowly release the park brake cable until it returns to its original position. 5. Release the park brake pedal. 6. Lower the vehicle. 7. Apply and release the park brake pedal to ensure that there is no binding or sticking. Page 6804 7. If the level is low, add lubricant until the level is between 17-21 mm (0.6-0.8 inch) below the fill plug opening. Use the proper fluid. 8. Notice: Refer to Fastener Notice in Service Precautions. Install the rear axle fill plug and gasket. ^ Tighten the rear axle fill plug to 33 Nm (24 ft. lbs.). 9. Lower the vehicle. 8.6 Inch Axle Lubricant Replacement - Rear Drive Axle (8.6 Inch Axle) Removal Procedure 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Remove the rear axle fill plug. 3. Remove the rear axle housing cover bolts (1). Discard the rear axle housing cover bolts. 4. Carefully remove the rear axle housing cover (2) and drain the lubricant into a suitable container. 5. Remove any gasket material from the rear axle housing and/or the rear axle housing cover. 6. Inspect the bottom of the rear axle housing for excessive metal particle accumulation. This accumulation is an indication of extreme wear. Installation Procedure Page 12012 7.3. If equipped, connect the rear seat heater's connector and install the switch. 8. Install the floor console: 8.1. Install the floor console's retaining bolts (C) and retaining nuts (F). 8.2. Align the rear cover; make sure that the air duct connects firmly to the air nozzle. Screw in the cover (E). 8.3. Install the ashtray/cover (D). 8.4. Install the ignition switch cover (B). 8.5. Plug in the immobilizer unit (A) connector. Install the unit, bayonet fitting. 9. Remove the OnStar(R) control modules and secure the wiring: 9.1. Remove the right-hand rear luggage compartment trim in accordance with WIS - 8. Body - Interior equipment - Adjustment/Replacement. 9.2. Unplug the connectors (A) from the OnStar(R) control modules. 9.3. Remove the console (B) together with the OnStar(R) control modules. Page 13718 2. Using a flat-blade tool, break the bond between the sealer and the door. 3. Pull the waterproof sealing tape from the deflectors. 4. Remove the water deflectors. Installation Procedure 1. Using waterproof tape or 3M(R) 777 (or equivalent), install the water deflectors to the door. 2. Install the trim panel to the door. Page 9782 C405 Right Clearance Lamp Harness To License Lamp Harness (With RPO Codes NYS Or R05) Page 14236 1. Position the module into the vehicle. 2. Connect the lower electrical harness connectors (2). 3. Slide the module (2) to the left to engage the lower retainers. NOTE: Refer to Fastener Notice in Service Precautions. 4. Install the module retaining screws (3). Tighten Tighten the screws to 3 N.m (26 lb in). 5. Connect the upper electrical harness connectors (3). 6. Install the seat cushion. 7. If a new memory seat module was installed, calibrate the seat. Refer to Memory Seat Calibration Procedure. Page 14281 WA379E/86 - WA382E/11 Page 1661 3. If equipped with a 6.0L engine, connect the HO2S electrical connector. 4. If equipped with a 4.8L or 5.3L engine, connect the HO2S electrical connector. 5. Install the HO2S connector clip to the frame. 6. Disconnect the CPA retainer. 7. Lower the vehicle. OnStar(R) - Cellular Antenna Replacement Parts Global Positioning System Antenna: Technical Service Bulletins OnStar(R) - Cellular Antenna Replacement Parts Bulletin No.: 00-08-46-002A Date: April 12, 2005 INFORMATION Subject: OnStar(R) System Cellular Antenna Replacement Parts Availability Models: 1996-2005 Passenger Cars and Light Duty Trucks 2003-2005 HUMMER H2 with OnStar(R) and Glass Mounted Antennas Supercede: This bulletin is being revised to update the model years, models and parts information. Please discard Corporate Bulletin Number 00-08-46-002 (Section 08 - Body & Accessories). Replacement parts for the OnStar(R) system cellular antenna are available as follows: ^ Cellular Antenna Kit - If the antenna mast or exterior base is damaged or missing or if the antenna base has separated from the exterior glass surface. ^ Cellular Antenna Inner Coupling - If the antenna coupling on the inside of the glass requires replacement. Important: If glass replacement is required, both the Cellular Antenna Kit and the Cellular Antenna Inner Coupling are required. The kits listed contain all the necessary parts and instructions needed to properly install a new cellular antenna exterior base or interior coupling to the glass surface. To obtain maximum adhesion during installation, the instructions included in the kits must be followed carefully and exactly as written. Important: Do not attempt to reinstall the original cellular antenna exterior base or interior coupling using any type of glue, adhesive tapes, etc. Doing so may eliminate the cellular signal transfer through the glass and reduce the maximum performance of the system that includes air bag deployment notification. Important: To obtain maximum adhesion between the new cellular exterior base or interior coupling and the glass surface, the base, coupling and glass must be kept dry and above 15°C (60°F) during the installation and for the 24 hours immediately following the installation. Not keeping the vehicle dry and above the temperature listed for 24 hours may result in the new cellular antenna exterior base or interior coupling coming off. Parts Information Parts are currently available from GMSPO. Automatic Transmission - 4L60-E/4L65-E Page 5158 Accelerator Pedal Position Sensor: Description and Operation ACCELERATOR PEDAL POSITION (APP) SENSOR The accelerator pedal assembly contains 2 individual APP sensors within the assembly. The APP sensors 1 and 2 are potentiometer type sensors, each with the following circuits: - A 5-volt reference circuit - A low reference circuit - A signal circuit The APP sensors are used to determine the pedal angle. The control module provides each APP sensor a 5-volt reference circuit and a low reference circuit. The APP sensors then provide the control module with signal voltage proportional to pedal movement. Both APP sensor signal voltages are low at rest position and increase as the pedal is applied. Service and Repair Cabin Ventilation Duct: Service and Repair Pressure Relief Valve Replacement Removal Procedure Use a flat-bladed tool to pry the pressure release valve from the cab back panel. Remove the pressure relief valve from the vehicle. Installation Procedure Align the pressure relief valve into the opening of the rear cab. Press the Pressure Relief Valve into the Cab Back Panel until the locking tabs are fully seated. Page 9955 3. Connect the electrical connectors to the module. 4. Program the control module. Refer to Service Programming System (SPS) in Programming. 5. Install the spare tire to the vehicle. 6. Lower the vehicle. 7. Perform a learn alignment. See: Testing and Inspection/Programming and Relearning Page 2668 Fuse Block- I/P C3 Part 2 Page 12242 5. Choose the outstanding core you wish to process, by selecting the Virtual Core Button on the far right side of the screen. 6. Enter the information in the required fields and select the submit button. Record the confirmation number. Canadian Dealers 1. Return the removed Analog / Digital-Ready OnStar(R) VCIM to the Parts Manager. 2. The Parts Manager will log onto https://adt.onstar.gm.mass.ca and enter information as prompted. All Dealers If the website indicates that the VCIM needs to be physically returned to the distributor, please use the pre-paid shipping label that was included in the kit to return the removed VCIM. Important: To avoid a $250 core non-return charge, you must do one of the following within 30 days of kit shipment: 1. Submit the necessary VCIM data through the website, as indicated above. 2. Mail the removed core from the customer's vehicle back to the distributor. 3. Return the unused digital upgrade kit back to the distributor using the pre-paid shipping label that is included in the kit box. Returning the Upgraded Vehicle to the Customer Returning the Upgraded Vehicle to the Customer 1. Place the new OnStar Subscriber Information (Owner's Manual kit) in the customer's vehicle where they can review some of the new features of the Digital-Capable system. The continuous digit dialing feature should be highlighted to the customer to avoid a return to the dealership for dialing instructions. Advise the customer to discard any existing OnStar(R) Owner's Manuals that may be in the vehicle. 2. Have the Service Advisor, Service Manager or Sales Consultant review the new OnStar(R) Hands-Free Calling procedure with the customer. The customer is uses to their analog OnStar(R) Hands-Free Calling system, which uses individual digit dial to make a call. The Generation 6 Digital-Capable system uses continuous digit dial, and the customer needs to be made aware of this change. 3. U.S. Dealers Only: Staple the "Tip Sheet - OnStar(R) Generation 6 Digitally-Capable System", that was included in the kit, to the customer's copy of the repair order. This tip sheet will help your customer better understand their new OnStar(R) system. 4. Canadian Dealers Only: Refer the customer to the Hands-Free Calling Quick Review Card from the new OnStar(R) Owner's Manual kit for help with the new dialing procedure. 5. Fill out the form entitled "GM Limited Warranty for Upgraded OnStar(R) Digital Equipment Program Participants" and staple a copy of this to the customer's repair order. You may want to keep a copy for your records. 6. Encourage your customer to press their blue OnStar(R) button the next day. The OnStar(R) Advisor will be able to review some of the new features of their digital OnStar(R) system. Closing the Onstar(R) Upgrade Exchange Closing the OnStar(R) Upgrade Exchange 1. Collect payment from the customer. Your dealership's open account (sales) will be charged for the cost of the chosen subscription plan, any applicable subscription taxes, and the $15 upgrade charge after the vehicle has been configured through the TIS2WEB process. 2. None of the costs associated with the OnStar Digital Upgrade program may be claimed as a GM goodwill event. These costs must be paid by the customer, and may not be included in any goodwill offered to the customer. GM employees or representatives or field personnel are not able to offer goodwill for this program. If the dealership decides to pay for the upgrade for their customer, be aware that your GM or OnStar(R) contact will not be able to reimburse you for this cost. 3. Use labor code Z2096 to submit your claim for the labor time published below plus 0.2 hr Administrative Allowance and an additional $20.00 Net Amount. ^ For all dealer claim submissions (excluding U.S. Saturn), use Complaint Code MH - Technical Bulletin, and Failure Code 93 - Technical Service Bulletin. Page 2048 Important When performing adjustments to vehicles requiring a 4-wheel alignment, set the rear wheel alignment angles first in order to obtain proper front wheel alignment angles. Perform the following steps in order to measure the front and rear alignment angles: 1. Install the alignment equipment according to the manufacturer's instructions. 2. Jounce the front and the rear bumpers 3 times prior to checking the wheel alignment. 3. Measure the alignment angles and record the readings. If necessary, adjust the wheel alignment to vehicle specification and record the before and after measurements. Refer to Wheel Alignment Specifications in SI. Important Technicians must refer to SI for the correct wheel alignment specifications. SI is the only source of GM wheel alignment specifications that is kept up-to-date throughout the year. Test drive vehicle to ensure proper repair. Page 13812 10. Install the electrical center cover by securing the retaining clips (1) on both sides. 11. Install the center retaining nut. Tighten the center retaining nut to 2.5 N.m (22 lb in). 12. Install the left hinge pillar trim panel. 13. Close the hood. Page 8384 6. Important: After installing the cable to the rear axle holding clip, verify that clip is securely retaining the cable. If not, crimp the clip by hand taking care not to pinch or kink the cable. Install the cable to the differential clip. 7. For 25/35 series vehicles, connect the cable at the equalizer. 8. For 25/35 series vehicles, enable the park brake cable automatic adjuster. Refer to Enabling the Park Brake Cable Automatic Adjuster. 9. For all 15 series vehicles, pull down on the park brake cable in front of the equalizer and install the left park brake cable to the equalizer bar. 10. Remove the safety stands. 11. Remove the safety stands and lower the vehicle. 12. Adjust the park brake cable. (W/NYS) Park Brake Cable Replacement - Right Rear (w/NYS) Page 13391 Electrical Symbols Part 3 Page 13255 Page 16073 High Temperature Conditions Tools Required J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency MEASURING FREQUENCY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage MEASURING VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop MEASURING VOLTAGE DROP NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Page 1026 3. Connect the electrical connectors to the module. 4. Program the control module. Refer to Service Programming System (SPS) in Programming. 5. Install the spare tire to the vehicle. 6. Lower the vehicle. 7. Perform a learn alignment. See: Testing and Inspection/Programming and Relearning Description and Operation Clockspring Assembly / Spiral Cable: Description and Operation INFLATABLE RESTRAINT STEERING WHEEL MODULE COIL The steering wheel module coil is attached to the steering column and is located under the steering wheel. The steering wheel module coil consists of two or more current-carrying coils. The coils allow the rotation of the steering wheel while maintaining continuous electrical contact between the driver deployment loop and the steering wheel module. Four coil wires are used for the steering wheel module deployment loop. Additional coil wires are used for accessories attached to the steering wheel depending on the vehicle model. The steering wheel module coil connector is located near the base of the steering column. The connector contains a shorting bar that shorts the steering wheel module coil deployment loop circuitry to prevent unwanted deployment of the air bag when it is disconnected. Page 13977 After installing floor mats, make certain they cannot move and do not interfere with the accelerator or brake pedals. Disclaimer Page 274 Parts Information Page 8218 12. Remove the brake rotor. Do not force the rotor off. If the rotor is difficult to remove, ease it off by gently rotating it as you pull outward. 13. If the brake rotor cannot be removed perform the following: 1. Assemble J-46277 to J 2619-01. 2. Insert J-46277 between the rotor friction surfaces in the vent section of the rotor.DO NOT place the J-46277 on the rotor friction surface. 3. Using J-46277 and J 2619-01 remove the rotor from the hub assembly. 4. Inspect the park brake components for the following conditions: ^ Bent or broken hold down spring ^ Broken, cracked or worn brake shoe lining ^ Bent or damaged brake shoe ^ Worn, bent or damaged backing plate 5. If any of these conditions are found replace the affected parts. Installation Procedure 1. Important: Whenever the brake rotor has been separated from the hub/axle flange, any rust or contaminants should be cleaned from the hub/axle flange and the brake rotor mating surfaces. Failure to do this may result in excessive assembled lateral runout (LRO) of the brake rotor, which could lead to brake pulsation. Use the J 42450-A to clean all rust and contaminants from the mating surface of the hub flange. 2. Use the J 41013 to clean all rust and contaminants from the inside diameter of the hat section of the brake rotor to prevent any foreign material from getting between the brake rotor and the hub flange. 3. Inspect the mating surfaces of the hub/axle flange and the rotor to ensure that there are no foreign particles or debris remaining. 4. Align the rotor to its original position on the hub, if applicable, and install the rotor. 5. If the brake rotor was removed and installed as part of a brake system repair, measure the assembled lateral runout (LRO) of the brake rotor to ensure optimum performance of the disc brakes. Refer to Brake Rotor Assembled Lateral Runout (LRO) Measurement. Locations Coolant Temperature Sensor/Switch (For Computer): Locations Full Engine View Left Side Page 2141 Steps 14 - 15 The number(s) below refer to the step(s) in the diagnostic table. 2. The chirping noise may not be engine related. This step is to verify that the engine is making the noise. If the engine is not making the noise do not proceed any further in this table. 3. The noise may be an internal engine noise. Remove the drive belt(s) and operate the engine for a few seconds, this will verify if the chirping noise is related to the drive belt(s) or not. With the drive belt(s) removed the water pump will not operate and the engine may overheat. Also diagnostic trouble codes (DTCs) may set when the engine is operated with the drive belt(s) removed. 4. Inspect the drive belt(s) for signs of pilling. Pilling is the small balls, pills, or strings in the drive belt grooves caused by the accumulation of rubber dust. 6. Misalignment of the accessory drive pulley(s) may be caused from improper mounting or incorrect installation of an accessory drive component, or the pulley may be bent inward or outward from a previous repair. Test for a misaligned accessory drive pulley using a straight edge in the pulley grooves across two or three pulleys. If a misaligned pulley is found, refer to that accessory drive component for the proper removal and installation procedure for that pulley. 10. Inspection of the fasteners can eliminate the possibility that a incorrect bolt, nut, spacer, or washer was installed. 12. Inspection of the accessory drive pulley(s) should include inspecting for bends, dents, or other damage to the pulley(s) that would prevent the drive belt(s) from seating properly in the pulley grooves or on the smooth surface of the pulley when the back side of the drive belt is used to drive the pulley. 14. Replacing the drive belt(s) when it is not damaged or there is not excessive pilling will only be a temporary repair. Page 16084 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Weather Pack Connectors WEATHER PACK CONNECTORS The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. Page 4944 10. Remove the left exhaust manifold pipe nuts. 11. Remove the right exhaust manifold pipe nuts. 12. Remove the exhaust muffler nuts. 13. Remove the catalytic converter. 14. If necessary, remove the oxygen sensors. Installation Procedure Notice: Refer to Fastener Notice in Service Precautions. Page 11910 switch lighting connector. 3.3. Undo the floor console's retaining bolts (C). 3.4. Take out the rear ashtray/cover (D). 3.5. Remove the screw (E) for the rear cover. 3.6. Remove the floor console's retaining nuts (E). 3.7. Detach the floor console (G) by pulling it straight back and lifting it slightly. 3.8. If required, detach the switch for the rear seat heater and unplug the connector. 4. Remove the switch and the floor console: 4.1. Detach the window lift module (A) by loosening it in the front edge (snap fastener). Unplug the window lift module's connector. 4.2. Detach the switch for the roof lighting (B) and unplug its connector. Lift away the floor console. 5. Pry out the signal line from the SRS control module to the OnStar(R) control module and secure it: 5.1. Unplug the SRS control module's connector (A). Page 9807 Junction Block - I/P Wire Entry Part 4 Page 7658 1. Install the J 43484 (2) to the J 8092 (1). 2. Install the seal onto the J 43484 (2). 3. Using the J 43484 (2) and the J 8092 (1), install the seal. 4. Install the front propeller shaft. 5. Check the fluid level, add fluid if necessary. 6. Install the transfer case shield, if equipped. Transfer Case Output Shaft Seal Replacement - Rear Transfer Case Output Shaft Seal Replacement - Rear ^ Tools Required J 37668-A Seal Installer - J 45380 Transfer Case Rear Bushing Remover and Installer Removal Procedure 1. Remove the transfer case shield, if equipped. 2. Remove the rear propeller shaft. 3. Remove the rear output shaft seal. Page 15187 Audible Warning Device: Electrical Diagrams Audible Warnings diagram Page 11483 Tighten Tighten the bolt to 9 N.m (79 lb in). 4. Connect the electrical connector to the sensor (2). 5. Install the CPA. 6. Enable the SIR system. Refer to SIR Disabling and Enabling Zone 1. Page 5396 1. Remove the caps from the fuel and vent openings in the tank. 2. Install the fuel fill pipe and vent pipe to the tank. NOTE: Refer to Fastener Notice in Service Precautions. 3. Tighten the vent pipe clamp (1) at the tank. 4. Tighten the fuel fill pipe clamp (2) at the tank. Tighten Tighten the clamps to 2.5 N.m (22 lb in). 5. Remove the caps from the fuel feed and EVAP pipes. 6. If equipped with a rear auxiliary tank, connect the fuel and EVAP quick connect fittings. Page 12072 For vehicles repaired under warranty, use the table. Disclaimer Page 7044 Drive/Propeller Shaft: Symptom Related Diagnostic Procedures - Symptoms - Propeller Shaft Symptoms - Propeller Shaft Before beginning diagnosis, review the system description and operation in order to familiarize yourself with the system function. Refer to Propeller Shaft Description and Operation. Classifying the Symptom Propeller Shaft symptoms can usually be classified into the following categories: ^ Leaks ^ Noises ^ Vibrations Leak and noise related symptoms are diagnosed within the Propeller Shaft. For vibration related symptoms, refer to Diagnostic Starting Point - Vibration Diagnosis and Correction. Visual/Physical Inspection ^ Inspect the system for aftermarket devices which could affect the operation of the Propeller Shaft. ^ Inspect the easily accessible or visible system components for obvious damage or conditions which could cause the symptom. Symptom List Refer to a symptom diagnostic procedure from the following list in order to diagnose the symptom: ^ Leak at Front Slip Yoke See: Leak at Front Slip Yoke ^ Universal Joint Noise See: Universal Joint Noise ^ Ping, Snap, or Click Noise See: Ping, Snap, or Click Noise ^ Knock or Clunk Noise See: Knock or Clunk Noise ^ Scraping Noise See: Scraping Noise ^ Squeak Noise See: Squeak Noise Service and Repair Timing Chain: Service and Repair Timing Chain and Sprockets Replacement ^ Tools Required J 8433 Two Jaw Puller - J 41816-2Crankshaft End Protector - J 41558 Crankshaft Sprocket Remover - J 41665 Crankshaft Balancer and Sprocket Installer Removal Procedure 1. Remove the oil pump. 2. Rotate the crankshaft until the timing marks on the crankshaft and the camshaft sprockets are aligned. Notice: Do not turn the crankshaft assembly after the timing chain has been removed in order to prevent damage to the piston assemblies or the valves. 3. Remove the camshaft sprocket bolts. 4. Remove the camshaft sprocket and timing chain. 5. Use the J 8433, the J 41816-2 and the J 41558 in order to remove the crankshaft sprocket. 6. Remove the crankshaft sprocket. Page 9851 5. Push on the tab (3) so that the electrical center can be rotated on the studs located at (2). 6. Remove all connectors by removing the bolt (1) for each connector. 7. Disconnect all connectors from the electrical center block. 8. Push on the tabs (2) in order to lift the electrical center (1) out of the housing. 9. To replace the engine electrical center bracket remove the 4 retaining bolts (1). 10. Remove the engine electrical center bracket assembly from the fender. INSTALLATION PROCEDURE Page 9326 4. Connect the wire connectors to the lower portion of the electrical center block. 5. Connect the wire connectors with the bolts to the electrical center block. Tighten Tighten all connector bolts (1) to 9 N.m (80 lb in). 6. Ensure all wire connectors are securely connected. 7. Set the electrical center block in its resting position till the tabs (3) locks in place. 8. Install the lower part of the cover (1). 9. With the cover (2) off, use the fuse location information to install all fuses and relays. 10. Install the cover. 11. Install the fender upper brace. 12. Install the 4 fender upper brace bolts. Tighten Tighten the 4 retaining bolts to 25 N.m (18 lb ft). 13. Connect the negative battery cable. 14. Start vehicle and ensure all components function properly. Page 15938 Electrical Symbols Part 11 Page 2302 Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 7185 1. Install a NEW shift lever insulator, if required. 2. Apply gasket maker GM P/N 12378517 or equivalent to the surface of the control lever assembly. 3. Push the shift lever assembly back through the insulator, position and turn the shift lever assembly back into place. 4. With a flat tool pull back the insulator between the body and transmission to install the shift lever assembly bolts. Notice: Refer to Fastener Notice in Service Precautions. 5. Install the shift lever assembly bolts. ^ Tighten the bolts to 23 Nm (17 ft. lbs.). 6. Install the control lever and boot. Page 8610 Page 8631 Page 2381 Coolant: Fluid Type Specifications ENGINE COOLANT The cooling system in your vehicle is filled with DEX-COOL engine coolant. This coolant is designed to remain in your vehicle for 5 years or 150,000 miles (240 000 km), whichever occurs first, if you add only DEX-COOL extended life coolant. A 50/50 mixture of clean, drinkable water and DEX-COOL coolant will: ^ Give freezing protection down to -34°F (-37°C). ^ Give boiling protection up to 265°F (129°C). ^ Protect against rust and corrosion. ^ Help keep the proper engine temperature. ^ Let the warning lights and gages work as they should. NOTICE: Using coolant other than DEX-COOL may cause premature engine, heater core or radiator corrosion. In addition, the engine coolant may require changing sooner, at 30,000 miles (50 000 km) or 24 months, whichever occurs first. Any repairs would not be covered by your warranty. Always use DEX-COOL (silicate-free) coolant in your vehicle. WHAT TO USE Use a mixture of one-half clean, drinkable water and one-half DEX-COOL coolant which won't damage aluminum parts. If you use this coolant mixture, you don't need to add anything else. CAUTION: Adding only plain water to your cooling system can be dangerous. Plain water, or some other liquid such as alcohol, can boil before the proper coolant mixture will. Your vehicle's coolant warning system is set for the proper coolant mixture. With plain water or the wrong mixture, your engine could get too hot but you would not get the overheat warning. Your engine could catch fire and you or others could be burned. Use a 50/50 mixture of clean, drinkable water and DEX-COOL coolant. NOTICE: If you use an improper coolant mixture, your engine could overheat and be badly damaged. The repair cost would not be covered by your warranty. Too much water in the mixture can freeze and crack the engine, radiator, heater core and other parts. If you have to add coolant more than four times a year, check your cooling system. NOTICE: If you use the proper coolant, you do not have to add extra inhibitors or additives which claim to improve the system. These can be harmful. Page 10210 Steering Gear Seal: Service and Repair Steering Gear Stub Shaft Seals and Bearing Replacement - Off Vehicle ^ Tools Required J 29810 Stub Shaft Seal Protector Disassembly Procedure 1. Remove the steering gear from the vehicle, 2. Remove the adjuster plug lock nut (5) from the adjuster plug (4). 3. Remove the adjuster plug (4) from the gear assembly (1). 4. Remove the adjuster spring (3) and the rack bearing (2). 5. Remove the spool shaft boot (1) from the rack and pinion gear assembly. 6. Remove the retaining ring (2) from the valve bore of the rack and pinion gear assembly. 7. Remove the dust cover (4) from the bottom of the rack and pinion gear assembly. 8. Remove the hex lock nut (3) from the lower end of the pinion and valve assembly while holding the stub shaft with a 14 mm crowfoot wrench. 9. Using an arbor press (1), press on the threaded end of the pinion until removal of the following items is possible: 1. The stub shaft (4) 2. The stub shaft seal (2) 3. The stub shaft bearing annulus assembly (3) Important: When performing the following procedure, do not remove pinion and valve assembly from the rack and pinion gear assembly (5). Press the pinion and valve assembly only far enough to allow removal of the stub shaft bearing annulus (3) and the stub shaft seal (2). Assembly Procedure Page 495 Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses CIRCUIT PROTECTION - FUSES The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the Page 13031 Installation Refrigerant Filter: Service and Repair Installation AIR CONDITIONING (A/C) REFRIGERANT FILTER INSTALLATION TOOLS REQUIRED J 39400-A Halogen Leak Detector IMPORTANT: The A/C Refrigerant filter, ACDelco P/N 15-1696 must be installed to the A/C evaporator tube between the condenser and evaporator. The installation of this A/C refrigerant filter eliminates the need for flushing. 1. Remove the air cleaner. 2. Measure 50 mm (2 in) from the bend on the evaporator tube (2) near the expansion tube end and mark the location. 3. Measure 50.8 mm (2 in) from the mark on the evaporator tube (2) from the previous step. IMPORTANT: Do not allow metal burrs to enter the evaporator tube (2) during cutting or when removing the burrs. 4. Using a tubing cutter, cut the marked section of the evaporator tube (2). 5. Remove the burrs from the evaporator tube (2). 6. Remove the nuts (4), the ferrules (3), and the O-rings (2) from the A/C refrigerant filter (1). IMPORTANT: DO NOT install the O-rings (2) in this step. 7. Push the nuts (4) and ferrules (3) over each of the evaporator tube halves. 8. Install the ferrules (3) with the small end toward the nut (4). Page 12359 Garage Door Opener Page 3355 27. Important: DO NOT allow foreign material to enter the oil passages of the oil pan, cap or cover the openings as required. Drill (3) out the oil pan gasket retaining rivets (2), if required. 28. Remove the gasket (1) from the pan. 29. Discard the gasket and rivets. 30. If required, clean and inspect the engine oil pan. Installation Procedure Important: ^ The alignment of the structural oil pan is critical. The rear bolt hole locations of the oil pan provide mounting points for the transmission bellhousing. To ensure the rigidity of the powertrain and correct transmission alignment, it is important that the rear of the block and the rear of the oil pan must NEVER protrude beyond the engine block and transmission bellhousing plane. ^ Do not reuse the oil pan gasket. ^ It is not necessary to rivet the NEW gasket to the oil pan. 1. Apply a 5 mm (0.20 inch) bead of sealant GM P/N 12378190, or equivalent 20 mm (0.80 inch) long to the engine block. Apply the sealant directly onto the tabs of the front cover gasket that protrudes into the oil pan surface. 2. Apply a 5 mm (0.20 inch) bead of sealant GM P/N 12378190, or equivalent 20 mm (0.8 inch) long to the engine block. Apply the sealant directly onto the tabs of the rear cover gasket that protrudes into the oil pan surface. Page 9835 Relay Box: Diagrams Junction Block - Rear Lamps - C1 Page 12127 Parts Information Page 4646 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors USING CONNECTOR TEST ADAPTERS IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-B Connector Test Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Locations Full Engine View Left Side Page 6248 14. Important: It is not necessary to remove the selector cable from the bracket. Remove the transmission range selector cable bracket (2) bolts and bracket from the transmission. Reposition the bracket with cable. 15. Remove the oil pan bolts. 16. Important: The transmission oil pan gasket is reusable. Inspect the gasket and replace as needed. Remove the oil pan and gasket. 17. Remove the magnet from the bottom of the pan, if necessary. 18. Remove the oil filter. 19. Remove the filter neck seal. 20. Clean the transmission case and the oil pan gasket surfaces with solvent. Installation Procedure Page 12593 10.4. Remove the end cap from the new optic cable, connect to the connector and refit the secondary catch (D). Fit the terminal housing (C) to the connector and refit the locking strip (B). 10.5. Secure the old optic cable together with the new one (E). Important: The optic cable must not be bent with a radius less than 25 mm (1 in). Important: Secure the wiring harness so that there is no risk of chafing and rattling. 11. CV: Remove the rear seat in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. The O-bus connector H2-9 is located behind the left speaker. 12. M04-05: Disconnect the optic cables on the OnStar(R) control modules and join the cables: 12.1. Cut off the cable tie holding the connector (H2-9) against REC. Page 6662 Installation Procedure 1. Install the checkballs (1-7) into the valve body. 2. Install the valve body to the transmission case while simultaneously connecting the manual valve link to the manual valve. 3. Verify that the manual valve link (3) is installed properly to the inside detent lever (1) and the manual valve (2). 4. Install one bolt (M6 X 1.0 X 47.5) hand tight in the center (1) of the valve body to hold it in place. Page 5532 Throttle Body: Service and Repair Throttle Body Cleaning Procedure THROTTLE BODY CLEANING PROCEDURE IMPORTANT: Over an extended period of time and mileage, deposits may accumulate on the back of the throttle plate. Typically these deposits pose no problem. Occasionally the deposit may accumulate to a point where perceived pedal effort or throttle valve movement is effected. This procedure should not be performed on vehicles with mileage under 80450 km (50,000 mi). 1. Remove the air cleaner intake duct. CAUTION: Turn OFF the ignition before inserting fingers into the throttle bore. Unexpected movement of the throttle blade could cause personal injury. NOTE: Do not insert any tools into the throttle body bore in order to avoid damage to the throttle valve plate. 2. Inspect the throttle body bore and the throttle plate for deposits. You will need to open the throttle plate in order to inspect all surfaces. NOTE: Do not use any solvent that contains Methyl Ethyl Ketone (MEK). This solvent may damage fuel system components. 3. Clean the throttle body bore and the throttle plate using a clean shop towel with GM Top Engine Cleaner, P/N 1052626 or AC-Delco Carburetor Tune-Up Conditioner, P/N X66-P, or an equivalent product. 4. Install the air cleaner intake duct. Page 14999 Notice: When installing the new support cable, make sure that the left side (LS) is installed on the left (driver's) side of the vehicle, and the right side (RS) is installed on the right (passenger) side. The support cables are marked with an LS or RS on the end of the cable that attaches to the tailgate. Installing a support cable on the incorrect side of the vehicle may result in the cable getting damaged when the tailgate is closed. 9. Install one new flat washer on the bolt followed by a new support cable. The end of the support cable should go over the washer and onto the shoulder of the bolt. 10. Install the bolt, flat washer, and cable assembly into the latch and tailgate. Tighten Tighten the bolt to 25 Nm (18 lb-ft). 11. If the other bolt was loosened earlier, Tighten Tighten the bolt to 25 Nm (18 lb-ft). 12. Verify that the support cable end rotates freely on the bolt. 13. Attach the opposite end of the support cable to the pickup box. 14. Repeat the procedure on the other support cable~ Important: Depending on the condition of the tailgate and related parts, one of the two new support cables (either left or right) may NOT be tight (taut) when the tailgate is fully open. This condition may be caused by several factors including a damaged hinge, pickup box, or the tailgate itself may be slightly bent due to overloading at some previous time. Replacing either or both support cables a second time will NOT correct this condition. Replacement of any additional parts to correct this condition will NOT be covered under this recall. 15. Remove the tailgate support, close, open and re-close the tailgate. Verify that the support cables fold properly. Service and Repair Maintenance Indicator - A/T: Service and Repair This vehicle does not use a Trans Fluid Life index, and has no monitor to reset. Instruments - Unable to Reset Oil Life Monitor Oil Change Reminder Lamp: Customer Interest Instruments - Unable to Reset Oil Life Monitor Bulletin No.: 04-06-04-043 Date: June 17, 2004 TECHNICAL Subject: Unable to Reset Engine Oil Life Monitor (Reprogram PCM) Models: 2004 Buick Rainier 2004 Cadillac Escalade, Escalade ESV, Escalade EXT 2004 Chevrolet Avalanche, Express, SSR, Silverado, Suburban, Tahoe, Trailblazer 2004 GMC Envoy, Savana, Sierra, Yukon, Yukon XL with V8 Engine (VINs G, N, P, T, U, V, Z - RPOs L18, LQ9, LM4, LM7, LQ4, LR4, L59) and Electronic Throttle Control Condition Some owners may comment that they are unable to reset the Engine Oil Life Monitor. Correction Reprogram the PCM with calibration operating system P/N 12587603 or later. The new calibration was released beginning with TIS satellite data update version 8.0 for 2003, available August 2003. As always, make sure your TECH2(R) is updated with the latest software version. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 9270 Location View Location View Page 8148 Brake Caliper: Service and Repair Brake Caliper Overhaul - Rear Brake Caliper Overhaul - Rear (15 Series) Caution: Refer to Brake Dust Caution in Service Precautions. Caution: Refer to Brake Fluid Irritant Caution in Service Precautions. Disassembly Procedure Important: ^ Replace all the components included in the repair kits used to service this brake caliper. ^ Lubricate the rubber parts with clean brake fluid to make assembly easier. ^ The torque values specified are for dry, non lubricated fasteners. ^ Perform the service operations on a clean bench free from all mineral oil materials. 1. Remove the brake caliper from the vehicle. 2. Caution: Do not place your fingers in front of the piston in order to catch or protect the piston while applying compressed air. This could result in serious injury. Place a thin piece wood in front of the piston in order to prevent damage. Remove the piston by directing compressed air into the brake hose inlet fitting port of the brake caliper housing. 3. Remove the piston boot. 4. Remove the piston seal. 5. Remove the brake caliper bleed screw cap. 6. Remove the brake caliper bleed screw. 7. Inspect the brake caliper bore and the piston seal groove for scoring and corrosion. If you find excessive scoring or corrosion around the piston seal area, replace the brake caliper housing. Page 320 these systems will then completely power OFF. OnStar(R) Module Expected Current Draw The expected current draw of the OnStar(R) module in various ignition modes are as follows: ^ Ignition ON ‐ 240 to 400 mA ^ Ignition OFF ‐ 3 to 20 mA for 48 hours ^ Ignition OFF ‐ 0.2 to 0.8 mA after 48 hours (120 hours on specified vehicle communication platforms (VCPs)). Note During extended voltage testing for battery parasitic draw, it is possible to observe a voltage spike caused by the following: ^ A cellular registration call that was triggered by the local cellular system. ^ The OnStar(R) system has set a monthly trigger for a vehicle data upload call for the OnStar(R) Vehicle Diagnostic E‐mail upload. OnStar(R) System States of Readiness The OnStar(R) system will use the following 4 states of readiness, depending upon the type of cellular market the vehicle is in when the ignition is turned OFF. ^ High power ^ Low power ^ Sleep ^ Digital standby The high power state is in effect whenever the ignition is in the ON or RUN position, retained accessory power (RAP) is enabled, and/or the OnStar(R) system is sending or receiving calls or when the system is performing a remote function. The low power state is in effect when the OnStar(R) system is idle with the ignition in the ON or RUN position, or with RAP enabled. The sleep state is entered after the vehicle has been shut OFF and the RAP has timed out. At a predetermined time recorded within the VCIM, the system re-enters the low power state to listen for a call from the OnStar(R) Call Center for 1 minute. After this interval, the system will again return to the sleep state for 9 minutes. If a call is sent during the 1 minute interval, the OnStar(R) system will receive the call and immediately go into the high power mode to perform any requested functions. If a call is not received during the 1 minute interval, the system will go back into the sleep mode for another 9 minutes. This process will continue for up to 48 hours, after which the OnStar(R) system will turn OFF until the ignition is turned to the ON or RUN position. The digital standby power state is entered after the vehicle has been shut off and the RAP has timed out while in a digital cellular area. When in digital standby mode, the OnStar(R) module is able to perform all remote functions as commanded by an OnStar(R) advisor at any time, for a continuous 48 hours. After 48 hours, the OnStar(R) module will go into sleep mode until a wake up signal from the vehicle is seen by the CIM. If the OnStar module loses the digital cellular signal it will revert to analog mode and follow the standard sleep state (9 minutes OFF, 1 minute standby) based on the time of the GPS signals, this will continue until a digital cellular signal is again received. If the OnStar(R) system loses battery power while the system is in a standby or sleep mode, the system will remain OFF until battery power is restored and the ignition is turned to the ON or RUN position. Deactivated OnStar(R) Accounts In the event that a customer has not upgraded their vehicle to a digital system, the account has been deactivated. The customers have been previously notified of the steps required to upgrade their vehicles. After the OnStar(R) account has been deactivated, customers will experience the following: ^ The OnStar(R) status LED will not illuminate ^ The OnStar(R) system will NOT attempt to connect to the OnStar(R) Call Center in the event of a collision or if the vehicle's front air bags deploy for any other reason. ^ An emergency button press will result in a demo message being played, indicating the service has been deactivated and needs to be upgraded. Page 8777 Electrical Symbols Part 6 Specifications Compression Check: Specifications The minimum compression in any one cylinder should not be less than 70 percent of the highest cylinder. No cylinder should read less than 690 kPa (100 psi). For example, if the highest pressure in any one cylinder is 1035 kPa (150 psi), the lowest allowable pressure for any other cylinder would be 725 kPa (105 psi). Multiply the highest cylinder pressure by 70 percent, 1035 kPa x 70 percent = 725 kPa (150 psi x 70 percent = 105 psi), in order to determine the lowest allowable pressure in any other cylinder. Page 4549 Steps 6 - 12 Scan Tool Does Not Power Up SCAN TOOL DOES NOT POWER UP CIRCUIT DESCRIPTION The data link connector (DLC) is a standardized 16 cavity connector. Connector design and location is dictated by an industry wide standard, and is required to provide the following: Scan tool power battery positive voltage at terminal 16 - Scan tool power ground at terminal 4 - Common signal ground at terminal 5 Page 11265 A/C Low Pressure Switch Page 15601 Daytime Running Lamp (DRL) - Left (Export) TPMS System - Service And Re-Learning Sensor IDs Tire Pressure Module: Technical Service Bulletins TPMS System - Service And Re-Learning Sensor IDs INFORMATION Bulletin No.: 10-03-16-001 Date: July 19, 2010 Subject: TPMS System Service and Re-Learning Sensor IDs Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks 2010 and Prior HUMMER H2 2009 and Prior HUMMER H3 2010 and Prior Saturn Models 2009 and Prior Saab 9-7X with Wheel-Mounted Tire Pressure Sensors In the event that the spare tire, which is normally not equipped with a tire pressure monitor (TPM) sensor, is installed in place of one of the road tires and the vehicle is driven above 40 km/h (25 mph) for 20 minutes or more, the TPM indicator icon on the instrument panel cluster (IPC) will flash for approximately one minute and then remain on steady each time the ignition is turned ON, indicating a diagnostic trouble code (DTC) has been set. The driver information center (DIC), if equipped, will also display a SERVICE TIRE MONITOR type message. When the road tire is repaired and reinstalled in the original location, the TPM indicator icon illumination and DIC message may remain displayed until the DTC is cleared. To ensure that the TPM indicator and the DIC message are cleared after service, it is necessary to clear any TPM DTCs using a scan tool. If a scan tool is unavailable, performing the TPM relearn procedure using a TPM diagnostic tool will provide the same results. It is advised to perform the relearn procedure away from other vehicles to prevent picking up a stray sensor signal. If one or more of the TPM sensors are missing or damaged and have been replaced, then the relearn procedure must be performed. Disclaimer Page 14032 Trim Panel: Service and Repair Garnish Molding Replacement - Windshield Pillar Garnish Molding Replacement - Windshield Pillar Removal Procedure 1. Pull the molding straight out in order to release the retainers. 2. Remove the windshield garnish molding. Installation Procedure 1. Ensure the bottom of the molding is seated in the slots on the I/P. 2. Align the molding retainers to the slots. 3. Press the moldings straight in till fully seated. Page 13156 4.2. Release the back end of the connector (C) and remove from the contact rail (D). 4.3. M00-01: Disconnect pin 39, cut off the cable terminal and insulate the end using tape (E). Fold back the cable and secure using tape (F). 4.4. M02-04: Disconnect pin 58, cut off the cable terminal and insulate the end using tape (E). Fold back the cable and secure using tape (F). 4.5. Assemble the contact rail and end. 4.6. Connect connector (A) and secure the cable using a cable tie (B). 5. Assemble the gear shift housing (A). AUT: Connect connector (B). 6. Assemble the center console, see WIS - Body - Interior. 7. Remove the OnStar(R) control module and secure the cable harness: 7.1. 5D: Remove the right-hand cover from the luggage compartment floor. Page 15218 7. Insert the J 38125-13A (GM P/N 12031876-1) tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the Terminal Repair Kit to ensure that the correct release tool is used. 8. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. REPAIR PROCEDURE Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. Page 4475 Splice Pack - SP205 Page 4651 TOOLS REQUIRED J 34142-B 12 V Unpowered Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. When testing for voltage: 1. Attach 1 lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach 1 lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Using Connector Test Adapters USING CONNECTOR TEST ADAPTERS NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-B Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires USING FUSED JUMPER WIRES TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Connector Position Assurance Locks CONNECTOR POSITION ASSURANCE LOCKS The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Terminal Position Assurance Locks TERMINAL POSITION ASSURANCE LOCKS The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Push to Seat Connectors PUSH TO SEAT CONNECTORS TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Page 8772 Electrical Symbols ELECTRICAL SYMBOLS Electrical Symbols Part 1 Door Window Channel Front Door Window Glass Weatherstrip: Service and Repair Door Window Channel Window Run Channel Replacement - Front Door Removal Procedure 1. Remove the window. 2. Remove the window glass weatherstrip. 3. Remove the window run channel bolts. 4. Remove the front and the rear window run channels from the door. Installation Procedure 1. Install the front and the rear window run channels to the door. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the front and the rear window run channel bolts. 1. Tighten the front bolt to 9 N.m (80 lb in). 2. Tighten the rear bolt to 9 N.m (80 lb in). 3. Install the window glass weatherstrip. 4. Install the window. Page 7929 Page 7599 Parts Information Parts are currently available from GMSPO. Warranty Information Page 5807 Page 4029 For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to refer to the table above. Disclaimer Page 4445 Engine Control Module: Service and Repair POWERTRAIN CONTROL MODULE (PCM) REPLACEMENT Service of the powertrain control module (PCM) should consist of either replacement of the PCM or programming of the electrically erasable programmable read only memory (EEPROM). If the diagnostic procedures call for the PCM to be replaced, the replacement PCM should be checked to ensure that the correct part is being used. If the correct part is being used, remove the faulty PCM and install the new service PCM. REMOVAL PROCEDURE IMPORTANT: To prevent internal PCM damage, the ignition switch must be OFF when disconnecting or connecting power to the PCM. - Remove any debris from around the PCM connector surfaces before servicing the PCM. Inspect the PCM module connector gaskets when diagnosing or replacing the PCM. Ensure that the gaskets are installed correctly. The gaskets prevent contaminant intrusion into the PCM. - The replacement PCM must be programmed. 1. Disconnect the negative battery cable. 2. If equipped with regular production option (RPO) NYS, remove the harness ground clip from the PCM cover. 3. Release the PCM cover mounting tabs. 4. Release the PCM cover from the mounting bracket. Service and Repair Oil Filter Adapter: Service and Repair Oil Filter Adapter Replacement Removal Procedure 1. Drain the engine oil. 2. Remove the oil filter. 3. Remove the oil filter adapter (1). Installation Procedure 1. Notice: Refer to Fastener Notice in Service Precautions. Install the oil filter adapter (1). ^ Tighten the adapter to 55 Nm (40 ft. lbs.). Weatherstrip Replacement - Auxiliary Front Door Weatherstrip: Service and Repair Weatherstrip Replacement - Auxiliary Weatherstrip Replacement - Auxiliary Removal Procedure 1. Open the door. 2. Pull the weather-strip from the pinchweld flange. Installation Procedure 1. Push the weather-strip over the pinch-weld flange. 2. Close the door. Page 9732 C206 I/P Harness To Body Harness (With RPO Codes Y91/HP2) Part 1 Page 12964 Speaker - LR Door - Crew Cab Page 14116 Driver Door Module (DDM) - C4 (With RPO Code YE9) Part 2 Diagrams Power Door Lock Actuator: Diagrams Door Latch Assembly (Lock Actuator) - Driver C1 Page 4251 Accelerator Pedal Position Sensor: Description and Operation ACCELERATOR PEDAL POSITION (APP) SENSOR The accelerator pedal assembly contains 2 individual APP sensors within the assembly. The APP sensors 1 and 2 are potentiometer type sensors, each with the following circuits: - A 5-volt reference circuit - A low reference circuit - A signal circuit The APP sensors are used to determine the pedal angle. The control module provides each APP sensor a 5-volt reference circuit and a low reference circuit. The APP sensors then provide the control module with signal voltage proportional to pedal movement. Both APP sensor signal voltages are low at rest position and increase as the pedal is applied. Page 6266 Fluid Line/Hose: Technical Service Bulletins A/T - Cooler Line Fitting Applications Bulletin No.: 08-07-30-004 Date: January 31, 2008 INFORMATION Subject: 4L60-E, 4L65-E, 4L70-E HYDRA-MATIC(R) Automatic Transmission (RPOs M30, M70 M32, M33, MK2 MD6) Oil Cooler Fitting Change Models: 1997-2008 GM Light Duty Trucks (Including Saab) with 4L60-E, 4L65-E, 4L70-E HYDRA-MATIC(R) Automatic Transmission (RPOs M30, M70, M3, M33, MK2, MD6) Aluminum cooler line fittings - These new fittings (2) cannot be used on earlier cases because the threaded hole is not the same size. Old style fittings (1) will continue to be available through SPO parts. Service cases will be the new case and fittings. The old cases with the old thread design will not be maintained for service. The connection on the hose side will accept both the short snout and the newer longer snout cooler hose assemblies. The fittings (1) have a new torque specification of 20 N.m (14 lb ft). They also have one inner and one outer "0" ring that are not serviced separately. Page 11423 Repairs and Inspections Required After a Collision: Service and Repair Steering Column Steering Column Intermediate Shaft The redesigned steering column has a convoluted style intermediate shaft (Figs.1.22.and 1.23). The C1500 has one convoluted area, while all other models have two. These convoluted areas must be inspected for damage after every airbag deployment. Test the straightness of the shaft at various locations along the convoluted area by placing a straight edge against the intermediate shaft. The intermediate shaft must be replaced if bent or damaged. Page 14374 If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Sir/SRS Wiring Repairs SIR/SRS WIRING REPAIRS TOOLS REQUIRED J 38125-D Terminal Repair Kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-D contains the following items: - Special sealed splices - in order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping tool - A heat torch - An instruction manual The sealed splices have the following 2 critical features: - A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-D also serves as a generic terminal repair kit. The kit contains the following items: - A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors Page 5637 Spark Plug: Application and ID SPARK PLUG TYPE: AC P/N ................................................................................................................................................. .............................................................. 25171803 NGK P/N .............................................................................................................................................. .............................................................. 12567759 Page 12929 INSTALLATION PROCEDURE NOTE: Refer to Fastener Notice in Service Precautions. 1. Install the audio amplifier to the floor console lower bracket. 2. Install the amplifier screws. Tighten Tighten the screws to 3.4 N.m (30 lb in). 3. Install the floor console. 4. Connect the floor console electrical connector. 5. Install the screws (1) that retaining the upper console bracket to the lower console bracket. Tighten Tighten the retaining screws to 2 N.m (18 lb in). Page 12010 switch lighting connector. 3.3. Undo the floor console's retaining bolts (C). 3.4. Take out the rear ashtray/cover (D). 3.5. Remove the screw (E) for the rear cover. 3.6. Remove the floor console's retaining nuts (E). 3.7. Detach the floor console (G) by pulling it straight back and lifting it slightly. 3.8. If required, detach the switch for the rear seat heater and unplug the connector. 4. Remove the switch and the floor console: 4.1. Detach the window lift module (A) by loosening it in the front edge (snap fastener). Unplug the window lift module's connector. 4.2. Detach the switch for the roof lighting (B) and unplug its connector. Lift away the floor console. 5. Pry out the signal line from the SRS control module to the OnStar(R) control module and secure it: 5.1. Unplug the SRS control module's connector (A). Page 8462 Use clean, new power steering fluid only. 12. Fill the pump reservoir with fluid to the FULL COLD level. 13. Attach J 43485, Power Steering Bleeder Adapter, to J 35555, Metal Mityvac, or equivalent. 14. Place J 43485 on or in the pump reservoir filler neck. 15. Apply a vacuum of 68 kpa (20 in Hg) maximum. 16. Wait 1 minute. 17. Remove 1 J43485 and J 35555. 18. Reinstall the pump reservoir cap. 19. Start the engine. Allow the engine to idle. 20. Turn the steering wheel 180-360 degrees in both directions 5 times. 21. Switch the ignition off 22. Verify the fluid level. 23. Release the park brake and unblock the wheels. Page 8465 Page 3681 Coolant Temperature Sensor/Switch (For Computer): Service and Repair ENGINE COOLANT TEMPERATURE (ECT) SENSOR REPLACEMENT REMOVAL PROCEDURE NOTE: Use care when handling the coolant sensor. Damage to the coolant sensor will affect the operation of the fuel control system. 1. Drain the cooling system to a level below the engine cooling temperature (ECT) sensor. Refer to Draining and Filling Cooling System in Cooling System. 2. Disconnect the ECT sensor electrical connector (5). 3. Remove the ECT sensor. INSTALLATION PROCEDURE NOTE: Replacement components must be the correct part number for the application. Components requiring the use of the thread locking compound, lubricants, corrosion inhibitors, or sealants are identified in the service procedure. Some replacement components may come with these coatings already applied. Do not use these coatings on components unless specified. These coatings can affect the final torque, which may affect the operation of the component. Use the correct torque specification when installing components in order to avoid damage. - Use care when handling the coolant sensor. Damage to the coolant sensor will affect the operation of the fuel control system. Page 3059 8. Install the inner bearing. 9. Important: Each time you replace the wheel hub bearings, install a new oil seal in order to prevent the wheel hub from leaking. Install the new oil seal using the J 44420 (2) and the J 8092 (1). 10. Install the rotor, if necessary. 11. Apply a light coat of high melting point EP bearing lubricant to the axle housing spindle. 12. Install the wheel hub to the axle housing. 13. Install the adjusting nut to the hub using the J 2222-C. 14. Adjust the wheel bearings. 15. Install the axle shaft. 16. Install the brake caliper. 17. Install the tire and wheel assembly. Page 9204 C202 I/P Harness To Brake/Clutch Harness Part 2 Page 2725 Junction Block - I/P Wire Entry Part 4 Diagrams Page 12235 ^ Pay the dealer the regular retail price (no discounts are available) for one of the following 1-year, non-refundable OnStar(R) Analog-to-Digital Transition (ADT) Service Subscription Plans: ^ 1-year Safe & Sound Subscription: $199 ($289 in Canada) ^ 1-year Directions & Connections Subscription: $399 ($579 in Canada) ^ Pay the dealer the applicable state and local sales taxes on the subscription: ^ U.S. Dealers: Taxes only apply in these states: CT, DC, FL, HI, ND, NJ, NM, NY, SC, SD, TX, and WV ^ Canadian Dealers: All applicable taxes ^ Pay the dealer a one-time charge of $15 for the upgrade: ^ U.S. Dealers: Do not collect taxes on the $15 ^ Canadian Dealers: Collect all applicable taxes on the $15 Note: Dealers should NOT remit OnStar(R) ADT-related taxes to their taxing authority as OnStar(R) is responsible for tax remittance. Please Be Sure To Read these Important Points: ^ The 1-year OnStar(R) subscription is not refundable or transferable to another person. Upgraders can apply unused subscription months to a new or Certified Pre-Owned digital OnStar-equipped GM vehicle purchase or lease. As noted above, the digital upgrade program requires the subscriber to purchase a one-year prepaid OnStar(R) subscription. Assuming the subscriber intends to keep their vehicle, but subsequently purchases or leases a 2006 model year or newer OnStar(R)-equipped new or certified used GM vehicle, in the interest of subscriber satisfaction, they may apply remaining unused whole months of the subscription to the new vehicle. The subscription may not be applied to another person's vehicle. Important: This is a customer satisfaction measure that would usually occur several months after an upgrade. It is not intended to be leveraged as part of a new/used vehicle purchase or lease transaction. ^ The $15 charge is not refundable. ^ Dealer ADT kit orders are VIN specific. Dealer kit orders require a VIN and must be exchanged with the OnStar(R) unit in the vehicle with that VIN. Proper activation and enrollment depends on this step. ^ You must put the actual miles on the Repair Order. Do not estimate. ^ Customers will receive a Hands-Free Calling number once the digital hardware is installed and configured. ^ Any nametags that were stored in the old system will need to be re-set by the subscriber once the new hardware is installed. ^ Customers are responsible for the charges described above regardless of whether their vehicle is in or out of the New Vehicle Warranty period. In addition, customers should not be charged labor costs. Dealers can charge GM the labor for the upgrade as specified at the end of this bulletin using the listed labor operation. ^ Vehicles eligible for an OnStar(R) hardware upgrade are listed in this bulletin. Vehicle upgradeability can also be determined by typing the VIN into the field entitled "Determine VIN Hardware Functionality" on the OnStar(R) Online Enrollment website, located in the sales or service workbench tab of GM GlobalConnect. Canadian Dealers can use a similar tool that is available within InfoNET. ^ Access to the sales and/or service workbench in the GM GlobalConnect website can be granted by the dealership's Partner Security Coordinator (PSC). If you are unsure who the PSC is, check with the Sales Manager. Ordering the Upgrade Kit/Upgrade kit Installation Ordering the Upgrade Kit 1. To order a kit, you will need to access the OnStar(R) Online Enrollment webpage, located under the sales or service workbench of GM GlobalConnect (infoNET for Canadian upgrade orders). These kits cannot be ordered from GMSPO. Page 5177 Air Filter Element: Service and Repair AIR CLEANER ELEMENT REPLACEMENT REMOVAL PROCEDURE 1. Remove the air cleaner outlet duct. 2. Disconnect the mass air flow/intake air temperature (MAF/IAT) sensor electrical connector (4). 3. Loosen the air cleaner housing top screws. 4. Remove the air cleaner housing cover. 5. Remove the air filter element. INSTALLATION PROCEDURE Page 9311 Junction Block - Rear Lamps - C4 Page 6323 Vehicle Speed Sensor (VSS) Tow/Haul Switch Location Page 6362 To correct this condition, replace the case cover (channel plate) gaskets (429 and 430). Refer to Unit Repair publication in SI of the appropriate vehicle being serviced. Visual inspection of the upper gasket (1) will reveal damage at the referenced area. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 7912 Transmission Position Switch/Sensor: Adjustments Automatic Transmission - 4L80-E/4L85-E Park/Neutral Position Switch Adjustment Important: ^ The following procedure is for vehicles that have not had the park/neutral position (PNP) switch removed or replaced. If the switch has been removed or replaced, refer to Park/Neutral Position Switch Replacement for the proper adjustment procedure. ^ Apply the park brake. ^ The engine must start in the park (P) or neutral (N) positions only. ^ Check the PNP switch for proper operation. If adjustment is required, proceed as follows: 1. Place the shift lever in the neutral (N) position. 2. With an assistant in the drivers seat, raise and suitably support the vehicle. Refer to Vehicle Lifting. 3. Loosen the PNP switch bolts. 4. With the vehicle in neutral (N), rotate the PNP switch while the assistant attempts to start the engine. 5. Following a successful start, turn the engine off. 6. Notice: Refer to Fastener Notice in Service Precautions. Tighten the PNP switch bolts. ^ Tighten the bolts to 25 Nm (18 ft. lbs.). 7. Lower the vehicle. 8. Check the PNP switch for proper operation. The engine must start in the park (P) or neutral (N) positions only. 9. Replace the PNP switch if proper operation can not be achieved. Wheels/Tires - Tire Radial Force Variation (RFV) Wheels: All Technical Service Bulletins Wheels/Tires - Tire Radial Force Variation (RFV) INFORMATION Bulletin No.: 00-03-10-006F Date: May 04, 2010 Subject: Information on Tire Radial Force Variation (RFV) Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X 2000-2005 Saturn L Series 2003-2007 Saturn ION Supercede: This bulletin is being revised to considerably expand the available information on Radial Force Variation (RFV) and should be reviewed in whole. Please discard Corporate Bulletin Number 00-03-10-006E (Section 03 - Suspension). Important - Before measuring tires on equipment such as the Hunter GSP9700, the vehicle MUST be driven a minimum of 16 km (10 mi) to ensure removal of any flat-spotting. Refer to Corporate Bulletin Number 03-03-10-007E - Tire/Wheel Characteristics of GM Original Equipment Tires. - Equipment such as the Hunter GSP9700 MUST be calibrated prior to measuring tire/wheel assemblies for each vehicle. The purpose of this bulletin is to provide guidance to GM dealers when using tire force variation measurement equipment, such as the Hunter GSP9700. This type of equipment can be a valuable tool in diagnosing vehicle ride concerns. The most common ride concern involving tire radial force variation is highway speed shake on smooth roads. Tire related smooth road highway speed shake can be caused by three conditions: imbalance, out of round and tire force variation. These three conditions are not necessarily related. All three conditions must be addressed. Imbalance is normally addressed first, because it is the simpler of the three to correct. Off-vehicle, two plane dynamic wheel balancers are readily available and can accurately correct any imbalance. Balancer calibration and maintenance, proper attachment of the wheel to the balancer, and proper balance weights, are all factors required for a quality balance. However, a perfectly balanced tire/wheel assembly can still be "oval shaped" and cause a vibration. Before balancing, perform the following procedures. Tire and Wheel Diagnosis 1. Set the tire pressure to the placard values. 2. With the vehicle raised, ensure the wheels are centered on the hub by loosening all wheel nuts and hand-tightening all nuts first by hand while shaking the wheel, then torque to specifications using a torque wrench, NOT a torque stick. 3. Visually inspect the tires and the wheels. Inspect for evidence of the following conditions and correct as necessary: - Missing balance weights - Bent rim flange - Irregular tire wear - Incomplete bead seating - Tire irregularities (including pressure settings) - Mud/ice build-up in wheel - Stones in the tire tread - Remove any aftermarket wheels and/or tires and restore vehicle to original condition prior to diagnosing a smooth road shake condition. 4. Road test the vehicle using the Electronic Vibration Analyzer (EVA) essential tool. Drive for a sufficient distance on a known, smooth road surface to duplicate the condition. Determine if the vehicle is sensitive to brake apply. If the brakes are applied lightly and the pulsation felt in the steering wheel increases, refer to the Brakes section of the service manual that deals with brake-induced pulsation. If you can start to hear the vibration as a low boom noise (in addition to feeling it), but cannot see it, the vehicle likely has a first order (one pulse per propshaft revolution) driveline vibration. Driveline first order vibrations are high enough in frequency that most humans can start to hear them at highway speeds, but are too high to be able to be easily seen. These issues can be caused by driveline imbalance or misalignment. If the vehicle exhibits this low boom and the booming pulses in-and-out on a regular basis (like a throbbing), chances are good that the vehicle could have driveline vibration. This type Drivetrain - Service 4WD Light/DTC C0374 Set Speed Sensor: Customer Interest Drivetrain - Service 4WD Light/DTC C0374 Set TECHNICAL Bulletin No.: 05-04-21-003C Date: April 15, 2008 Subject: Service 4WD Light Illuminated, DTC C0374 Set (Inspect Wiring Harness to Transfer Case Speed Sensors,, Replace Wiring Harness) Models: 2004-2007 Buick Rainier 2003-2006 Chevrolet Avalanche, Suburban, Tahoe 2003-2007 Chevrolet Silverado Classic, TrailBlazer, TrailBlazer EXT 2003-2006 GMC Yukon, Yukon XL 2003-2007 GMC Envoy, Envoy XL, Sierra Classic 2003-2004 Oldsmobile Bravada 2005-2007 Saab 9-7X With Four Wheel Drive or All-Wheel Drive and Active All-Wheel Drive (RPO NP4) or Active Two-Speed (RPO NP8) Transfer Case Supercede: This bulletin is being revised to update the Model and Warranty Information. Please discard Corporate Bulletin Number 05-04-21-003B (Section 04 - Driveline/Axle). Condition Some customers may comment on intermittent illumination of the Service 4WD light. Upon investigation, the technician may find DTC C0374 set. The customer may also comment on intermittent erratic operation of the 4WD or AWD system after driving through rain/snow or simply going through a car wash. Cause The speed sensor signal may have become corrupted. Possible openings in the speed sensor wire insulation (twisted pairs) can allow water intrusion. Also wire connections contaminated by water may result in short circuits and erroneous speed sensor readings. This most often occurs on the rear speed sensor circuit. Correction Inspect the wiring harness to the transfer case speed sensors. On Rainier, TrailBlazer, Envoy and 9-7X models, fabricate a replacement speed sensor harness between the C101 connector and the speed sensors. Completely inspect and test all wiring. Refer to Speed Signal Front Axle Actuator and Indicators schematic in SI. Replace the affected twisted pairs. Do not over-twist the two wires in the replacement harness. Wires should be twisted at a rate of 9 revolutions per foot. Use service connector pack, P/N 88987993 at the speed sensor end and terminal, P/N 15326267, at C101. Terminal testing tools and service terminals can be found in Terminal Repair Kit J 38125. Terminals are available from SPX/Kent-Moore. The smaller transfer case harness splices into the larger chassis harness a few inches in front of the crossmember. The chassis harness routes along the left side of the frame under the driver door area. Use nylon tie straps to secure the fabricated harness to the main chassis harness between the transfer case and C101. On the full-size pickup and full-size utility models, replace the 2.2 m (88 in) pigtail harness that runs from the C151 connector under the hood to the transfer case. Use either harness P/N 15832722 or 15224663 depending on vehicle equipment. Refer to Propshaft Speed Sensors Front Axle Actuator and Transfer Case Shift Control Switch schematic in SI. Important: Technicians should verify the integrity of the splice joints after the repair. All splice joints and connections should seal properly against water or a repeat condition can occur. Page 7937 1. Lubricate the output speed sensor seal with automatic transmission fluid. 2. Install the output speed sensor (2). Notice: Refer to Fastener Notice in Service Precautions. 3. Install the output speed sensor bolt. ^ Tighten the bolt to 11 Nm (96 inch lbs.). 4. Connect the output speed sensor (2) electrical connector. 5. Lower the vehicle. Service and Repair Parking Brake Warning Switch: Service and Repair Park Brake Warning Lamp Switch Replacement Removal Procedure 1. Caution: Refer to Battery Disconnect Caution in Service Precautions. Disconnect the negative battery cable. 2. Remove the MID-bussed electrical center from the bracket. 3. Disconnect the park brake warning lamp switch electrical connector. 4. Remove the park brake warning lamp switch mounting bolt. 5. Remove the park brake warning lamp switch. Installation Procedure Interior - Front Heated Seat(s) Inoperative Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Number Incorrect/Incorrectly Assigned INFORMATION Bulletin No.: 05-08-46-004C Date: December 23, 2010 Subject: OnStar(R) Phone Number Concerns (Phone Number Incorrect/Assigned to Another Vehicle/Phone) That Occur During Diagnosis of OnStar(R) System Models: 2000-2011 GM Passenger Cars and Trucks Equipped with OnStar(R) (RPO UE1) Supercede: This bulletin is being revised to update model years up to 2011. Please discard Corporate Bulletin Number 05-08-46-004B (Section 08 - Body and Accessories). During diagnosis of an OnStar(R) concern, the technician may be told that the OnStar(R) phone number is incorrect or tied to another vehicle and/or phone of some kind. To resolve these concerns, the Tech 2(R) with software version 22.005 (or higher), has the capability to change the OnStar(R) phone number. Service Procedure 1. With the Tech 2(R), build the vehicle to specifications within the Diagnostics area of the Tech 2(R). 2. For vehicles with physical-based diagnostics - under Body, go to the OnStar(R) section. Then select the Special Functions menu. For vehicles with functional-based diagnostics - under Body and Accessories, go to the Cellular Communication section. Select Module Setup and then Vehicle Communication Interface Module. 3. Locate the Program Phone Number prompt and select it. The original phone number will be displayed on the Tech 2(R) screen. 4. Contact the OnStar(R) team at the GM Technical Assistance Center (TAC) to obtain a new phone number. 5. Highlight the digits of the phone number one at a time and enter the new phone number using the number keys on the Tech 2(R). 6. Press the Soft key at the base of the screen for Done once these numbers have been changed on the screen. 7. Press the Soft key for Done again. The area code or new phone number has now been programmed into the phone. 8. Cycle the ignition to Off and open the driver's door. 9. Press the blue OnStar(R) button to make sure that a normal connection can be made to the OnStar(R) call center. If applicable, make sure the Hands-Free Calling (HFC) works properly by making a phone call. 10. If the system is working properly, fax or voicemail a case closing into the OnStar(R) team at TAC with the results. Dealers in Canada should submit case closing information through the GM infoNET. Please follow this diagnostic process thoroughly and complete each step. If the condition exhibited is resolved WITHOUT completing every step, the remaining steps do not need to be performed. If the procedure above does not resolve the condition, you must contact TAC for further assistance. This diagnostic approach was developed specifically for this condition and should not automatically be used for other vehicles with similar symptoms. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use: Warranty Information (Saab Models) For vehicles repaired under warranty, use the table. Page 7948 Page 7025 Do not reuse the nut. A new nut must be used when installing the wheel drive shaft. Remove the wheel driveshaft assembly retaining nut (2) and washer (3) from the wheel driveshaft. 7. Disengage the wheel drive shaft from the wheel hub and bearing using J 45859 or equivalent. 8. Remove the wheel hub and the 15-series bearing mounting bolts (4). 9. Remove the wheel hub and bearing (4) mounting bolts, 25/35 series. 10. Remove the wheel hub and bearing and splash shield from the vehicle. 11. Remove the O-ring seal from the steering knuckle bore, 25/35 series. 12. Remove the wheel speed sensor mounting bolt (5). 13. Clean and inspect the O-ring seal, 25/35 series. 14. Replace the seal if the following conditions exist: ^ Nicks ^ Cuts Page 8740 Negative: Service and Repair Replacement procedure BATTERY NEGATIVE CABLE REPLACEMENT REMOVAL PROCEDURE CAUTION: Refer to Battery Disconnect Caution in Service Precautions. 1. Disconnect the negative battery cable. 2. If equipped with a 4.8L, 5.3L, or 6.0L engine, remove the battery cable bracket bolt and bracket from the power steering pump. 3. If equipped, disconnect the accessory power fuse block front wiring harness electrical connector from the negative cable connector. Page 964 results from the alteration or modification of a vehicle using non-GM approved parts or accessories. Dealers should be especially cautious of accessory companies that claim the installation of their product will not void the factory warranty. Many times these companies have even given direction on how to quickly disassemble the accessory in an attempt to preclude the manufacturer from finding out that is has been installed. Any suspect repairs should be reviewed by the Fixed Operations Manager (FOM), and in Canada by the Warranty Manager (WM) for appropriate repair direction. If it is decided that a goodwill repair is to be made on the vehicle, even with the installation of such non-GM approved components, the customer is to be made aware of General Motors position on this issue and is to sign the appropriate goodwill documentation required by General Motors. It is imperative for dealers to understand that by installing such devices, they are jeopardizing not only the warranty coverage, but also the performance and reliability of the customer's vehicle. Disclaimer Page 14733 1. Remove the seat cushion trim cover (8) and the pad (7). 2. Remove the bolts from the hinge assembly, if equipped with folding seats. 3. Remove the seat cushion frame (5). INSTALLATION PROCEDURE 1. Install the seat cushion frame (5). NOTE: Refer to Fastener Notice in Service Precautions. Diagrams Engine Oil Level Switch Page 3235 Drive Belt: Description and Operation Drive Belt System Description The drive belt system consists of the following components: ^ The drive belt ^ The drive belt tensioner ^ The drive belt idler pulley ^ The crankshaft balancer pulley ^ The accessory drive component mounting brackets ^ The accessory drive components ^ The power steering pump, if belt driven ^ The generator ^ The A/C compressor, if equipped ^ The engine cooling fan, if belt driven ^ The water pump, if belt driven ^ The vacuum pump, if equipped ^ The air compressor, if equipped The drive belt system may use 1 belt or 2 belts. The drive belt is thin so that it can bend backwards and has several ribs to match the grooves in the pulleys. There also may be a V-belt style belt used to drive certain accessory drive components. The drive belts are made of different types of rubbers - chloroprene or EPDM - and have different layers or plys containing either fiber cloth or cords for reinforcement. Both sides of the drive belt may be used to drive the different accessory drive components. When the back side of the drive belt is used to drive a pulley, the pulley is smooth. The drive belt is pulled by the crankshaft balancer pulley across the accessory drive component pulleys. The spring loaded drive belt tensioner keeps constant tension on the drive belt to prevent the drive belt from slipping. The drive belt tensioner arm will move when loads are applied to the drive belt by the accessory drive components and the crankshaft. The drive belt system may have an idler pulley, which is used to add wrap to the adjacent pulleys. Some systems use an idler pulley in place of an accessory drive component when the vehicle is not equipped with the accessory. Page 9067 Relay Block I/P C7 (With RPO Codes Z82 Or T89) Service and Repair Rocker Arm Assembly: Service and Repair Valve Rocker Arm and Push Rod Replacement Removal Procedure 1. Remove the valve rocker arm cover. Important: Place the valve rocker arms, pushrods, and pivot support, in a rack so that they can be installed in the same location from which they were removed. 2. Remove the valve rocker arm bolts. 3. Remove the valve rocker arms. 4. Remove the valve rocker arm pivot support. 5. Remove the pushrods. 6. Clean and inspect the valve rocker arms and pushrods. Installation Procedure Important: When reusing the valve train components, always install the components to the original location and position. Valve lash is net build, no valve adjustment is required. Page 13539 6. Use fingers to squeeze the 2 locking legs of the cover. 7. Apply pressure and gently rock the cover until one locking leg is unseated. 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. Page 5038 Disclaimer Page 9383 15. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 16. Install the electrical ground wire terminal to the rivet stud. 17. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 18. Install the M6 conductive nut to the rivet stud and: Tighten Tighten to 8 Nm (71 lb in). 19. Verify proper system operation. M6 Weld Nut Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M6 weld nut at the electrical ground location is damaged or stripped, a M7 conductive self-threading bolt may be used to secure the ground wire terminal. 2. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the weld nut and allow to dry. 3. Remove any loose metal particles from the damaged or stripped weld nut with a stiff brush. 4. Select a M7 conductive self-threading bolt. Refer to the Parts Information section of this bulletin 5. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M7 conductive self-threading bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 6. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 7. Install the electrical ground wire terminal to the M7 conductive self-threading bolt. 8. Install the M7 conductive self-threading bolt and: Tighten Tighten to 9 Nm (80 lb in). 9. Verify proper system operation. M6 Weld Nut Alternative Repair Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the electrical ground location is accessible from both sides of the panel, a M6 conductive bolt and a M6 conductive nut may be used to secure the electrical ground wire terminal. Refer to the Parts Information section of this bulletin. 2. Select a location adjacent the damaged M6 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the new electrical ground site. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the ground location and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 8.5 mm (0.33 in) diameter hole through the panel. 5. Remove paint and primer from the area surrounding the 8.5 mm (0.33 in) hole until bare metal is visible. 6. Select a M6 conductive bolt. Refer to the Parts Information section of this bulletin. 7. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 8. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 9. Install the electrical ground wire terminal and the M6 conductive bolt to the ground location. 10. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 11. Install the M6 conductive nut to the bolt and: Engine Controls - MIL ON/Rough Idle/Misfire/DTC's Set Oxygen Sensor: All Technical Service Bulletins Engine Controls - MIL ON/Rough Idle/Misfire/DTC's Set Bulletin No.: 05-06-04-063 Date: October 12, 2005 TECHNICAL Subject: LM7, L59 or L33 Engines with Cold Start Rough or Incorrect Idle, Misfire, Malfunction Indicator Lamp (MIL) or Flashing Requiring 02 Sensor Replacement (Reprogram PCM) Models: 2004-2005 Cadillac Escalade 2004-2005 Chevrolet Avalanche, Silverado 1500, Suburban, Tahoe 2005 Chevrolet Silverado Hybrid (HP2) 2004-2005 GMC Sierra 1500, Yukon, Yukon XL 2005 GMC Sierra Hybrid (PH2) with Vortec 5300 5.3L V-8 Engine (VINs T, Z, B - RPOs LM7, L59, L33) Condition Some customers may comment on a Malfunction Indicator Lamp (MIL) On or that the MIL is flashing. An actual engine misfire may or may not be felt along with an incorrect idle speed. Typically this occurs during cold winter months, on cold engine starts. Some vehicles may have been previously serviced for the same condition. Technicians may also find the following DTCs stored with the Tech 2(R) P0131, P0133, P0134, P0137, P0138, P0140, P0151, P0153, P0154, P0157, P1133, which may be in conjunction with P0171, P0174, P0300 and P1138. Cause Water shock occurs when water droplets are present in the exhaust. The water in the exhaust contacts the sensor element inside the H02 sensor, causing the H02 sensor element to crack. Correction Upon diagnostic investigation, the technician may find that the H02 sensor requires replacement. In addition to replacing the affected H02 sensor, these vehicles should also be reflashed with the latest PCM calibration. An updated PCM calibration will be available to dealerships as part of TIS 2000 incremental satellite update 11.0 (NAO version 25.010) or greater. Always, make sure your Tech 2 is updated with the latest software version. Important: If a DTC P0420 or P0430 is stored along with DTC(s) P0300, the catalytic converter diagnostics in Service Information (SI) must be followed to determine if the catalytic converters are operating properly. Warranty Information For vehicles repaired under warranty, use the table. Page 13120 Circuit/System Testing Component Testing AWD/4WD - AWD/4WD Lamps/System Inop./DTC C0550 Control Module: Customer Interest AWD/4WD - AWD/4WD Lamps/System Inop./DTC C0550 Bulletin No.: 02-04-21-006E Date: July 20, 2006 TECHNICAL Subject: Inoperative 4WD/AWD Lamps, Inoperative 4WD/AWD System, DTC C0550 Set, No Communication with TCCM (Reprogram Transfer Case Control Module) Models: 2004 Buick Rainier 2002-2004 Chevrolet TrailBlazer, TrailBlazer EXT 2003-2004 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2002-2004 GMC Envoy, Envoy XL 2003-2004 GMC Sierra, Yukon, Yukon XL 2004 GMC Envoy XUV 2002-2004 Oldsmobile Bravada with Electronic Shift or Active Transfer Case (RPOs NP1, NP4 or NP8) Supercede: This bulletin is being revised to add Subject information and change the labor operation. This bulletin cancels and supersedes Bulletin Number 03-04-21-006. Please discard Corporate Bulletin Numbers 02-04-21-006D and 03-04-21-006 (Section 04 - Driveline/Axle). Condition Some customers may comment that the 4WD/AWD indicator lights on the selector switch do not work, or the 4WD/AWD system may be inoperative and/or the service 4WD light is illuminated. The condition is typically intermittent and always occurs at key-up. Upon investigation, the technician may find DTC C0550 set. Cause The Transfer Case Control Module (TCCM) has not received the wake-up call during key-up and has remained in the "sleep mode". When the TCCM is in the "sleep mode", it will not communicate with the class II bus or the Tech 2(R). Correction 1. Try to communicate with the TCCM. If no communication, go to step 2. If communication is possible, go to step 5. 2. Remove the underhood (ATCM or TREC) TCCM fuse. 3. Wait 30 seconds. 4. Reinstall the fuse. The module should wake up and communicate with the Tech 2(R). 5. Check for codes in the TCCM. If a C0550 is found current or in history with or without other codes, replace the module and go to step 6. 6. Reprogram the TCCM with the latest TIS software using normal SPS procedures. 7. Verify operation and that no codes are present. Important: For the 2002 model year, the TCCM must be replaced and reprogrammed. Warranty Information Page 6805 1. Install a new gasket and the rear axle housing cover (2). 2. Notice: Refer to Fastener Notice in Service Precautions. Important: Do not reuse the rear axle housing cover bolts. Install the new rear axle housing cover bolts (1). ^ Tighten the bolts to 40 Nm (30 ft. lbs.). 3. Fill the rear axle. Use the proper fluid. 4. Install the rear axle fill plug. ^ Tighten the rear axle fill plug to 33 Nm (24 ft. lbs.). 5. Lower the vehicle. 9.75 Inch Axle Lubricant Replacement - Rear Drive Axle (9.75 Inch Axle) Removal Procedure 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Remove the rear axle fill plug. Page 6260 8. Install the transmission support. 9. Install the transmission support side bracket and bolts. 10. Install the transmission support bolts and nuts. ^ Tighten the bolts/nuts to 95 Nm (70 ft. lbs.). 11. Install the transmission mount nuts. ^ Tighten the nuts to 40 Nm (30 ft. lbs.). 12. Remove the transmission jack. 13. Lower the vehicle. 14. Fill the transmission to the proper level with DEXRON® III transmission fluid. Page 264 ^ Pay the dealer the regular retail price (no discounts are available) for one of the following 1-year, non-refundable OnStar(R) Analog-to-Digital Transition (ADT) Service Subscription Plans: ^ 1-year Safe & Sound Subscription: $199 ($289 in Canada) ^ 1-year Directions & Connections Subscription: $399 ($579 in Canada) ^ Pay the dealer the applicable state and local sales taxes on the subscription: ^ U.S. Dealers: Taxes only apply in these states: CT, DC, FL, HI, ND, NJ, NM, NY, SC, SD, TX, and WV ^ Canadian Dealers: All applicable taxes ^ Pay the dealer a one-time charge of $15 for the upgrade: ^ U.S. Dealers: Do not collect taxes on the $15 ^ Canadian Dealers: Collect all applicable taxes on the $15 Note: Dealers should NOT remit OnStar(R) ADT-related taxes to their taxing authority as OnStar(R) is responsible for tax remittance. Please Be Sure To Read these Important Points: ^ The 1-year OnStar(R) subscription is not refundable or transferable to another person. Upgraders can apply unused subscription months to a new or Certified Pre-Owned digital OnStar-equipped GM vehicle purchase or lease. As noted above, the digital upgrade program requires the subscriber to purchase a one-year prepaid OnStar(R) subscription. Assuming the subscriber intends to keep their vehicle, but subsequently purchases or leases a 2006 model year or newer OnStar(R)-equipped new or certified used GM vehicle, in the interest of subscriber satisfaction, they may apply remaining unused whole months of the subscription to the new vehicle. The subscription may not be applied to another person's vehicle. Important: This is a customer satisfaction measure that would usually occur several months after an upgrade. It is not intended to be leveraged as part of a new/used vehicle purchase or lease transaction. ^ The $15 charge is not refundable. ^ Dealer ADT kit orders are VIN specific. Dealer kit orders require a VIN and must be exchanged with the OnStar(R) unit in the vehicle with that VIN. Proper activation and enrollment depends on this step. ^ You must put the actual miles on the Repair Order. Do not estimate. ^ Customers will receive a Hands-Free Calling number once the digital hardware is installed and configured. ^ Any nametags that were stored in the old system will need to be re-set by the subscriber once the new hardware is installed. ^ Customers are responsible for the charges described above regardless of whether their vehicle is in or out of the New Vehicle Warranty period. In addition, customers should not be charged labor costs. Dealers can charge GM the labor for the upgrade as specified at the end of this bulletin using the listed labor operation. ^ Vehicles eligible for an OnStar(R) hardware upgrade are listed in this bulletin. Vehicle upgradeability can also be determined by typing the VIN into the field entitled "Determine VIN Hardware Functionality" on the OnStar(R) Online Enrollment website, located in the sales or service workbench tab of GM GlobalConnect. Canadian Dealers can use a similar tool that is available within InfoNET. ^ Access to the sales and/or service workbench in the GM GlobalConnect website can be granted by the dealership's Partner Security Coordinator (PSC). If you are unsure who the PSC is, check with the Sales Manager. Ordering the Upgrade Kit/Upgrade kit Installation Ordering the Upgrade Kit 1. To order a kit, you will need to access the OnStar(R) Online Enrollment webpage, located under the sales or service workbench of GM GlobalConnect (infoNET for Canadian upgrade orders). These kits cannot be ordered from GMSPO. Page 12800 High OR Low The above conditions are met for more than 3 seconds. Circuit/System Verification These DTCs cannot be retrieved with a current status. To diagnose use the Scan Tool Does Not Communicate with a Class 2 Device. Refer to SI. An intermittent condition is likely to be caused by a short on the Class 2 serial data circuit. To diagnose use the Scan Tool Does Not Communicate with a Class 2 Device. Refer to SI. DTC B2455 DTC Descriptors DTC B2455 01: Cellular Phone Microphone Circuit Short to Battery DTC B2455 02: Cellular Phone Microphone Circuit Short to Ground DTC B2455 04: Cellular Phone Microphone Circuit Open Circuit Circuit/System Description Without RPO UAV The vehicle communication interface module (VCIM) uses the cellular phone microphone to allow driver communication with OnStar(R). With RPO UAV The vehicle communication interface module (VCIM) and navigation radio use the cellular phone microphone to allow driver communication with OnStar(R), as well as to operate the voice recognition/voice guidance feature of the navigation radio. Conditions for Running the DTC The ignition is in RUN or ACC position. System voltage is between 9.5 - 15.5 volts. The above conditions are met for more than 10 seconds. Conditions for Setting the DTC B2455 01: A short to battery is detected on the cellular microphone signal circuit. B2455 02: A short to ground is detected on the cellular microphone signal circuit. B2455 04: An open circuit is detected on the cellular microphone signal circuit. Action Taken When the DTC Sets The VCIM and/or navigation radio (RPO UAV) will not receive any signal from the microphone. The OnStar(R) status LED turns red. Voice recognition will not function. Conditions for Clearing the DTC Page 13244 Circuit/System Testing Component Testing Page 4686 Body Control Module (BCM) - C4 Part 2 Coolant Air Bleed Pipe Assembly Replacement Cooling System Air Bleeder Pipe / Hose: Service and Repair Coolant Air Bleed Pipe Assembly Replacement Coolant Air Bleed Pipe Assembly Replacement (4.8L, 5.3L, and 6.0L Engines) Removal Procedure 1. Drain the cooling system. 2. Remove the coolant air bleed pipe bolts/studs (1). 3. Remove the coolant air bleed pipe (2) with gaskets (3). 4. Remove the coolant air bleed pipe cover bolts (1) and covers (2). Specifications Exhaust Manifold: Specifications Exhaust manifold bolts. 1. Tighten the exhaust manifold bolts a first pass to 15 Nm (11 ft. lbs.). Tighten the exhaust manifold bolts beginning with the center two bolts. Alternate from side-to-side, and work toward the outside bolts. 2. Tighten the exhaust manifold bolts a final pass to 25 Nm (18 ft. lbs.). Tighten the exhaust manifold bolts beginning with the center two bolts. Alternate from side-to-side, and work toward the outside bolts. Service and Repair Brake Proportioning/Combination Valve: Service and Repair Combination Valve Replacement Removal Procedure Important: Note the identification code on the combination valve. The new valve must have the same identification number as the old valve. 1. Remove the combination valve electrical connector. 2. Remove the front and the rear brake pipes. 3. Remove the combination valve from the vehicle. Installation Procedure Important: Verify that the replacement combination valve has the same pin punched identification code as the code on the old combination valve. 1. Install the combination valve to the vehicle. 2. Notice: Refer to Fastener Notice in Service Precautions. Install the front and the rear brake pipes to the combination valve. ^ Tighten the brake pipe nuts to 25 Nm (18 ft. lbs.). 3. Connect the combination valve electrical connector. 4. Important: Verify that the combination valve metering rod is depressed during bleeding. Bleed the brake system. Page 13281 7.2. Remove the console (A). 7.3. Disconnect the connector (B) from the OnStar(R) control module. Important: Secure the cable harness to prevent the risk of scraping and rattling. 7.4. Fold back the cable harness and tape down the connector (C). Fold back the cable harness again and secure with cable ties (D). 7.5. 5D: Assemble the right-hand cover for the luggage compartment floor. 8. Fit the ground cable on the battery's negative cable. Page 1441 2. Connect the backup lamp switch electrical connector (3). 3. Lower the vehicle. Page 4301 When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage TESTING FOR A SHORT TO VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity TESTING FOR CONTINUITY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents TESTING FOR ELECTRICAL INTERMITTENTS Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground - Testing for Continuity - Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 msRECORD and emits an audible tone (beep). Page 10193 Steering Column Position Sensor: Service and Repair Steering Wheel Position Sensor Centering Steering Wheel Position Sensor Centering Removal Procedure 1. Important: Identify the type of steering wheel position sensor from the illustrations shown BEFORE removing the sensor from the steering column. Once you have identified the steering wheel position sensor, follow the instructions listed in the removal procedure. Verify the type of steering wheel position sensor. 2. From the technicians point of view, the FRONT of the sensor (1) connector will be on the right. 3. Important: If reusing the existing sensor, you do not have to align the sensor before removal. Centering is not required when it is time to reinstall. Remove the connector from the sensor. 4. Remove the sensor (1) from the adapter and bearing assembly. 5. To install the sensor, proceed to step 1 in the installation section. 6. From the technicians point of view, the FRONT of the sensor will have: ^ A foam ring (2) ^ A pin hole (1) for centering the pin. Note the location of the pin hole. ^ A flush rotor flange cuff (4) 7. Important: If reusing the existing sensor, you must make an alignment mark on the rotor flange cuff (3) before removing the sensor. Failure to do so will cause misalignment when installing the sensor. A new sensor will be required if misaligned. Make an alignment mark on the flush rotor flange cuff (3). 8. Remove the connector from the sensor. 9. Remove the sensor from the adapter and bearing assembly. 10. To install the sensor, proceed to step 5 in the installation procedure. Page 12215 7.3. If equipped, connect the rear seat heater's connector and install the switch. 8. Install the floor console: 8.1. Install the floor console's retaining bolts (C) and retaining nuts (F). 8.2. Align the rear cover; make sure that the air duct connects firmly to the air nozzle. Screw in the cover (E). 8.3. Install the ashtray/cover (D). 8.4. Install the ignition switch cover (B). 8.5. Plug in the immobilizer unit (A) connector. Install the unit, bayonet fitting. 9. Remove the OnStar(R) control modules and secure the wiring: 9.1. Remove the right-hand rear luggage compartment trim in accordance with WIS - 8. Body - Interior equipment - Adjustment/Replacement. 9.2. Unplug the connectors (A) from the OnStar(R) control modules. 9.3. Remove the console (B) together with the OnStar(R) control modules. Page 15636 Fog Lamp Switch Rear (With RPO Code T79) Automatic Transmission - 4L60-E/4L65-E Transmission Speed Sensor: Locations Automatic Transmission - 4L60-E/4L65-E Automatic Transmission Electronic Component Views (M30/M32) Electronic Components Page 1088 1. Connect the brake pedal position sensor (2) electrical connector (1). 2. Align the brake pedal position sensor (1) with the actuation arm (2) on the brake pedal and the brake pedal position sensor mounting bracket. Page 13098 Vehicles Built with Upgradeable OnStar(R) System Analog Modules Note: Page 3798 7. Insert the J 38125-13A (GM P/N 12031876-1) tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the Terminal Repair Kit to ensure that the correct release tool is used. 8. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. REPAIR PROCEDURE Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. Page 4864 2. Install the HO2S. Tighten Tighten the sensor to 42 N.m (31 lb ft). 3. If equipped with a 6.0L engine, connect the HO2S electrical connector. 4. If equipped with a 4.8L or 5.3L engine, connect the HO2S electrical connector. 5. Install the HO2S to the clips 6. Disconnect the CPA retainer. 7. Lower the vehicle. Engine Controls - Aftermarket Accessory Usage Engine Control Module: All Technical Service Bulletins Engine Controls - Aftermarket Accessory Usage INFORMATION Bulletin No.: 04-06-04-054B Date: November 18, 2010 Subject: Info - Non-GM Parts and Accessories (Aftermarket) Models: 2011 and Prior GM Passenger Cars and Trucks Supercede: This bulletin is being revised to add model years and update to the new U.S. Fixed Operation Manager (FOM) and Canada Warranty Manager (WM) names. Please discard Corporate Bulletin Number 04-06-04-054A (Section 06 - Engine/Propulsion System). The recent rise and expansion of companies selling non-GM parts and accessories has made it necessary to issue this reminder to dealers regarding GM's policy on the use and installation of these aftermarket components. When a dealer is performing a repair under the New Vehicle Limited Warranty, they are required to use only genuine GM or GM-approved parts and accessories. This applies to all warranty repairs, special policy repairs or any repairs paid for by GM. Parts and accessories advertised as being "the same" as parts manufactured by GM, but not sold through GM, do not qualify for use in warranty repairs, special policy repairs or any repairs paid for by GM. During a warranty repair, if a GM original equipment part is not available through GM Customer Care and Aftersales (GM CC&A;), ACDelco(R) distributors, other GM dealers or approved sources, the dealer is to obtain comparable, non-GM parts and clearly indicate, in detail, on the repair order the circumstances surrounding why non-GM parts were used. The dealer must give customers written notice, prior to the sale or service, that such parts or accessories are not marketed or warranted by General Motors. It should also be noted that dealers modifying new vehicles and installing equipment, parts and accessories obtained from sources not authorized by GM are responsible for complying with the National Traffic and Motor Vehicle Safety Act. Certain non-approved parts or assemblies, installed by the dealer or its agent not authorized by GM, may result in a change to the vehicle's design characteristics and may affect the vehicle's ability to conform to federal law. Dealers must fully understand that non-GM approved parts may not have been validated, tested or certified for use. This puts the dealer at risk for potential liability in the event of a part or vehicle failure. If a GM part failure occurs as the result of the installation or use of a non-GM approved part, the warranty will not be honored. A good example of non-authorized modification of vehicles is the result of an ever increasing supply of aftermarket devices available to the customer, which claim to increase the horsepower and torque of the Duramax(TM) Diesel Engines. These include the addition of, but are not limited to one or more of the following modifications: - Propane injection - Nitrous oxide injection - Additional modules (black boxes) that connect to the vehicle wiring systems - Revised engine calibrations downloaded for the engine control module - Calibration modules which connect to the vehicle diagnostic connector - Modification to the engine turbocharger waste gate Although the installation of these devices, or modification of vehicle components, can increase engine horsepower and torque, they may also negatively affect the engine emissions, reliability and/or durability. In addition, other powertrain components, such as transmissions, universal joints, drive shafts, and front/rear axle components, can be stressed beyond design safety limits by the installation of these devices. General Motors does not support or endorse the use of devices or modifications that, when installed, increase the engine horsepower and torque. It is because of these unknown stresses, and the potential to alter reliability, durability and emissions performance, that GM has adopted a policy that prevents any UNAUTHORIZED dealer warranty claim submissions to any remaining warranty coverage, to the powertrain and driveline components whenever the presence of a non-GM (aftermarket) calibration is confirmed - even if the non-GM control module calibration is subsequently removed. Refer to the latest version of Bulletin 09-06-04-026 (V8 Gas Engines) or 06-06-01-007 (Duramax(TM) Diesel Engines) for more information on dealer requirements for calibration verification. These same policies apply as they relate to the use of non-GM accessories. Damage or failure from the use or installation of a non-GM accessory will not be covered under warranty. Failure resulting from the alteration or modification of the vehicle, including the cutting, welding or disconnecting of the vehicle's original equipment parts and components will void the warranty. Additionally, dealers will NOT be reimbursed or compensated by GM in the event of any legal inquiry at either the local, state or federal level that Page 393 Labor Time Information Page 13562 Body Control Module (BCM) - C2 Part 3 Page 12923 Audio Amplifier C2 - With RPO Code UQ7, Y91 - Part 2 Page 2744 Junction Block - I/P Wire Entry Part 3 Page 13540 9. Use J 38125-12A to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. REPAIR PROCEDURE The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. 1. Cut the wire as close to the terminal as possible. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. Locations Page 3296 The dexos (TM) specification and trademarks are exclusive to General Motors, LLC. Only those oils displaying the dexos (TM) trademark and icon on the front label meet the demanding performance requirements and stringent quality standards set forth in the dexos (TM)specification. Look on the front label for any of the logos shown above to identify an authorized, licensed dexos 2(TM) engine oil. GM dexos 2(TM) Engine Oil Specification - dexos 2(TM) is approved and recommended by GM for use in Europe starting in model year 2010 vehicles, regardless of where the vehicle was manufactured. - dexos 2(TM) is the recommended service fill oil for European gasoline engines. Important The Duramax(TM) diesel engine is the exception and requires lubricants meeting specification CJ-4. - dexos 2(TM) is the recommended service fill oil for European light-duty diesel engines and replaces GM-LL-B-025 and GM-LL-A-025. - dexos 2(TM) protects diesel engines from harmful soot deposits and is designed with limits on certain chemical components to prolong catalyst life and protect expensive emission reduction systems. It is a robust oil, resisting degradation between oil changes and maintaining optimum performance longer. Disclaimer Page 14726 1. Remove the rear seat from the vehicle. 2. Remove the rear passenger seat riser. 3. Remove the hog rings and/or the J-clips from the rear edge of the seat cushion cover (3). 4. Disconnect the rear heater connector, if equipped. 5. Remove the seat belt buckles, if required. 6. Remove all of the remaining hog rings, and/or the J-clips that are retaining the seat cushion cover (3) to the seat cushion frame (8). 7. Release the hook, and the loop-strips that are retaining the seat cushion cover to the foam pad (4). 8. Remove the center screw retaining the latch cover, if equipped. 9. Remove the seat cushion cover from the foam pad. INSTALLATION PROCEDURE A/C - Underhood Rattle Noise on Hard Acceleration Refrigerant Filter: Customer Interest A/C - Underhood Rattle Noise on Hard Acceleration File In Section: 01 - HVAC Bulletin No.: 03-01-38~019A Date: September, 2004 TECHNICAL Subject: Underhood Rattle Noise Heard On Acceleration (Check A/C System Performance and Compressor Operation) Models: 2003-2004 Cadillac CTS 2002-2004 Cadillac Escalade, Escalade EXT 2003-2004 Cadillac Escalade ESV 2002-2004 Chevrolet Avalanche, Express, Silverado, Suburban, Tahoe 2002-2004 GMC Denali, Denali XL, Savana, Sierra, Yukon, Yukon XL 2002-2004 Commercial Upfitter Chassis Vehicles with Air Conditioning (A/C) This bulletin is being revised to update the service procedure and parts information. Please discard Corporate Bulletin Number 03-01-38-019 (Section 01 - HVAC). Condition Some customers may comment about an underhood rattle noise heard on acceleration or a sudden loss of A/C system performance. Cause This condition may be caused by liquid slugging of the A/C compressor. This condition may cause an internal failure in the A/C compressor. The serpentine belt tensioner and serpentine belt may also be damaged. Correction Technicians are to check the A/C system performance and compressor operation using the following repair procedure: 1. Open the hood and inspect the A/C compressor for damage and to see if the compressor is seized. Verify that the serpentine belt is not damaged or missing. If the A/C compressor is seized, proceed to Step 5. 2. Perform the A/C System Performance test. Refer to the Heating, Ventilation and Air Conditioning (HVAC) section of SI. Correct any performance concerns or refrigerant leaks that are found. 3. Inspect the vehicle for other possible sources of A/C compressor noise or performance concerns. Refer to Corporate Bulletin Number 01-01-38-013 for more information. 4. After all other possible sources of A/C compressor noise or performance concerns have been eliminated, only then should the A/C compressor be replaced. 5. Remove the A/C compressor. Refer to the A/C Compressor Replacement procedure in the HVAC section of SI. 6. Inspect the transmission cooler lines for damage due to contact from the serpentine belt. Replace the transmission cooler lines if necessary. 7. Install an inline A/C system filter. Refer to Corporate Bulletin Number 01-01-38-006C for more information about A/C system flushing and filter installation procedures. An A/C system flush is not to be done unless prior authorization is given by the GM Area Service Manager (in Canada, the District Service Manager). 8. Install an A/C Suction Screen. Refer to Corporate Bulletin Number 01-01-39-003A for more information about A/C suction screen repair recommendations and procedures. 9. Install a new A/C compressor. Refer to the Compressor Replacement procedure in the HVAC section of SI. 10. Install a new orifice tube for the front A/C system. Refer to the Expansion (Orifice) Tube Replacement procedure in SI. Page 9453 Auxiliary Power Outlet - Front (Except Z75) Service and Repair Parking Brake Actuator: Service and Repair Park Brake Actuator Replacement (15 Series) Caution: Refer to Brake Dust Caution in Service Precautions. Removal Procedure 1. Release the park brake. 2. Raise and support the vehicle. Refer Vehicle Lifting 3. Remove the tire and wheel assembly. 4. Relieve the tension from the park brake cables from the equalizer by pulling down on the intermediate cable and release the rear cables from the equalizer bar. 5. Remove the rear park brake cable from the park brake actuator lever. 6. For vehicles without RPO NYS, remove the park brake cable from the mounting bracket by depressing the locking tabs. 7. For vehicles with RPO NYS, remove the rear park brake bracket bolt. 8. Remove the rotor. 9. Remove the axle shaft. 10. Remove the park brake shoe. 11. Remove the backing plate bolts. 12. Remove the park brake actuator lever housing from the backing plate. Installation Procedure 1. Install the park brake actuator lever housing to the backing plate. 2. Perform the following procedure before installing the backing plate bolts. Page 14920 Front Passenger Door Module (FPDM) - C5 (Heated Seat Switch) Page 9709 C115 Chassis Harness To I/P Harness (With RPO Code NYS) Part 1 Page 9928 available, measurements may also be clearly and legibly handwritten into the Wheel Alignment Repair Order Questionnaire attached to this bulletin. 4. Attach the Wheel Alignment Repair Order Questionnaire below along with the print-out of "Before" and "After" wheel alignment measurements to the Repair Order and retain for use by GM. Wheel Alignment Equipment and Process Wheel alignments must be performed with a quality machine that will give accurate results when performing checks. "External Reference" (image-based camera technology) is preferred. Please refer to Corporate Bulletin Number 05-00-89-029B: General Motors Dealership Critical Equipment Requirements and Recommendations. Requirements: - Computerized four wheel alignment system. - Computer capable of printing before and after alignment reports. - Computer capable of time and date stamp printout. - Racking system must have jacking capability - Racking system must be capable of level to 1.6 mm (1/16 in) - Appropriate wheel stops and safety certification - Built-in turn plates and slip plates - Wheel clamps capable of attaching to 20" or larger wheels - Racking capable of accepting any GM passenger car or light duty truck - Operator properly trained and ASE-certified (U.S. only) in wheel alignment Recommendations: Racking should have front and rear jacking capability. Equipment Maintenance and Calibration: Alignment machines must be regularly calibrated in order to give correct information. Most manufacturers recommend the following: - Alignment machines with "internal reference" sensors should be checked (and calibrated, if necessary) every six months. - Alignment machines with "external reference" (image-based camera technology) should be checked (and calibrated, if necessary) once a year. - Racks must be kept level to within 1.6 mm (1/16 in). - If any instrument that is part of the alignment machine is dropped or damaged in some way, check the calibration immediately. Check with the manufacturer of your specific equipment for their recommended service/calibration schedule. Wheel Alignment Process When performing wheel alignment measurement and/or adjustment, the following steps should be taken: Preliminary Steps: 1. Verify that the vehicle has a full tank of fuel (compensate as necessary). 2. Inspect the wheels and the tires for damage. 3. Inspect the tires for the proper inflation and irregular tire wear. 4. Inspect the wheel bearings for excessive play. 5. Inspect all suspension and steering parts for looseness, wear, or damage. 6. Inspect the steering wheel for excessive drag or poor return due to stiff or rusted linkage or suspension components. 7. Inspect the vehicle trim height. 8. Compensate for frame angle on targeted vehicles (refer to Wheel Alignment Specifications in SI). Satisfactory vehicle operation may occur over a wide range of alignment angles. However, if the wheel alignment angles are not within the range of specifications, adjust the wheel alignment to the specifications. Refer to Wheel Alignment Specifications in SI. Give consideration to excess loads, such as tool boxes, sample cases, etc. Follow the wheel alignment equipment manufacturer's instructions. Measure/Adjust: Important Prior to making any adjustments to wheel alignment on a vehicle, technicians must verify that the wheel alignment specifications loaded into their wheel alignment machine are up-to-date by comparing these to the wheel alignment specifications for the appropriate model and model year in SI. Using incorrect and/or outdated specifications may result in unnecessary adjustments, irregular and/or premature tire wear and repeat customer concerns Page 4672 Control Module References Part 1 Page 15869 Turn Signal Multifunction Switch - C3 Page 8294 4. Raise and support the vehicle. Refer Vehicle Lifting 5. Remove the tire and wheel assembly. 6. Install a C-clamp over the body of the brake caliper, with the C-clamp ends against the rear of the caliper body and the outboard disc brake pad. 7. Slowly tighten the C-clamp until the pistons are pushed into the caliper bores enough to remove the caliper from the pads. 8. Remove the C-clamp from the caliper. 9. Clean all dirt and foreign material from the brake hose end. 10. Important: Install a rubber cap or plug to the exposed brake pipe fitting end to prevent brake fluid loss and contamination. Remove the brake hose to caliper bolt from the brake caliper. 11. Remove the brake hose from the caliper. 12. Remove and discard the 2 copper brake hose gaskets. These gaskets may be stuck to the brake caliper housing or the brake hose end. Page 13528 When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage TESTING FOR A SHORT TO VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity TESTING FOR CONTINUITY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents TESTING FOR ELECTRICAL INTERMITTENTS Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground - Testing for Continuity - Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 msRECORD and emits an audible tone (beep). Service and Repair Clutch Pedal Assembly: Service and Repair Clutch Pedal Replacement Removal Procedure 1. Remove the driver's side knee bolster and deflector. 2. Disconnect and reposition the junction block. 3. Disconnect the clutch pedal position switch electrical connector (1). 4. Push the clutch pedal in and squeeze the pushrod bushing tabs in, in order to release the pushrod bushing from the clutch pedal. 5. If equipped with a NV 3500 or NV 4500 transmission, disconnect the clutch master cylinder to clutch actuator cylinder quick connect fitting. 6. Remove the clutch master cylinder clip from the brake pressure module valve pipe. 7. If equipped with a ZF S6-650 transmission, disconnect the clutch master cylinder to clutch actuator cylinder quick connect fitting. Page 9717 C150 4-Wheel Drive Harness To 4-Wheel Drive Jumper Harness (With RPO Code NP8) Air Temperature Sensor - Upper Left Air Temperature Sensor - Upper Left Page 5102 Evaporative Emissions Hose: Service and Repair EVAP System Hoses/Pipes Replacement EVAPORATIVE EMISSION (EVAP) SYSTEM HOSES/PIPES REPLACEMENT REMOVAL PROCEDURE IMPORTANT: Clean the evaporative emission (EVAP) line connections and surrounding areas prior to disconnecting the fittings in order to avoid possible fuel system contamination. 1. Remove the fuel tank. 2. Disconnect and remove the EVAP line (1) from the roll over valve, sending unit and retaining clips. 3. Cap the fuel feed/return, and EVAP lines in order to prevent possible fuel/EVAP system contamination. INSTALLATION PROCEDURE 1. Remove the caps from the fuel feed/return, and EVAP lines. 2. Install and connect the EVAP line (1) to the roll over valve, sending unit and retaining clips. 3. Install the fuel tank. Page 8420 1. Connect the front park brake cable to the park brake lever. 2. Install the park brake lever. 3. Notice: Refer to Fastener Notice in Service Precautions. Install the park brake lever mounting nuts. ^ Tighten the nuts to 25 Nm (18 ft. lbs.). 4. Connect the park brake release cable and housing to the park brake lever. Page 4497 IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections TESTING FOR INTERMITTENT AND POOR CONNECTIONS TOOLS REQUIRED - J 35616-C GM-Approved Terminal Test Kit - J 38125-D Terminal Repair Kit - J 42675 Flat-Wire Probe Adapter Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector. - Poor terminal to wire connection - Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. - Wire insulation which is rubbed through - This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. - Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. Testing For Proper Terminal Contact It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-D or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-D, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. Page 14080 IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections TESTING FOR INTERMITTENT AND POOR CONNECTIONS TOOLS REQUIRED - J 35616-C GM-Approved Terminal Test Kit - J 38125-D Terminal Repair Kit - J 42675 Flat-Wire Probe Adapter Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector. - Poor terminal to wire connection - Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. - Wire insulation which is rubbed through - This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. - Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. Testing For Proper Terminal Contact It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-D or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-D, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. Page 7698 Parts Information Warranty Information (excluding Saab U.S. Models) Warranty Information (Saab U.S. Models) Page 12799 ^ I/O check Any faults detected during the initialization self-test shall generate a DTC. All nodes also continuously perform a self-test while in an active state. DTCs and their associated telltales will set as a result of unprogrammed or unlearned information. DTCs, which are defined for system configuration (e.g. Vehicle Option Content not programmed) do not support the history status bit (set =0). Warning indicator bit is also set, when applicable, while this DTC is present. Action Taken When the DTCs Sets The module suspends all message transmission. The module uses default values for all parameters received on the serial data circuits. The module inhibits the setting of all other communication DTCs. Conditions for Clearing the DTC A current DTC clears when the malfunction is no longer present. A history DTC clears when the module ignition cycle counter reaches the reset threshold of 50, without a repeat of the malfunction. Circuit/System Verification Refer to Data Link References to determine which serial data system is used for a specific module. The DTCs cannot be retrieved with a current status. Diagnosis is accomplished using the following symptom procedures: Scan Tool Does Not Communicate with High Speed GMLAN Device in SI. OR Scan Tool Does Not Communicate with Low Speed GMLAN Device in SI. DTC U1300, U1301, or U1305 Circuit Description Modules connected to the Class 2 serial data circuit monitor for serial data communications during normal vehicle operation. Operating information and commands are exchanged among the modules. In addition to this, Node Alive messages are transmitted by each module on the Class 2 serial data circuit about once every 2 seconds. When the module detects one of the following conditions on the Class 2 serial data circuit for approximately 3 seconds, the setting of all other Class 2 serial communication DTCs is inhibited and a DTC will set. Conditions for Running the DTCs Voltage supplied to the module is in the normal operating voltage range. The vehicle power mode requires serial data communication to occur. Conditions for Setting the DTCs No valid messages are detected on the Class 2 serial data circuit. The voltage level detected on the Class 2 serial data circuit is in one of the following conditions: Page 9120 Ground Strap: Service and Repair GROUND STRAP REPLACEMENT REMOVAL PROCEDURE 1. If necessary, remove the engine sight shield. 2. Remove the engine wiring harness ground bolt. 3. Reposition the engine wiring harness ground and ground strap. 4. Remove the ground strap nut from the stud at the front of dash. 5. Remove the ground strap from the stud. INSTALLATION PROCEDURE Page 15946 When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage TESTING FOR A SHORT TO VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity TESTING FOR CONTINUITY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents TESTING FOR ELECTRICAL INTERMITTENTS Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground - Testing for Continuity - Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 msRECORD and emits an audible tone (beep). Electrical - A/T Stuck in 2nd/3rd Gear/MIL ON/DTC's Wiring Harness: Customer Interest Electrical - A/T Stuck in 2nd/3rd Gear/MIL ON/DTC's Bulletin No.: 01-07-30-002E Date: September 23, 2005 TECHNICAL Subject: Malfunction Indicator Lamp (MIL) On, Transmission Stuck in Second or Third Gear, Instrument Cluster Inoperative (Verify and Repair Source of Voltage Loss In Transmission Solenoid Power Supply Circuit) Models: 2006 and Prior GM Passenger Cars and Light Duty Trucks 2005-2006 HUMMER H2 2006 HUMMER H3 2005-2006 Saab 9-7X with 4L60-E, 4L65-E, 4L80-E or 4L85-E Automatic Transmission (RPOs M30, M32, M33, MT1, MN8) Supercede: This bulletin is being revised to update model years, add additional models and add additional diagnostic information. Please discard Corporate Bulletin Number 01-07-30-002D (Section 07 Transmission/Transaxle). Condition Some customers may comment on one or more of the following conditions: ^ The Malfunction Indicator Lamp (MIL) is ON. ^ The transmission is defaulted to second gear (4L80/85-E). ^ The transmission is defaulted to third gear (4L60/65-E). ^ The instrument cluster is inoperative. Upon investigation, one or all of the diagnostic trouble codes (DTCs) P0740, P0753, P0758, P0785, P0787, P0973, P0976, P1860, P2761, P2764 and P2769 may be set depending on the vehicle. Cause The most likely cause of this condition may be a loss of voltage to the transmission solenoid power supply circuit. This condition may also be the result of an incorrect installation of an aftermarket electronic device such as a remote starter or alarm system. Correction Important: If the vehicle is equipped with an aftermarket electronic device and the DTCs are being set when the device is being used, verify that the appropriate fuse is being supplied battery voltage during operation. If voltage is not present at this fuse, these DTCs will be set due to lack of voltage at the solenoids. This condition is most likely to occur with an incorrectly installed remote starting system. If this is the case, refer the customer to the installer of the system for corrections. ANY REPAIRS DUE TO AFTERMARKET INSTALLATION OF ACCESSORIES IS A NON-WARRANTABLE ITEM. 1. With the ignition switch in the RUN position, test for battery voltage at the circuit fuse in the transmission solenoid power supply circuit. Refer to the appropriate SI Document for the transmission solenoid power supply circuit information. 2. If battery voltage is present at the fuse, inspect the ignition voltage circuit between the fuse and the transmission for possible opens. 3. If battery voltage is not present at the fuse, test for continuity between the fuse and the ignition switch. If NO continuity is between the fuse and the ignition switch, repair the open in that circuit. 4. If you have continuity between the fuse and the ignition switch, the most likely cause is the ignition switch. Replace the ignition switch using the appropriate Ignition Switch Replacement procedure in SI. Refer to group number 2.188 of the parts catalog for part description and usage of the ignition switch. Page 9121 1. Install the ground strap to the stud. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the ground strap nut to the stud at the front of dash. Tighten Tighten the nut to 9 N.m (80 lb in). 3. Position the ground strap and engine wiring harness ground. 4. Install the engine wiring harness ground bolt. Tighten Tighten the bolt to 16 N.m (12 lb ft). 5. If necessary, install the engine sight shield. Page 8050 8. Disconnect the 2 way ABS pump motor connector. 9. Remove the bolts (1) from the EBCM (2). 10. Notice: Do not use a tool to pry the EBCM or the BPMV. Excessive force will damage the EBCM. Important: Do not reuse the EBCM mounting bolts. Always install new bolts. Remove the EBCM (2) from the BPMV (3). Removal may require a light amount of force. 11. Clean the EBCM to BPMV mounting surfaces with a clean cloth. Installation Procedure 1. Important: Do not use RTV or any other type of sealant on the EBCM gasket or mating surfaces. Install the EBCM (2) onto BPMV (3). 2. Important: Do not reuse the old mounting bolts. Always install new bolts with the new BPMV. Install the four EBCM bolts. ^ Tighten the four bolts to 5 Nm (39 inch lbs.) in an X-pattern. 3. Connect the 2 way ABS pump motor connector to the EBCM. 4. Install the BPMV (3) to BPMV bracket (5). 5. Install the BPMV to bracket retaining bolts (4). ^ Tighten the bolts to 9 Nm (7 ft. lbs.). 6. Install the EHCU assembly (1, 2) to the vehicle frame (5). Page 6533 Transmission Cooler: Service and Repair Automatic Transmission - 4L80-E/4L85-E Transmission Oil Cooler Line Quick Connect Fitting Transmission Oil Cooler Line Quick Connect Fitting Removal Procedure 1. Important: Perform the following procedure when removing the retaining rings and cooler lines from the quick connect fittings located on the radiator and/or the transmission. Pull the plastic cap back from the quick connect fitting and down along the cooler line about 5 cm (2 inch). 2. Using a bent-tip screwdriver, pull on one of the open ends of the retaining ring in order to rotate the retaining ring around the quick connect fitting until the retaining ring is out of position and can be completely removed. 3. Remove the retaining ring from the quick connect fitting. 4. Discard the retaining ring. 5. Pull the cooler line straight out from the quick connect fitting. Installation Procedure 1. Important: ^ Do not reuse any of the existing oil lines or oil line fittings if there is excessive corrosion. ^ Do not reuse any of the existing retaining rings that were removed from the existing quick connect fittings. Install new retaining rings. ^ Ensure the following procedures are performed when installing the new retaining rings onto the fittings. Install a new retaining ring into the quick connect fitting using the following procedure: Page 2097 Air Filter Element: Service and Repair AIR CLEANER ELEMENT REPLACEMENT REMOVAL PROCEDURE 1. Remove the air cleaner outlet duct. 2. Disconnect the mass air flow/intake air temperature (MAF/IAT) sensor electrical connector (4). 3. Loosen the air cleaner housing top screws. 4. Remove the air cleaner housing cover. 5. Remove the air filter element. INSTALLATION PROCEDURE Page 8042 Electronic Brake Control Module: Service and Repair Electronic Brake Control Module (EBCM) Replacement Removal Procedure Important: After installation, calibrate the new EBCM to the tire size that is appropriate to the vehicle. 1. Caution: Refer to Battery Disconnect Caution in Service Precautions. Disconnect the negative battery cable. 2. Raise and suitably support the vehicle. 3. Important: The area around the EHCU MUST be free from loose dirt to prevent contamination of disassembled ABS components. Thoroughly wash all contaminants from around the EHCU. 4. Disconnect the chassis electrical connectors from the EBCM. Page 5624 1. Install the CKP sensor. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the CKP sensor bolt. Tighten Tighten the bolt to 25 N.m (18 lb ft). 3. Connect the CKP sensor electrical connector. 4. Install the starter. 5. Perform the CKP system variation learn procedure. See: Testing and Inspection/Programming and Relearning Page 8217 Follow the same tightening sequence for the front wheel hub extension that is used on an eight lug wheel. Install the front wheel hub extension nuts. ^ Tighten the front wheel hub extension nuts to 130 Nm (96 ft. lbs.). 11. Install the tire and wheel assembly. 12. Lower the vehicle. 13. With the engine OFF, gradually apply the brake pedal to approximately 2/3 of its travel distance. 14. Slowly release the brake pedal. 15. Wait 15 seconds, then repeat steps 13-14 until a firm pedal is obtained. This will properly seat the brake caliper pistons and brake pads. 16. Fill the master cylinder reservoir to the proper level with clean brake fluid. Refer to Master Cylinder Reservoir Filling in Hydraulic Brakes. (Except Dual Wheels or NYS) Brake Rotor Replacement - Rear (Except Dual Wheels or NYS) ^ Tools Required J 2619-01 Slide Hammer With Adapter - J 41013 Rotor Resurfacing Kit - J 42450-A Wheel Hub Resurfacing Kit - J-46277 Rotor Removal Tool Caution: Refer to Brake Dust Caution in Service Precautions. Removal Procedure 1. Release the park brake. 2. Raise and suitably support the vehicle. Refer Vehicle Lifting 3. Remove the tire and wheel assembly. 4. Mark the relationship of the rotor to the hub. 5. Install a C-clamp over the body of the brake caliper, with the C-clamp ends against the rear of the caliper body and the outboard disc brake pad. 6. Slowly tighten the C-clamp until the pistons are pushed into the caliper bores enough to remove the caliper from the pads. 7. Remove the C-clamp from the caliper. 8. Remove the brake caliper bracket mounting bolts. 9. Notice: Support the brake caliper with heavy mechanic's wire, or equivalent, whenever it is separated from its mount and the hydraulic flexible brake hose is still connected. Failure to support the caliper in this manner will cause the flexible brake hose to bear the weight of the caliper, which may cause damage to the brake hose and in turn may cause a brake fluid leak. Remove the brake caliper and brake caliper bracket as an assembly and support with heavy mechanic's wire or equivalent. DO NOT disconnect the hydraulic brake flexible hose from the caliper. 10. Remove the rotor retaining push nuts from the wheel studs, if applicable. 11. It may be necessary to strike the end of the hub or the rotor with a dead blow hammer to separate the rotor from the hub. Page 14242 Memory/Heated Seat Switch - Driver (DDM C5) Part 1 Page 13761 Fuel Door: Service and Repair Fuel Filler Door Replacement Removal Procedure 1. Open the fuel filler door. 2. Remove the screws from the fuel filler door. 3. Remove the push-pin retainer from the fuel filler door. 4. Reposition the filler neck assembly to the right. 5. Remove the screws from the fuel filler door. 6. Remove the fuel filler door. Installation Procedure 1. Position the fuel filler door to the quarter panel. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the screws to the fuel filler door. Tighten the screws to 9 N.m (80 lb in). Page 3450 6. Compress the valve spring using the J 38606. 7. Install the valve keys. ^ Use grease in order to hold the valve keys in place. ^ Make sure the keys seat properly in the groove of the valve stem. ^ Carefully release the valve spring pressure, making sure the valve keys stay in place. ^ Remove the J 38606. ^ Tap the end of the valve stem with a plastic faced hammer to seat the keys (if necessary). 8. Remove J 22794 from the spark plug port. 9. Notice: Refer to Fastener Notice in Service Precautions. Hand start the spark plug. ^ Tighten the spark plug to 15 Nm (11 ft. lbs.). 10. Install the spark plug wires at the ignition coil. 11. Install the spark plug wire to the spark plug. 12. Inspect the wires for proper installation: ^ Push sideways on each boot in order to check for proper installation. ^ Reinstall any loose boot. 13. Install the valve rocker arm. Page 8599 Yukon XL vehicles built within the VIN breakpoints shown. Important: Dealers should confirm vehicle eligibility through GMVIS (GM Vehicle Inquiry System) before beginning recall repairs. [Not all vehicles within the above breakpoints may be involved.] For US For dealers with involved vehicles, a Campaign Initiation Detail Report containing the complete Vehicle Identification Number, customer name and address data has been prepared and will be loaded to the GM DealerWorld, Recall Information website. Dealers that have no involved vehicles currently assigned will not have a report available in GM DealerWorld. For Canada For dealers with involved vehicles, a Campaign Initiation Detail Report containing the complete Vehicle Identification Number, customer name and address data has been prepared and is being furnished to involved dealers. Dealers that have no involved vehicles currently assigned will not receive a report with the recall bulletin. For Export For dealers with involved vehicles, a Campaign Initiation Detail Report containing the complete Vehicle Identification Number, customer name and address data has been prepared and is being furnished to involved dealers. Dealers that have no involved vehicles currently assigned will not receive a report with the recall bulletin. The Campaign Initiation Detail Report may contain customer names and addresses obtained from Motor Vehicle Registration Records. The use of such motor vehicle registration data for any other purpose other than follow-up necessary to complete this recall is a violation of law in several states/provinces/countries. Accordingly, you are urged to limit the use of this report to the follow-up necessary to complete this program. Parts Information A very small number of vehicles (less than 90 world-wide) will require the replacement of the hydraulic brake booster. Do not order boosters for shelf stock. When a replacement is required, order the appropriate booster from GMSPO. All replaced boosters (excluding Export) must be returned to the Warranty Parts Center. Hold the booster until you receive the request for return. Special Tool Beginning February 18, 2005, each dealer was shipped a Hydro-Boost Checking Tool, CH 47950, for use in this recall. This tool is being furnished at no charge. Additional tools, if required, may be purchased by contacting SPX Kent-Moore at 1-800-468-6657. Courtesy Transportation The General Motors Courtesy Transportation program is intended to minimize customer inconvenience when a vehicle requires a repair that is covered by the New Vehicle Limited Warranty. The availability of courtesy transportation to customers whose vehicles are within the warranty coverage period and involved in a product recall is very important in maintaining customer satisfaction. Dealers are to ensure that these customers understand that shuttle service or some other form of courtesy transportation is available and will be provided at no charge. Dealers should refer to the General Motors Service Policies and Procedures Manual for Courtesy Transportation guidelines. Page 15424 Oil Change Reminder Lamp: Service and Repair GM OIL LIFE SYSTEM - RESETTING The engine oil life monitor will indicate when to change the engine oil - usually between 5 000 km (3,000 miles) and 16 000 km (10,000 miles) since the last oil change. Under severe conditions, the "CHANGE OIL SOON" light may be displayed before 5 000 km (3,000 miles). The vehicle must not be driven more than 16 000 km (10,000 miles) or 12 months without an oil change. Reset the oil life monitor when the oil has been changed, use the following procedure: 1. Turn the ignition key to the RUN position. 2. Fully push and release the accelerator pedal 3 times within 5 seconds. 3. If the Change Oil Soon light flashes, the system is resetting. 4. Start the vehicle. 5. The oil life will change to 100%. 6. If the Change Oil Soon light comes back on, the system has not reset. Repeat the procedure. Instruments - Oil Life Monitoring System Oil Change Reminder Lamp: All Technical Service Bulletins Instruments - Oil Life Monitoring System Bulletin No.: 04-06-04-045 Date: June 22, 2004 INFORMATION Subject: Oil Life Monitoring System - PCM Reset Models: 2004 All GM Passenger Cars and Trucks Important: The Oil Life Monitoring System can be found on many General Motor's vehicles prior to 2004. Refer to SI and/or the Owner's Manual for detailed information. The purpose of this bulletin is to help technicians identify which vehicles are equipped with the oil life monitoring system. Although many General Motors vehicles prior to 2004 have been equipped with the oil life monitoring system, the 2004 model year vehicles were used as a starting point to validate the system/scan tool functionality. Customers have come to depend on the Oil Life Monitoring System found on most General Motor's vehicles to inform them when it's time for an oil change. If for any reason the PCM is replaced, it is important to access the "Percent of Oil Life Remaining" from the vehicle's current PCM PRIOR to removing the PCM. This value must be programmed into the new PCM (after it is installed in the vehicle) by using the scan tool. Note: Failure to reprogram the value to the new PCM will result in missed maintenance, which may cause damage to the engine. Important: If the replacement module is not programmed with the remaining engine oil life, the engine oil will need to changed at 5,000 km (3,000 mi) from the last engine oil change. Disclaimer Page 12020 8.5. Close the luggage compartment floor. 9. Fold down the left-hand rear side hatch in the luggage compartment. 10. M03: Replace the optic cable on the left-hand rear side: 10.1. Place the optic cable so that it is positioned behind the terminal housing on top of REC (A). 10.2. Remove the locking strip (B) on the 2-pin connector (H2-9) for the optic cable. 10.3. Open the terminal housing (C) with a screwdriver. Remove the secondary catch (D) on the connector and disconnect the optic cable coming from the OnStar(R) control modules. Page 9696 Note The rivet stud and surrounding panel area MUST BE properly refinished PRIOR to the installation of the electrical ground wire terminal and conductive nut to maintain a secure, stable and corrosion-free electrical ground. 11. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 12. Allow the refinished repair area to cure sufficiently before removing the protective material applied to the rivet stud threads. 13. Remove the painters tape or equivalent from the rivet stud threads. 14. Using GM approved residue-free solvent or equivalent, thoroughly clean the rivet stud threads to remove any adhesive and allow to dry. 15. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive rivet stud. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 16. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 17. Install the electrical ground wire terminal to the M6 conductive rivet stud. 18. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 19. Install the M6 conductive nut to the rivet stud and: Tighten Tighten to 8 Nm (71 lb in) 20. Verify proper system operation. Parts Information Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use: Warranty Information (Saab Models) Page 15985 Heated Glass Element: Symptom Related Diagnostic Procedures A Symptoms SYMPTOMS IMPORTANT: - For the inside rearview mirror with the automatic day-night feature, review the system operation in order to familiarize yourself with the system functions. Refer to Automatic Day-Night Mirror Description and Operation. - For the rear window defogger system, the following steps must be performed before using the symptom tables: 1. Perform the Diagnostic System Check - Defogger before using the symptom tables in order to verify that all of the following are true: - There are no DTCs set. - The control modules can communicate via the serial data link. See: Initial Inspection and Diagnostic Overview/Diagnostic System Check - Defogger 2. Review the system operation in order to familiarize yourself with the system functions. Refer to Rear Window Defogger Description and Operation. Visual/Physical Inspection Inspect for aftermarket devices which could affect the operation of the rear window defogger or the automatic day-night feature of the inside rearview mirror. - Inspect the easily accessible or visible system components for obvious damage or conditions which could cause the symptom. Intermittent Faulty electrical connections or wiring may be the cause of intermittent conditions. Symptom List Refer to a symptom diagnostic procedure from the following list in order to diagnose the symptom: Defogger Inoperative - Rear Window - Defogger Grid Lines Diagnosis - Mirrors - Automatic Day-Night Inoperative - Mirrors - Temperature Displays SC or OC - Mirrors - Compass Display Inoperative or Inaccurate Automatic Day/Night Mirror Inoperative - Mirrors MIRRORS - AUTOMATIC DAY-NIGHT INOPERATIVE DIAGNOSTIC AIDS The automatic day-night feature of the inside rearview mirror may not operate properly or become inoperative due to an intermittent short to battery voltage in the backup lighting system. TEST Page 9268 Relay Box: Locations Relay Block - I/P Location View Page 15631 Fog/Driving Lamp Bulb: Service and Repair Fog Lamp Bulb Replacement - Rear FOG LAMP BULB REPLACEMENT - REAR REMOVAL PROCEDURE 1. Remove the rear fog lamp lens (1) retaining screws (2). CAUTION: Refer to Halogen Bulb Caution in Service Precautions. 2. Remove the bulb from the rear fog lamp assembly by twisting the bulb counterclockwise and pulling the bulb out. INSTALLATION PROCEDURE 1. Install the bulb to the rear fog lamp assembly by inserting the bulb and twisting the bulb clockwise. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the rear fog lamp lens (1) retaining screws (2). Tighten Tighten the screws (2) to 2 N.m (18 lb in). 3. Inspect the operation of the rear fog lamp. Page 450 Remove all rust from the ground terminal, the cylinder head and the retaining nut or bolt. Position the main engine wiring harness ground terminal and install the nut or bolt. Tighten: Tighten the retaining nut or bolt to 16 N.m (12 lb ft). Apply some type of electrical moisture sealant to protect the harness terminal from further corrosion. Disclaimer Page 12771 In summary, whenever a vehicle subject to this program enters your vehicle inventory, or is in your dealership/facility for service through April 30, 2011, you must take the steps necessary to be sure the program correction has been made before selling or releasing the vehicle. Disclaimer Service Procedure Service Procedure Note Do NOT replace the inside rear view mirror in tandem with this concern. The mirror has no bearing on this specific issue. 1. Remove the OnStar(R) module (referred to as the Communication Interface Module (CIM) or Vehicle Communication Interface Module (VCIM) in SI). Refer to SI for module removal instructions. Note Inform customer that all Bluetooth devices must be paired with the new VCIM. Bluetooth devices that have not been paired to the new VCIM will not function properly. 2. Install the new OnStar(R) module (referred to as the Communication Interface Module (CIM) or Vehicle Communication Interface Module (VCIM) in SI). Refer to SI for module installation instructions. Page 8145 Brake Caliper: Service and Repair Brake Caliper Replacement - Rear Brake Caliper Replacement - Rear (1500 Series) Caution: Refer to Brake Dust Caution in Service Precautions. Caution: Refer to Brake Fluid Irritant Caution in Service Precautions. Removal Procedure 1. Inspect the fluid level in the brake master cylinder reservoir. 2. If the brake fluid level is midway between the maximum-full point and the minimum allowable level, no brake fluid needs to be removed from the reservoir before proceeding. 3. If the brake fluid level is higher than midway between the maximum-full point and the minimum allowable level, remove brake fluid to the midway point before proceeding. 4. Raise and support the vehicle. Refer Vehicle Lifting 5. Remove the tire and wheel assembly. 6. Install a C-clamp over the body of the brake caliper, with the C-clamp ends against the rear of the caliper body and the outboard disc brake pad. 7. Slowly tighten the C-clamp until the pistons are pushed into the caliper bores enough to remove the caliper from the pads. 8. Remove the C-clamp from the caliper. 9. Clean all dirt and foreign material from the brake hose end. 10. Important: Install a rubber cap or plug to the exposed brake pipe fitting end to prevent brake fluid loss and contamination. Remove the brake hose to caliper bolt from the brake caliper. 11. Remove the brake hose from the caliper. 12. Remove and discard the 2 copper brake hose gaskets. These gaskets may be stuck to the brake caliper housing or the brake hose end. Page 5620 Crankshaft Position Sensor: Description and Operation CRANKSHAFT POSITION (CKP) SENSOR The crankshaft position (CKP) sensor is a three wire sensor based on the magneto resistive principle. A magneto resistive sensor uses two magnetic pickups between a permanent magnet. As an element such as a reluctor wheel passes the magnets the resulting change in the magnetic field is used by the sensor electronics to produce a digital output pulse. The PCM supplies a 12-volt, low reference, and signal circuit to the CKP sensor. The sensor returns a digital ON/OFF pulse 24 times per crankshaft revolution. Page 16225 Front Door Window Glass Weatherstrip: Service and Repair Door Window Sealing Strip Sealing Strip Replacement - Front Door Window Belt Outer - Front Removal Procedure Important: The outer belt sealing strip seals between the inner and outer door panels and the window at the belt line. The outer sealing strip is replaceable. Do not remove the inner sealing strip, because the strip is attached to the glass run channel. 1. Lower the window. 2. Remove the outside mirror. 3. Remove the outer sealing strip from the door, lifting up on the forward end in order to unhook the rear of the strip from the window run channel. Installation Procedure 1. Hook the rear end of the sealing strip into the window run channel. Lower and press the strip into place. 2. Install the outside mirror. 3. Raise the window. Page 15710 Parking Lamp: Description and Operation PARK, TAIL AND MARKER LAMPS The park, tail and marker lamps, including the license lamps, are turned on when the headlamp switch is placed in the PARK or HEAD position or anytime the headlights are requested. The underhood fuse block supplies battery positive voltage to both the park lamp relay switch contacts and the park lamp coil circuit. The body control module (BCM) provides a ground or control circuit to the park lamp relay coil circuit. When the park lamps are turned on the BCM energizes the park lamp relay. Current flow is from the park lamp relay to the FR PRK 10-amp fuse, RR PRK 10-amp fuse, LR PRK 10-amp fuse, and the TRL PRK 10-amp fuse, and to their respective park and marker lamps. The front park and marker lamps are grounded at G100. The rear park and marker lamps are grounded at G401. The license lamps are grounded at G410. If the headlight switch is left in the ON position, the inadvertent power control feature will turn off the park, tail and marker lamps approximately 10 minutes after the ignition switch is turned to the OFF position. If the driver places the headlight switch in the ON position after the ignition switch has been turned OFF, or if the ignition switch is in the ACCY position, the park, tail and marker lamps will remain ON until turned OFF or the battery runs dead. Page 6984 8. Install the inner bearing. 9. Important: Each time you replace the wheel hub bearings, install a new oil seal in order to prevent the wheel hub from leaking. Install the new oil seal using the J 44420 (2) and the J 8092 (1). 10. Install the rotor, if necessary. 11. Apply a light coat of high melting point EP bearing lubricant to the axle housing spindle. 12. Install the wheel hub to the axle housing. 13. Install the adjusting nut to the hub using the J 2222-C. 14. Adjust the wheel bearings. 15. Install the axle shaft. 16. Install the brake caliper. 17. Install the tire and wheel assembly. Page 1414 5. Remove the fuel level sensor retaining clip. 6. Remove the fuel level sensor. INSTALLATION PROCEDURE 1. Install the fuel level sensor. Page 5509 Mass Air Flow (MAF) Sensor: Service and Repair MASS AIR FLOW (MAF)/INTAKE AIR TEMPERATURE (IAT) SENSOR REPLACEMENT REMOVAL PROCEDURE IMPORTANT: Use care when handling the mass air flow/intake air temperature (MAF/IAT) sensor. Do not dent, puncture, or otherwise damage the honeycell located at the air inlet end of the MAF/IAT. Do not touch the sensing elements or allow anything including cleaning solvents and lubricants to come in contact with them. Use a small amount of a non-silicone based lubricant, on the air duct only, to aid in installation. 1. Remove the air cleaner outlet duct. 2. Pull out the gray connector position assurance (CPA) retainer. 3. Push down on the black clip in order to disconnect the MAF/IAT sensor electrical connector (4). 4. Loosen the MAF/IAT clamp. 5. Remove the MAF/IAT sensor from the air cleaner assembly. INSTALLATION PROCEDURE IMPORTANT: The embossed arrow on the MAF/IAT sensor indicates the proper air flow direction. The arrow must point toward the engine. Page 8988 Application Table Part 2 Fuel System Description Fuel Level Sensor: Description and Operation Fuel System Description FUEL LEVEL SENSOR The fuel level sensor consists of a float, a wire float arm, and a ceramic resistor cord. The position of the float arm indicates the fuel level. The fuel level sensor contains a variable resistor, which changes resistance in correspondence to the amount of fuel in the fuel tank. The powertrain control module (PCM) sends the fuel level information via the class 2 circuit to the instrument panel (I/P) cluster. This information is used for the I/P fuel gage and the low fuel warning indicator, if applicable. The PCM also monitors the fuel level input for various diagnostics. Page 7272 Steps 1-3 Page 10233 Refer to the table as a guide in selecting the correct test adapter for frontprobing connectors: Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure SCAN TOOL SNAPSHOT PROCEDURE Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: - Snapshot - taken from the Snapshot menu choice - Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information Page 4284 Electrical Symbols ELECTRICAL SYMBOLS Electrical Symbols Part 1 Page 1995 TOOLS REQUIRED J 34142-B 12 V Unpowered Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. When testing for voltage: 1. Attach 1 lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach 1 lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Using Connector Test Adapters USING CONNECTOR TEST ADAPTERS NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-B Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires USING FUSED JUMPER WIRES TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Connector Position Assurance Locks CONNECTOR POSITION ASSURANCE LOCKS The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Terminal Position Assurance Locks TERMINAL POSITION ASSURANCE LOCKS The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Push to Seat Connectors PUSH TO SEAT CONNECTORS TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Disconnect/Connect Procedure (Single Battery) Negative: Service and Repair Disconnect/Connect Procedure (Single Battery) BATTERY NEGATIVE CABLE DISCONNECT/CONNECT PROCEDURE (SINGLE BATTERY) REMOVAL PROCEDURE CAUTION: Refer to Battery Disconnect Caution in Service Precautions. 1. Record the customer's pre-set radio stations. 2. Turn off all the lamps and accessories. 3. Turn the ignition OFF. 4. Loosen the negative battery cable bolt. 5. Remove the negative battery cable. INSTALLATION PROCEDURE CAUTION: Refer to Battery Disconnect Caution in Service Precautions. IMPORTANT: Clean any existing corrosion from the battery terminal bolt flange and battery cable end. 1. Install the negative battery cable. NOTE: Refer to Fastener Notice in Service Precautions. 2. Tighten the negative battery cable bolt. Tighten Page 5693 Page 15944 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors USING CONNECTOR TEST ADAPTERS IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-B Connector Test Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Page 14474 Memory Seat Module - C3 Part 1 Page 11699 Inflatable Restraint Front End Sensor (With RPO Code HVY) Page 10247 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. REPLACEMENT PROCEDURE After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Insure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the Terminal Removal Procedure. Repairing Connector Terminals REPAIRING CONNECTOR TERMINALS TOOLS REQUIRED J 38125-D Terminal Repair Kit Use the following repair procedures in order to repair the following: - Push to Seat terminals - Pull to Seat terminals - Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-D contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100 World terminals. Soldering Micro-Pack 100 World terminals may damage the terminal. Circuit Protection - Circuit Breakers CIRCUIT PROTECTION - CIRCUIT BREAKERS A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Suspension - Rattles/Squeaks From Front of Vehicle Suspension Strut / Shock Absorber: Customer Interest Suspension - Rattles/Squeaks From Front of Vehicle Bulletin No.: 03-03-08-002B Date: November 30, 2005 TECHNICAL Subject: Rattle/Squeak from Front of Vehicle (Replace Lower Portion of Upper Insulator Assembly) Models: 2002-2005 Cadillac Escalade, Escalade EXT 2003-2005 Cadillac Escalade ESV 2000-2005 Chevrolet Silverado, Suburban, Tahoe 2002-2005 Chevrolet Avalanche 2000-2005 GMC Sierra, Yukon, Yukon XL Supercede: This bulletin is being revised to update the correction and parts information. Please discard Corporate Bulletin Number 03-03-08-002A (Section 03 - Suspension). Condition Some customers may comment on a rattle or squeak type noise coming from the front of the vehicle. Cause The front shock absorber plastic pilot ring may be wearing out, causing the shock to misalign in the insulator. Correction DO NOT replace the shock. Replace the lower portion, P/N 15834275 , of the upper insulator assembly using the procedure listed below. This new insulator has a taller plastic pilot ring that is attached to the metal sleeve to aid in the proper alignment of the insulators. 1. Remove the front shock absorber. Refer to the Shock Absorber Replacement procedure in the Front Suspension sub-section of the Service Manual. 2. Remove the lower portion of the upper insulator from the shock and discard. 3. Install the new lower portion of the upper insulator to the shock. Important: Be sure to center the shock in the frame bracket and tighten the upper mounting nut when the vehicle is on the ground. 4. Install the front shock absorber. Refer to the Shock Absorber Replacement procedure in the Front Suspension sub-section of the Service Manual. Parts Information Warranty Information Page 16029 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the cover up until the dress cover releases. Repeat this procedure for the other locking tab. 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. 5. If the connector has a nose piece, use a small flat-blade tool to remove the nose piece by inserting the blade into the slot on the front of the connector and prying up on the nose piece. IMPORTANT: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 6. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. IMPORTANT: Be careful not to angle or rock the J 38125-13A tool when inserting it into the connector or the tool may break. Locations Accelerator Pedal Position (APP) Sensor Connector Exhaust System - Catalytic Converter Precautions Catalytic Converter: Technical Service Bulletins Exhaust System - Catalytic Converter Precautions Bulletin No.: 06-06-01-010A Date: February 04, 2008 INFORMATION Subject: Information on Close-Coupled Converter and Engine Breakdown or Non-Function Due to Severe Overheat or Lack of Oil Causing Piston(s) Connecting Rod(s) Crankshaft Cylinder(s) and/or Head(s) Camshaft(s) Intake and/or Exhaust Valve(s) Main and/or Rod Bearing(s) Damage Models: 2004-2008 GM Passenger Cars and Trucks with Close-Coupled Catalytic Converters Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 06-06-01-010 (Section 06 - Engine/Propulsion System). Certain 2004-2008 General Motors products may be equipped with a new style of catalytic converter technically known as the close-coupled catalytic converter providing quick catalyst warm-up resulting in lower tail pipe emissions earlier in the vehicle operating cycle. If an engine breakdown or non-function were to occur (such as broken intake/exhaust valve or piston) debris may be deposited in the converter through engine exhaust ports. If the engine is non-functioning due to a severe overheat event damage to the ceramic "brick" internal to the catalytic converter may occur. This may result in ceramic debris being drawn into the engine through the cylinder head exhaust ports. If a replacement engine is installed in either of these instances the replacement engine may fail due to the debris being introduced into the combustion chambers when started. When replacing an engine for a breakdown or non-function an inspection of the catalytic converters and ALL transferred components (such as exhaust/ intake manifolds) should be performed. Any debris found should be removed. In cases of engine failure due to severe overheat dealers should also inspect each catalytic converter for signs of melting or cracking of the ceramic "brick". If damage is observed the converter should be replaced. Disclaimer Page 6373 Seals and Gaskets: Service and Repair Automatic Transmission - 4L80-E/4L85-E Filler Tube and Seal Replacement Filler Tube and Seal Replacement Removal Procedure 1. Remove the oil level indicator. 2. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 3. Remove the fill tube bracket nut. 4. Place a drain pan under the transmission. 5. Remove the fill tube. 6. Remove the transmission fill tube seal. Installation Procedure 1. Install the transmission fill tube seal. 2. Install the fill tube. 3. Remove the drain pan from under the transmission. Page 8173 7. With the engine OFF, gradually apply the brake pedal to approximately 2/3 of it's travel distance. 8. Slowly release the brake pedal. 9. Wait 15 seconds, then repeat steps 7-8 until a firm pedal is obtained. This will properly seat the brake caliper pistons and brake pads. 10. Fill the master cylinder reservoir to the proper level with clean brake fluid. Refer to Master Cylinder Reservoir Filling in Hydraulic Brakes. 11. Burnish the disc brake pads and rotors. Refer to Burnishing Pads and Rotors. Page 13296 Page 15243 Cigar Lighter (With RPO Code YE9/UQ7) Testing and Inspection Ignition Relay: Testing and Inspection IGNITION RELAY DIAGNOSIS CIRCUIT DESCRIPTION The ignition relay is a normally open relay. The relay armature is held in the open position by spring tension. When the ignition switch is turned to the run or start position, current will flow through the relay coil. A wire connected to the other end of the relay coil completes the path to ground. The electromagnetic field created by the relay coil, overcomes the spring tension and moves the armature allowing the relay contacts to close. The closed relay contacts allow current to flow from the battery to the following fuses: PCM 1 - ETC/ECM - INJ 1 - INJ 2 - SBA, if equipped. When the ignition switch is turned to the OFF position, the electromagnetic field collapses. This action allows the spring tension to move the armature away from the relay contacts, which interrupts current flow to the fuses. If the ignition relay fails to close, the engine will crank, but will not run. The class 2 communications will be available with the use of a scan tool. The ignition relay table assumes that the vehicle battery is fully charged. TEST Page 9564 Fuse Block - Underhood C6 Page 14124 Front Passenger Door Module (FPDM) - C4 (With RPO Code YE9) Part 1 Page 15009 Involved are certain 2000 Chevrolet CK, 2000-2004 model year Chevrolet Silverado and GMC Sierra trucks, and 2002-2004 model year Cadillac Escalade EXT and Chevrolet Avalanche trucks, and 2003-2004 Chevrolet Kodiak and GMC TopKick trucks built within the VIN breakpoints shown. Important: Dealers should confirm vehicle eligibility through GMVIS (GM Vehicle Inquiry System) before beginning recall repairs. [Not all vehicles within the above breakpoints may be involved.] For US For dealers with involved vehicles, a Campaign Initiation Detail Report containing the complete Vehicle Identification Number, customer name and address data has been prepared and will be loaded to the GM DealerWorld, Recall Information website. Dealers that have no involved vehicles currently assigned will not have a report available in GM DealerWorld. For Canada For dealers with involved vehicles, a Campaign Initiation Detail Report containing the complete Vehicle Identification Number, customer name and address data has been prepared and is being furnished to involved dealers. Dealers that have no involved vehicles currently assigned will not receive a Page 10711 6. Install the wheel hub and bearing (5) and splash shield (6) to the vehicle, 15 series. 7. Install the wheel hub and bearing mounting bolts, the 15 series. 8. Install the wheel hub and bearing mounting bolts, 25/35 series. ^ Tighten the wheel hub to knuckle bolts to 180 Nm (133 ft. lbs.). 9. Install the nut (2) and washer (3) retaining the wheel drive shaft assembly to the wheel hub and bearing. ^ Tighten the nut to 240 Nm (177 ft. lbs.). 10. Install the wheel speed sensor and brake hose mounting bracket bolt to the steering knuckle. ^ Tighten the brake hose clip bolt to 12 Nm (106 inch lbs.). 11. Install the rotor. Refer to Brake Rotor Replacement - Front in Disc Brakes. 12. Install the tire and wheel. 13. Lower the vehicle. Page 3693 11. Reposition the outlet hose clamp at the water pump. 12. Remove the outlet hose from the water pump. 13. Reposition the surge tank outlet hose clamp at the water pump. 14. Remove the surge tank outlet hose from the water pump. 15. Reposition the heater inlet hose clamp at the water pump. 16. Remove the heater inlet hose from the water pump. 17. Remove the water pump bolts. 18. Remove the water pump and gaskets. 19. Discard the water pump gaskets. Installation Procedure Page 16134 Electrical Symbols Part 10 Page 7958 Four Wheel Drive Selector Switch: Service and Repair Transfer Case - NVG 263-NP1 Transfer Case Shift Control Switch Replacement Removal Procedure 1. Remove the instrument panel (IP) cluster bezel. 2. Pull the tabs on the side of the transfer case driver control switch out. 3. Pull the transfer case driver control switch straight out from the panel. Installation Procedure 1. Important: Make sure that the transfer case control switch is seated properly in the instrument panel before installing the instrument panel trim bezel. Install the transfer case driver control switch into the instrument panel. 2. Install the IP cluster bezel. Page 563 Disclaimer Connector Views Vanity Lamp: Connector Views Vanity Mirror Lamp - Left (With RPO Code Y91) Page 11076 Parts required to complete this special coverage are to be obtained from General Motors Customer Care and Aftersales (GMCC&A;). Service Procedure Note The resistor module connector and blower motor resistor will need to be replaced if one or more of the symptoms below is present. - The HVAC blower may not function on certain or all blower speed settings - A burning plastic smell or smoke may be present in the vehicle - The HVAC blower may run continually with the ignition in the OFF position Determine if one or more of the above symptoms is present. If required refer to HVAC diagnostic information in SI. Refer to Resistor Module Connector and Blower Motor Resistor Replacement in this bulletin if one or more of the symptoms is present. Other HVAC repairs are NOT covered in this product safety special coverage bulletin. Resistor Module Connector and Blower Motor Resistor Replacement 1. Remove the blower fuses (Htr A/C & HVAC 1 fuses). 2. Lower the close-out panel enough to gain access to the resistor module connector. 3. Disconnect the connector from the resistor module. Note Connector replacement is required even if the connector was replaced on a previous service repair. 4. Remove the tape from the wiring harness to expose the wiring. 5. Cut the wires back far enough from the connector to eliminate any melted insulation on the wire. Note Use the old connector as a map for splicing the wires for the new connector. Be sure to use the correct crimping tool from the terminal repair kit J 38125. Use only Duraseal splice sleeves. Other splice sleeves may not protect the splice from moisture or provide a good electrical connection. 6. Install the new connector. Use the yellow splice sleeves provided with the connector. 7. Install the new blower motor resistor. 8. Reinstall the fuses. Test the blower motor to make sure all speeds are functional. 9. Reinstall the hush panel/close-out panel. Customer Reimbursement Customer requests for reimbursement of previously paid repairs to correct the condition described in this bulletin are to be submitted to the dealer prior to or by December 31, 2012. Repairs must have occurred within the 10 years of the date the vehicle was originally placed in service, or 240,000 kilometres, whichever occurs first. When a customer requests reimbursement, they must provide the following: Locations Center of the I/P - Accessory Switches Page 16101 Control Module References Part 2 Page 2098 1. Install a NEW air filter element. 2. Install the air cleaner housing cover. 3. Tighten the air cleaner housing top screws until snug. 4. Connect the MAF/IAT sensor electrical connector (4). 5. Install the air cleaner outlet duct. Page 7019 Interior - Console Lock Cylinder and Key Replacement Console Lock Cylinder: Technical Service Bulletins Interior - Console Lock Cylinder and Key Replacement Bulletin No.: 01-08-49-017A Date: August 13, 2007 INFORMATION Subject: Center Front Floor Console Compartment Lock Cylinder and Key Replacement Models: 1999-2000 Cadillac Escalade 2002 Cadillac Escalade 1999-2006 Chevrolet Silverado 2000-2002 Chevrolet Suburban, Tahoe 2007 Chevrolet Silverado Classic 1999-2000 GMC Denali 1999-2006 GMC Sierra 2000-2002 GMC Yukon, Yukon XL 2001-2002 GMC Yukon Denali, Yukon Denali XL 2007 GMC Sierra Classic Supercede: This bulletin is being revised to add additional model years, revise the pricing information and provide contact information for a new lock cylinder supplier. Please discard Corporate Bulletin Number 01-08-49-017 (Section 08 - Body and Accessories). All pricing information listed in this bulletin is in U.S. dollars and is subject to change without notice. Currently there are different methods for obtaining replacement lock cylinders and keys used in the center front floor console compartment on the above vehicles. If a replacement lock cylinder and/or keys are required, follow the appropriate procedure listed for that vehicle. 1999-2007 Chevrolet Silverado (Classic) 2000-2002 Chevrolet Suburban, Tahoe 1999-2007 GMC Sierra (Classic) 2000-2002 GMC Yukon, Yukon XL The lock cylinder used in the center front floor console compartment on these vehicles is sonically welded to the inside of the console cover/lid and as a result cannot be serviced by itself. If a replacement lock cylinder is needed, it will be necessary to order a replacement console cover assembly from GMSPO. The new cover assembly comes complete with a new coded lock cylinder and two new coded keys. See Group 16.650 of the appropriate GMSPO Parts Catalog for part number information. Also on these vehicles, if the customer has lost or damaged their console keys and the lock cylinder is okay, replacement keys can be obtained directly from A-1 Manufacturing. To order replacement keys, dealers should call A-1 at 1-877-725-2121, extension 16, and supply them with the three-digit code from the lock cylinder. In addition, dealers may E-mail A-1 at [email protected] or [email protected]. If contacted by 12 noon Eastern Standard Time (EST, A-1 will cut 2 keys to the code supplied and ship UPS with the following charges (shipping included): 1 day delivery -$31.70 2 day delivery - $27.00 3 day delivery - $23.40 In addition, dealers can order a set of 174 master keys (2 keys cut to each of the 174 codes). Each 2-key set comes in a labeled poly zippered bag. In addition to the 348 master keys (174 master keys X 2), 50 blank keys will also be included in poly bags for dealers to cut from the masters using a profile key cutter. Master keys and blanks will be shipped via UPS Ground with the following charges (including shipping): One set of 174 master keys (348 keys) and 50 blanks in poly bags - $254.10 Additional 50 blank keys in poly bags - $42.75 1999-2000 Cadillac Escalade 2002 Cadillac Escalade 1999-2000 GMC Yukon Denali Page 5344 18. If equipped with 4WD, remove the torsion bar bracket. 19. Disconnect the fuel and EVAP lines at the fuel tank. 20. Cap the fuel and EVAP lines at the fuel tank in order to avoid possible system contamination. 21. If vehicle is a regular cab, remove the fuel and EVAP bundle clip nuts. 22. If vehicle is a crew cab or extended cab, remove the fuel and EVAP bundle clip nuts. 23. Remove the fuel and EVAP bundle. INSTALLATION PROCEDURE Page 10917 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves SPLICING COPPER WIRE USING SPLICE SLEEVES TOOLS REQUIRED J 38125-D Terminal Repair Kit IMPORTANT: Use only GM splice sleeves, other splice sleeves may not protect the splice from moisture or a provide good electrical connection. Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. Page 9719 C152 Chassis Harness To Engine Harness Part 1 Page 11211 Housing Assembly HVAC: Service and Repair HVAC Module Assembly Replacement HVAC MODULE ASSEMBLY REPLACEMENT TOOLS REQUIRED J 43181 Quick Connect Connector Removal Tool REMOVAL PROCEDURE 1. Drain the engine coolant. Refer to Draining and Filling Cooling System (with HP2)Draining and Filling Cooling System (without HP2) in Cooling System. 2. If equipped remove the auxiliary battery. 3. Using the J 43181 disconnect the inlet heater hose from the heater core. 3.1. Install the J 43181 to the heater core pipe. 3.2. Close the tool around the heater core pipe. 3.3. Firmly pull the tool into the quick connect end of the heater hose. 3.4. Firmly grasp the heater hose. Pull the heater hose forward in order to disengage the inlet hose from the heater core. 4. Using the J 43181 disconnect the surge tank outlet hose from the heater core. 4.1. Install the J 43181 to the heater core pipe. 4.2. Close the tool around the heater core pipe. 4.3. Firmly pull the tool into the quick connect end of the heater hose. 4.4. Firmly grasp the heater hose. Pull the heater hose forward in order to disengage the surge tank outlet hose from the heater core. 5. Remove the accumulator. 6. Remove the instrument panel carrier. 7. Remove the HVAC module drain hose. 8. Disconnect the electrical harnesses and the ground connections from the HVAC module. 9. Remove the nuts (4) from the HVAC module (2). 10. Remove the bolts (3) from the HVAC module (2). Page 14768 3. Peel the seat cushion heater off of the pad. 4. Disconnect the seat cushion heater wiring harness. INSTALLATION PROCEDURE 1. Replace the inflatable restraint passenger presence system if the passenger seat cushion foam is damaged. 2. Connect the cushion heater wiring harness. 3. Install the seat cushion heater. 4. Install the seat cushion trim cover. 5. Install the seat trim panel. 6. Re-zero the inflatable restraint passenger presence system for the front passenger seat. Refer to Passenger Presence System Rezeroing Procedure in Restraint Systems. Automatic Transmission - 4L60-E/4L65-E Transmission Position Switch/Sensor: Adjustments Automatic Transmission - 4L60-E/4L65-E Park/Neutral Position Switch Adjustment Important: ^ The following procedure is for vehicles that have not had the park/neutral position (PNP) switch removed or replaced. If the PNP switch has been removed or replaced, refer to Park/Neutral Position Switch Replacement for the proper adjustment procedure. ^ Apply the park brake. ^ The engine must start in the park (P) or neutral (N) positions only. ^ Check the PNP switch for proper operation. If adjustment is required, proceed as follows: 1. Place the transmission range selector in the neutral (N) position. 2. With an assistant in the drivers seat, raise and suitably support the vehicle. Refer to Vehicle Lifting. 3. Loosen the park/neutral position (PNP) switch bolts. 4. With the vehicle in the neutral (N) position, rotate the switch while the assistant attempts to start the engine. 5. Following a successful start, turn the engine off. 6. Notice: Refer to Fastener Notice in Service Precautions. ^ Tighten the PNP switch bolts. ^ Tighten the bolts to 25 Nm (18 ft. lbs.). 7. Lower the vehicle. 8. Check the PNP switch for proper operation. The engine must start in the park (P) or neutral (N) positions only. 9. Replace the PNP switch if proper operation can not be achieved. Page 8813 Control Module References Part 1 Page 10108 3. Install the electrical wiring harness clip (4) to the bracket. 4. Notice: Refer to Fastener Notice in Service Precautions. Install the bolt retaining the wiring harness bracket (3) to the engine block. ^ Tighten the bolt retaining the ground to the engine block to 9 Nm (80 inch lbs.). 5. Connect the electrical connectors (2) to the wiring harness. 6. Install the coolant surge tank to the vehicle. 7. Connect the energy storage box after servicing the vehicle. Page 9264 Junction Block - I/P Wire Entry Part 2 Page 13648 Front Door Hinge: Service and Repair Hinge Replacement - Front Door - Body Side Hinge Replacement - Front Door - Body Side Removal Procedure 1. Remove all of the related panels and components. 2. Remove any excess sealer surrounding the existing hinge and scribe the location of the hinge on the hinge pillar. 3. Lightly hand-sand the existing hinge with 100 grit or finer sandpaper in order to locate the 4 welds that attach the hinge to the pillar. Important: Punch the center of the weld so that as much of the weld as possible is removed during the drilling. 4. Center punch each of the four weld marks on the original hinge. Important: Do not drill into the hinge pillar. 5. Drill through the hinge base only, at each punch location. Use a 13 mm (1/2 in) rotabroach hole saw or equivalent. 6. Remove the hinge. If necessary, use a chisel in order to separate the hinge from the pillar. 7. Remove all of the remaining weld from the pillar surface in order to ensure a flush fit of the service hinge. Installation Procedure OnStar(R) - Generation 6 Service Procedures Technical Service Bulletin # 09-08-46-001 Date: 090409 OnStar(R) - Generation 6 Service Procedures INFORMATION Bulletin No.: 09-08-46-001 Date: April 09, 2009 Subject: Servicing Vehicles Upgraded to OnStar(R) Generation 6 Digital‐Capable System (Follow Information Below) Models Attention: This bulletin is being issued to provide dealer personnel with information and the procedures to diagnose an upgraded OnStar(R) Generation 6 Digital-Capable system. Program Overview Since it was launched in 1996, OnStar® has relied on an analog wireless network to provide communication to and from OnStar-equipped vehicles. As part of an industry wide change in the North American wireless telecommunications industry, wireless carriers are transitioning to digital technology and will no longer support the analog wireless network beginning early 2008. Effective January 1, 2008, OnStar(R) service in the United States and Canada will be available only through vehicles that are capable of operating on the digital network. Refer to Corporate Bulletin Number 05-08-46-006H for information about upgrading certain vehicles to digital service. Details were covered in both the November 2006 and December 2007 issues of TechLink, which are available in the Archives of the TechLink website. Vehicles eligible for an OnStar(R) hardware upgrade are listed in this bulletin. Vehicle upgradeability can also be determined by typing the VIN into the field entitled "Determine VIN Hardware Functionality" on the OnStar(R) Online Enrollment website, located in the sales or service workbench tab of GM GlobalConnect. Canadian Dealers can use a similar tool that is available within the OnStar(R) Canada Online Enrollment site that can be accessed from the OnStar(R) Brand Resources in GlobalConnect. Access to the sales and/or service workbench in the GM GlobalConnect website can be granted by the dealership's Partner Security Coordinator (PSC). Page 3015 longer. Important Whenever a wheel is refinished, the mounting surface and the wheel nut contact surfaces must not be painted or clearcoated. Coating these surfaces could affect the wheel nut torque. When re-mounting a tire on an aluminum wheel, coated balance weights must be used in order to reduce the chance of future cosmetic damage. Disclaimer Page 9704 C102 I/P Harness To Chassis Harness Part 2 Page 4479 Electrical Symbols ELECTRICAL SYMBOLS Electrical Symbols Part 1 Page 10067 3. Notice: Refer to Power Steering Hose Disconnected Notice in Service Precautions. Place a drain pan under the vehicle. 4. Siphon the fluid from the reservoir to prevent excess spillage. 5. Remove the clamp retaining the power steering cooler inlet hose (3) to the power steering gear. 6. Remove the clamp retaining power steering cooler outlet hose (2) to the power steering pump (1). 7. Remove the bolts (2) retaining the power steering cooler from the radiator support. 8. Remove the power steering cooler from the vehicle. Installation Procedure 1. Notice: Page 1405 Fuel Pump And Sender Assembly Components Body - Dimple In Body Side Molding(s) Upper Side Moulding / Trim: Customer Interest Body - Dimple In Body Side Molding(s) Bulletin No.: 04-08-111-002B Date: October 26, 2006 TECHNICAL Subject: Dimple in Body Side Molding (Replace Moldings) Models: 2004 Chevrolet Avalanche without Body Hardware (RPO WBH) 2004 Chevrolet Silverado, Suburban, Tahoe with Body/Side Exterior-Molding-in-Color (RPO B85) Supercede: This bulletin is being revised to change the Warranty and add a revised parts information statement. Please discard Corporate Bulletin Number 04-08-111-002A (Section 08 - Body and Accessories). Condition Some customers may comment on a raised surface or a dimple in the exterior molded-in-color body side door moldings. This condition may be more pronounced in warmer climates. This does not apply to standard colored keyed black body side moldings. Cause Engineering has determined that this condition may be caused by a bar code label on the backside of the molding that dimples the molding. Correction Replace ALL of the exterior body side door moldings. Refer to Molding Replacement-Body Side procedure in SI. Dealer Action Please contact all customers that were told they would be called when a repair became available. Parts Information Page 14408 Door Control Module Diagram 2 Part 2 Page 7193 1. Install the control lever insulator, if removed. 2. Install the control lever boot to the control lever, if removed. 3. Install the control lever. 4. If alignment of the control lever is necessary, or if the shift lever assembly was replaced perform the following: 1. The nut must be seated at the bottom of the thread runout on the shift lever. 2. Seat the control lever against the shift lever assembly adjustment nut. 3. Back the control lever off the nut in order to align the index mark on the control lever perpendicular to the edge of the control lever boot retainer. 5. Ensure that the index mark is located on the passenger side and that the shift pattern is aligned parallel to the vehicle centerline or rotated no more than 6 degrees clockwise. 6. Notice: Refer to Fastener Notice in Service Precautions. Hold the control lever and tighten the shift lever assembly nut against the control lever. ^ Tighten the nut to 37 Nm (27 ft. lbs.). 7. Seat the control lever boot to the floor. 8. Install the control lever boot screws, if removed. ^ Tighten the screws to 1.6 Nm (14 inch lbs.). 9. Install the control lever boot retainer, if removed. Page 12848 switch lighting connector. 3.3. Undo the floor console's retaining bolts (C). 3.4. Take out the rear ashtray/cover (D). 3.5. Remove the screw (E) for the rear cover. 3.6. Remove the floor console's retaining nuts (E). 3.7. Detach the floor console (G) by pulling it straight back and lifting it slightly. 3.8. If required, detach the switch for the rear seat heater and unplug the connector. 4. Remove the switch and the floor console: 4.1. Detach the window lift module (A) by loosening it in the front edge (snap fastener). Unplug the window lift module's connector. 4.2. Detach the switch for the roof lighting (B) and unplug its connector. Lift away the floor console. 5. Pry out the signal line from the SRS control module to the OnStar(R) control module and secure it: 5.1. Unplug the SRS control module's connector (A). Page 16135 Electrical Symbols Part 11 Page 5574 8. If equipped with RPO HP2, position the auxiliary heater water pump and install it onto the studs. 9. Install the auxiliary heater water pump bracket bolts. Tighten Tighten the bolts to 15 N.m (11 lb ft). 10. Connect the ignition coil electrical connector. 11. Install the spark plug wire to the ignition coil. 12. If equipped with RPO HP2, connect the Energy Storage Box(ESB). Page 14471 Driver Seat (1 Of 2) Page 4627 Body Control Module: Locations Body Control Module (BCM) Locations Traction Control Switch: Locations ABS Component Views Traction Control Switch Page 13260 Input Shaft Speed Sensor Replacement Transmission Speed Sensor: Service and Repair Input Shaft Speed Sensor Replacement Input Shaft Speed Sensor Replacement Removal Procedure 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. Disconnect the input speed sensor electrical connector (1). 3. Remove the input speed sensor bolt. 4. Remove the input speed sensor (1). 5. Inspect the input speed sensor (1) for any evidence of damage. Installation Procedure Locations Air Induction Components Page 15899 1. Install the bulb to the socket. 2. Install the lens cover. 3. Install the underhood lamp to the hood. 4. Connect the in-line electrical connector. Page 8793 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly, Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Pull to Seat Connectors PULL TO SEAT CONNECTORS TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Locations Fog/Driving Lamp Switch: Locations Instrument Panel Switches-LH A/C - Blower Motor Inop. or Works On Low Speed Only Blower Motor Resistor: All Technical Service Bulletins A/C - Blower Motor Inop. or Works On Low Speed Only Bulletin No.: 05-01-38-012C Date: November 02, 2006 TECHNICAL Subject: EI05082 - Loss of Blower Motor Speeds Except for Low Speed or Inoperative (Replace Blower Motor Resistor and Resistor Module Connector) Models: 2004-2006 Chevrolet Avalanche, Silverado, Suburban, Tahoe, TrailBlazer, TrailBlazer EXT 2007 Chevrolet Silverado (Classic) Built Prior to September 1, 2006 2004-2006 GMC Envoy, Envoy XL, Sierra, Yukon, Yukon Denali, Yukon XL 2007 GMC Sierra (Classic) Built Prior to September 1, 2006 with HVAC System AC Front, Manual Temp Control (RPO CJ3) or Heater Only (RPO C42) Supercede: This bulletin is being revised to clarify the Warranty Information. Please discard Corporate Bulletin Number 05-01-38-012B (Section 01 - HVAC). Condition Some customers may comment that the blower will only work on low speeds or has become inoperative. Correction REPLACE THE BLOWER MOTOR RESISTOR AND RESISTOR MODULE CONNECTOR. Replace the blower motor resistor and module connector using the following procedure: Remove the blower fuse. Fullsize Trucks and Utility Vehicles - Htr A/C & HVAC 1 fuses Midsize Utility Vehicles - Blower Fuse 35 located in the Underhood Fuse Block Lower the hush panel or close-out panel enough to gain access to the resistor module connector. Disconnect the connector from the resistor module. Remove the tape from the wiring harness to expose the wiring. Page 3440 Disclaimer Page 14286 WA534F/54 - WA5456/43 Page 14086 7. Insert the J 38125-13A (GM P/N 12031876-1) tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the Terminal Repair Kit to ensure that the correct release tool is used. 8. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. REPAIR PROCEDURE Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. Service and Repair Suspension Mode Switch: Service and Repair Electronic Suspension Ride Control Switch Replacement Removal Procedure 1. Remove the instrument panel trim bezel. 2. Remove the switch from the lower opening of the switch plate panel. 3. Disconnect the electrical connector. Installation Procedure 1. Connect the electrical connector. 2. Install the switch into the lower opening of the switch plate panel. 3. Install the instrument panel trim bezel. Page 3310 15. Important: Do not manually depress the retaining clip when installing the plastic cap. Snap the plastic cap onto the quick connect fitting. 16. Ensure that the plastic cap is fully seated against the fitting. 17. Ensure that no gap is present between the cap and the fitting. Service and Repair Power Steering Fluid Reservoir: Service and Repair Power Steering Reservoir Replacement - Off Vehicle Disassembly Procedure 1. Drain the power steering fluid from the power steering pump. 2. Remove the pump mounting studs (2). 3. Remove the connector and fitting assembly (5). To remove the variable assist steering actuator (3) and retaining ring (4); refer to Power Steering Pump Flow Control Valve Actuator Replacement - On Vehicle. 4. Remove the O-ring seal (6) from the connector and fitting assembly (4). 5. If replacement is required, remove the control valve assembly and the flow control spring from the pump housing assembly; refer to Power Steering Pump Flow Control Valve Replacement - Off Vehicle (Regular). 6. Remove the reservoir assembly (1) from the pump housing assembly (2). 7. Remove the O-ring seals (1) (4). 8. Remove the magnet (3). 9. Clean the magnet (3). 10. Inspect the welch plug in the power steering pump housing (2). Do not remove. If the welch plug is deformed or dislodged, replace the power steering pump housing (2). Assembly Procedure Restraints - Passenger Presence System Information Seat Occupant Sensor: All Technical Service Bulletins Restraints - Passenger Presence System Information INFORMATION Bulletin No.: 06-08-50-009F Date: December 23, 2010 Subject: Information on Passenger Presence Sensing System (PPS or PSS) Concerns With Custom Upholstery, Accessory Seat Heaters or Other Comfort Enhancing Devices Models: 2011 and Prior GM Passenger Cars and Trucks Equipped with Passenger Presence Sensing System Supercede: This bulletin is being revised to update the model years. Please discard Corporate Bulletin Number 06-08-50-009E (Section 08 - Body and Accessories). Concerns About Safety and Alterations to the Front Passenger Seat Important ON A GM VEHICLE EQUIPPED WITH A PASSENGER SENSING SYSTEM, USE THE SEAT COVERS AND OTHER SEAT-RELATED EQUIPMENT AS RELEASED BY GM FOR THAT VEHICLE. DO NOT ALTER THE SEAT COVERS OR SEAT-RELATED EQUIPMENT. ANY ALTERATIONS TO SEAT COVERS OR GM ACCESSORIES DEFEATS THE INTENDED DESIGN OF THE SYSTEM. GM WILL NOT BE LIABLE FOR ANY PROBLEMS CAUSED BY USE OF SUCH IMPROPER SEAT ALTERATIONS, INCLUDING ANY WARRANTY REPAIRS INCURRED. The front passenger seat in many GM vehicles is equipped with a passenger sensing system that will turn off the right front passenger's frontal airbag under certain conditions, such as when an infant or child seat is present. In some vehicles, the passenger sensing system will also turn off the right front passenger's seat mounted side impact airbag. For the system to function properly, sensors are used in the seat to detect the presence of a properly-seated occupant. The passenger sensing system may not operate properly if the original seat trim is replaced (1) by non-GM covers, upholstery or trim, or (2) by GM covers, upholstery or trim designed for a different vehicle or (3) by GM covers, upholstery or trim that has been altered by a trim shop, or (4) if any object, such as an aftermarket seat heater or a comfort enhancing pad or device is installed under the seat fabric or between the occupant and the seat fabric. Aftermarket Seat Heaters, Custom Upholstery, and Comfort Enhancing Pads or Devices Important ON A GM VEHICLE EQUIPPED WITH A PASSENGER SENSING SYSTEM, USE ONLY SEAT COVERS AND OTHER SEAT-RELATED EQUIPMENT RELEASED AS GM ACCESSORIES FOR THAT VEHICLE. DO NOT USE ANY OTHER TYPE OF SEAT COVERS OR SEAT-RELATED EQUIPMENT, OR GM ACCESSORIES RELEASED FOR OTHER VEHICLE APPLICATIONS. GM WILL NOT BE LIABLE FOR ANY PROBLEMS CAUSED BY USE OF SUCH IMPROPER SEAT ACCESSORIES, INCLUDING ANY WARRANTY REPAIRS MADE NECESSARY BY SUCH USE. Many types of aftermarket accessories are available to customers, upfitting shops, and dealers. Some of these devices sit on top of, or are Velcro(R) strapped to the seat while others such as seat heaters are installed under the seat fabric. Additionally, seat covers made of leather or other materials may have different padding thickness installed that could prevent the Passenger Sensing System from functioning properly. Never alter the vehicle seats. Never add pads or other devices to the seat cushion, as this may interfere with the operation of the Passenger Sensing System and either prevent proper deployment of the passenger airbag or prevent proper suppression of the passenger air bag. Disclaimer Page 8124 9.1. Push the mud flap to make contact with the front side of the underbody cross sill and mark location of the hole (5) of the mud flap. 9.2. Center punch the marked location and drill a 5.159 mm (13/64 in) hole. 9.3. Install the screw. Tighten Tighten the screw to 4 N.m (35 lb in). 9.4. Repeat the above steps for hole location 6. 10. Repeat the above steps for the opposite side. Parts Information Parts are expected to be available from GMSPO on June 30, 2004. Warranty Information Please advise the customer that the mud flaps can be purchased as an accessory. Installation and/or cost of the mud flaps will not be covered under the vehicle's warranty. Disclaimer Page 12039 5. Choose the outstanding core you wish to process, by selecting the Virtual Core Button on the far right side of the screen. 6. Enter the information in the required fields and select the submit button. Record the confirmation number. Canadian Dealers 1. Return the removed Analog / Digital-Ready OnStar(R) VCIM to the Parts Manager. 2. The Parts Manager will log onto https://adt.onstar.gm.mass.ca and enter information as prompted. All Dealers If the website indicates that the VCIM needs to be physically returned to the distributor, please use the pre-paid shipping label that was included in the kit to return the removed VCIM. Important: To avoid a $250 core non-return charge, you must do one of the following within 30 days of kit shipment: 1. Submit the necessary VCIM data through the website, as indicated above. 2. Mail the removed core from the customer's vehicle back to the distributor. 3. Return the unused digital upgrade kit back to the distributor using the pre-paid shipping label that is included in the kit box. Returning the Upgraded Vehicle to the Customer Returning the Upgraded Vehicle to the Customer 1. Place the new OnStar Subscriber Information (Owner's Manual kit) in the customer's vehicle where they can review some of the new features of the Digital-Capable system. The continuous digit dialing feature should be highlighted to the customer to avoid a return to the dealership for dialing instructions. Advise the customer to discard any existing OnStar(R) Owner's Manuals that may be in the vehicle. 2. Have the Service Advisor, Service Manager or Sales Consultant review the new OnStar(R) Hands-Free Calling procedure with the customer. The customer is uses to their analog OnStar(R) Hands-Free Calling system, which uses individual digit dial to make a call. The Generation 6 Digital-Capable system uses continuous digit dial, and the customer needs to be made aware of this change. 3. U.S. Dealers Only: Staple the "Tip Sheet - OnStar(R) Generation 6 Digitally-Capable System", that was included in the kit, to the customer's copy of the repair order. This tip sheet will help your customer better understand their new OnStar(R) system. 4. Canadian Dealers Only: Refer the customer to the Hands-Free Calling Quick Review Card from the new OnStar(R) Owner's Manual kit for help with the new dialing procedure. 5. Fill out the form entitled "GM Limited Warranty for Upgraded OnStar(R) Digital Equipment Program Participants" and staple a copy of this to the customer's repair order. You may want to keep a copy for your records. 6. Encourage your customer to press their blue OnStar(R) button the next day. The OnStar(R) Advisor will be able to review some of the new features of their digital OnStar(R) system. Closing the Onstar(R) Upgrade Exchange Closing the OnStar(R) Upgrade Exchange 1. Collect payment from the customer. Your dealership's open account (sales) will be charged for the cost of the chosen subscription plan, any applicable subscription taxes, and the $15 upgrade charge after the vehicle has been configured through the TIS2WEB process. 2. None of the costs associated with the OnStar Digital Upgrade program may be claimed as a GM goodwill event. These costs must be paid by the customer, and may not be included in any goodwill offered to the customer. GM employees or representatives or field personnel are not able to offer goodwill for this program. If the dealership decides to pay for the upgrade for their customer, be aware that your GM or OnStar(R) contact will not be able to reimburse you for this cost. 3. Use labor code Z2096 to submit your claim for the labor time published below plus 0.2 hr Administrative Allowance and an additional $20.00 Net Amount. ^ For all dealer claim submissions (excluding U.S. Saturn), use Complaint Code MH - Technical Bulletin, and Failure Code 93 - Technical Service Bulletin. Description and Operation Malfunction Indicator Lamp: Description and Operation MALFUNCTION INDICATOR LAMP (MIL) OPERATION The malfunction indicator lamp (MIL) is located in the instrument panel cluster. The MIL will display as either SERVICE ENGINE SOON or one of the following symbols when commanded ON: The MIL indicates that an emissions related fault has occurred and vehicle service is required. The following is a list of the modes of operation for the MIL: The MIL illuminates when the ignition is turned ON, with the engine OFF. This is a bulb test to ensure the MIL is able to illuminate. - The MIL turns OFF after the engine is started if a diagnostic fault is not present. - The MIL remains illuminated after the engine is started if the control module detects a fault. A diagnostic trouble code (DTC) is stored any time the control module illuminates the MIL due to an emissions related fault. The MIL turns OFF after three consecutive ignition cycles in which a Test Passed has been reported for the diagnostic test that originally caused the MIL to illuminate. - The MIL flashes if the control module detects a misfire condition which could damage the catalytic converter. - When the MIL is illuminated and the engine stalls, the MIL will remain illuminated as long as the ignition is ON. - When the MIL is not illuminated and the engine stalls, the MIL will not illuminate until the ignition is cycled OFF and then ON. Page 5373 22. If vehicle is a regular cab, remove the fuel feed, EVAP, and return pipe assembly nuts. 23. If vehicle is a crew or extended cab, remove the fuel feed, EVAP, and return pipe assembly nuts. 24. Remove the fuel feed, EVAP, and return pipe assembly. INSTALLATION PROCEDURE 1. Install the fuel feed, EVAP, and return pipe assembly. NOTE: Refer to Fastener Notice in Service Precautions. 2. If vehicle is a crew or extended cab, install the fuel feed, EVAP, and return pipe assembly nuts. Tighten Tighten the nuts to 12 N.m (106 lb in). Page 12319 Electrical Symbols Part 10 Page 4180 Knock Sensor: Description and Operation KNOCK SENSOR (KS) SYSTEM DESCRIPTION PURPOSE The knock sensor (KS) system enables the control module to control the ignition timing for the best possible performance while protecting the engine from potentially damaging levels of detonation. The control module uses the KS system to test for abnormal engine noise that may indicate detonation, also known as spark knock. SENSOR DESCRIPTION This KS system uses one or two broadband one-wire sensors. The sensor uses piezo-electric crystal technology that produces an AC voltage signal of varying amplitude and frequency based on the engine vibration, or noise, level. The amplitude and frequency are dependant upon the level of knock that the KS detects. The control module receives the KS signal through a signal circuit. The KS ground is supplied by the engine block through the sensor housing. One way the control module monitors the system is by output of a bias voltage on the KS signal wire. The bias voltage creates a voltage drop that the control module monitors and uses to help diagnose KS faults. The KS noise signal rides along this bias voltage, and due to the constantly fluctuating frequency and amplitude of the signal, will always be outside of the bias voltage parameters. Another way the control module monitors the system is by learning the average normal noise output from the KS. The control module learns a minimum noise level, or background noise, at idle from the KS and uses calibrated values for the rest of the RPM range. The control module uses the minimum noise level to calculate a noise channel. The control module uses this noise channel, and the KS signal that rides along the noise channel, in much the same way as the bias voltage type does. As engine speed and load change, the noise channel upper and lower parameters will change to accommodate the normal KS signal. In order to determine which cylinders are knocking, the control module only uses KS signal information when each cylinder is near top dead center (TDC) of the firing stroke. If the control module has determined that knock is present, it will retard the ignition timing to attempt to eliminate the knock. The control module will always try to work back to a zero compensation level, or no spark retard. An abnormal KS signal will fall within the noise channel or will not be present. KS diagnostics are calibrated to detect faults with the KS circuitry inside the control module, the KS wiring, or the KS voltage output. Page 8878 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors USING CONNECTOR TEST ADAPTERS IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-B Connector Test Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Page 4634 Electrical Symbols Part 4 Page 1752 Knock Sensor: Service and Repair KNOCK SENSOR (KS) REPLACEMENT REMOVAL PROCEDURE 1. Remove the intake manifold. 2. Gently pry up the rubber covers. 3. Disconnect the knock sensor electrical connectors. 4. Remove the knock sensors. INSTALLATION PROCEDURE NOTE: Refer to Fastener Notice in Service Precautions. Engine Controls - Aftermarket Accessory Usage Engine Control Module: All Technical Service Bulletins Engine Controls - Aftermarket Accessory Usage INFORMATION Bulletin No.: 04-06-04-054B Date: November 18, 2010 Subject: Info - Non-GM Parts and Accessories (Aftermarket) Models: 2011 and Prior GM Passenger Cars and Trucks Supercede: This bulletin is being revised to add model years and update to the new U.S. Fixed Operation Manager (FOM) and Canada Warranty Manager (WM) names. Please discard Corporate Bulletin Number 04-06-04-054A (Section 06 - Engine/Propulsion System). The recent rise and expansion of companies selling non-GM parts and accessories has made it necessary to issue this reminder to dealers regarding GM's policy on the use and installation of these aftermarket components. When a dealer is performing a repair under the New Vehicle Limited Warranty, they are required to use only genuine GM or GM-approved parts and accessories. This applies to all warranty repairs, special policy repairs or any repairs paid for by GM. Parts and accessories advertised as being "the same" as parts manufactured by GM, but not sold through GM, do not qualify for use in warranty repairs, special policy repairs or any repairs paid for by GM. During a warranty repair, if a GM original equipment part is not available through GM Customer Care and Aftersales (GM CC&A;), ACDelco(R) distributors, other GM dealers or approved sources, the dealer is to obtain comparable, non-GM parts and clearly indicate, in detail, on the repair order the circumstances surrounding why non-GM parts were used. The dealer must give customers written notice, prior to the sale or service, that such parts or accessories are not marketed or warranted by General Motors. It should also be noted that dealers modifying new vehicles and installing equipment, parts and accessories obtained from sources not authorized by GM are responsible for complying with the National Traffic and Motor Vehicle Safety Act. Certain non-approved parts or assemblies, installed by the dealer or its agent not authorized by GM, may result in a change to the vehicle's design characteristics and may affect the vehicle's ability to conform to federal law. Dealers must fully understand that non-GM approved parts may not have been validated, tested or certified for use. This puts the dealer at risk for potential liability in the event of a part or vehicle failure. If a GM part failure occurs as the result of the installation or use of a non-GM approved part, the warranty will not be honored. A good example of non-authorized modification of vehicles is the result of an ever increasing supply of aftermarket devices available to the customer, which claim to increase the horsepower and torque of the Duramax(TM) Diesel Engines. These include the addition of, but are not limited to one or more of the following modifications: - Propane injection - Nitrous oxide injection - Additional modules (black boxes) that connect to the vehicle wiring systems - Revised engine calibrations downloaded for the engine control module - Calibration modules which connect to the vehicle diagnostic connector - Modification to the engine turbocharger waste gate Although the installation of these devices, or modification of vehicle components, can increase engine horsepower and torque, they may also negatively affect the engine emissions, reliability and/or durability. In addition, other powertrain components, such as transmissions, universal joints, drive shafts, and front/rear axle components, can be stressed beyond design safety limits by the installation of these devices. General Motors does not support or endorse the use of devices or modifications that, when installed, increase the engine horsepower and torque. It is because of these unknown stresses, and the potential to alter reliability, durability and emissions performance, that GM has adopted a policy that prevents any UNAUTHORIZED dealer warranty claim submissions to any remaining warranty coverage, to the powertrain and driveline components whenever the presence of a non-GM (aftermarket) calibration is confirmed - even if the non-GM control module calibration is subsequently removed. Refer to the latest version of Bulletin 09-06-04-026 (V8 Gas Engines) or 06-06-01-007 (Duramax(TM) Diesel Engines) for more information on dealer requirements for calibration verification. These same policies apply as they relate to the use of non-GM accessories. Damage or failure from the use or installation of a non-GM accessory will not be covered under warranty. Failure resulting from the alteration or modification of the vehicle, including the cutting, welding or disconnecting of the vehicle's original equipment parts and components will void the warranty. Additionally, dealers will NOT be reimbursed or compensated by GM in the event of any legal inquiry at either the local, state or federal level that Page 1299 Engine Oil Pressure (EOP) Sensor Page 8820 Alternator: Connector Views Generator - (With RPO Code SBA) Page 2090 Disclaimer Page 3530 Disclaimer Page 15591 Clearance Lamp: Description and Operation CLEARANCE LAMPS The clearance lamps, are turned ON when the headlamp switch is placed in the PARK or HEAD position or anytime the headlamps are requested. The underhood fuse block supplies battery positive voltage to both the park lamp relay switch contacts and the park lamp coil circuit. The body control module (BCM) provides a ground or control circuit to the park lamp relay coil circuit. When the park lamps are turned ON, the BCM energizes the park lamp relay. Current flow is from the park lamp relay to the INT PRK 10-amp fuse, and to the clearance and roof lamps. If the headlamp switch is left in the ON position, the inadvertent power control feature will turn OFF the park, tail and clearance lamps approximately 10 minutes after the ignition switch is turned to the OFF position. If the driver places the headlamp switch in the ON position after the ignition switch has been turned OFF, or if the ignition switch is in the ACCY position, the park, tail and marker lamps will remain ON until turned OFF or the battery runs dead. Page 1930 6. With the output gear encoder assembly in hand, carefully align the casting and output gear timing marks (1). 7. At the same time, be sure to align the encoder phasing post (1) with the phasing slot (2) in the casting and insert the shaft into the bushing. 8. Verify that the output gear and idler are engaged properly. 9. Seat the harness wires on the casting channel. 10. Place the shim on the output shaft gear. 11. Press a NEW seal into the cover. Page 9527 Application Table Part 1 Page 271 5. Choose the outstanding core you wish to process, by selecting the Virtual Core Button on the far right side of the screen. 6. Enter the information in the required fields and select the submit button. Record the confirmation number. Canadian Dealers 1. Return the removed Analog / Digital-Ready OnStar(R) VCIM to the Parts Manager. 2. The Parts Manager will log onto https://adt.onstar.gm.mass.ca and enter information as prompted. All Dealers If the website indicates that the VCIM needs to be physically returned to the distributor, please use the pre-paid shipping label that was included in the kit to return the removed VCIM. Important: To avoid a $250 core non-return charge, you must do one of the following within 30 days of kit shipment: 1. Submit the necessary VCIM data through the website, as indicated above. 2. Mail the removed core from the customer's vehicle back to the distributor. 3. Return the unused digital upgrade kit back to the distributor using the pre-paid shipping label that is included in the kit box. Returning the Upgraded Vehicle to the Customer Returning the Upgraded Vehicle to the Customer 1. Place the new OnStar Subscriber Information (Owner's Manual kit) in the customer's vehicle where they can review some of the new features of the Digital-Capable system. The continuous digit dialing feature should be highlighted to the customer to avoid a return to the dealership for dialing instructions. Advise the customer to discard any existing OnStar(R) Owner's Manuals that may be in the vehicle. 2. Have the Service Advisor, Service Manager or Sales Consultant review the new OnStar(R) Hands-Free Calling procedure with the customer. The customer is uses to their analog OnStar(R) Hands-Free Calling system, which uses individual digit dial to make a call. The Generation 6 Digital-Capable system uses continuous digit dial, and the customer needs to be made aware of this change. 3. U.S. Dealers Only: Staple the "Tip Sheet - OnStar(R) Generation 6 Digitally-Capable System", that was included in the kit, to the customer's copy of the repair order. This tip sheet will help your customer better understand their new OnStar(R) system. 4. Canadian Dealers Only: Refer the customer to the Hands-Free Calling Quick Review Card from the new OnStar(R) Owner's Manual kit for help with the new dialing procedure. 5. Fill out the form entitled "GM Limited Warranty for Upgraded OnStar(R) Digital Equipment Program Participants" and staple a copy of this to the customer's repair order. You may want to keep a copy for your records. 6. Encourage your customer to press their blue OnStar(R) button the next day. The OnStar(R) Advisor will be able to review some of the new features of their digital OnStar(R) system. Closing the Onstar(R) Upgrade Exchange Closing the OnStar(R) Upgrade Exchange 1. Collect payment from the customer. Your dealership's open account (sales) will be charged for the cost of the chosen subscription plan, any applicable subscription taxes, and the $15 upgrade charge after the vehicle has been configured through the TIS2WEB process. 2. None of the costs associated with the OnStar Digital Upgrade program may be claimed as a GM goodwill event. These costs must be paid by the customer, and may not be included in any goodwill offered to the customer. GM employees or representatives or field personnel are not able to offer goodwill for this program. If the dealership decides to pay for the upgrade for their customer, be aware that your GM or OnStar(R) contact will not be able to reimburse you for this cost. 3. Use labor code Z2096 to submit your claim for the labor time published below plus 0.2 hr Administrative Allowance and an additional $20.00 Net Amount. ^ For all dealer claim submissions (excluding U.S. Saturn), use Complaint Code MH - Technical Bulletin, and Failure Code 93 - Technical Service Bulletin. Page 15574 Brake Light Switch: Service and Repair STOP LAMP SWITCH REPLACEMENT REMOVAL PROCEDURE 1. Disconnect the electrical connector from the stop lamp switch (2). 2. Remove the pushrod retaining clip (4). 3. Remove the stop lamp switch (2). INSTALLATION PROCEDURE 1. Install the stop lamp switch (2). 2. Install the pushrod retaining clip (4). 3. Connect the electrical connector to the stop lamp switch (2). Page 6719 3. Install the NEW clutch pilot bearing into the crankshaft using J 38836. 4. Inspect the clutch pilot bearing for proper installation. 5. Install the clutch assembly. Page 1490 1. Install the bulb (1) into the socket. 2. Connect the electrical connector. 3. Install the switch until the tabs (1) click in place. 4. Close the compartment door. Page 356 Page 12464 8.2. Remove the console (A) together with the OnStar(R) control modules. 8.3. Remove the connectors (B). Important: The optic cable must not be bent with a radius less than 25 mm (1 in). Important: Secure the wiring harness so that there is no risk of chafing and rattling. 8.4. Fold back the wiring harness and tape over the connectors (C). Fold back the wiring harness once more and secure with cable ties (D). Page 5822 2. Connect the selector switch electrical connectors (2, 3). 3. Slide the selector switch into the housing until the switch snaps into place. Important: Make sure that the selector switch is seated properly in the housing before installing the I/P cluster bezel. 4. Install the I/P cluster bezel. Page 10840 3. Connect the electrical connector to the recirculation actuator (1). 4. Install the air distribution duct Page 15454 Door Latch Assembly (Door Jamb Switch) - RR - C2 (Crew Cab Only) Page 12157 For vehicles repaired under warranty, use the table. Disclaimer Page 6196 If clutch debris is found, it is also very important to inspect the Pressure Control (PC) solenoid valve (377) fluid screens. Clean or replace the PC solenoid (377) as necessary. It is also important to flush and flow check the transmission oil cooler using J45096. Refer to SI Automatic Transmission Oil Cooler Flushing and Flow Test for the procedure. The notches above each sprag must point up as shown when assembled into the outer race. Bearing Assembly, Input Sun Gear Snap Ring, Overrun Clutch Hub Retaining Hub, Overrun Clutch Wear Plate, Sprag Assembly Retainer and Race Assembly, Sprag Forward Sprag Assembly Retainer Rings, Sprag Assembly Outer Race, Forward Clutch Washer, Thrust (Input Carrier to Race) The following information applies when this sprag is used in 1982-86 transmissions. The new design sprag can be used on models 1982 through 1986, by replacing the entire assembly (637 - 644). Individual components are NOT Page 765 5. Install the instrument panel storage tray. 6. Install the instrument cluster trim plate bezel. IMPORTANT: Do not adjust any controls on the HVAC control module while the HVAC control module is calibrating. If interrupted improper HVAC performance will result. 7. Start the vehicle and let run for one minute. Page 14296 WA817K/63 - WA817K/63 Page 10423 9. Close the hood. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 8708 Parts Information Place unused material on dealer shelf for future use. Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Page 14186 4. Disconnect the inside door lock rod from the handle retainer clip. 5. Disconnect the manual door lock rod from the door retainer clips. 6. Remove the rubber plug in order to disengage the outside handle rod retainer. 7. Disconnect the cylinder lock rod (1). 8. Remove the bolts (2) which retain the door lock actuator to the door. 9. Remove the door lock actuator and control rods as an assembly. 10. Disconnect the electrical connector from the door lock actuator, if equipped. 11. Remove the control rods as necessary. Installation Procedure 1. Install the control rods to the assembly. 2. Connect the electrical connectors to the door lock actuator, if equipped. 3. Install the door lock actuator to the door. 4. Connect the outside door handle control rod. 5. Connect the cylinder lock rod. Notice: Refer to Fastener Notice in Service Precautions. 6. Install the bolts which retain the door lock actuator to the door. Tighten the screws to 9 N.m (80 lb in). Propshaft Speed Sensor - Front Page 2210 Put unused material on the shelf for future use. Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Page 5749 1. Disconnect the shift control module electrical connectors. 2. Unsnap and remove the shift control module from the bracket. Installation Procedure Page 9680 Note The rivet stud and surrounding panel area MUST BE properly refinished PRIOR to the installation of the electrical ground wire terminal and conductive nut to maintain a secure, stable and corrosion-free electrical ground. 11. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 12. Allow the refinished repair area to cure sufficiently before removing the protective material applied to the rivet stud threads. 13. Remove the painters tape or equivalent from the rivet stud threads. 14. Using GM approved residue-free solvent or equivalent, thoroughly clean the rivet stud threads to remove any adhesive and allow to dry. 15. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive rivet stud. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 16. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 17. Install the electrical ground wire terminal to the M6 conductive rivet stud. 18. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 19. Install the M6 conductive nut to the rivet stud and: Tighten Tighten to 8 Nm (71 lb in) 20. Verify proper system operation. Parts Information Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use: Warranty Information (Saab Models) Page 11416 Technicians are to inspect the HVAC actuator harness for contact with the instrument panel support brace. Repair any damage to the actuator harness wiring and install protective plastic conduit over the harness. Install friction tape over the sharp edge of the instrument panel brace. Clear the diagnostic trouble codes and verify proper HVAC system operation. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 9341 - HVAC Actuator - Inflatable Restraint Sensing and Diagnostic Module (SDM) - Any AIR BAG module - Seatbelt Lap Anchor Pretensioner - Seatbelt Retractor Pretensioner - An SIR system connection or connector condition resulting in the following DTCs being set: B0015, B0016, B0019, B0020, B0022, or B0023 - Powertrain Control Module (PCM) - Remote Control Door Lock Receiver (RCDLR) - Transmission Control Module (TCM) Correction Important DO NOT replace the control module, wiring or component for the following conditions: - The condition is intermittent and cannot be duplicated. - The condition is present and by disconnecting and reconnecting the connector the condition can no longer be duplicated. Use the following procedure to correct the conditions listed above. 1. Install a scan tool and perform the Diagnostic System Check - Vehicle. Retrieve and record any existing history or current DTCs from all of the control modules (refer to SI). ‹› If any DTC(s) are set, refer to Diagnostic Trouble Code (DTC) List - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). ‹› If DTCs are not set, refer to Symptoms - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). 2. When identified, use the appropriate DTC Diagnostics, Symptoms, Schematics, Component Connector End Views and Component Locator documents to locate and disconnect the affected harness connector(s) which are causing the condition. Note Fretting corrosion looks like little dark smudges on electrical terminals and appear where the actual electrical contact is being made. In less severe cases it may be unable to be seen or identified without the use of a magnifying glass. Important DO NOT apply an excessive amount of dielectric lubricant to the connectors as shown, as hydrolock may result when attempting to mate the connectors. Use ONLY a clean nylon brush that is dedicated to the repair of the conditions in this bulletin. 3. With a one-inch nylon bristle brush, apply dielectric lubricant to both the module/component side and the harness side of the affected connector(s). 4. Reconnect the affected connector(s) and wipe away any excess lubricant that may be present. 5. Attempt to duplicate the condition by using the following information: - DTC Diagnostic Procedure - Circuit/System Description - Conditions for Running the DTC - Conditions for Setting the DTC - Diagnostic Aids - Circuit/System Verification ‹› If the condition cannot be duplicated, the repair is complete. ‹› If the condition can be duplicated, then follow the appropriate DTC, Symptom or Circuit/System Testing procedure (refer to SI). Repair Order Documentation Page 9271 Relay Box: Diagrams Junction Block - Rear Lamps - C1 Page 9678 Tighten Tighten to 8 Nm (71 lb in). Note The repair area MUST BE properly refinished to maintain a secure, stable and corrosion-free electrical ground. 12. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 13. Verify proper system operation. M8 Weld Nut Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M8 weld nut electrical ground location is accessible from both sides of the panel, a M8 conductive bolt and a M8 conductive nut may be used to secure the electrical ground wire terminal. Refer to the Parts Information section of this bulletin. 2. Select a location adjacent the M8 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the new electrical ground site. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the ground location and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 10 mm (0.40 in) diameter hole through the panel. 5. Remove paint and primer from the area surrounding the 10 mm (0.40 in) hole until bare metal is visible. 6. Select a M8 conductive bolt. Refer to the Parts Information section of this bulletin. 7. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M8 conductive bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 8. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 9. Install the electrical ground wire terminal and the M8 conductive bolt to the ground location. 10. Select a M8 conductive nut. Refer to the Parts Information section of this bulletin. 11. Install the M8 conductive nut to the bolt and: Tighten Tighten to 22 Nm (16 lb ft). Note The repair area MUST BE properly refinished to maintain a secure, stable and corrosion-free electrical ground. 12. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 13. Verify proper system operation. M8 Weld Nut Alternative Repair Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M8 weld nut electrical ground location is not accessible from both sides of the panel, a M6 conductive rivet stud and a M6 conductive nut may be used to secure the electrical ground wire terminal. 2. Select a location adjacent the damaged M8 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the M6 conductive rivet stud flange. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the repair site and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 10 mm (0.40 in) diameter hole through the panel. Page 10200 2. Rotate the coil hub slowly, counterclockwise until the centering window appears yellow and both arrows (2) line up. This is the CENTER position. 3. While holding the coil hub in the CENTER position, align the SIR coil with the horn tower and slide onto the steering shaft assembly. 4. If the front side (3) of the SIR coil has NO centering window, but the back side (2) includes a spring service lock (1), perform the following steps: 0. Hold the SIR coil with the back side up. 1. While depressing the spring service lock, rotate the coil hub in the direction of the arrow (4) until the coil ribbon stops. 2. Still pressing the spring service lock, rotate the coil hub in the opposite direction 21⁄2 revolutions. 3. Release the spring service lock between locking tabs. The SIR coil is now centered. 4. Align the centered SIR coil with the horn tower and slide onto the steering shaft assembly. 5. If the front side (2) of the SIR coil has NO centering window, and the back side (1) includes NO spring service lock, perform the following steps: 0. Hold the SIR coil with the face up. 1. Rotate the coil hub in the direction of the arrow until the coil ribbon stops. 2. Rotate the coil hub, slowly, counterclockwise, for 21⁄2 revolutions. This is the CENTER position. 3. While maintaining the coil hub in the CENTER position, align the centered SIR coil with the horn tower and slide onto the steering shaft assembly. 6. If double wire harness strap is installed onto the wire harness assembly and column, you must route the wires up against the steering column. One wire harness strap will surround one lead from the coil to the steering column. The other wire harness strap will surround all leads to the steering column. Page 11142 Tighten the screws to 2 Nm (18 lb in). 5. Install the HVAC module assembly. Page 9939 Memory Steer Description Memory steer is when the vehicle wants to lead or pull in the direction the driver previously turned the vehicle. Additionally, after turning in the opposite direction, the vehicle will want to lead or pull in that direction. Wander Description Wander is the undesired drifting or deviation of a vehicle to either side from a straight path with hand pressure on the steering wheel. Wander is a symptom of the vehicle's sensitivity to external disturbances, such as road crown and crosswind, and accentuated by poor on-center steering feel. Scrub Radius Description Ideally, the scrub radius is as small as possible. Normally, the SAI angle and the centerline of the tire and the wheel intersect below the road surface, causing a positive scrub radius. With struts, the SAI angle is much larger than the long arm/short arm type of suspension. This allows the SAI angle to intersect the camber angle above the road surface, forming a negative scrub radius. The smaller the scrub radius, the better the directional stability. Installing aftermarket wheels that have additional offset will dramatically increase the scrub radius. The newly installed wheels may cause the centerline of the tires to move further away from the spindle. This will increase the scrub radius. A large amount of scrub radius can cause severe shimmy after hitting a bump. Four-wheel drive vehicles with large tires use a steering damper to compensate for an increased scrub radius. Scrub radius is not directly measurable by the conventional methods. Scrub radius is projected geometrically by engineers during the design phase of the suspension. Page 12201 Page 5349 14. Thoroughly wash all contaminants from around the EHCU. 15. Disconnect the chassis electrical harness connectors from the electronic brake control module (EBCM). IMPORTANT: Make sure that brake lines are tagged and kept in order for proper reassembly. 16. Disconnect the brake lines from the brake pressure modulator valve (BPMV). 17. Remove the bolts (4) attaching the EHCU bracket to the frame (5). 18. Remove the EHCU (1). 19. If equipped with 4WD, remove the torsion bar bracket. 20. Disconnect the fuel feed and return pipes at the fuel tank. 21. Cap the fuel pipes at the fuel tank. Engine - Noise/Damage Oil Filter Application Importance Oil Filter: Technical Service Bulletins Engine - Noise/Damage Oil Filter Application Importance INFORMATION Bulletin No.: 07-06-01-016B Date: July 27, 2009 Subject: Information on Internal Engine Noise or Damage After Oil Filter Replacement Models: 2010 and Prior Passenger Cars and Trucks (Including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X Supercede: This bulletin is being updated to add model years. Please discard Corporate Bulletin Number 07-06-01-016A (Section 06 - Engine/Propulsion System). Important Engine damage that is the result of an incorrect or improperly installed engine oil filter is not a warrantable claim. The best way to avoid oil filter quality concerns is to purchase ACDelco(R) oil filters directly from GMSPO. Oil filter misapplication may cause abnormal engine noise or internal damage. Always utilize the most recent parts information to ensure the correct part number filter is installed when replacing oil filters. Do not rely on physical dimensions alone. Counterfeit copies of name brand parts have been discovered in some aftermarket parts systems. Always ensure the parts you install are from a trusted source. Improper oil filter installation may result in catastrophic engine damage. Refer to the appropriate Service Information (SI) installation instructions when replacing any oil filter and pay particular attention to procedures for proper cartridge filter element alignment. If the diagnostics in SI (Engine Mechanical) lead to the oil filter as the cause of the internal engine noise or damage, dealers should submit a field product report. Refer to Corporate Bulletin Number 02-00-89-002I (Information for Dealers on How to Submit a Field Product Report). Disclaimer Page 13892 Windshield Moulding / Trim: Service and Repair Windshield Upper Reveal Molding Replacement Windshield Upper Reveal Molding Replacement Tools Required * Urethane Adhesive Kit GM P/N 12346392 or Equivalent * Isopropyl Alcohol or Equivalent * Cartridge-type Caulking Gun * Plastic Paddle Removal Procedure 1. Remove both right and left sides of the reveal molding. Caution: Refer to Glass and Sheet Metal Handling Caution in Service Precautions. Important: The windshield reveal molding fills the cavities between the body and windshield. If the reveal molding is stretched or damaged it and cannot be reused it must be replaced. 2. Remove the upper windshield reveal molding. 1. Use a flat-bladed tool in order to carefully pry the end of the upper reveal molding out about 76 mm (3 in). 2. Grasp the corner of the windshield reveal molding by hand or use a suitable tool to slowly pull the reveal molding away from the windshield. 3. If the windshield reveal molding will not release, use a utility knife to aid in the releasing of the molding. Installation Procedure 1. Clean the top edge of the windshield surface with a 50/50 mixture of isopropyl alcohol and water by volume on a dampened lint - free cloth. 2. The new reveal molding should be fitted to the windshield prior to installation. Caution: Refer to Window Retention Caution in Service Precautions. 3. Verify all primers and urethane adhesive are within expiration dates. Important: Use care when applying the prep (clear #1) to the windshield. This primer dries almost instantly, and may stain the viewing area of the windshield if not applied evenly. 4. Use a new dauber in order to apply glass prep (clear #1) to the channel area approximately 13 mm (1/2 in) to the upper edge of the windshield. 5. Wipe the glass primed area immediately with a clean lint-free cloth. 6. Shake the glass primer (black #2) for at least one minute. Using a new dauber in order to apply glass primer (black #2) to the top edge of the windshield. Page 14191 Door Lock Switch - Front Passenger (Base Only) Service and Repair Vacuum Brake Booster: Service and Repair Vacuum Brake Booster Replacement Removal Procedure Caution: Refer to Brake Fluid Irritant Caution in Service Precautions. Notice: Refer to Brake Fluid Effects on Paint and Electrical Components Notice in Service Precautions. 1. Apply the park brake and block the wheels. 2. Remove the brake master cylinder. 3. Remove the vacuum hose from the brake booster check valve. 4. Remove the pushrod retaining clip (4) from the brake pedal stud (1). 5. Remove the stop lamp switch (2) and the pushrod (3) from the brake pedal stud (1). 6. Remove the 4 vacuum booster mounting nuts. 7. Remove the vacuum booster. 8. Remove the gasket from the booster and discard. Installation Procedure Page 13507 Body Control Module: Locations Body Control Module (BCM) Page 16041 - Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-D in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-D if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Page 12823 Rear Wheel Steering Control Module Bracket Replacement Steering Control Module: Service and Repair Rear Wheel Steering Control Module Bracket Replacement Rear Wheel Steering Control Module Bracket Replacement Removal Procedure 1. Remove the rear wheel steering control module from the bracket. 2. Remove the bolts retaining the bracket (2) to the frame. 3. Remove the bracket (2) from the vehicle. Installation Procedure 1. Install the bracket (2) to the vehicle. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the bolts retaining the bracket (2) to the frame. ^ Tighten the bracket retaining bolts to 10 Nm (81 inch lbs.). 3. Install the rear wheel steering control module to the vehicle. Page 12212 2. Disconnect the C2 32-way blue connector from the VIU and tape the connector to a secure location. Refer to Cellular Communications Connector End Views and related schematics in SI, if required. Important: DO NOT perform the OnStar(R) reconfiguration and/or programming procedure. 3. Secure the VIU in its original brackets and/or mounting locations and reinstall the VIU and interior components that were removed to gain access to the VIU. Refer to OnStar Vehicle Interface Unit Replacement in SI. 2002 Through 2006 Model Year Vehicles (Except Saab Vehicles) 2002 through 2006 Model Year Vehicles (Except Saab Vehicles) Important: The Tech 2 diagnostic tool must be updated with version 28.002 or later in order to successfully perform the VCIM setup procedure and disable the analog system. 1. Connect the Tech 2 to the data link connector (DLC), which is located under the instrument panel of the vehicle. 2. Turn the Tech 2 ON by pressing the power button. Important: Tech 2 screen navigation to get to the setup procedure depends on the year and make of the vehicle. The actual name of the setup procedure (Setup New OnStar or VCIM Setup) depends on model year and vehicle make as well. Example Tech 2 navigation to the setup procedure Tech 2 screen is provided below. ^ Diagnostics >> (2) 2002 >> Passenger Car >> Body >> C >> OnStar >> Special Functions >> Setup New OnStar >> ^ Diagnostics >> (5) 2005 >> Passenger Car >> (4) Buick >> C >> Body >> Vehicle Comm. Interface Module >> Module Setup >> VCIM Setup >> 3. Setup VCIM using the Tech 2. Follow on-screen instructions when you have reached the setup Tech 2 screen. 2000-2002 Saab 9-3 (9400) 4D/5D; 2000-2003 Saab 9-3 (9400) CV 2000-2002 Saab 9-3 (9400) 4D/5D; 2000-2003 Saab 9-3 (9400) CV 1. Remove the ground cable from the battery's negative terminal. 2. Apply the handbrake brake. 3. Detach the floor console. 4. Remove the switch and the floor console: 3.1. Twist loose the immobilizer unit (A), bayonet fitting. Unplug the unit's connector. 3.2. Remove the ignition switch cover (B) by first undoing the rear edge of the cover and then unhooking the front edge. Unplug the ignition Page 8743 9. If equipped with a 4.8L, 5.3L, or 6.0L engine, position the negative cable and engine wiring harness ring terminals to the engine block. Position the anti-rotation tab on the negative cable in the correct location. 10. Install the engine wiring harness ground/negative cable bolt. Tighten Tighten the bolt to 25 N.m (18 lb ft). 11. Lower the vehicle. 12. Install the negative cable clip to the positive cable clip. 13. If equipped, connect the accessory power fuse block front wiring harness electrical connector to the negative cable connector. Page 8071 Parts Information Place unused material on dealer shelf for future use. Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Page 4784 Engine Coolant Temperature (ECT) Sensor Testing and Inspection Ignition Relay: Testing and Inspection IGNITION RELAY DIAGNOSIS CIRCUIT DESCRIPTION The ignition relay is a normally open relay. The relay armature is held in the open position by spring tension. When the ignition switch is turned to the run or start position, current will flow through the relay coil. A wire connected to the other end of the relay coil completes the path to ground. The electromagnetic field created by the relay coil, overcomes the spring tension and moves the armature allowing the relay contacts to close. The closed relay contacts allow current to flow from the battery to the following fuses: PCM 1 - ETC/ECM - INJ 1 - INJ 2 - SBA, if equipped. When the ignition switch is turned to the OFF position, the electromagnetic field collapses. This action allows the spring tension to move the armature away from the relay contacts, which interrupts current flow to the fuses. If the ignition relay fails to close, the engine will crank, but will not run. The class 2 communications will be available with the use of a scan tool. The ignition relay table assumes that the vehicle battery is fully charged. TEST Flywheel to Crankshaft Flex Plate: Specifications Flywheel to Crankshaft Engine Flywheel Bolts - First Pass ........................................................................................................................................................... 20 Nm (15 ft. lbs.) Engine Flywheel Bolts - Second Pass ....................................................................................................................................................... 50 Nm (37 ft. lbs.) Engine Flywheel Bolts - Final Pass ........................................................................................................................................................ 100 Nm (74 ft. lbs.) Page 15299 13. If necessary, lower the vehicle. 14. Using a scan tool, clear the DTCs. 15. Start the vehicle and inspect for leaks. Important: Advise the customer that a similar condition may occur if the vehicle is fueled with the engine running AND the rear tank is fueled first. The engine must be shut off (as required by law) during vehicle refueling. Parts Information Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 3334 Notice: Refer to Fastener Notice in Service Precautions. 2. Install the oil filter to the engine block. ^ Tighten the oil filter to 30 Nm (22 ft. lbs.). 3. Install the oil drain plug to the engine block. ^ Tighten the oil pan drain plug to 25 Nm (18 ft. lbs.). 4. Lower the vehicle. 5. Fill the crankcase with the proper quantity and grade of engine oil. Refer to Capacities - Approximate Fluid and Fluid and Lubricant Recommendations. 6. Remove the oil level indicator. 7. Wipe the indicator with a clean cloth. 8. Install the oil level indicator. 9. Remove the oil level indicator in order to check the level. 10. Add oil if necessary. 11. Close the hood. Page 9943 Alignment: Service and Repair Measuring Wheel Alignment (W/Rear Wheel Steering) Measuring Wheel Alignment (w/Rear Wheel Steering) Learn Wheel Alignment After replacement of the handwheel position sensor, rear wheel position sensor, or rear wheel steering control module it is necessary to perform the learn wheel alignment procedure. Alignment Procedure Steering and vibration complaints are not always the result of improper alignment. One possible cause is wheel and tire imbalance. Another possibility is tire lead due to worn or improperly manufactured tires. Lead/pull is defined as follows: at a constant highway speed on a typical straight road, lead/pull is the amount of effort required at the steering wheel to maintain the vehicles straight path. Lead is the vehicle deviation from a straight path on a level road without pressure on the steering wheel. Refer to Radial Tire Lead/Pull Correction in Tires and Wheels in order to determine if the vehicle has a tire lead problem. Before performing any adjustment affecting wheel alignment, perform the following inspections and adjustments in order to ensure correct alignment readings: ^ Inspect the tires for the proper inflation and irregular tire wear. ^ Inspect the runout of the wheels and the tires. ^ Inspect the wheel bearings for backlash and excessive play. ^ Inspect the ball joints and tie rod ends for looseness or wear. ^ Inspect the control arms and stabilizer shaft for looseness or wear. ^ Inspect the steering gear for looseness at the frame. Refer to Fastener Tightening Specifications in Power Steering System. ^ Inspect the struts/shock absorbers for wear, leaks, and any noticeable noises. Refer to Struts or Shock Absorbers On-Vehicle Testing in Suspension General Diagnosis. ^ Inspect the vehicle trim height. Refer to Trim Height Inspection Procedure in Suspension General Diagnosis. ^ Inspect the steering wheel for excessive drag or poor return due to stiff or rusted linkage or suspension components. ^ Inspect the fuel level. The fuel tank should be full or the vehicle should have a compensating load added. Give consideration to excess loads, such as tool boxes, sample cases, etc. If normally carried in the vehicle, these items should remain in the vehicle during alignment adjustments. Give consideration also to the condition of the equipment being used for the alignment. Follow the equipment manufacturer's instructions. Satisfactory vehicle operation may occur over a wide range of alignment settings. However, if the setting exceeds the service allowable specifications, correct the alignment to the service preferred specifications. Refer to Wheel Alignment Specifications. Perform the following steps in order to measure the front and rear alignment angles: 1. Install the alignment equipment according to the manufacturer's instructions. 2. Jounce the front and the rear bumpers 3 times prior to checking the wheel alignment. 3. Measure the alignment angles and record the readings. 4. Important: When performing adjustments to vehicles requiring a 4-wheel alignment, set the rear wheel alignment angles first in order to obtain proper front alignment angles. Adjust alignment angles to vehicle specification, if necessary. Refer to Wheel Alignment Specifications then perform the learn alignment procedure. Learn Wheel Alignment Procedure 1. Turn ignition to ON position, with the engine ON. 2. Install the scan tool. 3. Center the steering wheel. 4. Lift the rear of the vehicle off the ground ensuring the rear wheels are centered. 5. Go to the Learn Alignment menu choice in the scan tool. Follow the prompts on the scan tool. Important: When prompted by the scan tool you must turn the steering wheel a full 90 degrees to the left and a full 90 degrees to the right and then to center and hold. If this step is not done properly then it is possible to cause a false DTC for the steering wheel position sensor. 6. Press the continue button. 7. Use the scan tool to clear all rear wheel steering DTCs. (W/O Rear Wheel Steering) Measuring Wheel Alignment (w/o Rear Wheel Steering) Page 14675 Page 14738 1. Remove the front nuts (2) on the underside of the seat cushion. 2. Remove the front seat trim panel. 3. Unsnap the lumbar cable (6). Disconnect the lumbar wire harness if equipped with power lumbar. 4. Disconnect the electrical connectors. 5. Remove the pressure sensor (2) from the front passenger seat frame, if equipped with the Inflatable Restraint Passenger Presence System. 6. Lift the seat cushion up off the rear plastic holders (1) on the underside of the seat cushion, and pull forward. 7. Remove the seat switch bezel. 8. Remove the lumbar actuator (5). Diagrams Roof Beacon Relay (With RPO Code 5X7, 5G4, TRW, Or 5Y0) Campaign - HVAC Blower Not Functional Runs Continuously Blower Motor Resistor: All Technical Service Bulletins Campaign - HVAC Blower Not Functional Runs Continuously SPECIAL COVERAGE Bulletin No.: 11046 Date: April 07, 2011 Subject: 11046 - Special Coverage Adjustment - Heating, Ventilation, and Air Conditioning Blower Not Fully Functional on All Blower Speeds, Inoperative, or Runs Continuously with the Ignition Off Models: 2003-2006 Chevrolet Avalanche, Suburban, Tahoe 2003-2007 Chevrolet Silverado 2003-2006 GMC Yukon, Yukon XL 2003-2007 GMC Sierra Equipped with Manual HVAC (CJ3) or Heavy Duty Heater (C42) Due to part availability, owner letters will be released in phases starting with older model year first. Owners for model year vehicles not included in first phase owner mailing will receive an owner advisory letter. The letter will inform the customer that parts are not yet available and that another letter will be sent to them when parts become available. A copy of this letter will be attached to the dealer message announcing this bulletin. In the meantime, if a customer brings their vehicle to the dealership with the condition described in this bulletin, repair the vehicle using the parts called out in this bulletin. Condition On some 2003-2006 model year Chevrolet Avalanche, Suburban, Tahoe; GMC Yukon, Yukon XL; and 2003-2007 model year Chevrolet Silverado and GMC Sierra vehicles equipped with a manual heating, ventilation, and air conditioning (HVAC) system (CJ3) or heavy duty heater (C42), the interface between the electrical terminals of the relay resistor module and the wiring connector that powers the module may be incapable of conducting higher current levels for sustained periods of blower motor operation. In addition, moisture and other contaminants may enter the fresh air intake plenum and contact the internal circuit of the module or corrode the terminals. Either of the above may cause the relay resistor module or wiring connector to overheat, resulting in one or more of the following symptoms: - The HVAC blower may not function on certain or all blower speed settings - A burning plastic smell or smoke may be present in the vehicle - The HVAC blower may run continually with the ignition in the OFF position In very rare events, if the above symptoms are ignored, a fire could occur. Special Coverage Adjustment This special coverage covers the condition described above for a period of 10 years or 240,000 km, whichever occurs first, from the date the vehicle was originally placed in service, regardless of ownership. Dealers are to install a new blower motor resistor and resistor module connector. The repairs will be made at no charge to the customer. For vehicles covered by Vehicle Service Contracts, all eligible claims with repair orders on or after April 8, 2011 are covered by this special coverage and must be submitted using the labor operation codes provided with this bulletin. Claims with repair orders prior to April 8, 2011 must be submitted to the Service Contract provider. Vehicles Involved Involved are certain 2003-2006 model year Chevrolet Avalanche, Suburban, Tahoe; GMC Yukon, Yukon XL; and 2003-2007 model year Chevrolet Silverado and GMC Sierra vehicles equipped with a manual HVAC (CJ3) or heavy duty heater (C42). Important Dealers are to confirm vehicle eligibility prior to beginning repairs by using the Applicable Warranties section in the Global Warranty Management system. Parts Information Page 16250 Front Door Window Regulator: Service and Repair Front Side Door Window Regulator Motor Replacement Window Regulator Motor Replacement - Front Door Removal Procedure 1. Raise the window. If the window motor is inoperable, remove the window to gain access to the window motor retaining screws. Refer to Window Replacement - Front Door. 2. Remove the door trim panel. 3. Remove the water deflector. 4. Remove the door speaker. 5. Support the window. 6. Disconnect the wiring harness from the window regulator motor. 7. Remove the 3 bolts (1) from the window motor. Important: Do not allow the cable gear to come out of the housing. A failure will result with the cable coming off the spool. 8. Separate the motor from the cable housing by wiggling the window motor. Observe the orientation of the window motor. 9. Remove the motor from the door regulator assembly. Installation Procedure 1. Install the motor to the cable housing by wiggling it into place. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the 3 bolts(1) to the window motor. Tighten Tighten the bolts to 5 N.m (44 lb in). 3. Install the window, if removed. 4. Connect the wiring harness to the window regulator motor. 5. Remove the window support. 6. Connect the wire connector to the switch to inspect the operation of the window. After inspection disconnect the wiring harness and continue the installation. 7. Install the speaker. 8. Install the water deflector. 9. Install the door trim panel. Page 5274 Fuel Injector: Description and Operation Fuel System Description (Cab Chassis) FUEL INJECTORS The Multec 2 fuel injector assembly is a solenoid device, controlled by the PCM, that meters pressurized fuel to a single engine cylinder. The PCM energizes the high-impedance (12.0 ohms) injector solenoid (2) to open a normally closed ball valve (3). This allows fuel to flow into the top of the injector, past the ball valve, and through a director plate at the injector outlet. The director plate has two machined holes that control the fuel flow, generating a spray of finely atomized fuel at the injector tip. Fuel from the injector tip is directed at the intake valve, causing it to become further atomized and vaporized before entering the combustion chamber. This fine atomization improves fuel economy and emissions. Page 839 4. Connect the wire connectors to the lower portion of the electrical center block. 5. Connect the wire connectors with the bolts to the electrical center block. Tighten Tighten all connector bolts (1) to 9 N.m (80 lb in). 6. Ensure all wire connectors are securely connected. 7. Set the electrical center block in its resting position till the tabs (3) locks in place. 8. Install the lower part of the cover (1). 9. With the cover (2) off, use the fuse location information to install all fuses and relays. 10. Install the cover. 11. Install the fender upper brace. 12. Install the 4 fender upper brace bolts. Tighten Tighten the 4 retaining bolts to 25 N.m (18 lb ft). 13. Connect the negative battery cable. 14. Start vehicle and ensure all components function properly. Page 9707 C104 I/P Harness To Forward Lamp Harness (With Out RPO Code YE9) Page 5277 Steps 4 - 7 Initial Inspection and Diagnostic Overview Power Take-Off: Initial Inspection and Diagnostic Overview Diagnostic Starting Point DIAGNOSTIC STARTING POINT - POWER TAKE-OFF (PTO) IMPORTANT: The following steps must be completed before using the symptom tables. 1. Perform the Power Take-Off (PTO) Diagnostic System Check emphasis before using the Symptom Tables in order to verify that all of the following are true: Refer to Diagnostic System Check - Power Take-Off (PTO). - There are no DTCs set. - The control module(s) can communicate via the serial data link. See: Diagnostic System Check 2. Review the system Description and Operation in order to familiarize yourself with the system functions. Refer to emphasis Power Take-Off (PTO) Description and Operation. Visual/Physical Inspection Inspect the easily accessible and visible system components for obvious damage or conditions which could cause the symptom. - Inspect the transmission for the proper transmission fluid level. - Inspect the hydraulic reservoir for the proper hydraulic fluid level. - Inspect the upfitter connections at the transmission. Intermittent Faulty electrical connections or wiring may be the cause of intermittent conditions. Symptom List Refer to a symptom diagnostic procedure from the following list in order to diagnose the symptom: Power Take-Off Does Not Engage emphasis - Engine RPM Does Not Increase With Power Take-Off Engaged emphasis - Power Take-Off Indicator Inoperative emphasis Diagnostic System Check DIAGNOSTIC SYSTEM CHECK - POWER TAKE-OFF (PTO) TEST DESCRIPTION Wheels - Chrome Wheel Staining/Pitting/Corrosion Wheels: All Technical Service Bulletins Wheels - Chrome Wheel Staining/Pitting/Corrosion INFORMATION Bulletin No.: 00-03-10-002F Date: April 21, 2011 Subject: Chemical Staining, Pitting, Corrosion and/or Spotted Appearance of Chromed Aluminum Wheels Models: 2012 and Prior GM Cars and Trucks Supercede: This bulletin is being revised to update model years, suggest additional restorative products and add additional corrosion information. Please discard Corporate Bulletin Number 00-03-10-002E (Section 03 - Suspension). Important You may give a copy of this bulletin to the customer. What is Chemical Staining of Chrome Wheels? Figure 1 Chemical staining in most cases results from acid based cleaners (refer to Figure 1 for an example). These stains are frequently milky, black, or greenish in appearance. They result from using cleaning solutions that contain acids on chrome wheels. Soap and water is usually sufficient to clean wheels. If the customer insists on using a wheel cleaner they should only use one that specifically states that it is safe for chromed wheels and does not contain anything in the following list. (Dealers should also survey any products they use during prep or normal cleaning of stock units for these chemicals.) - Ammonium Bifluoride (fluoride source for dissolution of chrome) - Hydrofluoric Acid (directly dissolves chrome) - Hydrochloric Acid (directly dissolves chrome) - Sodium Dodecylbenzenesulfonic Acid - Sulfamic Acid - Phosphoric Acid - Hydroxyacetic Acid Notice Many wheel cleaner instructions advise to take care to avoid contact with painted surfaces. Most customers think of painted surfaces as the fenders, quarter panels and other exterior sheet metal. Many vehicles have painted brake calipers. Acidic wheel cleaners may craze, crack, or discolor the paint on the brake calipers. Damage from wheel cleaners is not covered under the vehicle new car warranty. Soap and water applied with a soft brush is usually all that is required to clean the calipers. Whenever any wheel cleaner is used, it must be THOROUGHLY rinsed off of the wheel with clean, clear water. Special care must be taken to rinse under the hub cap, balance weights, wheel nuts, lug nut caps, between the wheel cladding and off the back side of the wheel. Wheels returned to the Warranty Parts Center (WPC) that exhibit damage from wheel cleaners most often have the damage around and under the wheel weight where the cleaner was incompletely flushed away. Notice Page 8780 Electrical Symbols Part 10 Page 8922 Auxiliary Power Outlet: Description and Operation POWER OUTLETS - DESCRIPTION AND OPERATION The 120-volt auxiliary power outlets (APO) are located in the cab and within the pickup bed. The APOs provide 120 volts A/C at 60 hertz with a total a total circuit current of 20 amps. All of the APOs are protected by a ground fault detector located in the starter generator control module (SGCM). The ground fault detector will turn OFF all the outlets if a short to ground is detected or a current overload of greater than 20 amps occurs. After correcting the APOs circuit fault, the APO momentary push button switch on the instrument panel (I/P) may be pressed to reset the ground fault detector. The 120-volt APOs are activated with a momentary push button that located on the I/P. There are 3 states displayed by the 120-volt APO switch indicator lamp. If the lamp is illuminated, then the APOs circuit is activated and the vehicle is in the normal mode. A flashing indicator lamp signals that the system is in the continuous mode. If the indicator is OFF, the 120-volt A/C APOs are OFF. For more information on the hybrid system, review the following Description and Operations. - Energy Storage Box (ESB) Description and Operation in Starting and Charging - Hybrid Control Module (HCM) Description and Operation in Starting and Charging - Starter/Generator Description and Operation in Starting and Charging - Starter/Generator Control Module (SGCM) Description and Operation in Starting and Charging Page 8866 Electrical Symbols Part 4 Locations Center of the I/P - Accessory Switches Page 1206 Seat Memory Switch: Diagrams Driver Door Module (DDM) - C5 (Memory/Heated Seat Switch) Part 1 Page 8523 Page 8636 Ambient Light Sensor: Diagrams Ambient Light Sensor OnStar(R) - Re-establishing OnStar(R) Communications Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Re-establishing OnStar(R) Communications Bulletin No.: 00-08-46-004C Date: January 17, 2008 INFORMATION Subject: Re-establishing Communications with OnStar(R) Center After Battery Disconnect Models: 2000-2008 GM Passenger Cars and Trucks (Including Saturn and Saab) with Digital OnStar(R) (RPO UE1) Supercede: This bulletin is being revised to add models and model years. Please discard Corporate Bulletin Number 00-08-46-004B (Section 08 - Body and Accessories). When servicing any of the above models and a battery cable is disconnected or power to the OnStar(R) Vehicle Communication Interface Module (VCIM) is interrupted for any reason the following procedure must be performed to verify proper Global Positioning System (GPS) function. Never swap OnStar(R) Vehicle Communication Interface Modules (VCIM) from other vehicles. Transfer of OnStar(R) modules from other vehicles should not be done. Each OnStar(R) module has a unique identification number. The VCIM has a specific Station Identification (STID). This identification number is used by the National Cellular Telephone Network and OnStar(R) systems and is stored in General Motors Vehicle History files by VIN. After completing ALL repairs to the vehicle you must perform the following procedure: Move the vehicle into an open area of the service lot. Sit in the vehicle with the engine running and the radio turned on for five minutes. Press the OnStar(R) button in the vehicle. When the OnStar(R) advisor answers ask the advisor to verify the current location of the vehicle. If the vehicle location is different than the location the OnStar(R) advisor gives contact GM Technical Assistance (TAC) and choose the OnStar(R) prompt. GM OnStar(R) TAC will assist in the diagnosis of a failed VCIM and, if appropriate, order a replacement part. Replacement parts are usually shipped out within 24 hours, and a pre-paid return package label will be included for returning the faulty part. By returning the faulty part, you will avoid a non-return core charge. Disclaimer Page 8997 Junction Block - I/P Wire Entry Part 4 Page 12251 networks, and will not require an upgrade in connection with the cellular industry's transition to the digital network. In order to verify the type of OnStar(R) Hardware in a vehicle, type the VIN into the VIN look-up tool, which is available at the OnStar(R) Online Enrollment website within GM GlobalConnect (for U.S. dealers) or InfoNet (for Canadian dealers). Disclaimer Page 6381 Park Neutral Position (PNP) Switch C175 Page 6467 9. Important: Avoid unnecessary twisting/bending of the range selector cable when removing the cable from the support. Remove the range selector cable from the support. 10. Remove the cable grommet from the floor panel. 11. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 12. Remove the clips on the cable from the floor panel reinforcement. 13. Ensure the transmission manual shaft is positioned in mechanical park. 14. Remove the retainer that secures the cable to the bracket. Page 2474 1. Install the filter neck seal. 2. Install the oil filter. 3. Install the oil pan gasket to the pan. 4. Install the magnet into the bottom of the pan, if necessary. 5. Install the oil pan and bolts. ^ Tighten the oil pan bolts to 24 Nm (18 ft. lbs.). 6. Position the bracket with cable. Install the transmission range selector cable bracket (2) and bolts to the transmission. ^ Tighten the selector bracket bolts to 25 Nm (18 ft. lbs.). 7. Connect the range selector cable end (2) to the transmission range selector lever ball stud (1). Transfer Case - NVG 149-NP3 Case: Service and Repair Transfer Case - NVG 149-NP3 Transfer Case Shield Replacement Removal Procedure 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. Remove the transfer case shield bolts, if equipped. 3. Remove the transfer case shield, if equipped. Installation Procedure 1. Position the transfer case shield, if equipped. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the transfer case shield bolts, if equipped. ^ Tighten the bolts to 20 Nm (15 ft. lbs.). 3. Lower the vehicle. Page 6801 Installation Procedure 1. Install the drain plug. ^ Tighten the drain plug to 33 Nm (24 ft. lbs.). Notice: Refer to Fastener Notice in Service Precautions. 2. Fill the differential carrier assembly with axle lubricant. Use the correct fluid. 3. Install the fill plug. ^ Tighten the fill plug to 33 Nm (24 ft. lbs.). 4. Install the front differential carrier shield, if equipped. 5. Lower the vehicle. Initial Inspection and Diagnostic Overview Heated Glass Element: Initial Inspection and Diagnostic Overview Diagnostic Starting Point - Heated Glass Element DIAGNOSTIC STARTING POINT For the inside rearview mirror with the automatic day-night feature, begin the diagnosis by reviewing the system Description and Operation. Reviewing the Description and Operation information will help you determine the correct symptom diagnostic procedure when a malfunction exists. Reviewing the Description and Operation information will also help you determine if the condition described by the customer is normal operation. Refer to Symptoms - Heated Glass Element in order to identify the correct procedure for diagnosing the system and where the procedure is located. See: Symptom Related Diagnostic Procedures For the rear window defogger, begin the diagnosis with the Diagnostic System Check - Defogger. The Diagnostic System Check will provide the following information: - The identification of the control modules which command the system - The ability of the control modules to communicate through the serial data circuit - The identification of any stored diagnostic trouble codes (DTCs) and their status The use of the Diagnostic System Check will identify the correct procedure for diagnosing the system and where the procedure is located. Diagnostic System Check - Defogger DIAGNOSTIC SYSTEM CHECK - DEFOGGER TEST DESCRIPTION Testing and Inspection Drive Belt Tensioner: Testing and Inspection Drive Belt Tensioner Diagnosis Inspection Procedure 1. Notice: Allowing the drive belt tensioner to snap into the free position may result in damage to the tensioner. Important: When the engine is operating the drive belt tensioner arm will move. Do not replace the drive belt tensioner because of movement in the drive belt tensioner arm. Remove the drive belt. 2. Move the drive belt tensioner through its full travel. ^ The movement should feel smooth. ^ There should be no binding. ^ The tensioner should return freely. 3. If any binding is observed, replace the drive belt tensioner. 4. Install the drive belt. Page 6816 17. Measure the rotating torque of the pinion using an inch-pound torque wrench. The rotating torque of the pinion should be between 1.0-2.3 Nm (10-20 inch lbs.) for used bearings, or 1.7-3.4 Nm (15-30 inch lbs.) for new bearings. 18. If the rotating torque measurement is below 1.0 Nm (10 inch lbs.) for used bearings, or 1.7 Nm (15 inch lbs.) for new bearings, continue to tighten the pinion nut. ^ Tighten the pinion nut, in small increments, as needed, until the torque required in order to rotate the pinion is between 1.0-2.3 Nm (10-20 inch lbs.) for used bearings, or 1.7-3.4 Nm (15-30 inch lbs.) for new bearings. 19. Once the specified torque is obtained, rotate the pinion several times to ensure the bearings have seated. Inspect the rotating torque and adjust if necessary. 20. Install the differential assembly. 21. Fill the axle with lubricant. Use the proper fluid. 22. Lower the vehicle. Testing and Inspection Radiator Cap: Testing and Inspection Pressure Cap Testing ^ Tools Required J 24460-01 Cooling System Pressure Tester - J 42401 Radiator Cap / Surge Tank Test Adapter Pressure Cap Testing 1. Caution: To avoid being burned, do not remove the radiator cap or surge tank cap while the engine is hot. The cooling system will release scalding fluid and steam under pressure if radiator cap or surge tank cap is removed while the engine and radiator are still hot. Remove the pressure cap. 2. Wash the pressure cap sealing surface with water. 3. Use the J 24460-01 (1) with J 42401 (2) in order to test the pressure cap. 4. Test the pressure cap for the following conditions: ^ Pressure release when the J 24460-01 exceeds the pressure rating of the pressure cap. ^ Maintain the rated pressure for at least 10 seconds.Note the rate of pressure loss. 5. Replace the pressure cap under the following conditions: ^ The pressure cap does not release pressure which exceeds the rated pressure of the cap. ^ The pressure cap does not hold the rated pressure. Page 12299 7. Disconnect the wire connector (1). 8. Slightly lift up the DVD player assembly so that the hook can be removed from its resting position. 9. Remove the DVD player from the vehicle. INSTALLATION PROCEDURE 1. Install the DVD player hook (1) into the hook opening. 2. Connect the wire connector (1) to the DVD player assembly. Page 9061 Relay Block - I/P C5 Part 2 Page 1979 Electrical Symbols Part 5 Page 673 Page 9457 Auxiliary Power Outlet: Electrical Diagrams Cigar Lighter/Auxiliary Outlets Diagram 1 Page 8407 8. Pull down on the park brake cable in front of the equalizer and install the left park brake cable to the equalizer bar. 9. Remove the safety stands. 10. Lower the vehicle. Park Brake Cable Replacement - Intermediate Park Brake Cable Replacement - Intermediate Removal Procedure 1. Release the park brake. 2. Raise and support the vehicle. Refer Vehicle Lifting 3. For all 15 series vehicles, relieve the tension from the park brake cable by pulling down on the park brake cable in front of the equalizer then removing the cables from the equalizer bar. 4. For 25/35 series vehicles, disable the park brake cable automatic adjuster. Refer to Disabling the Park Brake Cable Automatic Adjuster. 5. For 25/35 series vehicles, disconnect the intermediate cable from the rear park brake cable. Page 5650 Vehicle Speed Sensor (VSS) Tow/Haul Switch Location Page 1002 Steps 10 - 14 Automatic Transmission - 4L60-E/4L65-E Shift Solenoid: Diagrams Automatic Transmission - 4L60-E/4L65-E Page 5662 1. The shift lock control actuator must lock the shift lever clevis when the shift lever clevis is put into the park position. 2. Depress the brake pedal to move the shift lever out of the park position. 3. The actuator will be energized. 4. Readjust the shift lock control actuator if needed. 5. Install the BCM. 6. Enable the SIR system. Recall 04V240000: Incorrect Spare Tire on Vehicle Spare Tire: Recalls Recall 04V240000: Incorrect Spare Tire on Vehicle Make / Models : Model/Build Years: GMC / 1500 2004 Regency / Chevrolet 1500 2004 MANUFACTURER: General Motors Corp. NHTSA CAMPAIGN ID Number : 04V240000 Recall Date : MAY 14, 2004 COMPONENT: Tires: Temporary/Emergency Spare Tire Potential Number Of Units Affected : 285 SUMMARY: The spare tire and wheel assembly that was provided on certain conversion vehicles will not fit on the front wheel hub due to offset of the wheel. However, it will fit on the rear wheels. CONSEQUENCE: If someone has a flat tire on the front wheel, they will not be able to install the provided spare tire. REMEDY: Dealers will install a spare wheel with the correct offset. Owner notification began on June 11, 2004. Owners should contact Regency at 1-800-989-4727. NOTES: Customers can also contact The National Highway Traffic Safety Administration's Auto Safety Hotline at 1-888-DASH-2-DOT (1-888-327-4236). Page 16011 Electrical Symbols Part 6 Page 6873 8. Install a new pinion oil seal using the J 44414. 9. Apply sealant, GM P/N 12346004 (Canadian P/N 10953480) or equivalent, to the splines of the pinion yoke. 10. Install the pinion yoke. Align the marks made during removal. 11. Seat the pinion yoke onto the pinion shaft by tapping it with a soft-faced hammer until a few pinion shaft threads show through the yoke. Notice: Do not hammer the pinion flange/yoke onto the pinion shaft. Pinion components may be damaged if the pinion flange/yoke is hammered onto the pinion shaft. 12. Install the washer and a new pinion nut. 13. Install the J 8614-01 onto the pinion yoke as shown. 14. Tighten the pinion nut while holding the J 8614-01. ^ Tighten the nut until the pinion end play is just taken up. Rotate the pinion while tightening the nut to seat the bearings. Notice: Refer to Fastener Notice in Service Precautions. Important: If the rotating torque is exceeded, the pinion will have to be removed and a new collapsible spacer installed. 15. Measure the rotating torque of the pinion. Compare this measurement with the rotating torque recorded during removal. ^ Tighten the nut in small increments, as needed, until the rotating torque is 0.40-0.57 Nm (3-5 inch lbs.) greater than the rotating torque recorded during removal. 16. Once the specified torque is obtained, rotate the pinion several times to ensure the bearings have seated. Recheck the rotating torque and adjust if necessary. Page 9241 C322 Seat Motor Jumper Harness To Seat Jumper Harness (With RPO Code AN3) Part 1 Page 11640 Tighten Tighten the bolts to 3 N.m (26 lb in). 4. Fold the rear seat to the closed position. Page 4038 Note The rivet stud and surrounding panel area MUST BE properly refinished PRIOR to the installation of the electrical ground wire terminal and conductive nut to maintain a secure, stable and corrosion-free electrical ground. 11. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 12. Allow the refinished repair area to cure sufficiently before removing the protective material applied to the rivet stud threads. 13. Remove the painters tape or equivalent from the rivet stud threads. 14. Using GM approved residue-free solvent or equivalent, thoroughly clean the rivet stud threads to remove any adhesive and allow to dry. 15. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive rivet stud. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 16. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 17. Install the electrical ground wire terminal to the M6 conductive rivet stud. 18. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 19. Install the M6 conductive nut to the rivet stud and: Tighten Tighten to 8 Nm (71 lb in) 20. Verify proper system operation. Parts Information Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use: Warranty Information (Saab Models) Page 16068 Electrical Symbols Part 11 OnStar(R) - Incorrect GPS Position Reported During Call Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Incorrect GPS Position Reported During Call Bulletin No.: 02-08-46-006C Date: January 08, 2008 INFORMATION Subject: Incorrect OnStar(R) Global Positioning System (GPS) Location Reported During OnStar(R) Call Models: 2000-2008 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2008 HUMMER H2 2006-2008 HUMMER H3 2005-2008 Saab 9-7X with OnStar(R) Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 02-08-46-006B (Section 08 - Body and Accessories). A small number of the above-mentioned vehicles may exhibit a condition in which the vehicle reports an inaccurate location to the OnStar(R) Call Center. This condition can only be identified via a button press to the OnStar(R) Call Center by the customer. Call Center personnel will be able to identify this inaccurate location condition. Customers will then be notified through the mail by OnStar(R) if their vehicle exhibits this condition. Once this condition has been identified OnStar(R) will instruct the customer to return to the dealership to have this condition corrected. It is not necessary to reconfigure the vehicle after the following procedure. In order to correct this condition you must cycle power to the OnStar(R) system. This can be done by either removing the fuses powering the OnStar(R) system or disconnecting the OnStar(R) module (VCIM) from the vehicle. As a last resort you can disconnect the vehicle's battery. The power needs to be removed from the system for approximately 15 minutes. After completing this procedure the vehicle should be taken to an area with an unobstructed view of the sky. The vehicle should be kept running for approximately 10 minutes to allow the vehicle to reacquire the global positioning system (GPS). Then contact the OnStar(R) Call Center via the blue OnStar(R) button and ask the advisor to verify the GPS position. If the OnStar(R) advisor still has an inaccurate GPS location refer to the Navigation Systems and Cellular Communications sub-sections in the Service Manual in order to diagnose and repair the concern. If the normal diagnostics lead to module replacement you will need to contact Technical Assistance (TAC) and choose the OnStar(R) prompt. GM OnStar(R) TAC will assist in the diagnosis and if appropriate order a replacement part. Replacement parts are usually shipped out within 24 hours and a pre-paid return package label will be included for returning the faulty part. By returning the faulty part you will avoid a significant non-return core charge. Warranty Information (excluding Saab US Models) For vehicles repaired under warranty, use the table. Warranty Information (Saab US Models) Page 4435 Page 11146 3. Install the evaporator cover (1) to the HVAC module assembly (2). Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems. 4. Install the screws to the evaporator cover (1). Tighten Tighten the screws to 2 Nm (18 lb in). 5. Connect the electrical connector to the recirculation actuator (1). 6. Install the HVAC module assembly. Air Temperature Sensor Replacement - Upper Right Discharge Air Temperature Sensor / Switch: Service and Repair Air Temperature Sensor Replacement - Upper Right AIR TEMPERATURE SENSOR REPLACEMENT - UPPER RIGHT REMOVAL PROCEDURE 1. Remove the I/P upper trim panel. 2. Disconnect the electrical connector (1) from the upper right air temperature sensor (2). 3. Remove the upper right air temperature sensor (1) from the air distributor duct (3). INSTALLATION PROCEDURE 1. Install the upper right air temperature sensor (1) to the air distributor duct (3). 2. Connect the electrical connector (1) from the upper right air temperature sensor (2). 3. Install the I/P upper trim panel. Navigation System - Software/DVD Update Program Navigation System: All Technical Service Bulletins Navigation System - Software/DVD Update Program INFORMATION Bulletin No.: 06-08-44-012E Date: April 20, 2010 Subject: DVD Navigation Update Program, Navigation Disc Diagnostic Aid, AVN Software Update Discs and Ordering Information Models: 2002-2010 GM Passenger Cars and Trucks (including Saturn) 2004-2010 HUMMER H2, H3 2005-2009 Saab 9-7X Attention: Please direct this information to your Sales Consultants, Service Consultants, Parts Personnel and Used Car Department. This bulletin ONLY applies to North American dealers/retailers. Supercede: This bulletin is being revised to include the 2010 model year and update the usage table. Please discard Corporate Bulletin Number 06-08-44-012D (Section 08 - Body and Accessories). DVD Navigation Update Program The data on the DVD map disc ages at a rate of 15-20% per year. As the data ages, the functionality of the navigation system declines. Offering GM customers new navigation DVDs will ensure that the customers have the latest information for their system. General Motors offered a Navigation Disc Update Program for 2006 and 2007 model year vehicles. This program concluded on December 31, 2009. The DVD Navigation Update Program policy has changed and customers are no longer eligible for free annual updates, however, a navigation DVD update disc can be purchased for $199 (USD) + shipping. If the navigation disc is needed for a warranty situation, the disc can be purchased for $120 (USD). The dealer must provide a VIN and RO# to qualify for the reduced price. The dealer must call the GM Navigation Disc Center, as this option is not available on the website. The GM Navigation Disc Center launched on March 15, 2006. There are two ways to obtain an updated disc: - Via the web through gmnavdisc.com - GM Navigation Disc Center Navigation Disc Diagnostic Aid The following table can be used to identify acceptable discs for testing the navigation unit's map drive functionality. This should only be used to verify the map drive's ability to read the map disc properly and to determine if there is an issue with the unit's map drive or the disc. Some functions, such as voice recognition, may not work properly with some of the discs in the list. If the disc is found to be defective always contact the GM Navigation Disc Center to obtain the most recent disc for the vehicle. AVN Software Update Discs Technical Service Bulletins are sometimes generated to address specific navigation radio operational or performance issues. When a navigation radio bulletin is issued, it may contain instructions to utilize an advanced vehicle navigation (AVN) software update with a specific part number. GM dealers must order advanced vehicle navigation (AVN) software update discs as directed in the specific bulletin. AVN software update discs are for the dealer to update the navigation radio software only. They do NOT update or replace the navigation map disc that is supplied with the vehicle. Please order these parts only as needed. There is a limited supply of these discs available. Do not order these discs for stock. AVN software update discs can be used to reprogram more than one vehicle. The first update disc for each P/N is free. Subsequent copies of the same P/N for the same dealer will cost $50 (USD). To obtain an AVN software update disc, follow the specific ordering information provided in the bulletin. Page 3667 1. Install the outlet hose to the radiator. 2. Position the outlet hose clamp at the radiator. 3. Install the outlet hose to the water pump. 4. Position the outlet hose clamp at the water pump. 5. Important: Align the arrow at the throttle body end of the duct with the throttle body attaching stud. Install the air cleaner outlet duct. 6. Install the radiator inlet hose clip to the outlet duct. 7. Tighten the air cleaner outlet duct clamps at the following locations: ^ Throttle body ^ MAF/IAT sensor Tighten the air cleaner outlet duct clamp screws to 7 Nm (62 inch lbs.). 8. Fill the cooling system. Page 14033 Trim Panel: Service and Repair Molding Replacement - Rear Window Lower Molding Replacement - Rear Window Lower Removal Procedure 1. Lightly pull the lower edge of the molding in order to release the clips. On extended cab fold the rear bench seat up. This will move the assembly forward so that the molding can be accessed. 2. Lift the molding up and away from the glass in order to release the upper retainers. Installation Procedure 1. Align the molding clips with the holes in the body panel along the back glass. 2. Snap the molding into place. Fuel System Description Fuel Level Sensor: Description and Operation Fuel System Description FUEL LEVEL SENSOR The fuel level sensor consists of a float, a wire float arm, and a ceramic resistor cord. The position of the float arm indicates the fuel level. The fuel level sensor contains a variable resistor, which changes resistance in correspondence to the amount of fuel in the fuel tank. The powertrain control module (PCM) sends the fuel level information via the class 2 circuit to the instrument panel (I/P) cluster. This information is used for the I/P fuel gage and the low fuel warning indicator, if applicable. The PCM also monitors the fuel level input for various diagnostics. Page 9853 4. Connect the wire connectors to the lower portion of the electrical center block. 5. Connect the wire connectors with the bolts to the electrical center block. Tighten Tighten all connector bolts (1) to 9 N.m (80 lb in). 6. Ensure all wire connectors are securely connected. 7. Set the electrical center block in its resting position till the tabs (3) locks in place. 8. Install the lower part of the cover (1). 9. With the cover (2) off, use the fuse location information to install all fuses and relays. 10. Install the cover. 11. Install the fender upper brace. 12. Install the 4 fender upper brace bolts. Tighten Tighten the 4 retaining bolts to 25 N.m (18 lb ft). 13. Connect the negative battery cable. 14. Start vehicle and ensure all components function properly. Page 15011 Page 15143 Electrical Symbols Part 6 Page 2560 Brake Bleeding: Service and Repair Hydraulic Brake System Bleeding (Manual) Hydraulic Brake System Bleeding (Manual) Caution: Refer to Brake Fluid Irritant Caution in Service Precautions. Notice: Refer to Brake Fluid Effects on Paint and Electrical Components Notice in Service Precautions. Notice: When adding fluid to the brake master cylinder reservoir, use only Delco Supreme 11, GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. The use of any type of fluid other than the recommended type of brake fluid, may cause contamination which could result in damage to the internal rubber seals and/or rubber linings of hydraulic brake system components. 1. Place a clean shop cloth beneath the brake master cylinder to prevent brake fluid spills. 2. With the ignition Off and the brakes cool, apply the brakes 3-5 times, or until the brake pedal effort increases significantly, in order to deplete the brake booster power reserve. 3. If you have performed a brake master cylinder bench bleeding on this vehicle, or if you disconnected the brake pipes from the master cylinder, you must perform the following steps: 1. Ensure that the brake master cylinder reservoir is full to the maximum-fill level. If necessary add Delco Supreme 11, GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container.If removal of the reservoir cap and diaphragm is necessary, clean the outside of the reservoir on and around the cap prior to removal. 2. With the rear brake pipe installed securely to the master cylinder, loosen and separate the front brake pipe from the front port of the brake master cylinder. 3. Allow a small amount of brake fluid to gravity bleed from the open port of the master cylinder. 4. Reconnect the brake pipe to the master cylinder port and tighten securely. 5. Have an assistant slowly depress the brake pedal fully and maintain steady pressure on the pedal. 6. Loosen the same brake pipe to purge air from the open port of the master cylinder. 7. Tighten the brake pipe, then have the assistant slowly release the brake pedal. 8. Wait 15 seconds, then repeat steps 3.3-3.7 until all air is purged from the same port of the master cylinder. 9. With the front brake pipe installed securely to the master cylinder - after all air has been purged from the front port of the master cylinder loosen and separate the rear brake pipe from the master cylinder, then repeat steps 3.3-3.8. 10. After completing the final master cylinder port bleeding procedure, ensure that both of the brake pipe-to-master cylinder fittings are properly tightened. 4. Fill the brake master cylinder reservoir with Delco Supreme 11, GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. Ensure that the brake master cylinder reservoir remains at least half-full during this bleeding procedure. Add fluid as needed to maintain the proper level.Clean the outside of the reservoir on and around the reservoir cap prior to removing the cap and diaphragm. 5. Install a proper box-end wrench onto the RIGHT REAR wheel hydraulic circuit bleeder valve. 6. Install a transparent hose over the end of the bleeder valve. 7. Submerge the open end of the transparent hose into a transparent container partially filled with Delco Supreme 11, GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. 8. Have an assistant slowly depress the brake pedal fully and maintain steady pressure on the pedal. 9. Loosen the bleeder valve to purge air from the wheel hydraulic circuit. 10. Tighten the bleeder valve, then have the assistant slowly release the brake pedal. 11. Wait 15 seconds, then repeat steps 8-10 until all air is purged from the same wheel hydraulic circuit. 12. With the right rear wheel hydraulic circuit bleeder valve tightened securely - after all air has been purged from the right rear hydraulic circuit install a proper box-end wrench onto the LEFT REAR wheel hydraulic circuit bleeder valve. 13. Install a transparent hose over the end of the bleeder valve, then repeat steps 7-11. 14. With the left rear wheel hydraulic circuit bleeder valve tightened securely - after all air has been purged from the left rear hydraulic circuit - install a proper box-end wrench onto the RIGHT FRONT wheel hydraulic circuit bleeder valve. 15. Install a transparent hose over the end of the bleeder valve, then repeat steps 7-11. 16. With the right front wheel hydraulic circuit bleeder valve tightened securely - after all air has been purged from the right front hydraulic circuit install a proper box-end wrench onto the LEFT FRONT wheel hydraulic circuit bleeder valve. 17. Install a transparent hose over the end of the bleeder valve, then repeat steps 7-11. 18. After completing the final wheel hydraulic circuit bleeding procedure, ensure that each of the 4 wheel hydraulic circuit bleeder valves are properly tightened. 19. Fill the brake master cylinder reservoir to the maximum-fill level with Delco Supreme 11, GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. 20. Slowly depress and release the brake pedal. Observe the feel of the brake pedal. 21. If the brake pedal feels spongy, repeat the bleeding procedure again. If the brake pedal still feels spongy after repeating the bleeding procedure, Page 14083 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly, Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Pull to Seat Connectors PULL TO SEAT CONNECTORS TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Page 11453 7. Disconnect the SDM wiring harness connector (1) from the SDM (3). 8. Remove the SDM mounting fasteners. 9. Remove the SDM from the vehicle. IMPORTANT: The following repair procedures should only be used in the event that the inflatable restraint sensing and diagnostic module (SDM) mounting studs and/or fasteners are damaged to the extent that the SDM may no longer be properly mounted. 10. Repair the fasteners using the following procedure: 10.1. Remove the stripped nut and discard the nut. 10.2. Drill out the weld spots to the weld stud from the floor pan side, then remove and discard the stud. 10.3. Condition the floor panel attaching surface where the new stud is to be installed. 10.4. Install new weld stud GM P/N 115115602 and clamp the weld stud. 10.5. Migweld the stud at the drilled holes from above or below the floor pan, as required. 10.6. Apply body sealer GM P/N 9984248 around any exposed openings. 10.7. Install a new fastener GM P/N 11515933. INSTALLATION PROCEDURE 1. Remove any dirt, grease, or other contaminants from the mounting surface. 2. Install the SDM (3) horizontally to the vehicle. 3. Point the arrow on the SDM toward the front of the vehicle. NOTE: Refer to Fastener Notice in Service Precautions. 4. Install the SDM mounting fasteners. Tighten Tighten fasteners to 10 N.m (89 lb in). 5. Connect the SDM wiring harness connector (1) to the SDM. Page 7089 Parts Information Parts are currently available from GMSPO. Warranty Information Page 5698 ^ TCC PWM solenoid (5) ^ 3-2 control solenoid (6) 9. Install the 1-2 accumulator. 10. Connect the transmission harness 20-way connector (1) to the transmission pass-through connector. Align the arrows on each half of the connector and insert straight down. 11. Install the transmission filter. Page 818 Relay Box: Locations Relay Block - I/P Location View Page 15892 Turn Signal Switch: Diagrams Turn Signal Multifunction Switch - C1 Page 12847 2. Disconnect the C2 32-way blue connector from the VIU and tape the connector to a secure location. Refer to Cellular Communications Connector End Views and related schematics in SI, if required. Important: DO NOT perform the OnStar(R) reconfiguration and/or programming procedure. 3. Secure the VIU in its original brackets and/or mounting locations and reinstall the VIU and interior components that were removed to gain access to the VIU. Refer to OnStar Vehicle Interface Unit Replacement in SI. 2002 Through 2006 Model Year Vehicles (Except Saab Vehicles) 2002 through 2006 Model Year Vehicles (Except Saab Vehicles) Important: The Tech 2 diagnostic tool must be updated with version 28.002 or later in order to successfully perform the VCIM setup procedure and disable the analog system. 1. Connect the Tech 2 to the data link connector (DLC), which is located under the instrument panel of the vehicle. 2. Turn the Tech 2 ON by pressing the power button. Important: Tech 2 screen navigation to get to the setup procedure depends on the year and make of the vehicle. The actual name of the setup procedure (Setup New OnStar or VCIM Setup) depends on model year and vehicle make as well. Example Tech 2 navigation to the setup procedure Tech 2 screen is provided below. ^ Diagnostics >> (2) 2002 >> Passenger Car >> Body >> C >> OnStar >> Special Functions >> Setup New OnStar >> ^ Diagnostics >> (5) 2005 >> Passenger Car >> (4) Buick >> C >> Body >> Vehicle Comm. Interface Module >> Module Setup >> VCIM Setup >> 3. Setup VCIM using the Tech 2. Follow on-screen instructions when you have reached the setup Tech 2 screen. 2000-2002 Saab 9-3 (9400) 4D/5D; 2000-2003 Saab 9-3 (9400) CV 2000-2002 Saab 9-3 (9400) 4D/5D; 2000-2003 Saab 9-3 (9400) CV 1. Remove the ground cable from the battery's negative terminal. 2. Apply the handbrake brake. 3. Detach the floor console. 4. Remove the switch and the floor console: 3.1. Twist loose the immobilizer unit (A), bayonet fitting. Unplug the unit's connector. 3.2. Remove the ignition switch cover (B) by first undoing the rear edge of the cover and then unhooking the front edge. Unplug the ignition Page 2144 4. Misalignment of the accessory drive pulley(s) may be caused from improper mounting or incorrect installation of a accessory drive component, or the pulley may be bent inward or outward from a previous repair. Test for a misaligned pulley using a straight edge in the pulley grooves across two or three pulleys. If a misaligned pulley is found, refer to that accessory drive component for the proper removal and installation procedure of that pulley. 5. Inspection of the accessory drive pulley(s) should include inspecting for bends, dents, or other damage that would prevent the drive belt from seating properly in the pulley grooves or on the smooth surface of a pulley when the back side of the drive belt(s) is used to drive the pulley. 6. Accessory drive component brackets that are bent or cracked will also cause the drive belt(s) to fall off. 7. Inspection of the fasteners can eliminate the possibility that a incorrect bolt, nut, spacer, or washer was installed. Missing, loose, or incorrect fasteners may cause pulley misalignment from the accessory drive bracket(s) moving under load. Over tightening the fasteners may cause misalignment of the accessory component bracket(s). Page 9659 Remove all rust from the ground terminal, the cylinder head and the retaining nut or bolt. Position the main engine wiring harness ground terminal and install the nut or bolt. Tighten: Tighten the retaining nut or bolt to 16 N.m (12 lb ft). Apply some type of electrical moisture sealant to protect the harness terminal from further corrosion. Disclaimer Page 10047 Removal Procedure Notice: Refer to Power Steering Hose Disconnected Notice in Service Precautions. 1. Remove the power steering outlet hose (4) from the power steering gear (3). 2. Remove the power steering outlet hose (4) from the power steering cooler (5). Installation Procedure 1. Connect the power steering outlet hose (4) to the power steering cooler (5). 2. Connect the power steering outlet hose (4) to the power steering gear (3). Hand tighten only. 3. Notice: Refer to Fastener Notice in Service Precautions. Connect the power steering outlet hose (2) to the power steering pump (1). ^ Tighten both hose connections to 28 Nm (20 ft. lbs.). 4. Bleed the power steering system. Refer to Bleeding the Power Steering System. 5. Inspect all the hose connections for leaks. Page 938 1. Install the TAC module. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the TAC module nuts. Tighten Tighten the nuts to 9 N.m (80 lb in). 3. Connect the engine wiring harness electrical connector (1). 4. Install the red CPA retainer. 5. Connect the I/P harness electrical connector (2). Page 14983 Automatic Transmission - 4L60-E/4L65-E Shift Solenoid: Diagrams Automatic Transmission - 4L60-E/4L65-E Page 2377 Processes shown in the Table 3 are capable of recycling waste engine coolants (DEX-COOL(R) or conventional) to a conventional (green) coolant. Recycling conventional coolant can be accomplished at your facility by a technician using approved EQUIPMENT (listed by model number in Table 3), or by an approved coolant recycling SERVICE which may recycle the coolant at your facility or at an offsite operation. Refer to the table for GM approved coolant recyclers in either of these two categories. Should you decide to recycle the coolant yourself, strict adherence to the operating procedures is imperative. Use ONLY the inhibitor chemicals supplied by the respective (GM approved) recycling equipment manufacturer. Sealing Tablets Cooling System Sealing Tablets (Seal Tabs) should not be used as a regular maintenance item after servicing an engine cooling system. Discoloration of coolant can occur if too many seal tabs have been inserted into the cooling system. This can occur if seal tabs are repeatedly used over the service life of a vehicle. Where appropriate, seal tabs may be used if diagnostics fail to repair a small leak in the cooling system. When a condition appears in which seal tabs may be recommended, a specific bulletin will be released describing their proper usage. Water Quality The integrity of the coolant is dependent upon the quality of DEX-COOL(R) and water. DEX-COOL(R) is a product that has enhanced protection capability as well as an extended service interval. These enhanced properties may be jeopardized by combining DEX-COOL(R) with poor quality water. If you suspect the water in your area of being poor quality, it is recommended you use distilled or de-ionized water with DEX-COOL(R). "Pink" DEX-COOL(R) DEX-COOL(R) is orange in color to distinguish it from other coolants. Due to inconsistencies in the mixing of the dyes used with DEX-COOL(R), some batches may appear pink after time. The color shift from orange to pink does not affect the integrity of the coolant, and still maintains the 5 yr/150,000 mile (240,000 km) service interval. Back Service Only use DEX-COOL(R) if the vehicle was originally equipped with DEX-COOL(R). Page 7239 9. Use J 38125-12A to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. REPAIR PROCEDURE The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. 1. Cut the wire as close to the terminal as possible. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. Page 3356 3. Important: Be sure to align the oil gallery passages in the oil pan and engine block properly with the oil pan gasket. Pre-assemble the oil pan gasket to the pan. ^ Install the gasket onto the pan. ^ Install the oil pan bolts to the pan and through the gasket. 4. Install the oil pan, gasket and bolts to the engine block. 5. Tighten the oil pan bolts until snug. Do not overtighten. 6. Install the two bottom bellhousing bolts until snug, if equipped with a manual transmission. 7. Install the transmission converter cover bolts until snug, if equipped with the 4L80-E automatic transmission. Page 4731 PCM Location Interior - Heated Seats Intermittently Inoperative Seat Heater Control Module: Customer Interest Interior - Heated Seats Intermittently Inoperative Bulletin No.: 05-08-05-008 Date: August 18, 2005 TECHNICAL Subject: Intermittent Heated Seats Inoperative, DTC B3941 Set (Reprogram Driver Seat Module) Models: 2003-2005 Cadillac Escalade, Escalade ESV, Escalade EXT 2003-2005 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2003-2005 GMC Sierra, Yukon, Yukon XL, Yukon Denali All with Seat FRT, Individual (Non BKT) (RPO AN3) 2003-2005 HUMMER H2 with Seat, Front Bucket Deluxe (RPO AR9) Condition Some customers may comment that occasionally the seat heater will not operate when activated. If the ignition key is cycled OFF and back ON again, the heated seat will operate correctly. Also, on some LB7 diesel engine vehicles, the seat heater may turn itself off during the first 10 minutes of operation. This occurs only with the first activation for the day and works correctly with subsequent activations immediately after the event. These conditions are intermiffent and DTC B3941 may be set. Correction Technicians are to reprogram the driver seat module with an updated software calibration. This new service calibration was released with TIS satellite data update version 6.5 available June 13, 2005. As always, make sure your Tech 2(R) is updated with the latest software version. Warranty Information Disclaimer Fuel System Description Fuel Rail: Description and Operation Fuel System Description FUEL RAIL ASSEMBLY The fuel rail assembly attaches to the engine intake manifold. The fuel rail assembly performs the following functions: Positions the injectors (3) in the intake manifold - Distributes fuel evenly to the injectors - Integrates the fuel dampener (2) into the fuel metering system Page 8518 been prepared, and are being furnished to involved dealers. The customer name and address data will enable dealers to follow up with customers involved in this recall. Any dealer not receiving a computer listing with the recall bulletin has no involved vehicles currently assigned. These dealer listings may contain customer names and addresses obtained from Motor Vehicle Registration Records. The use of such motor vehicle registration data for any other purpose is a violation of law in several states/provinces/countries. Accordingly, you are urged to limit the use of this listing to the follow-up necessary to complete this recall. PARTS INFORMATION Parts required to complete this recall are to be obtained from General Motors Service Parts Operations (GMSPO). Please refer to your "involved vehicles listing" before ordering parts. Normal orders should be placed on a DRO = Daily Replenishment Order. In an emergency situation, parts should be ordered on a CSO = Customer Special Order. Important It is estimated that only 20% of involved vehicles will require Valve Kit Repair. Please order parts accordingly. COURTESY TRANSPORTATION The General Motors Courtesy Transportation program is intended to minimize customer inconvenience when a vehicle requires a repair that is covered by the New Vehicle Limited Warranty. The availability of courtesy transportation to customers whose vehicles are within the warranty coverage period and involved in a product recall is very important in maintaining customer satisfaction. Dealers are to ensure that these customers understand that shuttle service or some other form of courtesy transportation is available and will be provided at no charge. Dealers should refer to the General Motors Service Policies and Procedures Manual for Courtesy Transportation guidelines. Page 12337 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Micro-Pack 100W Connectors MICRO-PACK 100W CONNECTORS TOOLS REQUIRED J 38125-D Terminal Repair Kit REMOVAL PROCEDURE There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2)has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. IMPORTANT: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Page 9744 C223 I/P Harness To Body Harness (Except NYS And HP2) Part 1 Locations Starter - Without RPO Code HP2 Electrical - Information For Electrical Ground Repair Grounding Point: All Technical Service Bulletins Electrical - Information For Electrical Ground Repair INFORMATION Bulletin No.: 10-08-45-001B Date: October 25, 2010 Subject: Information for Electrical Ground Repair - Use New Replacement Fasteners with Conductive Finish Models: 2011 and Prior GM Passenger Cars and Trucks (including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X Supercede: This bulletin is being revised to add the 2011 model year and update the Warranty Information. Please discard Corporate Bulletin Number 10-08-45-001A (Section 08 - Body and Accessories). Electrical Ground Repair Overview Proper electrical system function relies on secure, stable and corrosion-free electrical ground connections. Loose, stripped, or corroded connections increase the possibility of improper system function and loss of module communication. These conditions may also lead to unnecessary repairs and component replacement. In general, electrical ground connections are accomplished using one, or a combination of the following attachment methods: - Welded M6 stud and nut - Welded M6 nut and bolt - Welded M8 nut and bolt Determine which attachment method is used and perform the appropriate or alternative repair as described in this bulletin. M6 Weld Stud Replacement Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. Select a location adjacent the damaged or missing M6 ground stud having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the M6 conductive rivet stud flange. 2. Using GM approved residue-free solvent or equivalent, remove any grease from the repair site and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 3. Drill a 10 mm (0.40 in) diameter hole through the panel. 4. Remove paint and primer from the area surrounding the 10 mm (0.40 in) hole until bare metal is visible. Page 9810 Application Table Page 479 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors USING CONNECTOR TEST ADAPTERS IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-B Connector Test Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Page 13406 When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage TESTING FOR A SHORT TO VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity TESTING FOR CONTINUITY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents TESTING FOR ELECTRICAL INTERMITTENTS Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground - Testing for Continuity - Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 msRECORD and emits an audible tone (beep). Page 7480 3. If the vehicle is a 1500 series, position the transfer case shield, if equipped. Notice: Refer to Fastener Notice in Service Precautions. 4. Install the transfer case shield bolts, if equipped. ^ Tighten the bolts/screws to 20 Nm (15 ft. lbs.). 5. Lower the vehicle. Page 15215 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly, Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Pull to Seat Connectors PULL TO SEAT CONNECTORS TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Page 6446 6. Connect the internal wiring harness electrical connectors to the following components: ^ Transmission fluid pressure switch (1) ^ 1-2 shift control solenoid (2) ^ 2-3 shift control solenoid (3) ^ Pressure control solenoid (4) ^ TCC PWM solenoid (5) ^ 3-2 control solenoid (6) 7. Install the 1-2 accumulator, if necessary. 8. Install the transmission filter. Page 14119 Front Passenger Door Module (FPDM) - C1 (With RPO Code YE9) Page 7946 Vehicle Speed Sensor (VSS) Tow/Haul Switch Location Page 1265 Wheel Speed Sensor: Diagrams ABS Connector End Views Wheel Speed Sensor (WSS) - LF Page 14297 WA817K/63 - WA822K/97 Automatic Transmission - 4L60-E/4L65-E Shift Solenoid: Locations Automatic Transmission - 4L60-E/4L65-E Automatic Transmission Electronic Component Views (M30/M32) Automatic Transmission Electronic Component Views (M30/M32) Electronic Components Page 8045 2. Install the EBCM to the BPMV. 3. Notice: Refer to Fastener Notice in Service Precautions. Install the new screws (1) in the EBCM (2). ^ Tighten the screws to 5 Nm (39 inch lbs.) in an X-pattern. Page 3940 Camshaft Position (CMP) Sensor Page 9783 C410 Right Rear Lamp Harness To Chassis Harness (With RPO Code T79) Page 8990 Application Table Part 4 Page 10904 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Weather Pack Connectors WEATHER PACK CONNECTORS The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. Page 12791 ^ SP303 The following modules, components, and splice pack are connected to the star portion of the class 2 serial data circuit: ^ SP300 ^ Audio amplifier ^ Driver door module (DDM) ^ Driver door switch assembly (DDSA) ^ Memory seat module (MSM) ^ Left rear door module (LRDM) AND ^ SP303 ^ Antenna module ^ Front passenger door module (FPDM) ^ Rear integration module (RIM) ^ Right rear door module (RRDM) ^ Theft deterrent module (TDM) ^ Vehicle communication interface module (VCIM). Refer to Data Communication Schematics and Data Link Communications Description and Operation in SI. Part 2 Conditions for Running the DTC Voltage supplied to the module is in the normal operating voltage range of 9 - 16 volts. DTCs B1327, B1328, U1300, U1301, U1305 are not set as current. The vehicle power mode requires serial data communication to occur. Conditions for Setting the DTC A message containing a critical operating parameter has not been received within the last 5 seconds after establishing class 2 serial data communication. Action Taken When the DTC Sets The module uses a default value for the missing parameter. Conditions for Clearing the DTC A current DTC clears when the malfunction is no longer present. A history DTC clears when the module ignition cycle counter reaches the reset threshold, without a repeat of the malfunction. Diagnostic Aids When a malfunction such as an open fuse to a module occurs while modules are communicating, a DTC U1001-1254 Loss of XXX Communications is set current. When the modules stop communicating the current DTC U1001-1254 Loss of XXX Communications is cleared but the history DTC remains. When the modules begin to communicate again, the module with the open fuse will not be learned by the other modules so U1000 or U1255 is set current by the other modules. If the malfunction occurs when the modules are not communicating, only U1000 or U1255 is set. Page 15216 Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA and/or the secondary locks. Micro .64 Connectors MICRO .64 CONNECTORS TOOLS REQUIRED J 38125-D Terminal Repair Kit REMOVAL PROCEDURE Follow the steps below in order to remove terminals from Micro 64 connectors. 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. 2. Disconnect the connector from the component. Page 5358 14. Install the fuel line clip(s) to the bracket(s) on the transmission. 15. Install the HO2S sensor connector to the bracket. 16. Install the fuel pipe bracket to the bellhousing stud. 17. Install the fuel pipe bracket nut. Tighten Tighten the nut to 10 N.m (89 lb in). 18. Lower the vehicle. 19. Remove the caps from the fuel rail and EVAP lines. 20. Connect the EVAP canister purge tube (2) fitting. 21. Connect the fuel feed line (1) fitting at the engine. 22. Install the fuel fill cap. 23. Connect the negative battery cable. 24. Use the following procedure in order to inspect for leaks: 24.1. Turn the ignition ON, with the engine OFF, for 2 seconds. 24.2. Turn the ignition OFF for 10 seconds. 24.3. Turn the ignition ON, with the engine OFF. 24.4. Inspect for fuel leaks. Page 2562 Brake Bleeding: Service and Repair Hydraulic Brake System Bleeding (Pressure) Hydraulic Brake System Bleeding (Pressure) ^ Tools Required J 29532 Diaphragm Type Brake Pressure Bleeder, or equivalent - J 35589-A Brake Pressure Bleeder Adapter Caution: Refer to Brake Fluid Irritant Caution in Service Precautions. Notice: Refer to Brake Fluid Effects on Paint and Electrical Components Notice in Service Precautions. Notice: When adding fluid to the brake master cylinder reservoir, use only Delco Supreme 11®, GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. The use of any type of fluid other than the recommended type of brake fluid, may cause contamination which could result in damage to the internal rubber seals and/or rubber linings of hydraulic brake system components. 1. Place a clean shop cloth beneath the brake master cylinder to prevent brake fluid spills. 2. With the ignition OFF and the brakes cool, apply the brakes 3-5 times, or until the brake pedal effort increases significantly, in order to deplete the brake booster power reserve. 3. If you have performed a brake master cylinder bench bleeding on this vehicle, or if you disconnected the brake pipes from the master cylinder, you must perform the following steps: 1. Ensure that the brake master cylinder reservoir is full to the maximum-fill level. If necessary add Delco Supreme 11®, GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container.If removal of the reservoir cap and diaphragm is necessary, clean the outside of the reservoir on and around the cap prior to removal. 2. With the rear brake pipe installed securely to the master cylinder, loosen and separate the front brake pipe from the front port of the brake master cylinder. 3. Allow a small amount of brake fluid to gravity bleed from the open port of the master cylinder. 4. Reconnect the brake pipe to the master cylinder port and tighten securely. 5. Have an assistant slowly depress the brake pedal fully and maintain steady pressure on the pedal. 6. Loosen the same brake pipe to purge air from the open port of the master cylinder. 7. Tighten the brake pipe, then have the assistant slowly release the brake pedal. 8. Wait 15 seconds, then repeat steps 3.3-3.7 until all air is purged from the same port of the master cylinder. 9. With the front brake pipe installed securely to the master cylinder - after all air has been purged from the front port of the master cylinder loosen and separate the rear brake pipe from the master cylinder, then repeat steps 3.3-3.8. 10. After completing the final master cylinder port bleeding procedure, ensure that both of the brake pipe-to-master cylinder fittings are properly tightened. 4. Fill the brake master cylinder reservoir to the maximum-fill level with Delco Supreme 11®, GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container.Clean the outside of the reservoir on and around the reservoir cap prior to removing the cap and diaphragm. 5. Install the J 35589-A to the brake master cylinder reservoir. 6. Check the brake fluid level in the J 29532 , or equivalent. Add Delco Supreme 11®, GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container as necessary to bring the level to approximately the half-full point. 7. Connect the J 29532 , or equivalent, to the J 35589-A. 8. Charge the J 29532 , or equivalent, air tank to 175-205 kPa (25-30 psi). 9. Open the J 29532 , or equivalent, fluid tank valve to allow pressurized brake fluid to enter the brake system. 10. Wait approximately 30 seconds, then inspect the entire hydraulic brake system in order to ensure that there are no existing external brake fluid leaks. Any brake fluid leaks identified require repair prior to completing this procedure. 11. Install a proper box-end wrench onto the RIGHT REAR wheel hydraulic circuit bleeder valve. 12. Install a transparent hose over the end of the bleeder valve. 13. Submerge the open end of the transparent hose into a transparent container partially filled with Delco Supreme 11®, GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. 14. Loosen the bleeder valve to purge air from the wheel hydraulic circuit. Allow fluid to flow until air bubbles stop flowing from the bleeder, then tighten the bleeder valve. 15. With the right rear wheel hydraulic circuit bleeder valve tightened securely - after all air has been purged from the right rear hydraulic circuit install a proper box-end wrench onto the LEFT REAR wheel hydraulic circuit bleeder valve. 16. Install a transparent hose over the end of the bleeder valve, then repeat steps 13-14. 17. With the left rear wheel hydraulic circuit bleeder valve tightened securely - after all air has been purged from the left rear hydraulic circuit - install a proper box-end wrench onto the RIGHT FRONT wheel hydraulic circuit bleeder valve. 18. Install a transparent hose over the end of the bleeder valve, then repeat steps 13-14. 19. With the right front wheel hydraulic circuit bleeder valve tightened securely - after all air has been purged from the right front hydraulic circuit install a proper box-end wrench onto the LEFT FRONT wheel hydraulic circuit bleeder valve. 20. Install a transparent hose over the end of the bleeder valve, then repeat steps 13-14. 21. After completing the final wheel hydraulic circuit bleeding procedure, ensure that each of the 4 wheel hydraulic circuit bleeder valves are properly tightened. 22. Close the J 29532 , or equivalent, fluid tank valve, then disconnect the J 29532 , or equivalent, from the J 35589-A. 23. Remove the J 35589-A from the brake master cylinder reservoir. Page 2420 Page 15171 If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Sir/SRS Wiring Repairs SIR/SRS WIRING REPAIRS TOOLS REQUIRED J 38125-D Terminal Repair Kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-D contains the following items: - Special sealed splices - in order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping tool - A heat torch - An instruction manual The sealed splices have the following 2 critical features: - A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-D also serves as a generic terminal repair kit. The kit contains the following items: - A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors Page 4813 Fuel Tank Pressure Sensor: Service and Repair FUEL TANK PRESSURE SENSOR REPLACEMENT REMOVAL PROCEDURE 1. Remove the fuel tank. 2. Using a slight rocking motion, while pulling straight up, remove the fuel tank pressure sensor (1). INSTALLATION PROCEDURE 1. Install the fuel tank pressure sensor (1). 2. Install the fuel tank. Page 6385 Service and Repair Compressor Clutch Relay: Service and Repair COMPRESSOR RELAY REPLACEMENT REMOVAL PROCEDURE 1. Remove the cover from the underhood convenience center (1). 2. Remove the compressor relay (2). INSTALLATION PROCEDURE 1. Install the compressor relay (2). 2. Install the cover to the underhood convenience center (1). OnStar(R) - Aftermarket Device Interference Information Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Aftermarket Device Interference Information INFORMATION Bulletin No.: 08-08-46-004 Date: August 14, 2008 Subject: Information on Aftermarket Device Interference with OnStar(R) Diagnostic Services Models: 2009 and Prior GM Passenger Car and Truck (including Saturn) 2009 and Prior HUMMER H2, H3 Models 2009 and Prior Saab 9-7X with OnStar(R) (RPO UE1) This bulletin is being issued to provide dealer service personnel with information regarding aftermarket devices connected to the Diagnostic Link Connector (DLC) and the impact to OnStar(R) diagnostic probes and Vehicle Diagnostic e-mails. Certain aftermarket devices, when connected to the Diagnostic Link Connector, such as, but not limited to, Scan Tools, Trip Computers, Fuel Economy Analyzers and Insurance Tracking Devices, interfere with OnStar's ability to perform a diagnostic probe when requested (via a blue button call) by a subscriber. These devices also prohibit the ability to gather diagnostic and tire pressure data for a subscriber's scheduled OnStar(R) Vehicle Diagnostic (OVD) e-mail. These aftermarket devices utilize the Vehicles serial data bus to perform data requests and/or information gathering. When these devices are requesting data, OnStar(R) is designed not to interfere with any data request being made by these devices as required by OBD II regulations. The OnStar(R) advisor is unable to definitively detect the presence of these devices and will only be able to inform the caller or requester of the unsuccessful or incomplete probe and may in some cases refer the subscriber/requester to take the vehicle to a dealer for diagnosis of the concern. When performing a diagnostic check for an unsuccessful or incomplete OnStar(R) diagnostic probe, or for concerns regarding completeness of the OnStar(R) Vehicle Diagnostic (OVD) e-mail, verify that an aftermarket device was not present at the time of the requested probe. Regarding the OVD e-mail, if an aftermarket device is interfering (including a Scan Tool of any type), the e-mail will consistently display a "yellow" indication in diagnostics section for all vehicle systems except the OnStar(R) System and Tire Pressure data (not available on all vehicles) will not be displayed (i.e. section is collapsed). Successful diagnostic probes and complete OVD e-mails will resume following the removal or disconnecting of the off-board device. Disclaimer Page 12225 12.2. Cars with brackets for e.g. an amplifier: Remove the pin strap (A) from the bracket and remove the tape (B) holding the optic cables. 12.3. Remove the locking strip (C) on the 2-pin connector (H2-9). Open the terminal housing with a screwdriver. Remove the secondary catch (E) on the connector and remove the optic cables coming from the OnStar(R) control modules. 12.4. Loosen one of the optic cables remaining in H2-9 (F), connect it to the connector and fit the secondary catch (E). Connect the connector so that the optic cables are opposite each other (G). Connect the terminal housing (D) and refit the locking strip (C). Page 13862 Page 3309 10. Install the pipe to the exhaust manifold. 11. Install the exhaust manifold pipe nuts. Tighten the nuts to 50 Nm (37 ft. lbs.). 12. Lower the vehicle. 13. If equipped with a 6.0L engine, perform the following: 1. Install the oil cooler hoses to the hose clip on the fan shroud. 2. Snap the oil cooler hose clip shut. 14. Important: ^ Ensure the oil cooler line being installed has a plastic cap on the end that connects to the quick connect fitting. If no plastic cap exists, or the plastic cap is damaged, obtain a new cap. Install the cap onto the cooler line prior cooler line installation. ^ Do not use the plastic cap in order to install the cooler line into the fitting. If equipped with a 8.1L engine perform the following: 3. Install the oil cooler hoses to the clip. 4. Install the oil cooler lines to the radiator. Install the cooler line straight into the quick connect fitting. Insert the cooler line end into the quick connect fitting until a click is either heard or felt. 5. Pull back sharply on the cooler line in order to ensure that the cooler line is installed in the quick connect fitting. Locations Brake Light Switch: Locations ABS Component Views Stoplamp Switch Page 1113 5. Install the front door trim panel. 6. If equipped with camper mirrors program the door module. Refer to Service Programming System (SPS) in Programming. Page 5540 Camshaft Position (CMP) Sensor Page 11859 6. Install the front console side panel screw (1). Tighten Tighten the screws to 2 N.m (18 lb in). 7. Move the front seat fully forward. 8. Install the rear console side panel screw (2). Tighten Tighten the retaining screw to 2 N.m (18 lb in). 9. Reposition the inboard seat track trim (1). 10. Install the floor console storage bin. 11. Install the floor console end panel. 12. Install the floor console cupholder. 13. Install the floor console bezel. Fuse Block - I/P Fuse Block: Application and ID Fuse Block - I/P Location View Page 12336 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Weather Pack Connectors WEATHER PACK CONNECTORS The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. Page 9640 8. Install the left side end panel. Page 12620 networks, and will not require an upgrade in connection with the cellular industry's transition to the digital network. In order to verify the type of OnStar(R) Hardware in a vehicle, type the VIN into the VIN look-up tool, which is available at the OnStar(R) Online Enrollment website within GM GlobalConnect (for U.S. dealers) or InfoNet (for Canadian dealers). Disclaimer Page 15825 Steering Wheel and Column Sub-System Components Page 8392 3. For all 15 series vehicles, relieve the tension from the park brake cable by pulling down on the park brake cable in front of the equalizer and removing the left park brake cable from the equalizer bar. 4. For 25/35 series vehicles, disable the park brake cable automatic adjuster. Refer to Disabling the Park Brake Cable Automatic Adjuster. 5. For 25/35 series vehicles, disconnect the cable at the equalizer. Page 15139 Electrical Symbols Part 2 Page 12244 A/C - Blower Motor Runs After Vehicle Is Shut OFF Blower Motor Relay: Customer Interest A/C - Blower Motor Runs After Vehicle Is Shut OFF TECHNICAL Bulletin No.: 03-01-38-015A Date: October 27, 2008 Subject: HVAC Blower Motor May Run Continuously After Vehicle is Turned Off (Replace Blower Resistor Relay) Models: 2004 Chevrolet Avalanche, Silverado, Suburban, Tahoe, TrailBlazer, TrailBlazer EXT 2004 GMC Envoy, Envoy XL, Sierra, Yukon, Yukon XL with Manual Control HVAC (RPO CJ3) Built Prior to August, 2003 Supercede: This bulletin is being revised to update the parts information. Please discard Corporate Bulletin Number 03-01-38-015 (Section 01 - HVAC). Condition Some customers may comment on the HVAC blower motor running after the vehicle has been turned off. The blower may run for just a few minutes or continuously until the battery is discharged. Cause A new style HVAC blower relay/resistor may stick in the "on" position. When the HVAC fan blower relay has been energized, the contacts may "micro-weld" together. After this occurrence, the HVAC blower may not respond to the HVAC controller commands. Correction Replace the HVAC blower resistor/relay with the type used previous to the 2004 model year. The appropriate part numbers are listed in the table below. For specific repair procedures, refer to the 2004 Service Information (SI) under Blower Motor Resistor Assembly Replacement (SI Document ID # 526350 (C/K) or # 729996 (S/T). Parts Information Warranty Information Disclaimer Page 7722 2. Connect the front speed sensor electrical connector (5). 3. Install the transfer case shield, if equipped. Transfer Case Speed Sensor Replacement - Left Rear Transfer Case Speed Sensor Replacement - Left Rear Removal Procedure 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. Disconnect the left rear speed sensor electrical connector (4). 3. Remove the left rear speed sensor. Installation Procedure Page 13099 2007 Model Year Vehicles and Newer all have Digital OnStar(R) Modules. Part 1 OnStar(R) Description and Operation This OnStar(R) digital system consists of the following components: ^ Vehicle Communication Interface Module (VCIM) ^ OnStar(R) button assembly ^ Microphone ^ Cellular antenna ^ Navigation antenna Note This system also interfaces with the factory installed vehicle audio system. Vehicle Communication Interface Module (VCIM) The vehicle communication interface module (VCIM) is a cellular device that allows the user to communicate data and voice signals over the national cellular network. Power is provided by a dedicated, fused B+ circuit. Ground is provided through the vehicle wiring harness attached to the module. The ignition state is determined by the VCIM through serial data messaging. Dedicated circuits are used to connect the VCIM to a microphone, the button assembly, and to command the status LED. The VCIM communicates with the rest of the vehicle modules using the serial data bus. The module houses 2 technology systems, one to process GPS data, and another for cellular information. The cellular system connects the OnStar(R) system to the cellular carrier's communication system by interacting with the national cellular infrastructure. The module sends and receives all cellular communications over the cellular antenna and cellular antenna coax. GPS satellites orbiting earth are constantly transmitting signals of their current location. The OnStar(R) system uses the GPS signals to provide location on demand. The module also has the capability of activating the horn, initiating door lock/unlock, or activating the exterior lamps using the serial data circuits. These functions can be commanded by the OnStar(R) Call Center per: a customer request. OnStar(R) Button Assembly The OnStar(R) button assembly may be part of the rearview mirror, or a separate, stand alone unit. The button assembly is comprised of 3 buttons and a status LED. The buttons are defined as follows: ^ The answer/end call button, which is black with a white phone icon, allows the user to answer and end calls or initiate speech recognition. ^ The blue OnStar(R) call center button, which displays the OnStar(R) logo, allows the user to connect to the OnStar(R) call center. ^ The emergency button, which displays a white cross with a red background, sends a high priority emergency call to the OnStar(R) call center when pressed. The VCIM supplies 10 volts to the OnStar(R) button assembly on the keypad supply voltage circuit. When pressed, each button completes a circuit across a resistor allowing a specific voltage to be returned to the VCIM on the keypad signal circuit. Depending upon the voltage range returned the VCIM is able to identify which button has been pressed. The OnStar(R) status LED is located with the button assembly. The LED is green when the system is ON and operating normally. When the status LED is green and flashing, it is an indication that a call is in progress. When the LED is red, this indicates a system malfunction is present. In the event there is a system malfunction and the OnStar(R) system is still able to make a call, the LED will flash red during the call. If the LED does not illuminate, this may indicate that the customers OnStar(R) subscription is not active or has expired. Push the blue OnStar button to connect to an advisor who can then verify the account status. Each LED is controlled by the VCIM over dedicated LED signal circuits. Ground for the LED is provided by the wiring harness attached to the button assembly. Page 12448 Page 8650 Install the brake assist pump nuts. ^ Tighten the nuts to 18 Nm (13 ft. lbs.). 3. Connect the electrical connector. 4. Install the vacuum hose to the brake assist pump. Page 6432 Park Neutral Position (PNP) Switch C175 Service and Repair Parking Brake Pedal: Service and Repair Park Brake Pedal Assembly Replacement Removal Procedure 1. Caution: Refer to Battery Disconnect Caution in Service Precautions. Disconnect the negative battery cable. 2. Raise and support the vehicle. Refer Vehicle Lifting 3. For all 15 series vehicles, relieve the tension from the park brake cable by pulling down on the park brake cable in front of the equalizer then removing the cables from the equalizer bar. 4. For 25/35 series vehicles, disable the park brake cable automatic adjuster. Refer to Disabling the Park Brake Cable Automatic Adjuster. 5. Remove the safety stands and lower the vehicle. 6. Remove the left side hinge pillar panel. Refer to Trim Panel Replacement - Hinge Pillar in Interior Trim. 7. Remove the MID-bussed electrical center from the bracket. 8. Disconnect the park brake warning lamp connection. Page 10062 3. Install the booster outlet hose to the power steering pump nipple and retaining clamp (2). 4. Install the booster inlet hose (1) to the booster. 5. Install the gear inlet hose to the booster. ^ Tighten both power steering inlet hose fittings to 32 Nm (24 ft. lbs.). Notice: Refer to Fastener Notice in Service Precautions. 6. Install the booster outlet hose (3) to the booster and install the retaining clamp (2). 7. Remove the drain pan from under the vehicle. 8. Bleed the power steering system. Refer to Bleeding the Power Steering System. 9. Connect the energy storage box before after servicing the vehicle. (Rack and Pinion) Power Steering Cooler Pipe/Hose Replacement (Rack and Pinion) Page 12465 8.5. Close the luggage compartment floor. 9. Fold down the left-hand rear side hatch in the luggage compartment. 10. M03: Replace the optic cable on the left-hand rear side: 10.1. Place the optic cable so that it is positioned behind the terminal housing on top of REC (A). 10.2. Remove the locking strip (B) on the 2-pin connector (H2-9) for the optic cable. 10.3. Open the terminal housing (C) with a screwdriver. Remove the secondary catch (D) on the connector and disconnect the optic cable coming from the OnStar(R) control modules. Page 10293 1. Install the upper end of the intermediate shaft into the upper shaft. 2. Install the lower end of the intermediate shaft coupler. 1. If you are reinstalling the same shaft, align the marks made during the removal procedure. 2. Install the lower end of the intermediate shaft coupler onto the steering gear worm shaft. 3. Install the bolt to the lower shaft coupler. 4. Notice: Refer to Fastener Notice in Service Precautions. Install the bolt to the upper end of the shaft. ^ Tighten the upper bolt to 47 Nm (35 ft. lbs.). ^ Tighten the coupler pinch bolt to 47 Nm (35 ft. lbs.). 5. For vehicles equipped with a 6.6L Diesel, remove the left charge air cooler hose. 6. Remove the J 42640 from the steering column lower access hole. Page 1167 Seat Adjuster Switch- Front Passenger (With RPO Code AN3) Part 1 Page 4396 saver mode, the TAC module removes the voltage from the motor control circuits, which removes the current draw used to maintain the idle position and allows the throttle to return to the spring loaded default position. Reduced Engine Power Mode When the PCM detects a condition with the TAC system, the PCM may enter a reduced engine power mode. Reduced engine power may cause one or more of the following conditions: Acceleration limiting-The control module will continue to use the accelerator pedal for throttle control; however, the vehicle acceleration is limited. - Limited throttle mode-The control module will continue to use the accelerator pedal for throttle control; however, the maximum throttle opening is limited. - Throttle default mode-The control module will turn off the throttle actuator motor and the throttle will return to the spring loaded default position. - Forced idle mode-The control module will perform the following actions: Limit engine speed to idle by positioning throttle position, or by controlling fuel and spark if throttle is turned off. - Ignore accelerator pedal input. - Engine shutdown mode-The control module will disable fuel and de-energize the throttle actuator. Page 9954 Steering Control Module: Service and Repair Rear Wheel Steering Control Module Replacement Rear Wheel Steering Control Module Replacement Removal Procedure 1. Notice: Refer vehicle Lifting. Raise the vehicle. Refer to Vehicle Lifting. 2. Remove the spare tire from the vehicle to gain access to the control module. 3. Disconnect the electrical connectors from the control module. 4. Remove the bolts (1) retaining the control module (2) to the bracket. 5. Remove the control module from the vehicle. Installation Procedure 1. Install the control module to the vehicle. 2. Notice: Refer to Fastener Notice in Service Precautions. Install the control module (2) retaining bolts (1). ^ Tighten the bolts to 24 Nm (18 ft. lbs.). Page 1605 Top Of Engine Page 4129 1. Lubricate a NEW O-ring seal with transmission fluid. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the VSS and bolt. ^ Tighten the bolt to 10 Nm (89 inch lbs.). 3. If equipped with the 8.1L engine, connect the VSS electrical connector (5). 4. If equipped with the 6.6L engine, connect the VSS electrical connector (4). 5. Lower the vehicle. 6. Check the transmission fluid level. Add if necessary. Page 3406 10. Install the crankshaft balancer. Page 16047 Control Module References Part 1 Page 14174 Door Latch Assembly (Lock Actuator) - Front Passenger C1 OnStar(R) - Cellular Antenna Replacement Parts Global Positioning System Antenna: Technical Service Bulletins OnStar(R) - Cellular Antenna Replacement Parts Bulletin No.: 00-08-46-002A Date: April 12, 2005 INFORMATION Subject: OnStar(R) System Cellular Antenna Replacement Parts Availability Models: 1996-2005 Passenger Cars and Light Duty Trucks 2003-2005 HUMMER H2 with OnStar(R) and Glass Mounted Antennas Supercede: This bulletin is being revised to update the model years, models and parts information. Please discard Corporate Bulletin Number 00-08-46-002 (Section 08 - Body & Accessories). Replacement parts for the OnStar(R) system cellular antenna are available as follows: ^ Cellular Antenna Kit - If the antenna mast or exterior base is damaged or missing or if the antenna base has separated from the exterior glass surface. ^ Cellular Antenna Inner Coupling - If the antenna coupling on the inside of the glass requires replacement. Important: If glass replacement is required, both the Cellular Antenna Kit and the Cellular Antenna Inner Coupling are required. The kits listed contain all the necessary parts and instructions needed to properly install a new cellular antenna exterior base or interior coupling to the glass surface. To obtain maximum adhesion during installation, the instructions included in the kits must be followed carefully and exactly as written. Important: Do not attempt to reinstall the original cellular antenna exterior base or interior coupling using any type of glue, adhesive tapes, etc. Doing so may eliminate the cellular signal transfer through the glass and reduce the maximum performance of the system that includes air bag deployment notification. Important: To obtain maximum adhesion between the new cellular exterior base or interior coupling and the glass surface, the base, coupling and glass must be kept dry and above 15°C (60°F) during the installation and for the 24 hours immediately following the installation. Not keeping the vehicle dry and above the temperature listed for 24 hours may result in the new cellular antenna exterior base or interior coupling coming off. Parts Information Parts are currently available from GMSPO. Remote Control Battery Replacement DVD Player: Service and Repair Remote Control Battery Replacement BATTERY REPLACEMENT To change the batteries, do the following: 1. Remove the battery compartment door located on the bottom of the remote control. 2. Remove the batteries from the compartment. 3. Replace the 2 AA-size batteries in the proper orientation. If the remote control is to be stored for a long period of time, remove the batteries and keep them in a cool, dry place. Do not store the remote control in heat or direct sunlight. This could damage the remote control and would not be covered by your vehicle warranty. Keep the remote control stored in a cool, dry place. Interior - Seat Memory Feature Appears Inoperative Memory Positioning Module: Customer Interest Interior - Seat Memory Feature Appears Inoperative Bulletin No.: 04-08-50-003 Date: February 26, 2004 INFORMATION Subject: Enabling Memory Seat Feature via DIC If Feature Appears Inoperative Models: 2003-2004 Cadillac Escalade, Escalade ESV, Escalade EXT 2003-2004 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2003-2004 GMC Sierra, Yukon, Yukon Denali, Yukon Denali XL 2003-2004 HUMMER H2 with Steering Wheel Controls (RPO UK3) (standard on H2) If the memory seat feature appears inoperative, check the Driver Information Center (DIC). Many of the memory seat modules that were returned through the Warranty Parts Center for a condition of inoperative have shown No Trouble Found. The Driver Information Center (DIC), programmed for Seat Entry and Exit, is set to the default "Off" mode at the assembly plant. DO NOT REPLACE THE MEMORY SEAT MODULE. Perform the following procedure. Important: The following procedure will need to be completed for each Remote/Key selection. Using the DIC menu, do the following steps: 1. Set the "Seat Recall" to either "At Key In" or "On Remote" based on the customer's preference. 2. Set the "Exit Seat" to "On". 3. Adjust the following items: Memory Seat: 3.1. Driver's Seat (including the seat back, recliner, lumbar, and side wings) 3.2. Throttle and Brake Pedals (not available on H2 or Silverado and Sierra Trucks) 3.3. Outside Mirrors 3.4. Radio Station Presets 3.5. Last Chosen Climate Control System Settings (not available on Silverado or Sierra Trucks) 3.6. Press and hold the "1" or "2" (for driver 1 or 2) button of the memory control for three seconds. A double chime will sound to let you know that the position has been stored. Easy Exit Seat: 3.1. Press and release the 1 or 2 button or press the unlock button on the desired remote keyless entry transmitter. The seat will move to the stored memory position. 3.2. Adjust the seat to the desired exit position. 3.3. Press and hold the exit button of the memory control (located on the door) for three seconds. A double chime will sound to let you know that the position has been stored for the identified driver (1 or 2). Page 371 10.4. Remove the end cap from the new optic cable, connect to the connector and refit the secondary catch (D). Fit the terminal housing (C) to the connector and refit the locking strip (B). 10.5. Secure the old optic cable together with the new one (E). Important: The optic cable must not be bent with a radius less than 25 mm (1 in). Important: Secure the wiring harness so that there is no risk of chafing and rattling. 11. CV: Remove the rear seat in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. The O-bus connector H2-9 is located behind the left speaker. 12. M04-05: Disconnect the optic cables on the OnStar(R) control modules and join the cables: 12.1. Cut off the cable tie holding the connector (H2-9) against REC. Page 8350 may cause contamination which could result in damage to the internal rubber seals and/or rubber linings of hydraulic brake system components. Notice: Refer to Brake Fluid Effects on Paint and Electrical Components Notice in Service Precautions. 1. Visually inspect the brake fluid level through the brake master cylinder reservoir. 2. If the brake fluid level is at or below the half-full point during routine fluid checks, the brake system should be inspected for wear and possible brake fluid leaks. 3. If the brake fluid level is at or below the half-full point during routine fluid checks, and an inspection of the brake system did not reveal wear or brake fluid leaks, the brake fluid may be topped-off up to the maximum-fill level. 4. If brake system service was just completed, the brake fluid may be topped-off up to the maximum-fill level. 5. If the brake fluid level is above the half-full point, adding brake fluid is not recommended under normal conditions. 6. If brake fluid is to be added to the master cylinder reservoir, clean the outside of the reservoir on and around the reservoir cap prior to removing the cap and diaphragm. Use only Delco Supreme 11®, GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. Page 3021 service operation. A simple distraction or time constraint that rushes the job may result in personal injury if the greatest of care is not exercised. Make it a habit to double check your work and to always side with caution when installing wheels. Disclaimer Page 1482 Accessory Switch Housing Page 9185 C119 Accessory Jumper Harness To Brake/Clutch Harness (With RPO Code 9L4) Service and Repair Clutch Master Cylinder: Service and Repair Clutch Master Cylinder Replacement Removal Procedure 1. Disconnect the clutch pedal position switch electrical connector (1). 2. Push the clutch pedal in and squeeze the pushrod bushing tabs in, in order to release the pushrod bushing from the clutch pedal. 3. If equipped with a NV 3500 or NV 4500 transmission, disconnect the clutch actuator cylinder to clutch master cylinder quick connect fitting. 4. Remove the clutch master cylinder clip from the brake pressure module valve pipe. 5. If equipped with a ZF S6-650 transmission, disconnect the clutch actuator cylinder to clutch master cylinder quick connect fitting. 6. Rotate the clutch master cylinder 45 degrees clockwise to the unlocked position. Page 12223 8.5. Close the luggage compartment floor. 9. Fold down the left-hand rear side hatch in the luggage compartment. 10. M03: Replace the optic cable on the left-hand rear side: 10.1. Place the optic cable so that it is positioned behind the terminal housing on top of REC (A). 10.2. Remove the locking strip (B) on the 2-pin connector (H2-9) for the optic cable. 10.3. Open the terminal housing (C) with a screwdriver. Remove the secondary catch (D) on the connector and disconnect the optic cable coming from the OnStar(R) control modules. Transfer Case - 1st & 2nd Clutch Hub & Apply Plate Transfer Case Clutch: Technical Service Bulletins Transfer Case - 1st & 2nd Clutch Hub & Apply Plate Bulletin No.: 05-04-21-005 Date: August 03, 2005 INFORMATION Subject: First and Second Design Clutch Hub and Apply Plate for NV246 Transfer Case Models: 1999-2004 Chevrolet Full Size Pickups and Utilities 1999-2004 GMC Full Size Pickups and Utilities with NV246 Transfer Case (RPO NP8) If service requires replacement of the first design Clutch Hub (17) that is no longer available form GMSPO ,the second design Clutch Hub (17) requires a second design Apply Plate (18) also be replaced in order to obtain proper stack up height in the transfer case. ^ 1999-2002 vehicles that require replacement of the Clutch Hub (17), P/N 88962324 second design also require the Apply Plate (18), P/N 88962331 second design to be replaced at the same time in order to obtain proper stack up height in the transfer case. ^ 2003-2004 vehicles that require replacement of the Clutch Hub (17), P/N 88962324 second design also require the Apply Plate (18), P/N 88962327 second design to be replaced at the same time in order to obtaining proper stack up height in the transfer case. Important: ^ A clutch plate shim package is necessary in order to have the proper shims available for setting the correct clutch pack preload. Improper preload may cause driveability concerns and failure of the transfer case. ^ Transfer case shims are available from GMSPO. Refer to Corporate Bulletin Number 04-04-21-003. ^ Whenever the second design Clutch Hub and the second design Apply Plate are used, a revised stack height will have to be used. This implements a shim J-44295-4 (0.085 in. thick) in conjunction with the clutch pack shimming kit J-44295 to achieve the correct stack height. Refer to SI Unit Repair, Transfer Case Assemble. Disclaimer Page 5405 11. Install the fuel tank filler housing. 12. Install the fuel tank filler housing to fuel tank fill pipe bolts. Tighten Tighten the screws to 2.3 N.m (20 lb in). 13. Install the fuel tank filler housing to body TORX(R) screws (1) and pushpin retainer (2). Tighten Tighten the screws to 2.3 N.m (20 lb in). Page 13127 Page 9113 Remove all rust from the ground terminal, the cylinder head and the retaining nut or bolt. Position the main engine wiring harness ground terminal and install the nut or bolt. Tighten: Tighten the retaining nut or bolt to 16 N.m (12 lb ft). Apply some type of electrical moisture sealant to protect the harness terminal from further corrosion. Disclaimer Page 2708 Application Table Part 2 Page 3704 1. If necessary, install the oxygen sensors. 1. Apply anti-seize compound GM P/N 12377953 or equivalent to the threads of the old oxygen sensors. 2. Install the oxygen sensors. Tighten the sensors to 42 Nm (31 ft. lbs.). 2. Install the catalytic convertor. 3. Install NEW exhaust manifold pipe seals to the exhaust manifolds. 4. Install the right exhaust manifold pipe nuts until snug. 5. Install the left exhaust manifold pipe nuts until snug. 6. Tighten the exhaust manifold pipe nuts. Tighten the nuts to 50 Nm (39 ft. lbs.). 7. Install the exhaust muffler nuts. Tighten the nuts to 40 Nm (30 ft. lbs.). Page 13086 Disclaimer Page 9060 Relay Block - I/P C5 Part 1 Tires/Wheels - Tire Slowly Goes Flat/Warning Light ON Wheels: All Technical Service Bulletins Tires/Wheels - Tire Slowly Goes Flat/Warning Light ON TECHNICAL Bulletin No.: 08-03-10-006C Date: April 27, 2010 Subject: Tire Slowly Goes Flat, Tire Air Loss, Low Tire Pressure Warning Light Illuminated, Aluminum Wheel Bead Seat Corrosion (Clean and Resurface Wheel Bead Seat) Models: 2000-2011 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2009 HUMMER H2 2006-2010 HUMMER H3 2005-2009 Saab 9-7X Supercede: This bulletin is being revised to update the model years. Please discard Corporate Bulletin Number 08-03-10-006B (Section 03 - Suspension). Condition Some customers may comment on a tire that slowly loses air pressure over a period of days or weeks. Cause Abrasive elements in the environment may intrude between the tire and wheel at the bead seat. There is always some relative motion between the tire and wheel (when the vehicle is driven) and this motion may cause the abrasive particles to wear the wheel and tire materials. As the wear continues, there may also be intrusion at the tire/wheel interface by corrosive media from the environment. Eventually a path for air develops and a 'slow' leak may ensue. This corrosion may appear on the inboard or outboard bead seating surface of the wheel. This corrosion will not be visible until the tire is dismounted from the wheel. Notice This bulletin specifically addresses issues related to wheel bead seat corrosion that may result in an air leak. For issues related to porosity of the wheel casting that may result in an air leak, please refer to Corporate Bulletin Number 05-03-10-006F - Low Tire Pressure, Leaking Cast Aluminum Wheels (Repair with Adhesive Sealant) Correction In most cases, this type of air loss can be corrected by following the procedure below. Important DO NOT replace a wheel for slow air loss unless you have evaluated and/or tried to repair the wheel with the procedure below. Notice The repair is no longer advised or applicable for chromed aluminum wheels. 1. Remove the wheel and tire assembly for diagnosis. Refer to Tire and Wheel Removal and Installation in SI. 2. After a water dunk tank leak test, if you determine the source of the air leak to be around the bead seat of the wheel, dismount the tire to examine the bead seat. Shown below is a typical area of bead seat corrosion.Typical Location of Bead Seat Corrosion Brakes - Low Speed ABS Activation/No DTC's Set Wheel Speed Sensor: All Technical Service Bulletins Brakes - Low Speed ABS Activation/No DTC's Set TECHNICAL Bulletin No.: 03-05-25-007D Date: May 01, 2009 Subject: Antilock Brake (ABS) Activation At Low Speeds (Clean Wheel Speed Sensor Mounting Surface) Models: 2002-2006 Cadillac Escalade, Escalade EXT 2003-2006 Cadillac Escalade ESV 1999-2006 Chevrolet Silverado 2001-2006 Chevrolet Suburban, Tahoe 2002-2006 Chevrolet Avalanche 2003-2006 Chevrolet Express 2007 Chevrolet Silverado Classic 1999-2006 GMC Sierra 2001-2006 GMC Yukon, Yukon Denali, Yukon XL, Yukon Denali XL 2003-2006 GMC Savana 2007 GMC Sierra Classic 2003-2006 HUMMER H2 .............................................................................................................................................................. .................................................................................. Supercede: This bulletin is being revised to add the 2007 Silverado/Sierra Classic models. Please discard Corporate Bulletin Number 03-05-25-007C (Section 05 - Brakes). .............................................................................................................................................................. .................................................................................. Condition Some customers may comment on ABS activation at low speeds, usually below 8 km/h (5 mph). Upon investigation, the technician will find no DTCs set. Cause The cause of this condition may be an increased air gap between the wheel speed sensor and the hub reluctor ring due to rust and debris built up on the sensor mounting surface. Correction Measure AC voltage and clean the wheel speed sensor mounting surfaces. 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in the General Information sub-section of the Service Manual. 2. Disconnect both the front wheel speed sensor connectors at the frame and harness. 3. Place a Digital Volt Meter (DVM) across the terminals of each wheel speed sensor connector. 4. Rotate the wheel clockwise approximately one revolution per second. The minimum reading should be at least 350 ACmV's. If the reading is less than 350 ACmV's, remove the wheel speed sensor. Refer to the applicable Wheel Speed Sensor Replacement procedure in the ABS sub-section of the Service Manual. 5. Plug the wheel speed sensor bore in order to prevent debris from falling into the hub during service. 6. Clean the wheel speed sensor mounting surface using a wire brush, sand paper, emery cloth, scotch brite, or other suitable material. Be sure to thoroughly clean the wheel speed sensor surface. There should be no rust or corrosion. 7. Check the sensor head to determine if it has been warped/distorted due to the corrosion build up or other causes. Check the mounting surface on the sensor head for flatness by placing it on the edge of a metal machinists scale or other suitable straight edge to measure the flatness. Check the sensor for flatness in multiple (minimum 3) positions/directions. If the sensor head is distorted, replace the sensor. 8. Apply (spray) two thin coats of the specified rust penetrating lubricant (corrosion inhibitor) to the complete sensor mounting surface on the bearing hub. Allow to dry for 3-5 minutes between coats. Use ONLY Rust Penetrating Lubricant, P/N 89022217 (in Canada, P/N 89022218). 9. When the corrosion inhibitor is dry to the touch (about 10 minutes), apply a thin layer of bearing grease to the hub surface and sensor O-ring prior to sensor installation. Use ONLY Wheel Bearing Lubricant, P/N 01051344 (in Canada, P/N 993037). 10. Install either the original sensor or a new one in the hub. Ensure that the sensor is seated flush against the hub. Refer to the applicable Wheel Speed Sensor Replacement procedure in the ABS sub-section of the Service Manual. 11. Place the DVM across the sensor terminals and recheck the voltage while rotating the wheel. The voltage should now read at least 350 ACmV's. Page 7683 12. Install the cover. Notice: Refer to Fastener Notice in Service Precautions. 13. Install 2 NEW screws (1) to the casting. ^ Tighten the screws to 2 Nm (18 inch lbs.). 14. Install 2 NEW longer screws (2) to the motor cover. ^ Tighten the screws to 3 Nm (26 inch lbs.). 15. Install the encoder motor. Page 13277 12.2. Cars with brackets for e.g. an amplifier: Remove the pin strap (A) from the bracket and remove the tape (B) holding the optic cables. 12.3. Remove the locking strip (C) on the 2-pin connector (H2-9). Open the terminal housing with a screwdriver. Remove the secondary catch (E) on the connector and remove the optic cables coming from the OnStar(R) control modules. 12.4. Loosen one of the optic cables remaining in H2-9 (F), connect it to the connector and fit the secondary catch (E). Connect the connector so that the optic cables are opposite each other (G). Connect the terminal housing (D) and refit the locking strip (C). Page 1112 5. Using a wide plastic flat-bladed tool, release the retaining clips on both sides of the door module. 6. Remove the door module from the switch panel bezel. INSTALLATION PROCEDURE 1. Install the door module into the switch panel bezel until it snaps into place. 2. Install the switch panel bezel and module to the door panel. NOTE: Refer to Fastener Notice in Service Precautions. 3. Install the screw that retains the switch panel bezel (1) to the front door panel. Tighten Tighten the screw to 2 N.m (18 lb in). 4. Connect the electrical connectors. HVAC System - Manual Control Module HVAC: Diagrams HVAC System - Manual HVAC Control Module - C1 Part 1 Page 2716 Location View Page 5009 Page 11476 Inflatable Restraint Front End Sensor (With RPO Code HVY) Page 14730 10. Using a side motion, carefully separate the seat cushion trim cover from the seat cushion pad. CAUTION: Replace the passenger presence system as a complete assembly to prevent possible injury to the occupant. The bladder, the pressure sensor, the seat cushion, and the control module are assembled and calibrated as a unit. Using only some of the components in the service kit will cause the passenger presence system to operate improperly. 11. If replacing the front passenger seat cushion you must also replace the Inflatable Restraint Passenger Presence System. 12. Remove the pad from the seat cushion frame. 13. Remove the seat cushion heater element, if equipped. INSTALLATION PROCEDURE 1. Install the seat cushion heater element, if equipped. 2. Install the Inflatable Restraint Passenger Presence System. 3. Install the seat cushion pad to the seat cushion frame. 4. Using a side motion, carefully pull the seat cushion cover onto the frame pad. 5. Attach the seat trim cover to the seat cushion frame. Page 15965 Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips SPLICING COPPER WIRE USING SPLICE CLIPS IMPORTANT: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. TOOLS REQUIRED J 38125-D Terminal Repair Kit 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-D in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. Page 10219 Electrical Symbols Part 3 Page 10910 Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses CIRCUIT PROTECTION - FUSES The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the Suspension - Rattles/Squeaks From Front of Vehicle Suspension Strut / Shock Absorber: All Technical Service Bulletins Suspension - Rattles/Squeaks From Front of Vehicle Bulletin No.: 03-03-08-002B Date: November 30, 2005 TECHNICAL Subject: Rattle/Squeak from Front of Vehicle (Replace Lower Portion of Upper Insulator Assembly) Models: 2002-2005 Cadillac Escalade, Escalade EXT 2003-2005 Cadillac Escalade ESV 2000-2005 Chevrolet Silverado, Suburban, Tahoe 2002-2005 Chevrolet Avalanche 2000-2005 GMC Sierra, Yukon, Yukon XL Supercede: This bulletin is being revised to update the correction and parts information. Please discard Corporate Bulletin Number 03-03-08-002A (Section 03 - Suspension). Condition Some customers may comment on a rattle or squeak type noise coming from the front of the vehicle. Cause The front shock absorber plastic pilot ring may be wearing out, causing the shock to misalign in the insulator. Correction DO NOT replace the shock. Replace the lower portion, P/N 15834275 , of the upper insulator assembly using the procedure listed below. This new insulator has a taller plastic pilot ring that is attached to the metal sleeve to aid in the proper alignment of the insulators. 1. Remove the front shock absorber. Refer to the Shock Absorber Replacement procedure in the Front Suspension sub-section of the Service Manual. 2. Remove the lower portion of the upper insulator from the shock and discard. 3. Install the new lower portion of the upper insulator to the shock. Important: Be sure to center the shock in the frame bracket and tighten the upper mounting nut when the vehicle is on the ground. 4. Install the front shock absorber. Refer to the Shock Absorber Replacement procedure in the Front Suspension sub-section of the Service Manual. Parts Information Warranty Information Page 5279 Steps 4 - 5 Page 7090 For vehicles repaired under warranty, use the table. Disclaimer Page 8185 WORKSHEET - BRAKE LATHE CALIBRATION Important Brake lathe calibration should be performed and recorded monthly or if you are consistently measuring high LRO after rotor refinishing. Disclaimer GM Brake Service Procedure GM BRAKE SERVICE PROCEDURE 1. Remove the wheel and caliper. 2. Measure rotor thickness. In order to determine if the rotor can be refinished, do the following steps: Important Locations Door Module: Locations Driver Door Page 12455 switch lighting connector. 3.3. Undo the floor console's retaining bolts (C). 3.4. Take out the rear ashtray/cover (D). 3.5. Remove the screw (E) for the rear cover. 3.6. Remove the floor console's retaining nuts (E). 3.7. Detach the floor console (G) by pulling it straight back and lifting it slightly. 3.8. If required, detach the switch for the rear seat heater and unplug the connector. 4. Remove the switch and the floor console: 4.1. Detach the window lift module (A) by loosening it in the front edge (snap fastener). Unplug the window lift module's connector. 4.2. Detach the switch for the roof lighting (B) and unplug its connector. Lift away the floor console. 5. Pry out the signal line from the SRS control module to the OnStar(R) control module and secure it: 5.1. Unplug the SRS control module's connector (A). Drivetrain - Gen II Vs. Gen III Wheel Hub Changes Wheel Hub (Locking): Technical Service Bulletins Drivetrain - Gen II Vs. Gen III Wheel Hub Changes INFORMATION Bulletin No.: 08-03-08-003A Date: March 02, 2009 Subject: Wheel Hub Changes - Gen III vs. Gen II Models: 2008 and Prior Cadillac Escalade Models 2008 and Prior Chevrolet Avalanche, Silverado, Silverado Classic, Suburban, Tahoe 2008 and Prior GMC Sierra, Sierra Classic, Yukon Models Supercede: This bulletin is being revised to update the parts information in the table and to add an Illustrated Hub Gallery depicting all wheel hub part numbers called out below for visual identification purposes. Please discard Corporate Bulletin Number 08-03-08-003 (Section 03 - Suspension). General Motors Vehicle Engineering has introduced a new design Gen III front wheel hub for the above listed vehicles that replaces the Gen II product. These Gen II 4x2 and 4x4 applications that were previously serviced by seven part numbers are now serviced by three Gen III part numbers. Concerns have been expressed by technicians regarding the use of the new supersessions and whether the Gen III hubs will properly fit the vehicles being serviced, especially because of visual and functional differences (splines). This bulletin has been developed to address those concerns. Please refer to the table above for information on the Gen III replacement part for each Gen II application. At the end of the bulletin you will find an illustrated "Hub Gallery" with graphic depictions of both Gen II and replacement style Gen III parts. Using these illustrations you should be able to identify both the Gen II and Gen III wheel hubs. Warning If replacing wheel studs, please refer to the GM Parts Catalog for the correct stud part number for each application. Different types of studs are used depending on the wheel hub application. When replacing an older Gen II design 4x2 hub with a new 4x2/4x4 common Gen III hub, it is acceptable to have a bearing with splines on it for a 4x2 application that previously did not. However, the older Gen II design 4x4 hubs should NOT be used on a 4x2 vehicle. The Gen II 4x4 hub relies on the tension of the wheel drive shaft joint to hold everything together. The roll form feature on the inboard side of the new 4x2/4x4 Gen III hub eliminates this concern. The only hub that is not back serviceable is P/N 15719007 (not pictured) for 1999-2000 C25 applications due to a different hub flange to bearing flange offset. Important: Only the new part numbers referenced in this bulletin are interchangeable between the 4x2 and 4x4 applications with the exception of P/N 15719007 (Not Shown). Under no circumstances should any other 4x4 hub be used in a 4x2 application. Illustrated Hub Gallery Brakes - ABS Lamp ON/DTC's C0265/C0201/U1041 Set Electronic Brake Control Module: All Technical Service Bulletins Brakes - ABS Lamp ON/DTC's C0265/C0201/U1041 Set TECHNICAL Bulletin No.: 04-05-25-002E Date: March 11, 2009 Subject: ABS Light On, DTCs C0265, C0201, U1041 Set and/or Loss of Communication with Brake Module (Reground EBCM Ground) Models Supercede: This bulletin is being revised to add step 2 to the procedure and update the Parts and Warranty Information. Please discard Corporate Bulletin Number 04-05-25-002D (Section 05 - Brakes). Condition Some customers may comment that the ABS light is on. Upon further inspection, DTCs C0265 and C0201 may be set in the brake module. It is also possible for DTC U1041 to set in other modules. There may also be a loss of communication with the brake module. Cause A poor connection at the EBCM ground is causing unnecessary replacement of brake modules. Important: The EBCM ground is different for each application. Refer to the list below for the proper ground reference: ^ Midsize Utilities = Ground 304 ^ SSR = Ground 400 ^ Fullsize Trucks and Utilities = Ground 110 Correction Important: Do not replace the brake module to correct this condition. Perform the following repair before further diagnosis of the EBCM. Perform the following steps to improve the connection of the EBCM Ground: 1. Remove the EBCM Ground. The EBCM Ground is located on the frame beneath the driver's side door. If multiple grounds are found in this location, the EBCM ground can be identified as the heavy (12-gauge) wire. 2. If the original fastener has a welded on nut, remove the nut from the frame, and if required, enlarge the bolt hole to accommodate the new bolt and nut. 3. Clean the area, front and back, using a tool such as a *3M(TM) Scotch-Brite Roloc disc or equivalent. Page 16181 5. Install the front door trim panel. 6. If equipped with camper mirrors program the door module. Refer to Service Programming System (SPS) in Programming. Page 1280 Engine Coolant Temperature (ECT) Sensor Page 13759 Important: Clean the fuel filler cap and surrounding areas prior to removing the fuel filler housing in order to avoid possible contamination. 1. Remove the fuel fill cap. 2. Remove the fuel tank filler housing to fuel tank fill pipe screws. 3. Remove the fuel tank filler housing to body TORX® screws (1) and retainer (2). Important: It is NOT necessary to raise the vehicle in order to remove and/or install the fuel filler housing. 4. Remove the fuel filler housing from under the vehicle. 5. Install the new fuel filler housing, P/N 15289921, from under the vehicle. 6. Install the fuel tank filler housing to fuel tank fill pipe screws. Tighten Tighten the screws to 2.3 N.m (20 lb in). 7. Install the fuel tank filler housing to body TORX(R) screws and retainer. Tighten Tighten the screws to 2.3 N.m (20 lb in). Important: The new fuel cap, P/N 15225005 "tether strap" installs in the elongated hole in the fuel filler housing. DO NOT install the new fuel cap tether in the round hole in the fuel filler housing. Automatic Transmission - 4L60-E/4L65-E Page 14972 3. Engage the linkage rods (1). 4. Install the handle bezel. Notice: Refer to Fastener Notice in Service Precautions. 5. Tighten the handle bolts. Tighten the bolts to 25 N.m (18 lb ft). Interior - Heated Seats Intermittently Inoperative Seat Heater Control Module: All Technical Service Bulletins Interior - Heated Seats Intermittently Inoperative Bulletin No.: 05-08-05-008 Date: August 18, 2005 TECHNICAL Subject: Intermittent Heated Seats Inoperative, DTC B3941 Set (Reprogram Driver Seat Module) Models: 2003-2005 Cadillac Escalade, Escalade ESV, Escalade EXT 2003-2005 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2003-2005 GMC Sierra, Yukon, Yukon XL, Yukon Denali All with Seat FRT, Individual (Non BKT) (RPO AN3) 2003-2005 HUMMER H2 with Seat, Front Bucket Deluxe (RPO AR9) Condition Some customers may comment that occasionally the seat heater will not operate when activated. If the ignition key is cycled OFF and back ON again, the heated seat will operate correctly. Also, on some LB7 diesel engine vehicles, the seat heater may turn itself off during the first 10 minutes of operation. This occurs only with the first activation for the day and works correctly with subsequent activations immediately after the event. These conditions are intermiffent and DTC B3941 may be set. Correction Technicians are to reprogram the driver seat module with an updated software calibration. This new service calibration was released with TIS satellite data update version 6.5 available June 13, 2005. As always, make sure your Tech 2(R) is updated with the latest software version. Warranty Information Disclaimer Page 6763 Carrier Bearings: Service and Repair 9.75 Inch Axle Differential Side Bearings Replacement (9.75 Inch Axle) ^ Tools Required J 22888-D Side Bearing Remover Kit - J 24430 Differential Side Bearing Installer - J 36597 Side Bearing Puller Pilot - 9.25 inch - J 45711 Differential Side Bearing Remover - Dana 248 - J 45900 Differential Side Bearing Installer - Dana Axles - J 8092 Universal Driver Handle - 3/4 in - 10 Removal Procedure 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Remove the differential assembly. 3. Remove the differential side bearing by performing the following steps: 1. Install the J 45711 (2) and the J 36597 (1) as shown. 2. Remove the differential side bearing using the J 45711 and a hydraulic press. 4. Important: Mark the inboard shims left or right. Remove the inboard shims. Installation Procedure 1. Determine the shim thickness and preload for the differential assembly. 2. Install the differential side bearing by doing the following: 1. In order to protect the differential case, install the J 8107-3 in the case on the side opposite of the bearing installation. 2. Install the inboard shims. 3. Install the differential side bearing. 4. Install the J 24430 or the J 45900 (2) and the J 8092 (1) over the differential side bearing. 5. Drive the differential side bearing into position using the J 24430 or the J 45900 and the J 8092. 6. Install the differential assembly. 3. Fill the axle with lubricant. Use the proper fluid. 4. Lower the vehicle. A/C - Musty Odors Emitted From (HVAC) System Evaporator Core: All Technical Service Bulletins A/C - Musty Odors Emitted From (HVAC) System TECHNICAL Bulletin No.: 99-01-39-004C Date: June 12, 2009 Subject: Air Conditioning Odor (Install Evaporator Core Dryer Kit and Apply Cooling Coil Coating) Models: 1993-2010 GM Passenger Cars and Trucks (Including Saturn) 2010 and Prior HUMMER H2, H3 All Equipped with Air Conditioning Supercede: This bulletin is being revised to add the 2009 and 2010 model years. Please discard Corporate Bulletin Number 99-01-39-004B (Section 01 - HVAC). Condition Some customers may comment about musty odors emitted from the Heating, Ventilation and Air Conditioning (HVAC) system at vehicle start-up in hot, humid conditions. Cause This condition may be caused by condensate build-up on the evaporator core, which does not evaporate by itself in high humidity conditions. The odor may be the result of microbial growth on the evaporator core. When the blower motor fan is turned on, the microbial growth may release an unpleasant musty odor into the passenger compartment. There are several other possible sources of a musty odor in a vehicle. A common source is a water leak into the interior of the vehicle or foreign material in the HVAC air distribution system. Follow the procedures in SI for identifying and correcting water leaks and air inlet inspection. The procedure contained in this bulletin is only applicable if the odor source has been determined to be microbial growth on the evaporator core inside the HVAC module. Correction Many vehicles currently incorporate an afterblow function within the HVAC control module software. The afterblow feature, when enabled, employs the HVAC blower fan to dry the evaporator after vehicle shut down and this function will inhibit microbial growth. Technicians are to confirm that the customer concern is evaporator core odor and that the vehicle has the imbedded afterblow feature, as defined in the SI document for that specific vehicle model, model year and specific HVAC option. Refer to SI for enabling the afterblow function. Vehicles being delivered in areas prone to high humidity conditions may benefit from having the afterblow enabled calibration installed prior to any customer comment. Important If the vehicle is not factory equipped with the imbedded afterblow enable feature, it may be added with the Electronic Evaporator Dryer Module Kit (P/N 12497910 or AC Delco 15-5876). Important When installing the Electronic Evaporator Dryer Module, you MUST use the included electrical splice connectors to ensure a proper splice. Complete detailed installation instructions and self testing procedures are supplied with the kit. If necessary, the Electronic Evaporator Dryer Module may be installed underhood if it is protected from extreme heat and water splash areas. To immediately remove the evaporator core odor on all suspect vehicles, it is necessary to eliminate the microbial growth and prevent its re-occurrence. To accomplish this, perform the following procedure: Vehicle and Applicator Tool Preparation 1. The evaporator core must be dry. This may be accomplished by disabling the compressor and running the blower fan on the recirc heat setting for an extended period of time. Note Compressor engagement will cause the evaporator core to remain wet and will prevent full adherence of the Coiling Coil Coating to the evaporator core surfaces. 2. Verify that the air conditioning drain hose is not clogged and place a drain pan beneath the vehicle. Page 6665 13. Install the TCC solenoid bolts. ^ Tighten the bolts to 11 Nm (97 inch lbs.). 14. Install the internal wiring harness to the valve body. The internal wiring harness has a tab (1) on the edge of the conduit. 15. Place the tab between the valve body and the pressure switch in the location shown (2). Press the harness into position on the valve body bolt bosses (1, 3). 16. Install the TCC PWM solenoid (1) to the valve body. 17. Install the TCC PWM solenoid retainer (2). 18. Install the transmission fluid indicator stop bracket (1) and bolt (2). ^ Tighten the bolt to 11 Nm (97 inch lbs.). Page 14592 Memory Seat Module - C3 Part 1 A/T - 4T65E Fluid Leaking From A/T Vent Channel Plate: All Technical Service Bulletins A/T - 4T65E Fluid Leaking From A/T Vent TECHNICAL Bulletin No.: 01-07-30-032E Date: September 29, 2008 Subject: Transmission Oil Leaking From Transmission Vent (Replace Transmission Case Cover (Channel Plate) Gasket) Models: 1997-2009 GM Passenger Cars and Light Duty Trucks (including Saturn) with Hydra-Matic 4T65-E Automatic Transmission (RPOs MN3, MN7, M15, M76) Supercede: This bulletin is being revised to add the 2008 and 2009 model years. Please discard Corporate Bulletin Number 01-07-30-032D (Section 07 - Transmission/Transaxle). Condition Some customers may comment on a transmission oil leak. Cause This condition may be caused by an improperly torqued channel plate gasket. Correction To correct this condition, replace the case cover (channel plate) gaskets (429 and 430). Refer to Unit Repair publication in SI of the appropriate vehicle being serviced. Visual inspection of the upper gasket (1) will reveal damage at the referenced area. Parts Information Warranty Information Interior - Heated Seats Intermittently Inoperative Seat Heater Control Module: All Technical Service Bulletins Interior - Heated Seats Intermittently Inoperative Bulletin No.: 05-08-05-008 Date: August 18, 2005 TECHNICAL Subject: Intermittent Heated Seats Inoperative, DTC B3941 Set (Reprogram Driver Seat Module) Models: 2003-2005 Cadillac Escalade, Escalade ESV, Escalade EXT 2003-2005 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2003-2005 GMC Sierra, Yukon, Yukon XL, Yukon Denali All with Seat FRT, Individual (Non BKT) (RPO AN3) 2003-2005 HUMMER H2 with Seat, Front Bucket Deluxe (RPO AR9) Condition Some customers may comment that occasionally the seat heater will not operate when activated. If the ignition key is cycled OFF and back ON again, the heated seat will operate correctly. Also, on some LB7 diesel engine vehicles, the seat heater may turn itself off during the first 10 minutes of operation. This occurs only with the first activation for the day and works correctly with subsequent activations immediately after the event. These conditions are intermiffent and DTC B3941 may be set. Correction Technicians are to reprogram the driver seat module with an updated software calibration. This new service calibration was released with TIS satellite data update version 6.5 available June 13, 2005. As always, make sure your Tech 2(R) is updated with the latest software version. Warranty Information Disclaimer Page 8754 4. Install the auxiliary cable clip bolt to the frame. Tighten Tighten the bolt to 10 N.m (89 lb in). 5. Lower the vehicle. 6. Install the auxiliary positive battery cable clip to the battery tray. 7. Install the auxiliary positive battery cable to the auxiliary relay. 8. Install the auxiliary positive battery cable nut. Tighten Tighten the nut to 8 N.m (71 lb in). 9. Position the boot. 10. Connect the auxiliary battery negative cable Page 3625 3. Install the fan shroud retainers. 4. If equipped install the inlet radiator hose retainer to the fan shroud 5. If equipped install the throttle body heater hose retainer to the fan shroud. 6. Install the air cleaner outlet duct. 7. Tighten the air cleaner outlet duct clamp at the throttle body. Tighten the clamp screw to 7 Nm (62 inch lbs.). 8. Tighten the air cleaner outlet duct clamp at the mass airflow sensor. Tighten the clamp screw to 7 Nm (62 inch lbs.). Page 1976 Electrical Symbols Part 2 Page 927 Door Control Module Diagram 3 Part 1 Page 8882 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground TESTING FOR SHORT TO GROUND NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting With A Digital Multimeter TROUBLESHOOTING WITH A DIGITAL MULTIMETER NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TROUBLESHOOTING WITH A TEST LAMP Page 14359 IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections TESTING FOR INTERMITTENT AND POOR CONNECTIONS TOOLS REQUIRED - J 35616-C GM-Approved Terminal Test Kit - J 38125-D Terminal Repair Kit - J 42675 Flat-Wire Probe Adapter Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector. - Poor terminal to wire connection - Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. - Wire insulation which is rubbed through - This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. - Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. Testing For Proper Terminal Contact It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-D or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-D, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. Page 331 The number above refers to the step number on the diagnostic table. DTC U0073 or U2100 DTC Descriptors DTC U0073 00: Control Module Communication Bus Off DTC U0073 71: ECU HS Bus Off DTC U0073 72: ECU LS Bus Off DTC U2100 00: Controller Area Network (CAN) Bus Communication DTC U2100 47: Controller Area Network (CAN) Bus Communication Circuit/System Description The serial data circuits are serial data buses used to communicate information between the control modules. The serial data circuits also connect directly to the data link connector (DLC). Conditions for Running the DTCs Supply voltage at the modules are in the normal operating range. The vehicle power mode requires serial data communications. Conditions for Setting the DTC The module setting the DTC has attempted to establish communications on the serial data circuits more than 3 times. Page 9361 Important The M6 conductive rivet stud as shown, can accommodate a panel thickness range of 0.7-4.2 mm (0.03-0.17 in). If there are layers of sheet metal, they should be touching without any air gaps to ensure a good ground. 5. Select a M6 conductive rivet stud. Refer to the Parts Information section of this bulletin. Note Use the GE-50317 rivet stud tool kit. 6. Place the M6 conductive rivet stud (1) in the 10 mm (0.40 in) hole. Assemble the rivet stud tool (2) with the groove and flare side facing the rivet stud, then the washer and the M6 nut (3). 7. Using a wrench on the rivet stud tool, and a socket on the M6 nut, secure the M6 conductive rivet stud. 8. Ensure the rivet stud is securely fastened, WITHOUT ANY detectable movement. 9. Completely wrap the threads of the rivet stud with painters tape or equivalent. Note The rivet stud and surrounding panel area MUST BE properly refinished PRIOR to the installation of the ground wire terminal and conductive nut to maintain a secure, stable and corrosion-free electrical ground. 10. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 11. Allow the refinished repair area to cure sufficiently before removing the protective material applied to the rivet stud threads. 12. Remove the painters tape or equivalent from the rivet stud threads. 13. Using GM approved residue-free solvent or equivalent, thoroughly clean the rivet stud threads to remove any adhesive and allow to dry. 14. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive rivet stud. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. Page 1415 2. Install the fuel level sensor retaining clip. 3. Connect the fuel level sensor electrical connector. 4. Install the fuel level sensor electrical connector retaining clip. Interior - Front Heated Seat(s) Inoperative Seat Heater Switch: Customer Interest Interior - Front Heated Seat(s) Inoperative Bulletin No.: 04-08-50-007 Date: March 12, 2004 INFORMATION Subject: Service Information for Front Heated Seat Inoperative/Cold Models: 2003-2004 Cadillac Escalade/ESV/EXT 2003-2004 Chevrolet Avalanch/Silverado/Suburban/Tahoe 2003-2004 GMC Denali/Sierra/Yukon/Yukon XL 2003-2004 Hummer H2 The purpose of this bulletin is to provide the technician with the following service information: ^ Heated Seats Switch Operation ^ Heated Seats Switch Diagnostics ^ Heated Seats Switch Customer Information Switch Operation 1. The engine must be running for the heated seat feature to work. The heated seats will shut off automatically when the ignition is turned off. 2. Two buttons, located on the door, are used to control the heated seat. ^ Press the horizontal (RH) button to heat the entire seat, back and cushion. ^ Press the vertical (LH) button to heat ONLY the seat back. ^ The three light bars are an indicator of the level of heat selected for either the entire seat (horizontal button) or ONLY the seat back (vertical button). 3. To heat both the seat back and seat cushion at the same time, press the horizontal (RH) button with the heated seat symbol one time. ^ All 3 light bars will glow indicating the HIGH temperature setting. ^ The horizontal (RH) button does NOT have an ON/OFF indicator light. Page 6985 18. Inspect and add axle lubricant to the axle housing, if necessary. 19. Lower the vehicle. Page 15477 Fuel Pump/Sender Assembly - Secondary Page 8718 Wheel Speed Sensor: Service and Repair Wheel Speed Sensor Replacement (4WD) Caution: Refer to Brake Dust Caution in Service Precautions. Removal Procedure 1. Raise and support the vehicle. 2. Remove the tire and wheel. 3. Remove the brake rotor (2) shown on the 1500 series. Refer to Brake Rotor Replacement - Front in Disc Brakes. 4. Remove the WSS cable mounting clip from the knuckle. 5. Remove the WSS cable mounting clip from the upper control arm. 6. Remove the WSS cable mounting clip from the frame attachment point. 7. Remove the WSS cable electrical connector. Page 12844 Page 8464 Page 13100 OnStar(R) Microphone The OnStar(R), or cellular microphone, can be a part of the rearview mirror assembly, or on some vehicle lines, a separate, stand alone unit. In either case, the VCIM supplies approximately 10 volts to the microphone on the cellular microphone signal circuit, and voice data from the user is sent back to the VCIM over the same circuit. A cellular microphone low reference circuit or a drain wire provides a ground for the microphone. Cellular and GPS Antennas The vehicle will be equipped with one of the following types of antennas: ^ Separate, stand-alone cellular and navigation (GPS) antennas. ^ A combination cellular and navigation (GPS) antenna, which brings the functions of both into a single part. ^ A cellular, GPS, and digital radio receiver (DRR) antenna, which also incorporates the functionality of the DRR satellite antenna (XM). The cellular antenna is the component that allows the OnStar(R) system to send and receive data using electromagnetic waves by means of cellular technology. The antenna is connected at the base to a coax cable that plugs directly into the VCIM. The GPS antenna is used to collect the signals of the orbiting GPS satellites. Within the antenna is housed a low noise amplifier that allows for a more broad and precise reception of this data. The antenna is connected at the base to a coax cable that plugs directly into the VCIM. The cable also provides a path for DC current for powering the antenna. The OnStar(R) Call Center also has the capability of communicating with the vehicle during an OnStar(R) call to retrieve the latest GPS location and transmit it to the OnStar(R) Call Center. A history location of the last recorded position of the vehicle is stored in the module and marked as aged, for as long as the module power is not removed. Actual GPS location may take up to 10 minutes to register in the event of a loss of power. Audio System Interface When the OnStar(R) requires audio output, a serial data message is sent to the audio system to mute all radio functions and transmit OnStar(R) originated audio. The OnStar(R) audio is transmitted to the vehicle audio system by a dedicated signal circuit and a low reference circuit. The audio system will mute and an audible ring will be heard though the speakers if the vehicle receives a call with the radio ON. On some vehicles, the HVAC blower speed may be reduced when the OnStar(R) system is active to aid in reducing interior noise. When the system is no longer active, the blower speed will return to its previous setting. OnStar(R) Steering Wheel Controls Some vehicles may have a button on the steering wheel, that when pushed can engage the OnStar(R) system. The button may be a symbol of a face with sound waves, or may say MUTE, or be a symbol of a radio speaker with a slash through it. By engaging the OnStar(R) system with this feature, the user can interact with the system by use of voice commands. A complete list of these commands is supplied in the information provided to the customer. If the information is not available for reference, at any command prompt, the user can say "HELP" and the VCIM will return an audible list of available commands. The steering wheel controls consist of multiple momentary contact switches and a resistor network. The switches and resistor network are arranged so that each switch has a different resistance value. When a switch is pressed, a voltage drop occurs in the resistor network. This produces a specific voltage value unique to the switch selected, to be interpreted by the radio or the body control module (BCM). OnStar(R) Power Moding (DRX or Sleep Cycle) The OnStar(R) system uses a unique sleep cycle to allow the system to receive cellular calls while the ignition is in the OFF position and retained accessory power (RAP) mode has ended. A green status LED on the OnStar(R) keypad normally indicates an active OnStar(R) account. The OnStar(R) system will stay powered up after ignition off for an extended time in order to allow for remote services like door unlock, horn honk, light flash, etcetera to take place as requested by the customer. Power cycle (also referred to as DRX) times vary depending on the generation of the OnStar(R) system. Technicians may identify the OnStar(R) system generation by using a Tech 2 and following this menu path: (Body>VCIM>Module ID Information>Module Information 2) or by accessing www.onstarenrollment.com All Generation 6 digital systems are powered up continuously for 48 hours from ignition OFF. After 48 hours, the Generation 6 systems will enter a 9 minute OFF, 1 minute ON power cycle for an additional 72 hours. At the beginning and end of the 1 minute ON stage, you may or may not experience a short spike of current at the beginning and at the end. This allows for calls from OnStar to be received by the system. After 120 hours from ignition OFF, A/T - 4T80E, Slips in Gear/L/H Axle Seal Leaks Seals and Gaskets: Customer Interest A/T - 4T80E, Slips in Gear/L/H Axle Seal Leaks TECHNICAL Bulletin No.: 08-07-30-009B Date: May 01, 2008 Subject: HYDRA-MATIC(R) Front Wheel Drive 4T80-E (MH1) Left Front Axle Seal Leak, Transmission Slips in Gear (Replace Third Clutch Housing with Revised Service Part) Models: 2001-2008 GM Passenger Cars with HYDRA-MATIC(R) Front Wheel Drive 4T80-E Automatic Transmission (RPO - MH1) Supercede: This bulletin is being updated to revise the Warranty Information. Please discard Corporate Bulletin Number 08-07-30-009A (Section 07 - Transmission/Transaxle). Condition Some customers may comment on a transmission oil leak and/or that the transmission slips in gear. Cause An oil leak may be caused by bushing wear in the third clutch housing, causing excessive fluid build-up at axe sea. Correction Important: DO NOT replace the transmission for above concerns. Replace the third clutch housing with service P/N 8682114, which has revised bushing material to extend life and reduce left front axle seal leaks. Refer to Automatic/Transaxle - 4T80-E Transmission Off-Vehicle Repair Instructions for the replacement of the third clutch housing in SI. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 3817 Control Module References Part 3 Page 4179 Knock Sensor (KS) OnStar(R) - System Inoperative/No LED Lamp ON Fuse: All Technical Service Bulletins OnStar(R) - System Inoperative/No LED Lamp ON Bulletin No.: 04-08-46-005 Date: December 21, 2004 TECHNICAL Subject: OnStar(R) Generation 6 (Digital) System Inoperative/Has No Power, LED Light Not On (Remove/Reinstall OnStar(R) Fuse and Replace VCIM or Follow SI Diagnostics) Models: 2004-2005 Buick Rainier, Rendezvous 2005 Buick Allure (Canada), LaCrosse, LeSabre, Terrazza 2004-2005 Cadillac Escalade, Escalade ESV, Escalade EXT 2005 Cadillac CTS, DeVille 2004-2005 Chevrolet Avalanche, Silverado, Suburban, Tahoe, TrailBlazer, TrailBlazer EXT 2005 Chevrolet Colorado, Express, Impala, Monte Carlo, Uplander 2004-2005 GMC Denali, Denali XL, Envoy, Envoy XL, Envoy XUV, Sierra, Yukon, Yukon XL 2005 GMC Canyon, Savana 2004-2005 Pontiac Aztek 2005 Pontiac Bonneville, Grand Prix, Montana SV6, Vibe with Digital Gen 6 OnStar(R) (RPO UE1) Condition Some customers may comment any or all of the following conditions: ^ The OnStar(R) system may be inoperative. ^ The OnStar(R) system may have no power. ^ The OnStar(R) LED light may not be on. The technician may also not be able to communicate with the OnStar(R) Vehicle Communication Interface Module VCIM) with a Tech 2(R). Correction Remove the OnStar(R) fuse from the fuse box, wait five minutes and reinstall the fuse. If the OnStar(R) system DOES NOT return to normal functionality, then follow the diagnostics in SI for this condition. If the OnStar(R) system DOES return to normal functionality, you will need to replace the VCIM. If the VCIM is not replaced, there is the possibility that the customer will return to the dealership with the same conditions at a later date. Please contact the GM Technical Assistance Center (TAC), to obtain a new VCIM. The TAC consultant will verify your diagnosis and, if appropriate, order a replacement part. Replacement parts are usually shipped out within 24 hours, and a pre-paid return package label will be included for returning the faulty part. By returning the faulty part, you will avoid a significant non-return core charge. After the VCIM has been replaced, press the blue OnStar(R) button and request a full reconfiguration. When contacting TAC regarding this concern, the availability of certain information from the vehicle will streamline the process for the dealership technician as well as minimize the time necessary for TAC to provide the correct diagnosis. Please refer to Corporate Bulletin Number 01-00-89-011B for further information concerning the information necessary before contacting TAC. Dealers in Canada should refer to GM Service Policies & Procedures Section 5.3.1 "DEALER REQUIREMENTS FOR ASSISTANCE". Warranty Information Page 13479 The 1999 though early 2003 wiring harness jumper that plugs into the relay block will have a reddish/brown 6-way connector and a tag with the last four digits of the wiring harness part number. Second design 2003-05 may have a white plastic connector with part number 5418 as well. ^ The 1999 jumper is/was P/N 12171982 with a pink/purple tag identifier of 1982. This number has been superseded to 15366255, with a pink/purple tag identifier of 6255. ^ The 2000 jumper harness is P/N 15366255. The pink/purple tag identifier is 6255. ^ The 2001-2002 jumper is P/N 15086884. The orange tag identifier is 6884. ^ The 2003-05 jumper is P/N 15085418. The orange tag identifier is 5418. When transferring the brake controller with the wiring jumper attached from a 2001-2002 vehicle to a 2003-05 vehicle, a change to the jumper harness connector must be performed. Page 4174 Crankshaft Position Sensor: Service and Repair Crankshaft Position (CKP) Sensor Replacement CRANKSHAFT POSITION (CKP) SENSOR REPLACEMENT REMOVAL PROCEDURE IMPORTANT: Perform the CKP System Variation Learn Procedure whenever the crankshaft position sensor is removed or replaced. 1. Remove the starter. 2. Disconnect the crankshaft position (CKP) sensor electrical connector. 3. Clean the area around the CKP sensor before removal in order to avoid debris from entering the engine. 4. Remove the CKP sensor bolt. 5. Remove the CKP sensor. INSTALLATION PROCEDURE Page 690 Page 10570 onto the subject vehicle. - After match mounting, the tire/wheel assembly must be rebalanced. If match mounting tires to in-spec wheels produces assembly values higher than these, tire replacement may be necessary. Replacing tires at lower values will probably mean good tires are being condemned. Because tires can sometimes become temporarily flat-spotted, which will affect force variation, it is important that the vehicle be driven at least 16 km (10 mi) prior to measuring. Tire pressure must also be adjusted to the usage pressure on the vehicle's tire placard prior to measuring. Most GM vehicles will tolerate radial force variation up to these levels. However, some vehicles are more sensitive, and may require lower levels. Also, there are other tire parameters that equipment such as the Hunter GSP9700 cannot measure that may be a factor. In such cases, TAC should be contacted for further instructions. Important - When mounting a GM wheel to a wheel balancer/force variation machine, always use the wheel's center pilot hole. This is the primary centering mechanism on all GM wheels; the bolt holes are secondary. Usually a back cone method to the machine should be used. For added accuracy and repeatability, a flange plate should be used to clamp the wheel onto the cone and machine. This system is offered by all balancer manufacturers in GM's dealer program. - Any type of service equipment that removes tread rubber by grinding, buffing or truing is NOT recommended, and may void the tire warranty. However, tires may have been ground by the tire company as part of their tire manufacturing process. This is a legitimate procedure. Steering Wheel Shake Worksheet When diagnosing vibration concerns, use the following worksheet in conjunction with the appropriate Vibration Analysis-Road testing procedure in the Vibration Correction sub-section in SI. Page 14367 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Micro-Pack 100W Connectors MICRO-PACK 100W CONNECTORS TOOLS REQUIRED J 38125-D Terminal Repair Kit REMOVAL PROCEDURE There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2)has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. IMPORTANT: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Page 9288 1. Install the engine electrical center bracket assembly to the front fender. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the 4 retaining bolts (1). Tighten Tighten the 4 retaining bolts (1) to 9 N.m (80 lb in). 3. Align the electrical center block (1) stubs in the slots so that the tabs (2) retains it in place. Page 2423 Parts Information Parts are currently available from GMSPO. Warranty Information Emissions - MIL ON/DTC P0446 Stored In ECM Canister Purge Volume Control Valve: All Technical Service Bulletins Emissions - MIL ON/DTC P0446 Stored In ECM TECHNICAL Bulletin No.: 02-06-04-037I Date: September 16, 2010 Subject: Check Engine Light On, Fuel Tank Hard to Fill, DTCs P0442, P0446, P0455 or P0449 Set (Replace Evaporative Emission (EVAP) Vent Valve Solenoid Assembly and Add/Relocate Filter Box Using Service Kit) Models: 1999-2007 Chevrolet Silverado (Classic) Models 1999-2007 GMC Sierra (Classic) Models 2007-2010 Chevrolet Silverado Models (Including Hybrid) 2007-2010 GMC Sierra Models (Including Hybrid) Supercede: This bulletin is being revised to add the 2010 model year and to include the Hybrid models. Please discard Corporate Bulletin Number 02-06-04-037H (Section 06 - Engine/Propulsion System). Condition Some customers may comment about the check engine light being illuminated. They may also comment that their vehicle is difficult to fill with fuel or when filling, the pump continuously shuts off before the tank is full. When checking the vehicle for DTCs, the ECM may report one or more of the following DTCs set as current or in history: P0442, P0446, P0449 or P0455. Cause The EVAP canister vent solenoid (CVS) valve draws fresh air into the system through a vent. Under certain operating conditions, dirt and dust intrusion into the EVAP CVS fresh air intake/venting system, may result in restricted air flow. Under certain operating conditions, water, if ingested into the EVAP CVS fresh air intake/venting system, may reach the CVS valve causing corrosion in the CVS valve, and may cause restrictions in the fresh air intake path, when the valve is in the closed position. Correction (1999-2007 Classic/Old Style Models) After following the published SI diagnostics and determining that the EVAP canister vent valve is the cause of the MIL light, replace the existing EVAP canister vent valve assembly with a new assembly. This new assembly is a sealed unit that is designed to be vented through a remote filter box. To ensure correct installation, follow the procedures below. Important DO NOT replace the EVAP canister assembly for this concern unless it fails the leak test. 1999-2003 Model Year (Use Service Kit P/N 19207762) 1. Raise the vehicle. Suitably support the vehicle. 2. Disconnect the EVAP canister vent valve electrical connector, if equipped. 3. Disengage the two vent valve pipe clips securing the pipe to the underbody. Remove the clips from the underbody and discard. 4. Disconnect the vent valve pipe at the EVAP canister. 5. Remove and retain the EVAP canister vent valve bracket mounting bolt. 6. Remove the complete EVAP canister vent valve assembly with bracket attached and discard. Page 9459 Cigar Lighter/Auxiliary Outlets Diagram 3 Page 12175 Check - Vehicle. The Diagnostic System Check will provide the following information: ^ The identification of the control modules which command the system ^ The ability of the control modules to communicate through the serial data circuit ^ The identification of any stored diagnostic trouble codes (DTCs) and their status The use of the Diagnostic System Check will identify the correct procedure for diagnosing the system and where the procedure is located. Visual/Physical Inspection Perform the following visual inspections; ^ Inspect for aftermarket devices which could affect the operation of the Radio/Audio System. Refer to Checking Aftermarket Accessories in SI. ^ Inspect the easily accessible and visible system components for obvious damage or conditions which could cause the symptom. Intermittent Conditions Faulty electrical connections or wiring may be the cause of intermittent conditions. Refer to Testing for Intermittent Conditions and Poor Connections in SI. Symptom List Page 4395 Electronic Throttle Actuator: Description and Operation THROTTLE ACTUATOR CONTROL (TAC) SYSTEM DESCRIPTION The throttle actuator control (TAC) system delivers improved throttle response and greater reliability and eliminates the need for mechanical cable. The TAC system performs the following functions: - Accelerator pedal position (APP) sensing - Throttle positioning to meet driver and engine demands - Throttle position sensing - Internal diagnostics - Cruise control functions - Manage TAC electrical power consumption The TAC system components include the following: - The APP sensors - The throttle body assembly - The TAC module - The powertrain control module (PCM) Accelerator Pedal Position (APP) Sensor The accelerator pedal assembly contains 2 individual APP sensors within the assembly. The APP sensors 1 and 2 are potentiometer type sensors, each with the following circuits: A 5-volt reference circuit - A low reference circuit - A signal circuit The APP sensors are used to determine the pedal angle. The control module provides each APP sensor a 5-volt reference circuit and a low reference circuit. The APP sensors then provide the control module with signal voltage proportional to pedal movement. Both APP sensor signal voltages are low at rest position and increase as the pedal is applied. Throttle Body Assembly The throttle body assembly consists of the throttle body, the throttle position (TP) sensors, and the throttle actuator motor. The throttle body functions similar to a similar to a conventional throttle body with the following exceptions: An electric motor opens and closes the throttle valve. - The throttle blade is spring loaded in both directions and the default position is slightly open. - There are 2 individual TP sensors within the throttle body assembly. The TP sensors 1 and 2 are potentiometer type sensors, each with the following circuits: A 5-volt reference circuit - A low reference circuit - A signal circuit The TP sensors are used to determine the throttle plate angle. The control module provides each TP sensor a 5-volt reference circuit and a low reference circuit. The TP sensors then provide the control module with signal voltage proportional to throttle plate movement. Both TP sensor signal voltages are low at closed throttle and increase as the throttle opens. Throttle Actuator Control Module The TAC module is the control center for the throttle actuator control system. The TAC system is self-diagnosing and provides diagnostic information to the PCM through a dedicated serial data line. The TAC achieves throttle positioning by providing a pulse width modulated voltage to the TAC, as directed by the PCM. Powertrain Control Module The PCM determines the driver's intent, then calculates the appropriate throttle response. This information is sent to the TAC module through a dedicated serial data line. MODES OF OPERATION Normal Mode During the operation of the TAC system, several modes or functions are considered normal. The following modes may be entered during normal operation: Minimum pedal value-At key-up the PCM updates the learned minimum pedal value. - Minimum TP values-At key-up the PCM updates the learned minimum TP value. In order to learn the minimum TP value, the throttle blade is moved to the closed position. - Ice break mode-If the throttle is not able to reach a predetermined minimum throttle position, the ice break mode is entered. During the ice break mode, the control module commands the maximum pulse width several times to the throttle actuator motor in the closing direction. - Battery saver mode-After a predetermined time without engine RPM, the control module commands the battery saver mode. During the battery Page 1704 Accelerator Pedal Position Sensor: Service and Repair ACCELERATOR PEDAL POSITION (APP) SENSOR REPLACEMENT REMOVAL PROCEDURE NOTE: Handle the electronic throttle control components carefully. Use cleanliness in order to prevent damage. Do not drop the electronic throttle control components. Do not roughly handle the electronic throttle control components. Do not immerse the electronic throttle control components in cleaning solvents of any type. 1. Remove the connector position assurance (CPA) retainer. 2. Disconnect the accelerator pedal position (APP) sensor electrical connector. 3. Reposition the carpet to access the lower nut. 4. Remove the accelerator pedal nuts. 5. Remove the accelerator pedal assembly. INSTALLATION PROCEDURE A/T - 4L60-E/-4L65E No Shift/Slipping/Fluid Leaks Case: Customer Interest A/T - 4L60-E/-4L65E No Shift/Slipping/Fluid Leaks Bulletin No.: 04-07-30-025A Date: July 27, 2004 TECHNICAL Subject: Transmission Fluid Leak, Inoperative 2nd/3rd/4th Gears, No Movement, Case Cracked or Broken at 2-4 Servo (Repair Transmission and Install New Retaining Ring) Models: 2004 Chevrolet Corvette 2004 Pontiac GTO 2004 Light Duty Trucks with 4L60-E and 4L65-E Automatic Transmission (RPOs M30 or M32) Supercede: This bulletin is being revised to add the Corvette and GTO models and to include the 4L65-E transmission. Please discard Corporate Bulletin Number 04-07-30-025 (Section 07 Transmission/Transaxle). Condition Some customers may comment on a transmission leak, inoperative 2nd/4th gear, slipping 3rd/4th gear or no movement due to excess fluid loss. Cause This condition normally occurs at low mileage, usually under 1,600 km (1,000 mi), and investigation may show that the servo cover is loose or that the transmission case is cracked or broken at the servo bore. This condition may be caused by a servo cover retaining ring that did not retain the servo cover. The servo retaining ring design was changed for the 2004 MY from round wire to wire with two flat faces. In mid-April, 2004, the retaining ring design did revert back to a round design in production. It is possible that the transmission case may crack at the servo cover area due to the retaining ring being incorrectly seated. Correction Important: ^ In mid-April, 2004, the retaining ring design did revert back to a round design in production. ^ If the transmission fluid level has lowered due to loss of fluid, it is possible that damaged 3/4 clutches will result. ^ A cracked or broken case may usually be repaired at a significantly lower cost than transmission assembly replacement by replacing the case and any damaged clutches or bands. 1. Raise and suitably support the vehicle. 2. Inspect the transmission case around the servo cover for signs of cracks or damage to the case. ^ If the transmission case is cracked or damaged, replace the transmission case. Refer to the appropriate SI Document for Transmission Case Replacement. ^ If the servo cover is leaking and the case is not damaged, continue with the next step. 3. Remove the front exhaust pipe assembly. Refer to the appropriate SI Document. 4. Remove the heat shield if equipped. Refer to the appropriate SI Document. 5. Clean the servo cover area with Brake Clean and shop air. Page 4703 Electronic Throttle Control Module: Service and Repair THROTTLE ACTUATOR CONTROL (TAC) MODULE REPLACEMENT REMOVAL PROCEDURE 1. Disconnect the instrument panel (I/P) harness electrical connector (2). 2. Release the red connector position assurance (CPA) retainer. 3. Disconnect the engine wiring harness electrical connector (1). 4. Remove the throttle actuator control (TAC) module nuts. 5. Remove the TAC module. INSTALLATION PROCEDURE Page 3913 Steps 19 - 23 Page 8302 1. Raise and support the vehicle. Refer Vehicle Lifting 2. Remove the tire and wheel assembly. 3. Install a C-clamp over the body of the brake caliper, with the C-clamp ends against the rear of the caliper body and the outboard disc brake pad. 4. Slowly tighten the C-clamp until the pistons are pushed into the caliper bores enough to remove the caliper from the pads. 5. Remove the C-clamp from the caliper. 6. Remove the nut and the bolt from the quarter shaft shield. 7. Remove the shield. Automatic Transmission - 4L60-E/4L65-E Page 16130 Electrical Symbols Part 5 Page 7517 1. If a NEW control module is being installed, program the new module. 2. Install the shift control module to the bracket. 3. Connect the shift control module electrical connectors. 4. Start the engine and test the automatic transfer case system for proper shift operation. Page 6880 9. Install the retaining ring. 10. Install the axle shaft. 11. Inspect the lubricant level and add, if necessary. 12. Lower the vehicle. Page 9055 Relay Block - I/P C1 Part 6 Page 6910 10. For the 1500 models (except 1500 HD), assemble the bolts and the support plate to the base of the J-36652-01 and secure the base in a vise. 11. For the 1500 HD, 2500, 3500, and HUMMER H2 models, assemble the bolts and the support plate to the base of the J 36652-98 and secure the base in a vise. Page 4517 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves SPLICING COPPER WIRE USING SPLICE SLEEVES TOOLS REQUIRED J 38125-D Terminal Repair Kit IMPORTANT: Use only GM splice sleeves, other splice sleeves may not protect the splice from moisture or a provide good electrical connection. Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. Page 3952 1. If installing the old sensor, coat the threads with sealant GM P/N 12346004 (Canadian P/N 10953480) or equivalent. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the ECT sensor. Tighten Tighten the sensor to 20 N.m (15 lb ft). 3. Connect the ECT sensor electrical connector (5). 4. Refill the cooling. Refer to Draining and Filling Cooling System in Cooling System. Interior - Power Seat Switch Knobs Loose/Missing Power Seat Switch: All Technical Service Bulletins Interior - Power Seat Switch Knobs Loose/Missing Bulletin No.: 05-08-50-017 Date: December 14, 2005 TECHNICAL Subject: Power Front Seat (RPO AN3) Switch Knobs Loose or Missing (Replace Switch Knobs) Models: 2002-2006 Cadillac Escalade, Escalade EXT 2003-2006 Cadillac Escalade ESV 2002-2006 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2002-2006 GMC Sierra, Yukon, Yukon XL with Individual Front Seat Non-Bucket (RPO AN3) and Driver Front Seat Power Adjuster (AG1) and/or Passenger Front Seat Power Adjuster (AG2) Condition Some customers may comment that the power front seat adjuster switch knobs are loose and fall off or are missing. Correction Replace the front seat adjuster switch knob. These knobs were formerly available only as part of the power seat adjuster switch. DO NOT replace the switch if the knob only needs to be replaced. Parts Information Warranty Information Page 5259 Fuel Pressure Release: Service and Repair Fuel Pressure Relief Procedure FUEL PRESSURE RELIEF PROCEDURE TOOLS REQUIRED J 34730-1A Fuel Pressure Gage CAUTION: Relieve the fuel system pressure before servicing fuel system components in order to reduce the risk of fire and personal injury. After relieving the system pressure, a small amount of fuel may be released when servicing the fuel lines or connections. In order to reduce the chance of personal injury, cover the regulator and the fuel line fittings with a shop towel before disconnecting. This will catch any fuel that may leak out. Place the towel in an approved container when the disconnection is complete. 1. Disconnect the negative battery cable. 2. Install the J 34730-1A. 3. Loosen the fuel fill cap in order to relieve fuel tank vapor pressure. 4. Open the valve on J 34730-1A in order to bleed the system pressure. The fuel connections are now safe for servicing. 5. Drain any fuel remaining in the gage into an approved container. 6. Once the system pressure is completely relieved, remove the J 34730-1A. Locations Instrument Panel Switches-LH Page 6053 13. Remove the spacer plate to valve body gasket, the spacer plate and the spacer plate to transmission case gasket. 14. Remove the 3-4 accumulator piston (2). 15. Inspect the 3-4 accumulator spring for cracks. 16. Remove the 3-4 accumulator piston seal (1) from the 3-4 accumulator piston. 17. Inspect the 3-4 accumulator piston for the following conditions: ^ Porosity ^ Cracks ^ Scoring ^ Nicks and scratches Installation Procedure Page 14996 2. With the tailgate (1) completely open as shown in the upper part of the illustration, pull the RIGHT SIDE of the tailgate rearward as shown in the lower illustration. Do not pull on the left side of the tailgate. - If the tailgate hinge (2) will NOT disengage from the pickup box on the right side, no repair is needed to the hinge. Proceed to the section titled "Support Cable Replacement" and replace any support cable that HAD sealant in the earlier inspection. If neither of the support cables requires replacement, no further action is required. - If the tailgate hinge (3) will disengage from the pickup box on the right side, proceed to the next step. 3. With the right side of the tailgate disengaged from the pickup box, inspect the hinge on the right side of the tailgate for damage. The illustration above shows an undamaged hinge (1) and a damaged or bent hinge (2). - If the hinge is NOT damaged, no repair is needed to the hinge. Proceed to the section titled, "Support Cable Replacement" and replace any support cables that HAD sealant in the earlier inspection. If neither of the support cables require replacement, no further action is required. - If the hinge IS damaged or bent, the hinge needs to be replaced. Proceed to the section titled, "Hinge Replacement". Hinge Replacement - Escalade EXT, Avalanche, New Style Silverado and Sierra, Kodiak, TopKick The following procedure should only be performed if the right side of the tailgate could be disengaged from the pickup box. 1. Release (unhook) the left side tailgate support cable from the pickup box. Page 16146 TOOLS REQUIRED J 34142-B 12 V Unpowered Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. When testing for voltage: 1. Attach 1 lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach 1 lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Using Connector Test Adapters USING CONNECTOR TEST ADAPTERS NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-B Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires USING FUSED JUMPER WIRES TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Connector Position Assurance Locks CONNECTOR POSITION ASSURANCE LOCKS The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Terminal Position Assurance Locks TERMINAL POSITION ASSURANCE LOCKS The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Push to Seat Connectors PUSH TO SEAT CONNECTORS TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Page 4465 Fuel Tank Pressure Sensor: Description and Operation FUEL TANK PRESSURE SENSOR The FTP sensor measures the difference between the pressure or vacuum in the fuel tank and outside air pressure. The control module provides a 5-volt reference and a ground to the FTP sensor. The FTP sensor provides a signal voltage back to the control module that can vary between 0.1-4.9 volts. A high FTP sensor voltage indicates a low fuel tank pressure or vacuum. A low FTP sensor voltage indicates a high fuel tank pressure. Interior - Door Trim Panel Removal Precautions Front Door Panel: Technical Service Bulletins Interior - Door Trim Panel Removal Precautions Bulletin No.: 03-08-64-029 Date: August 26, 2003 INFORMATION Subject: Information on Removing Front Door Trim Panel to Avoid Breakage Models: 2003-2004 Cadillac Escalade, Escalade ESV, Escalade EXT 2003-2004 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2003-2004 GMC Denali, Denali XL, Sierra, Yukon, Yukon XL The purpose of this bulletin is to remind technicians to follow the front door trim panel removal procedure in SI. The front door trim panel will break if the screw at (2) in the illustration above is not removed. In order to prevent door trim panel breakage, follow the Trim Panel Replacement - Side Front Door procedure in SI. The front door trim panel may also be broken if the door switch bezel is not removed properly. Refer to Corporate Bulletin Number 03-08-64-022 for information about replacement of the door switch bezel. Disclaimer Input Shaft Speed Sensor Replacement Transmission Speed Sensor: Service and Repair Input Shaft Speed Sensor Replacement Input Shaft Speed Sensor Replacement Removal Procedure 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. Disconnect the input speed sensor electrical connector (1). 3. Remove the input speed sensor bolt. 4. Remove the input speed sensor (1). 5. Inspect the input speed sensor (1) for any evidence of damage. Installation Procedure Page 12822 Diagnostic Tips Review # 3 - Denso Navigation Radios Upper Control Arm Replacement Control Arm: Service and Repair Upper Control Arm Replacement Upper Control Arm Replacement Tools Required - J-42188-B Ball Joint Separator Removal Procedure 1. Raise and support the vehicle. 2. Remove the tire and wheel. 3. Remove the retaining bolt for the brake hose and the wheel speed sensor brackets. 4. Remove the nut at the upper ball joint. Discard the nut. 5. Disconnect the upper control arm from the steering knuckle using the J-42188-B. Page 3338 2. Install the oil filter. 3. Refill the engine oil. Refer to Capacities - Approximate Fluid and/or Fluid and Lubricant Recommendations in Maintenance and Lubrication. AWD/4WD - AWD/4WD Lamps/System Inop./DTC C0550 Control Module: Customer Interest AWD/4WD - AWD/4WD Lamps/System Inop./DTC C0550 Bulletin No.: 02-04-21-006E Date: July 20, 2006 TECHNICAL Subject: Inoperative 4WD/AWD Lamps, Inoperative 4WD/AWD System, DTC C0550 Set, No Communication with TCCM (Reprogram Transfer Case Control Module) Models: 2004 Buick Rainier 2002-2004 Chevrolet TrailBlazer, TrailBlazer EXT 2003-2004 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2002-2004 GMC Envoy, Envoy XL 2003-2004 GMC Sierra, Yukon, Yukon XL 2004 GMC Envoy XUV 2002-2004 Oldsmobile Bravada with Electronic Shift or Active Transfer Case (RPOs NP1, NP4 or NP8) Supercede: This bulletin is being revised to add Subject information and change the labor operation. This bulletin cancels and supersedes Bulletin Number 03-04-21-006. Please discard Corporate Bulletin Numbers 02-04-21-006D and 03-04-21-006 (Section 04 - Driveline/Axle). Condition Some customers may comment that the 4WD/AWD indicator lights on the selector switch do not work, or the 4WD/AWD system may be inoperative and/or the service 4WD light is illuminated. The condition is typically intermittent and always occurs at key-up. Upon investigation, the technician may find DTC C0550 set. Cause The Transfer Case Control Module (TCCM) has not received the wake-up call during key-up and has remained in the "sleep mode". When the TCCM is in the "sleep mode", it will not communicate with the class II bus or the Tech 2(R). Correction 1. Try to communicate with the TCCM. If no communication, go to step 2. If communication is possible, go to step 5. 2. Remove the underhood (ATCM or TREC) TCCM fuse. 3. Wait 30 seconds. 4. Reinstall the fuse. The module should wake up and communicate with the Tech 2(R). 5. Check for codes in the TCCM. If a C0550 is found current or in history with or without other codes, replace the module and go to step 6. 6. Reprogram the TCCM with the latest TIS software using normal SPS procedures. 7. Verify operation and that no codes are present. Important: For the 2002 model year, the TCCM must be replaced and reprogrammed. Warranty Information Page 6566 7. Use the modified screw extractor in order to remove the plug. 8. Remove the parking pawl shaft retainer, shaft and pawl. 9. Important: If the manual shaft binds in the case during removal, file or sand the shaft in the area adjacent to the detent lever. Remove the manual shaft. 10. Remove the manual shaft seal. Installation Procedure 1. Install the pawl shaft. 2. Install the parking pawl. 3. Install the plug using a 8 mm or (5/16 inch) rod with Loctite® or equivalent. 4. Install the retainer. 5. Install the pawl return spring. 6. Install the detent lever to the actuator. 7. Install the actuator over the parking pawl. 8. Install the manual shaft seal. 9. Lubricate the manual shaft with transmission oil and install the manual shaft into the case. 10. Install the nut on the shaft. 11. Install the roll pin. 12. Notice: Refer to Fastener Notice in Service Precautions. Page 8138 13. If necessary, lower the vehicle. 14. Using a scan tool, clear the DTCs. 15. Start the vehicle and inspect for leaks. Important: Advise the customer that a similar condition may occur if the vehicle is fueled with the engine running AND the rear tank is fueled first. The engine must be shut off (as required by law) during vehicle refueling. Parts Information Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Restraints - Driver/Passenger Seat Head Rest Information Head Restraint System: Technical Service Bulletins Restraints - Driver/Passenger Seat Head Rest Information INFORMATION Bulletin No.: 10-08-50-003A Date: March 24, 2011 Subject: Information on Driver or Passenger Seat Head Restraint Concerns with Comfort, Custom Upholstery or Other Comfort Enhancing Devices Models: 2012 and Prior GM Passenger Cars and Trucks Equipped with Adjustable Head Restraints Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 10-08-50-003 (Section 08 - Body and Accessories). Important ON A GM VEHICLE EQUIPPED WITH ADJUSTABLE HEAD RESTRAINTS, USE THE HEAD RESTRAINT COVERS, FOAM AND OTHER SEAT-RELATED EQUIPMENT AS RELEASED BY GM FOR THAT VEHICLE. DO NOT ALTER OR REPOSITION THE HEAD RESTRAINT SYSTEM. ANY ALTERATIONS TO HEAD RESTRAINTS DEFEATS THE INTENDED DESIGN OF THE SYSTEM. GM WILL NOT BE LIABLE FOR ANY PROBLEMS CAUSED BY USE OF SUCH IMPROPER DESIGN ALTERATIONS, INCLUDING ANY WARRANTY REPAIRS INCURRED. You may have a customer with a concern that the head restraint is uncomfortable or sits too far forward. The front driver and passenger seats are equipped with head restraints that have been designed to help minimize injuries while still providing comfort to the occupants. Each GM vehicle has its own specifically designed head restraint. The head restraints should only be used in the vehicle for which they were designed. The head restraint will not operate to its design intent if the original foam is replaced (1) by non-GM foam or head restraint, (2) by GM foam or head restraint designed for a different vehicle, (3) by GM foam or head restraint that has been altered by a trim shop or (4) if any object, such as an aftermarket comfort enhancing pad or device, is installed. Never modify the design of the head restraint or remove the head restraint from the vehicle as this may interfere with the operation of the seating and restraint systems and may prevent proper positioning of the passenger within the vehicle. Disclaimer Page 13569 Body Control Module (BCM) - C6 Part 2 Page 1209 Memory/Heated Seat Switch - Driver (DDM C5) Part 2 Testing and Inspection Wiper Arm: Testing and Inspection WIPER ARM TIP PRESSURE CHECK 1. Run the wiper arms to the mid-wipe position. 2. Remove the wiper blades from the wiper arms. 3. Attach a scale to the end of the wiper arm and measure the force required to lift the wiper arm perpendicular to the windshield to normal working height with the blade attached. 4. Replace the wiper arm if the measurement is not within the specification. Tip Pressure Driver Side - 8.1-9.5 Newtons (29- 34 Ounces) - Passenger Side - 5.8-7.0 Newtons (21- 25 Ounces) Locations Steering Column Page 14889 Seat Adjuster Switch - Driver (With RPO Code AN3) Part 2 Page 14885 For vehicles repaired under warranty, use the table. Disclaimer Page 13637 Front Door Interior Handle: Service and Repair Door Handle Components Door Handle Bezel Replacement (Inside Side Access) Door Handle Bezel Replacement (Inside Side Access) Removal Procedure 1. Insert a flat-bladed tool at the top between the door bezel and the door panel. 2. Carefully bend outward the retaining clips while pulling out the bezel. Installation Procedure Snap the handle bezel into place in the door trim panel. Handle Bezel Replacement - Inside Handle Bezel Replacement - Inside Removal Procedure 1. Insert a flat-bladed tool between the door handle bezel and the trim panel in order to release the handle bezel tab retainers. 2. Remove the door handle bezel from the door panel. Installation Procedure Page 2703 Application Tabel Part 1 Page 11921 10.4. Remove the end cap from the new optic cable, connect to the connector and refit the secondary catch (D). Fit the terminal housing (C) to the connector and refit the locking strip (B). 10.5. Secure the old optic cable together with the new one (E). Important: The optic cable must not be bent with a radius less than 25 mm (1 in). Important: Secure the wiring harness so that there is no risk of chafing and rattling. 11. CV: Remove the rear seat in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. The O-bus connector H2-9 is located behind the left speaker. 12. M04-05: Disconnect the optic cables on the OnStar(R) control modules and join the cables: 12.1. Cut off the cable tie holding the connector (H2-9) against REC. Page 12360 Garage Door Opener Transmitter: Electrical Diagrams Garage Door Opener Diagram Page 9032 Fuse Block- I/P C1 Part 6 Service and Repair Air Bag(s) Arming and Disarming: Service and Repair SIR Disabling and Enabling The SIR Identification Views shown below illustrate the approximate location of all SIR components available for the vehicle. This will assist in determining the appropriate SIR Disabling and Enabling for a given service procedure. Refer to See: Restraint Systems/Air Bag Systems/Locations/SIR Zone Identification Views There are several reasons for disabling the SIR system, such as repairs to the SIR system or servicing a component near or attached to an SIR component. There are several ways to disable the SIR system depending on what type of service is being performed. The following information covers the proper procedures for disabling/enabling the SIR system. SIR Service Precautions Caution: When performing service on or near the SIR components or the SIR wiring, the SIR system must be disabled. Failure to observe the correct procedure could cause deployment of the SIR components. Serious injury can occur. Failure to observe the correct procedure could also result in unnecessary SIR system repairs. The inflatable restraint sensing and diagnostic module (SDM) maintains a reserved energy supply. The reserved energy supply provides deployment power for the air bags if the SDM loses battery power during a collision. Deployment power is available for as much as 1 minute after disconnecting the vehicle power. Waiting 1 minute before working on the system after disabling the SIR system prevents deployment of the air bags from the reserved energy supply. General Service Instructions The following are general service instructions which must be followed in order to properly repair the vehicle and return it to its original integrity: - Do not expose inflator modules to temperatures above 65°C (150°F). - Verify the correct replacement part number. Do not substitute a component from a different vehicle. - Use only original GM replacement parts available from your authorized GM dealer. Do not use salvaged parts for repairs to the SIR system. Discard any of the following components if it has been dropped from a height of 91 cm (3 feet) or greater: - Inflatable restraint sensing and diagnostic module (SDM) - Any Inflatable restraint air bag module - Inflatable restraint steering wheel module coil - Any Inflatable restraint sensor - Inflatable restraint seat belt pretensioners - Inflatable restraint Passenger Presence System (PPS) module or sensor Disabling Procedure - Air Bag Fuse 1. Turn the steering wheel so that the vehicles wheels are pointing straight ahead. 2. Place the ignition in the OFF position. Important: The SDM may have more than one fused power input. To ensure there is no unwanted SIR deployment, personal injury, or unnecessary SIR system repairs, remove all fuses supplying power to the SDM. With all SDM fuses removed and the ignition switch in the ON position, the AIR BAG warning indicator illuminates. This is normal operation, and does not indicate a SIR system malfunction. 3. Locate and remove the fuse(s) supplying power to the SDM. Lamp Switch Assembly Replacement-Front Fog Lamp and Cargo Lamp Fog/Driving Lamp Switch: Service and Repair Lamp Switch Assembly Replacement-Front Fog Lamp and Cargo Lamp LAMP SWITCH ASSEMBLY REPLACEMENT - FRONT FOG LAMP AND CARGO LAMP REMOVAL PROCEDURE 1. Remove the instrument cluster bezel. 2. Remove the fog lamp switch and cargo switch from the housing. 3. Disconnect the electrical connector(s) from the fog lamp switch. 4. Remove the fog lamp and cargo lamp switch from the housing. INSTALLATION PROCEDURE 1. Connect the electrical connector(s) to the fog lamp and cargo lamp switch. 2. Install the fog lamp switch into the housing. 3. Install the IP trim bezel to the instrument panel. Page 10692 Suspension - Revised Stabilizer Link Service/Torque Stabilizer Link: Technical Service Bulletins Suspension - Revised Stabilizer Link Service/Torque Bulletin No.: 05-03-08-006 Date: April 12, 2005 SERVICE MANUAL UPDATE Subject: Revised Stabilizer Shaft Link Replacement Procedure and Fastener Tightening Specifications Models: 1999-2005 Chevrolet and GMC Full Size Pickup and Utility Models 2003-2005 HUMMER H2 This bulletin is being issued to revise the Stabilizer Shaft Link Replacement Procedure and Fastener Tightening Specifications in the Front Suspension sub-section of the Service Manual. Please replace the current information in the Service Manual with the following information. The following information has been updated within SI. If you are using a paper version of this Service Manual, please make a reference to this bulletin on the affected page. The following revision affects both the Fastener Tightening Specifications and the Stabilizer Shaft Link Replacement procedure. Pickup and Utility Models : Stabilizer Shaft Link Nuts - 10 Nm (89 lb in) Continue tightening the nut until 2 to 4 threads protrude above the nut. H2 : Stabilizer Shaft Link Nuts - 14 Nm (124 lb in) Continue tightening the nut until 2 to 4 threads protrude above the nut. The following Notice has been added to the Stabilizer Shaft Link Replacement procedure. Note: To avoid stabilizer shaft damage due to loss of clamp load, the threads of the link bolt must protrude 2 to 4 threads above the nut after the specified torque is achieved. Disclaimer Page 2029 INSTALLATION PROCEDURE 1. Install the door module into the switch panel bezel until it snaps into place. 2. Install the switch panel bezel and module to the door panel. NOTE: Refer to Fastener Notice in Service Precautions. 3. Install the screw that retains the switch panel bezel (1) to the front door panel. Tighten Tighten the screw to 2 N.m (18 lb in). 4. Connect the electrical connectors. Page 10650 Provide all information required on the form. Make a copy of the completed form for the customer to keep in the vehicle along with their Owner's Manual. File the original completed form in the Dealership's Vehicle Service History folder. Because this is not a warranty repair, dealers will incur a charge to obtain a VCI number. A VCI number will only be available for the following models: 1999-2007 Chevrolet Silverado and GMC Sierra (1500 Series Only) EXCLUDES 1999-2000 vehicles equipped with 4.3L engine (RPO L35) EXCLUDES vehicles equipped with Quadrasteer (RPO NYS) EXCLUDES Parallel Hybrid Truck (RPO HP2) EXCLUDES 2001-2004 vehicles equipped with Traction Control (RPO NW7) combined with 3.42 Axle Ratio (RPO GU6) Refer to the Model Application Chart to in the beginning of this bulletin to verify usage. Calibrations are not available for 1999 and 2000 model year vehicles with 3.08 axle. Calibrations are not available for 1999 and 2000 model year vehicles equipped with 4.3L engine (RPO L35). If original equipment tires/wheels are reinstalled, it will be necessary to reset the programming of the PCM and the ABS module to the original specifications. Labels After installing the recommended P275/55R20 tires, place the provided label on the vehicle. The label should be located on the doorjamb, near the original tire label, and should not cover up the original tire label. Be sure that the surface is clean and dry. The surface temperature should not be less than 21°C (70°F). The label is provided as a guide for tire inflation pressures and information relevant to occupant/cargo capacities. Page 3827 Body Control Module (BCM) - C3 Part 2 Page 8303 8. Remove the 2 brake caliper mounting bolts. 9. Notice: Support the brake caliper with heavy mechanic's wire, or equivalent, whenever it is separated from its mount and the hydraulic flexible brake hose is still connected. Failure to support the caliper in this manner will cause the flexible brake hose to bear the weight of the caliper, which may cause damage to the brake hose and in turn may cause a brake fluid leak. Remove the brake caliper and support with heavy mechanic's wire or equivalent. DO NOT disconnect the hydraulic brake hose from the brake caliper. 10. Remove the 2 brake caliper mounting bracket bolts. 11. Remove the disc brake pads from the brake caliper mounting bracket. 12. Remove the anti-rattle clips from the brake caliper mounting bracket. Installation Procedure Interior - Erratic Memory Seat Operation Power Seat Control Module: Customer Interest Interior - Erratic Memory Seat Operation Bulletin No.: 04-08-50-016C Date: August 12, 2005 TECHNICAL Subject: Memory Seat May Not Return to Requested Position (Reprogram Driver Seat Module) Models: 2003-2005 Cadillac Escalade, Escalade ESV, Escalade EXT 2003-2005 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2003-2005 GMC Sierra, Yukon, Yukon XL, Yukon Denali All with Seat FRT, Individual (Non BKT) (RPO AN3) 2003-2005 HUMMER H2 with Seat, Front Bucket Deluxe (RPO AR9) Supercede: This bulletin is being revised to update the correction information. Please discard Corporate Bulletin Number 04-08-50-016B (Section 08 - Body and Accessories). Condition Some customers may comment that with repeated cycling of the memory seat between the "exit" and one of the "presets", the position of the seat may "creep" forward or rearward out of expected adjustment. Cause There is a coding deficiency in the software for the memory seat module. Correction Technicians are to reprogram the driver seat module with an updated software calibration. The previous bulletin stated to use a service calibration that was released with TIS satellite data update version 4.5. Feedback has proved that calibration to be ineffective in eliminating the memory seat creep condition. An updated service calibration was released with TIS satellite data update version 6.5 available June 13, 2005. This new calibration has additional memory seat creep protection. As always, make sure your Tech 2(R) is updated with the latest software version. Important: After programming is complete, move the seat all the way rearward and down, then bump the seat slightly forward and up. This position will be just off the end of travel hard stops. Reset both memory seat exit positions at this position. Having the seat set at just off the hard stops will aid in reducing the creep condition. Warranty Information Page 14646 Seat Adjuster Switch - Driver (With RPO Code AN3) Part 2 AWD/4WD - AWD/4WD Lamps/System Inop./DTC C0550 Control Module: All Technical Service Bulletins AWD/4WD - AWD/4WD Lamps/System Inop./DTC C0550 Bulletin No.: 02-04-21-006E Date: July 20, 2006 TECHNICAL Subject: Inoperative 4WD/AWD Lamps, Inoperative 4WD/AWD System, DTC C0550 Set, No Communication with TCCM (Reprogram Transfer Case Control Module) Models: 2004 Buick Rainier 2002-2004 Chevrolet TrailBlazer, TrailBlazer EXT 2003-2004 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2002-2004 GMC Envoy, Envoy XL 2003-2004 GMC Sierra, Yukon, Yukon XL 2004 GMC Envoy XUV 2002-2004 Oldsmobile Bravada with Electronic Shift or Active Transfer Case (RPOs NP1, NP4 or NP8) Supercede: This bulletin is being revised to add Subject information and change the labor operation. This bulletin cancels and supersedes Bulletin Number 03-04-21-006. Please discard Corporate Bulletin Numbers 02-04-21-006D and 03-04-21-006 (Section 04 - Driveline/Axle). Condition Some customers may comment that the 4WD/AWD indicator lights on the selector switch do not work, or the 4WD/AWD system may be inoperative and/or the service 4WD light is illuminated. The condition is typically intermittent and always occurs at key-up. Upon investigation, the technician may find DTC C0550 set. Cause The Transfer Case Control Module (TCCM) has not received the wake-up call during key-up and has remained in the "sleep mode". When the TCCM is in the "sleep mode", it will not communicate with the class II bus or the Tech 2(R). Correction 1. Try to communicate with the TCCM. If no communication, go to step 2. If communication is possible, go to step 5. 2. Remove the underhood (ATCM or TREC) TCCM fuse. 3. Wait 30 seconds. 4. Reinstall the fuse. The module should wake up and communicate with the Tech 2(R). 5. Check for codes in the TCCM. If a C0550 is found current or in history with or without other codes, replace the module and go to step 6. 6. Reprogram the TCCM with the latest TIS software using normal SPS procedures. 7. Verify operation and that no codes are present. Important: For the 2002 model year, the TCCM must be replaced and reprogrammed. Warranty Information Page 1965 3. Remove the right rear speed sensor. Installation Procedure 1. Notice: Refer to Fastener Notice in Service Precautions. Install the right rear speed sensor. ^ Tighten the speed sensor to 15 Nm (11 ft. lbs.). 2. Connect the right rear speed sensor electrical connector (3). 3. Lower the vehicle. Page 7996 2. Connect the front speed sensor electrical connector (5). 3. Install the transfer case shield, if equipped. Transfer Case Speed Sensor Replacement - Left Rear Transfer Case Speed Sensor Replacement - Left Rear Removal Procedure 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. Disconnect the left rear speed sensor electrical connector (4). 3. Remove the left rear speed sensor. Installation Procedure Seat Recliner Motor Power Seat Motor: Diagrams Seat Recliner Motor Seat Recliner Motor - Driver (With RPO Code AN3) Page 11333 HVAC Control Module - C1 Part 2 Page 7760 2. Connect the front speed sensor electrical connector (5). 3. Install the transfer case shield, if equipped. Transfer Case Speed Sensor Replacement - Left Rear Transfer Case Speed Sensor Replacement - Left Rear Removal Procedure 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. Disconnect the left rear speed sensor electrical connector (4). 3. Remove the left rear speed sensor. Installation Procedure Page 13203 For vehicles repaired under warranty, use the table. Disclaimer Page 2424 For vehicles repaired under warranty, use the table. Disclaimer Page 3992 1. Install the knock sensors. Tighten Tighten the sensor to 20 N.m (15 lb ft). 2. Connect the knock sensor electrical connectors. 3. Push down on the rubber covers. 4. Install the intake manifold. Page 1210 Seat Memory Switch: Service and Repair MEMORY SEAT SWITCH REPLACEMENT REMOVAL PROCEDURE 1. Remove the front door trim panel. 2. Disconnect the electrical connector. 3. Release the front seat memory switch assembly retaining clips in order to remove the switch. 4. Remove the front seat memory switch assembly. INSTALLATION PROCEDURE 1. Install the front seat memory switch assembly to the front trim panel by pressing into place until fully seated. 2. Connect the electrical connector to the front seat memory switch assembly. 3. Install the front trim panel. Page 13056 4.2. Release the back end of the connector (C) and remove from the contact rail (D). 4.3. M00-01: Disconnect pin 39, cut off the cable terminal and insulate the end using tape (E). Fold back the cable and secure using tape (F). 4.4. M02-04: Disconnect pin 58, cut off the cable terminal and insulate the end using tape (E). Fold back the cable and secure using tape (F). 4.5. Assemble the contact rail and end. 4.6. Connect connector (A) and secure the cable using a cable tie (B). 5. Assemble the gear shift housing (A). AUT: Connect connector (B). 6. Assemble the center console, see WIS - Body - Interior. 7. Remove the OnStar(R) control module and secure the cable harness: 7.1. 5D: Remove the right-hand cover from the luggage compartment floor. Page 7170 4. Fill the space between the seal lips with grease GM P/N 1052497 or equivalent. 5. Install transfer case. 6. Check the transmission fluid level. Add as necessary. 7. Lower the vehicle. Page 7784 Park Neutral Position (PNP) Switch C175 Front Impact Sensor: Service and Repair Front INFLATABLE RESTRAINT FRONT END SENSOR REPLACEMENT REMOVAL PROCEDURE CAUTION: Do not strike or jolt the inflatable restraint front end sensor. Before applying power to the front end sensor make sure that it is securely fastened. Failure to observe the correct installation procedure could cause SIR deployment, personal injury, or unnecessary SIR system repairs. 1. Disable the SIR system. Refer to SIR Disabling and Enabling Zone 1. 2. Disconnect the electrical connector. 3. Remove the connector position assurance (CPA) from the connector. 4. Remove the sensor bolt. 5. Remove the sensor (2) from the vehicle. INSTALLATION PROCEDURE 1. Remove any dirt, grease, or other contaminants from the mounting surface (1). IMPORTANT: Refer to SIR Service Precautions. 2. Point the arrow on the sensor toward the front of the vehicle. NOTE: Refer to Fastener Notice in Service Precautions. 3. Install the sensor (2) horizontally to the radiator support. Page 5371 1. Relieve the fuel system pressure. Refer to the Fuel Pressure Relief Procedure. 2. Disconnect the fuel feed and return pipes (1) at the fuel rail. 3. Disconnect the evaporative emission (EVAP) canister purge tube (3). 4. Cap the fuel rail and EVAP pipes. 5. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 6. Remove the fuel pipe bracket nut (2). 7. Remove the fuel pipe bracket from the bellhousing stud. 8. Remove the heated oxygen sensor (HO2S) sensor connector from the bracket. 9. Remove the fuel hose/pipe clip from the bracket on the automatic transmission. 10. If equipped with 4-wheel drive (4WD), remove the fuel hose/pipe clip from the bracket on the transfer case. 11. Remove the clip from the bracket on the frame. 12. Remove the transfer case harness from the clip bracket. 13. Remove the EVAP canister. IMPORTANT: The area around the electro-hydraulic control unit (EHCU) MUST be free from loose dirt to prevent contamination of disassembled anti-lock brake components (ABS) components. Page 13579 1. Slide the BCM onto the bracket. 2. Connect all the connectors (1) except the brown connector. 3. Connect the brown connector. 4. Install the knee bolster. 5. Connect the negative battery cable(s). 6. Reprogram the BCM. Refer to Body Control Module (BCM) Programming/RPO Configuration. 7. Perform the Passlock Learn Procedure. See: Testing and Inspection/Programming and Relearning Page 9292 Relay Box: Service and Repair I/P Electrical Center or Junction Block Replacement - Left INSTRUMENT PANEL ELECTRICAL CENTER OR JUNCTION BLOCK REPLACEMENT - LEFT REMOVAL PROCEDURE 1. Remove the left side end panel. 2. Remove the knee bolster. 3. Disconnect all the wiring connectors from the fuse block. 4. Remove all the fuses. 5. Remove the turn signal relay from the back of the fuse block. 6. From behind the fuse block, remove the retaining bolt. 7. Insert a screw driver between the fuse block and the wire harness block to separate. 8. Push on the retainers in order to remove the fuse block. 9. Remove the fuse block from the vehicle. INSTALLATION PROCEDURE 1. Install the fuse block onto the I/P assembly until it clicks in place. 2. Install the wire harness block to the back of the fuse block. NOTE: Refer to Fastener Notice in Service Precautions. 3. Install the bolt. Tighten Tighten the bolt to 6 N.m (53 lb in). 4. Install the turn signal relay to the back of the fuse block. 5. Using the wiring diagram on the cover of the fuse panel, install the fuses. 6. Install the electrical connectors. 7. Install the knee bolster. Page 12557 Diagrams Dome Lamp - Rear (Except Crew Cab With RPO Code YE9) Specifications Parking Brake Cable: Specifications Park Brake Cable Bracket to Knuckle Bolt (NYS) ................................................................................................................................... 61 Nm (45 ft. lbs.) Park Brake Cable Guide to Frame Bolt ............................................................................................................................................... 12 Nm (106 inch lbs.) Park Brake Cable to Rear Axle Clip Bolt ................................................................................................................................................. 25 Nm (18 ft. lbs.) Park Brake Cable to Shock Absorber Bracket Bolt .................................................................................................................................. 25 Nm (18 ft. lbs.) Page 5746 Page 15583 Center Mounted Brake Lamp: Service and Repair HIGH MOUNTED STOP LAMP REPLACEMENT REMOVAL PROCEDURE 1. Ensure the headlamp switch is in the OFF position. 2. Remove the high mounted stop lamp screws. 3. Remove the high mounted stop lamp from the vehicle. 4. Disconnect the electrical connector. INSTALLATION PROCEDURE 1. Connect the electrical connector. 2. Install the high mounted stop lamp to the vehicle. NOTE: Refer to Fastener Notice in Service Precautions. 3. Install the high mounted stop lamp screws. Tighten Tighten the high mounted stop lamp screws to 2 N.m (17 lb in). 4. Inspect the operation. Page 12568 Page 13427 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves SPLICING COPPER WIRE USING SPLICE SLEEVES TOOLS REQUIRED J 38125-D Terminal Repair Kit IMPORTANT: Use only GM splice sleeves, other splice sleeves may not protect the splice from moisture or a provide good electrical connection. Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. Instruments - Oil Life Monitoring System Oil Change Reminder Lamp: All Technical Service Bulletins Instruments - Oil Life Monitoring System Bulletin No.: 04-06-04-045 Date: June 22, 2004 INFORMATION Subject: Oil Life Monitoring System - PCM Reset Models: 2004 All GM Passenger Cars and Trucks Important: The Oil Life Monitoring System can be found on many General Motor's vehicles prior to 2004. Refer to SI and/or the Owner's Manual for detailed information. The purpose of this bulletin is to help technicians identify which vehicles are equipped with the oil life monitoring system. Although many General Motors vehicles prior to 2004 have been equipped with the oil life monitoring system, the 2004 model year vehicles were used as a starting point to validate the system/scan tool functionality. Customers have come to depend on the Oil Life Monitoring System found on most General Motor's vehicles to inform them when it's time for an oil change. If for any reason the PCM is replaced, it is important to access the "Percent of Oil Life Remaining" from the vehicle's current PCM PRIOR to removing the PCM. This value must be programmed into the new PCM (after it is installed in the vehicle) by using the scan tool. Note: Failure to reprogram the value to the new PCM will result in missed maintenance, which may cause damage to the engine. Important: If the replacement module is not programmed with the remaining engine oil life, the engine oil will need to changed at 5,000 km (3,000 mi) from the last engine oil change. Disclaimer Page 4344 Door Control Module Diagram 2 Part 1 Page 3525 Disclaimer Page 15015 to provide these burdensome remedies, every effort must be made to promptly schedule an appointment with each customer and to repair their vehicle as soon as possible. In the recall notification letters, customers are told how to contact the US National Highway Traffic Safety Administration if the recall is not completed within a reasonable time. Dealer Recall Responsibility - All All unsold new vehicles in dealers possession and subject to this recall MUST be held and inspected/repaired per the service procedure of this recall bulletin BEFORE customers take possession of these vehicles. Dealers are to service all vehicles subject to this recall at no charge to customers, regardless of mileage, age of vehicle, or ownership, from this time forward. Customers who have recently purchased vehicles sold from your vehicle inventory, and for which there is no customer information indicated on the dealer listing, are to be contacted by the dealer. Arrangements are to be made to make the required correction according to the instructions contained in this bulletin. A copy of the customer letter is shown in this bulletin for your use in contacting customers. Recall follow-up cards should not be used for this purpose, since the customer may not as yet have received the notification letter. In summary, whenever a vehicle subject to this recall enters your vehicle inventory, or is in your dealership for service in the future, please take the steps necessary to be sure the recall correction has been made before selling or releasing the vehicle. GENERAL MOTORS PRODUCT PROGRAM CUSTOMER REIMBURSEMENT PROCEDURE If you have paid to have this recall condition corrected prior to receiving this notification, you may be eligible to receive reimbursement. Requests for reimbursement may include parts, labor, fees and taxes. Reimbursement may be limited to the amount the repair would have cost if completed by an authorized General Motors dealer. Your claim will be acted upon within 60 days of receipt. If your claim is: ^ Approved, you will receive a check from General Motors. ^ Denied, you will receive a letter from General Motors with the reason(s) for the denial, or ^ Incomplete, you will receive a letter from General Motors identifying the documentation that is needed to complete the claim and offered the opportunity to resubmit the claim when the missing documentation is available. Please follow the instructions on the claim Form previously show to file e a claim for reimbursement. If you have questions about this reimbursement procedure, please contact the toll free telephone number provided at the bottom of the form. If you need assistance with any other concern, please contact the appropriate Customer Assistance Center at the number shown. The Customer Assistance Center hours of operation are from 8:00 AM - 11:00 PM eastern standard time Monday through Friday. Disclaimer Capacity Specifications Fluid - M/T: Capacity Specifications Transmission Fluid NV3500 ................................................................................................................ ............................................................................................. 2.3L (2.4 Qt) NV4500 ............................ .............................................................................................................................................................. ................... 3.8L (4.0 Qt) 6 Speed (ZF) (RPO ML6) ........................................................................... ...................................................................................................... 6.0L (6.3 Qt) Page 11086 HVAC Control Module - C2 Part 1 Locations Manifold Pressure/Vacuum Sensor: Locations Full Engine View Left Side Page 7200 4. Install the transmission mount to crossmember nut. ^ Tighten the transmission mount to crossmember nut to 40 Nm (30 ft. lbs.). 5. Lower the vehicle. Page 6937 Constant Velocity Joint Boot: Service and Repair Outer Joint and Seal Replacement Wheel Drive Shaft Outer Joint and Boot Replacement - J 8059 Snap Ring Pliers - J 35910 Drive Axle Seal Clamp Pliers - J 36652-1 Drive Axle Clamp Swage Tool - J 36652-2 Axle Swage Tool Removal Procedure 1. Remove the wheel drive shaft. 2. Remove the wheel drive shaft seal cover, if applicable. Important: Use caution when using the hand grinder by the CV joint outer race (1). 3. Use a hand grinder to cut through the swage ring (2). 4. Use side cutters to cut off the small boot clamp (4). Page 6352 When Servicing transmissions with the new seal design, use the following precautions: ^ The outer diameter of the pump assembly and case bore must be clean and free of burrs or raised surfaces. Be aware of sharp edges that could damage the seal during installation. ^ The seal should be clean and dry before installation. It does not require lubrication for installation. ^ The seal should be inspected prior to installation for obvious damage. ^ It is preferable to hand-start the seal positioning the seal evenly around the case bore before installing the torque converter housing. ^ The seal can be easily removed by prying it out, typical of a pressed-on seal. ^ The seal may be reused, however a thorough inspection must be performed. Inspect the seal for the following conditions: ^ Distortion of the metal carrier or separation from the rubber seal. ^ A cut, deformed, or damaged seal. ^ Refer to the appropriate unit repair information in SI for seal removal and installation procedures. Parts Interchangeability Information In order to properly service the different designs, it is necessary to correctly identify and select corresponding parts for each level. This table provides a summary of the part usage for the different design levels. Page 6399 Diagrams Trailer Connector: Diagrams Trailer Connector - Heavy Duty Part 1 Page 4766 Mass Air Flow (MAF) Sensor: Service and Repair MASS AIR FLOW (MAF)/INTAKE AIR TEMPERATURE (IAT) SENSOR REPLACEMENT REMOVAL PROCEDURE IMPORTANT: Use care when handling the mass air flow/intake air temperature (MAF/IAT) sensor. Do not dent, puncture, or otherwise damage the honeycell located at the air inlet end of the MAF/IAT. Do not touch the sensing elements or allow anything including cleaning solvents and lubricants to come in contact with them. Use a small amount of a non-silicone based lubricant, on the air duct only, to aid in installation. 1. Remove the air cleaner outlet duct. 2. Pull out the gray connector position assurance (CPA) retainer. 3. Push down on the black clip in order to disconnect the MAF/IAT sensor electrical connector (4). 4. Loosen the MAF/IAT clamp. 5. Remove the MAF/IAT sensor from the air cleaner assembly. INSTALLATION PROCEDURE IMPORTANT: The embossed arrow on the MAF/IAT sensor indicates the proper air flow direction. The arrow must point toward the engine. Page 3777 Electrical Symbols Part 4 Page 8338 2. Bench bleed the master cylinder. 3. Install the master cylinder to the vehicle. 4. Notice: Refer to Fastener Notice in Service Precautions. Install the master cylinder mounting nuts. ^ Tighten the nuts to 33 Nm (24 ft. lbs.). 5. Remove the rubber cap or plug from the exposed brake pipe fitting ends. 6. Connect the brake pipes. ^ Tighten the pipe fittings to 25 Nm (18 ft. lbs.). 7. Connect the electrical connector to the brake fluid level sensor. 8. Bleed the hydraulic brake system. 9. Release the park brake and unblock the wheels. Page 7825 Vehicle Speed Sensor (VSS) Tow/Haul Switch Location Page 10045 3. Notice: Refer to Power Steering Hose Disconnected Notice in Service Precautions. Install a drain pan under the vehicle. 4. Remove the power steering gear inlet hose (3) from the power steering pump (1). 5. Remove the power steering gear inlet hose from the power steering gear. 6. Remove the power steering gear inlet hose from the vehicle. Installation Procedure 1. Notice: Refer to Installing Hoses Without Twists or Bends Notice in Service Precautions. Route the hose in the same position the hose occupied prior to removal. 2. Install the power steering gear inlet hose (3) to the power steering pump (1). Hand tighten only. 3. Notice: Refer to Fastener Notice in Service Precautions. Install the power steering gear inlet hose to the power steering gear. ^ Tighten both power steering gear inlet hose fittings to 28 Nm (20 ft. lbs.). 4. Remove the drain pan from under the vehicle. 5. Install the engine protection shield. 6. Lower the vehicle. 7. Bleed the power steering system. Refer to Bleeding the Power Steering System. Page 16109 Window Switch - RR (Crew Cab Only) Part 2 Page 8301 1. Install the brake caliper bracket (1). 2. Perform the following procedure before installing the brake caliper bracket mounting bolts. 1. Remove all traces of the original adhesive patch. 2. Clean the threads of the bolt with denatured alcohol or equivalent and allow to dry. 3. Apply Threadlocker GM P/N 12345493 (Canadian P/N 10953488) to the threads of the bolt. 3. Notice: Refer to Fastener Notice in Service Precautions. Install the caliper bracket mounting bolts (2). For vehicles equipped with JH5 brake systems, tighten the caliper bracket mounting bolts to 200 Nm (148 ft. lbs.). For vehicles equipped with JH6/JH7 brake systems, tighten the caliper bracket mounting bolts to 300 Nm (221 ft. lbs.). 4. Install the anti-rattle clips to the brake caliper mounting bracket. 5. Install the brake pads to the brake caliper mounting bracket. 6. Slide the brake pads in until they contact the rotor. 7. Install the brake caliper. 8. Install the tire and wheel assembly. 9. Lower the vehicle. 10. With the engine OFF, gradually apply the brake pedal to approximately 2/3 of it's travel distance. 11. Slowly release the brake pedal. 12. Wait 15 seconds, then repeat steps 10-11 until a firm pedal is obtained. This will properly seat the brake caliper pistons and brake pads. W/NYS Brake Caliper Bracket Replacement - Rear (15 Series w/NYS) Caution: Refer to Brake Dust Caution in Service Precautions. Removal Procedure Page 5607 Step 25 - 27 Page 4440 Engine Control Module: Description and Operation Powertrain Control Module (PCM) POWERTRAIN CONTROL MODULE (PCM) DESCRIPTION POWERTRAIN The powertrain has electronic controls to reduce exhaust emissions while maintaining excellent driveability and fuel economy. The powertrain control module (PCM) is the control center of this system. The PCM monitors numerous engine and vehicle functions. The PCM constantly looks at the information from various sensors and other inputs, and controls the systems that affect vehicle performance and emissions. The PCM also performs the diagnostic tests on various parts of the system. The PCM can recognize operational problems and alert the driver via the malfunction indicator lamp (MIL). When the PCM detects a malfunction, the PCM stores a diagnostic trouble code (DTC). The problem area is identified by the particular DTC that is set. The control module supplies a buffered voltage to various sensors and switches. Review the components and wiring diagrams in order to determine which systems are controlled by the PCM. The following are some of the functions that the PCM controls: The engine fueling - The ignition control (IC) - The knock sensor (KS) system - The evaporative emissions (EVAP) system - The secondary air injection (AIR) system (if equipped) - The exhaust gas recirculation (EGR) system - The automatic transmission functions - The generator - The A/C clutch control - The cooling fan control POWERTRAIN CONTROL MODULE FUNCTION The PCM constantly looks at the information from various sensors and other inputs and controls systems that affect vehicle performance and emissions. The PCM also performs diagnostic tests on various parts of the system. The PCM can recognize operational problems and alert the driver via the malfunction indicator lamp (MIL). When the PCM detects a malfunction, the PCM stores a diagnostic trouble code (DTC). The problem area is identified by the particular DTC that is set. The control module supplies a buffered voltage to various sensors and switches. The input and output devices in the PCM include analog-to-digital converters, signal buffers, counters, and output drivers. The output drivers are electronic switches that complete a ground or voltage circuit when turned on. Most PCM controlled components are operated via output drivers. The PCM monitors these driver circuits for proper operation and, in most cases, can set a DTC corresponding to the controlled device if a problem is detected. MALFUNCTION INDICATOR LAMP (MIL) OPERATION Page 15817 Steering Wheel and Column Sub-System Components Alternator - Incorrect Amperage Coding Alternator: Technical Service Bulletins Alternator - Incorrect Amperage Coding Bulletin No.: 04-06-03-001 Date: February 03, 2004 INFORMATION Subject: Incorrect Amp Code On Generator Models: 2003-2004 Cadillac Escalade, Escalade ESV, Escalade EXT 2003-2004 Chevrolet Avalanche, Express, Silverado, Suburban, Tahoe 2003-2004 GMC Denali XL, Savana, Sierra, Yukon, Yukon XL 2003-2004 HUMMER H2 The purpose of this bulletin is to inform the technician of an incorrect Amp code stamped on the generator. The code on the side of the generator reads 130 A and it should read 145 A. The 130 A has been stamped on the generators in error and does not indicate the actual amperage of the generator. A 130 A generator is not produced for this vehicle. The correct replacement for the above vehicles is the generator with the 145 A marking. Disclaimer Page 3551 Spark Plug: Application and ID SPARK PLUG TYPE: AC P/N ................................................................................................................................................. .............................................................. 25171803 NGK P/N .............................................................................................................................................. .............................................................. 12567759 Page 13665 1. Remove the door handle bezel. 2. Remove the door trim panel upper extension. 3. Using a suitable flat-bladed tool, gently pry the manual lock lever from the door trim panel. 4. Remove the push in fastener (3) at the front edge of the door trim. 5. Remove the cap (5) covering the screw on the rear edge of the trim panel. 6. Remove the trim panel screws. * Remove the screw (2) from within the opening where the manual door lock lever resides. * Remove the screw (4) from the opening in front of the armrest. * Remove the screw (6) from the rear edge of the trim panel. 7. Carefully slide the trim panel (1) up in order to release the retainers from the door. 8. Disconnect the electrical connectors. Installation Procedure 1. Connect the electrical connectors. 2. Carefully align the trim panel (1), to the door and slide the panel into the retainer slots in order to install the trim panel to the door. Notice: Refer to Fastener Notice in Service Precautions. 3. Install the trim panel screws (2,4,6). Tighten the trim panel screws (2,4,6) to 2 N.m (18 lb in). 4. Install the screw cover (5). 5. Install the push in fastener (3). 6. Install the manual lock lever to the trim panel. 1. Align the manual lock lever to the opening in the door trim panel. 2. Push inward until the manual lock lever is fully seated into the trim panel. 7. Install the door trim panel upper extension. 8. Install the door handle bezel. Trim Panel Replacement - Upper Extension Trim Panel Replacement - Upper Extension Removal Procedure 1. Open the front door. Page 6762 2. For the 11.5 inch axle, install the differential side bearings by doing the following: 1. In order to protect the differential case, install the J 8107-5 in the case on the side opposite the bearing installation. 2. Install the J 44420 (2) and the J 8092 (1) onto the differential case bearing as shown. 3. Drive the bearing onto the case using the J 44420 and the J 8092. 3. Install the differential assembly. Page 4094 Oxygen Sensor: Service and Repair Heated Oxygen Sensor (HO2S) Replacement Bank 2 Sensor 2 HEATED OXYGEN SENSOR (HO2S) REPLACEMENT BANK 2 SENSOR 2 REMOVAL PROCEDURE 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. Disconnect the connector position assurance (CPA) retainer. NOTE: Refer to Heated Oxygen and Oxygen Sensor Notice in Service Precautions. 3. Remove the heated oxygen sensor (HO2S) connector clip from the frame. 4. If equipped with a 4.8L or 5.3L engine, disconnect the HO2S electrical connector. NVG 246-NP8 Control Module: Service and Repair NVG 246-NP8 Transfer Case Control Module Reprogramming Transfer Case Control Module Reprogramming Set-up for Module Programming/Reprogramming Important: Ensure that the vehicle battery is fully charged and that a battery charger is no longer connected. If performing this procedure for module replacement, install new module before proceeding. Before reprogramming close the doors and wait two minutes to allow other modules to stop communicating via the class 2 data line. Failure to do so could result in a failed reprogramming procedure. ^ Turn OFF all accessories. ^ Turn ON the ignition, with the engine OFF. Remote Programming Feature 1. Connect the scan tool to the vehicle. 2. Power-up the scan tool and select the Service Programming feature. 3. Select the appropriate vehicle. 4. Press the Request Info button on the scan tool. 5. Disconnect the scan tool from the vehicle and connect the scan tool to the computer station. 6. Follow the menu select items for reprogramming and provide information as to what type of device you are programming and whether you are reprogramming or replacing the electronic control unit (ECU). 7. Select "vehicle" from the selection menu. 8. Select the module you wish to Program. 9. Select "Normal" for Programming Type. 10. Select the applicable software calibrations. 11. Transfer data file to the scan tool. 12. Reconnect the scan tool to the vehicle. 13. Turn ON the ignition, with the engine OFF. 14. Select the Service Programming feature on the scan tool. 15. Press the Program button on the scan tool. Programming Using Scan Tool Pass-Through Connection 1. Connect the scan tool to vehicle and power it up. 2. Connect the computer station to the scan tool. 3. Select "PC Using Scan Tool Connection" from the programming menu on the computer station. 4. Follow the menu select items for reprogramming and provide information as to what type of device you are programming and whether you are reprogramming or replacing the electronic control unit (ECU). 5. Select "vehicle" from the selection menu. 6. Select the module you wish to program. 7. Select "Normal" for Programming Type. 8. Select the applicable software calibrations. 9. Transfer data file to the scan tool. Transfer Case Shift Control Module Replacement Transfer Case Shift Control Module Replacement Removal Procedure Page 10165 4. Wait 1 minute before working on the system. Enabling Procedure - Air Bag Fuse 1. Place the ignition in the OFF position. 2. Install the fuse(s) supplying power to the SDM. 3. Turn the ignition switch to the ON position. The AIR BAG indicator will flash then turn OFF. 4. Perform the Diagnostic System Check - Vehicle if the AIR BAG warning indicator does not operate as described. Disabling Procedure - Negative Battery Cable 1. Turn the steering wheel so that the vehicles wheels are pointing straight ahead. 2. Place the ignition in the OFF position. 3. Disconnect the negative battery cable from the battery. 4. Wait 1 minute before working on system. Enabling Procedure - Negative Battery Cable 1. Place the ignition in the OFF position. 2. Connect the negative battery cable to the battery. 3. Turn the ignition switch to the ON position. The AIR BAG indicator will flash then turn OFF. 4. Perform the Diagnostic System Check - Vehicle if the AIR BAG warning indicator does not operate as described. Page 13538 Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. 1. Disconnect the connector from the component. 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. Page 13811 Notice: Refer to Fastener Notice in Service Precautions. 7. Attach the cable handle underneath the I/P. Tighten the cable handle nut to 11 N.m (97 lb in). 8. Install the park brake pedal assembly. 9. Install the electrical center by setting it into the retaining grooves (2), and securing the retaining clips (1) on both sides. Page 2709 Application Table Part 3 Page 13516 Electrical Symbols Part 6 Page 4656 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Weather Pack Connectors WEATHER PACK CONNECTORS The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. Page 4978 Canister Purge Solenoid: Description and Operation EVAP PURGE SOLENOID VALVE The EVAP purge solenoid valve controls the flow of vapors from the EVAP system to the intake manifold. The purge solenoid valve opens when commanded ON by the control module. This normally closed valve is pulse width modulated (PWM) by the control module to precisely control the flow of fuel vapor to the engine. The valve will also be opened during some portions of the EVAP testing, allowing engine vacuum to enter the EVAP system. Page 6374 4. Install the fill tube bracket nut. 5. Lower the vehicle. Notice: Refer to Fastener Notice in Service Precautions. 6. Install the oil level indicator. ^ Tighten the nut to 47 Nm (35 ft. lbs.). 7. Fill the transmission to the proper level with Dexron® III transmission fluid. Manual Shift Shaft Seal Replacement Manual Shift Shaft Seal Replacement ^ Tools Required J 43911 Selector Shaft Seal Remover - J 43909 Selector Shaft Seal Installer Removal Procedure 1. Remove the park/neutral position (PNP) switch. 2. Ensure that the jackscrew for J 43911 is backed off and will not interfere with installation of the removal tool. Slide the seal remover tool over the selector shaft (2) with the threaded end of the tool towards the seal. 3. Rotate the J 43911 so that the threads on the end of the tool engage the steel shell (1) of the seal. Use a wrench to be sure that the removal tool is firmly attached to the seal shell. 4. Rotate the jackscrew in the clockwise direction to remove the seal from the bore. Discard the seal that was removed. Installation Procedure 1. Carefully slide a new selector shaft seal (1) over the selector shaft (2) with the wide face of the steel case facing outward. Position the seal so that it is starting to enter the seal bore. 2. Using J 43909, remove the inner sleeve so that the tool will slide over the selector shaft. Page 8520 ^ If the color of the relief valve is silver or aluminum, continue to the next step. Important If present, the stamped number being described in the next step would be on the mounting surface for the master cylinder on the hydraulic brake booster. The number may be difficult to see if there is any corrosion on the unpainted surface. As a result, it may be necessary to clean the surface with a piece of emery or sandpaper. 3. Inspect the hydraulic brake booster at the location shown (4) for a stamped number. The location (4) is the same surface that the master cylinder mounts on, just above the outboard mounting bolt and nut (5). Also inspect for a paint mark (3) near the master cylinder outboard mounting bolt (5). If a stamped number is found it will be a 1, 2, 3, or 4. If a paint mark is found, it will be yellow, pink, or white. ^ If a yellow, pink, or white paint mark IS visible, no further inspection or repairs are required. Disregard any stamped number found when a yellow, pink, or white paint mark is visible. ^ If there are NO paint marks and there IS a stamped number 2, 3, or 4 visible, no further inspection or repairs are required. ^ If there are NO paint marks and there IS a stamped number 1 visible, then proceed to the next step. ^ If there are NO paint marks and there are NO stamped numbers visible, then proceed to the next step. Caution Care should be taken when working around the accumulator since it contains high-pressure compressed gas and hydraulic fluid. 4. With the ignition in the OFF position, pump the brake pedal a minimum of ten times. 5. On van models, remove the two bolts that attach the diagonal brace between the left front fender and radiator support. Remove the brace and the water deflector that is attached to it. 6. On all models, remove the two nuts that attach the master cylinder to the hydraulic brake booster. A 13 mm wrench installed on the bolt head may be required to prevent the bolt from spinning. Important On full size pickups and utilities, the bracket that attaches the brake combination valve will need to be removed from the mounting bolts at the same time that the master cylinder is removed and repositioned in the next step. Notice When repositioning the master cylinder in the next step, use care not to pinch, kink, or damage the brake hoses or pipes. 7. Remove and reposition the master cylinder away from the hydraulic brake booster so that the machined surface on the front of the booster where the master cylinder was mounted is visible. Page 11903 Diagrams Page 6819 Pinion Bearing: Service and Repair 10.5 Inch Axle Drive Pinion Bearings Replacement (10.5 Inch Axle) ^ Tools Required J 22388 Pinion Oil Seal Installer - Rear - J 22761 Differential Side Bearing Installer - J 22912-01 Split Plate Bearing Puller - J 24433 Pinion Cone and Side Bearing Installer - J 37624 Pi non Bearing Installer - J 8092 Universal Driver Handle - 3⁄4 in - 10 - J 8608 Rear Pinion Bearing Installer - J 8614-01 Flange and Pulley Holding Tool Removal Procedure 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Remove the differential assembly. 3. Remove the pinion gear bearing retainer. 4. Remove the pinion yoke and the oil seal. 5. Remove the outer pinion bearing. 6. Remove the pinion. 7. Remove the collapsible spacer. 8. Remove the inner pinion bearing from the pinion using the J 22912-01 and a hydraulic press. Page 13571 Door Control Module Diagram 2 Part 1 Page 8738 Tighten the bolt to 17 N.m (13 lb ft). 3. Re-set the customer's radio stations. Page 8282 11. Remove the 2 brake caliper mounting bolts. 12. Caution: Do not depress the brake pedal with the brake rotors/calipers and/or the brake drums removed. Damage to the brake system may result. If brake system damage occurs and is not repaired, vehicle damage and/or personal injury or death may result. Remove the brake caliper from the brake caliper mounting bracket. Installation Procedure 1. Notice: Refer to Fastener Notice in Service Precautions. Install the brake caliper to the brake caliper mounting bracket. 2. Install the 2 brake caliper mounting bolts. ^ Tighten the 2 brake caliper mounting bolts to 108 Nm (80 ft. lbs.). 3. Remove the rubber cap or plug from the exposed brake hose fitting end. 4. Important: Install 2 New copper brake hose gaskets. Assemble the 2 New copper brake hose gaskets and the brake hose to caliper bolt to the brake hose. 5. Install the brake hose to caliper bolt to the brake caliper. ^ Tighten the brake hose to caliper bolt to 40 Nm (30 ft. lbs.). 6. Bleed the hydraulic brake system. 7. Install the tire and wheel assembly. 8. Lower the vehicle. 9. Fill the master cylinder reservoir to the proper level with clean brake fluid. Refer to Master Cylinder Reservoir Filling in Hydraulic Brakes. Page 16075 Refer to the table as a guide in selecting the correct test adapter for frontprobing connectors: Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure SCAN TOOL SNAPSHOT PROCEDURE Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: - Snapshot - taken from the Snapshot menu choice - Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information Page 1513 Upper Steering Column Page 14292 WA811K/87 - WA812K/88 Page 5964 6. Remove the 1-2 shift solenoid retainer (395) and the 1-2 shift solenoid (267A). 7. Remove the 2-3 shift solenoid retainer (395) and the 2-3 shift solenoid (367A). 8. Remove the 3-2 control solenoid retainer (395) and the 3-2 control solenoid (394). Installation Procedure 1. Install the 3-2 control solenoid (394) and the 3-2 control solenoid retainer (395). Page 7919 4. Position the J 41364-A onto the PNP switch. Ensure that the two slots on the switch where the manual shaft is inserted are lined up with the lower two tabs on the tool. 5. Notice: Refer to Fastener Notice in Service Precautions. Rotate J 41364-A until the upper locator pin on the tool is lined up with the slot on the top of the switch. ^ Tighten the bolts to 25 Nm (18 ft. lbs.). 6. Remove J 41364-A from the PNP switch. If installing a new switch, remove the positive assurance bracket at this time. 7. Install the control lever to the manual shaft with the nut. 8. Install the manual shaft nut. ^ Tighten the nut to 25 Nm (18 ft. lbs.). 9. Install the range selector cable end (2) to the range selector lever ball stud (1). Page 8819 Control Module References Part 7 Page 15726 The information shown is for the 1999-2002 wiring harnesses and for the 2003-05 wiring harness. To modify a 12171982, 15366255 or 15086884 harness for use in a 2003-05 vehicle, switch the wires in cavities "A" and "D". To modify a 15085418 harness for use in a 1999-2002 vehicle (see model list at the front of this bulletin for applicable models), switch the wires in cavities "A" and "D". Warranty Information When the correct wiring harness P/N is matched to the specific model year of the vehicle, everything works properly. Therefore, conversion of an incorrect wiring jumper to match the vehicle would not be considered a warrantable repair. Disclaimer Page 7319 Remote Programming Feature 1. Connect the scan tool to the vehicle. 2. Power-up the scan tool and select the Service Programming feature. 3. Select the appropriate vehicle. 4. Press the Request Info button on the scan tool. 5. Connect the scan tool to the computer station. 6. Follow the menu select items for reprogramming and provide information about the type of device you are programming and whether you are reprogramming or replacing the electronic control unit (ECU). 7. Select "vehicle" from the selection menu. 8. Select the module you wish to program. 9. Select "Normal" for Programming Type. 10. Select the applicable software calibrations. 11. Transfer data file to the scan tool. 12. Connect the scan tool to the vehicle. 13. Turn ON the ignition, with the engine OFF. 14. Select the Service Programming feature on the scan tool. 15. Press the Program button on the scan tool. Programming Using Scan Tool Pass-Through Connection 1. Connect the scan tool to vehicle and power it up. 2. Connect the computer station to the scan tool. 3. Select "PC Using Scan Tool Connection" from the programming menu on the computer station. 4. Follow the menu select items for reprogramming and provide information about the type of device you are programming and whether you are reprogramming or replacing the electronic control unit (ECU). 5. Select "vehicle" from the selection menu. 6. Select the module you wish to program. 7. Select "Normal" for Programming Type. 8. Select the applicable software calibrations. 9. Transfer data file to the scan tool. Page 10906 Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. 1. Disconnect the connector from the component. 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. Page 2153 the noise. Belt separation is identified by the plys of the belt separating, this may be seen at the edge of the belt or felt as a lump in the belt. 5. Small amounts of pilling is a normal condition and acceptable. When the pilling is severe the drive belt(s) does not have a smooth surface for proper operation. Drive Belt Squeal Drive Belt Squeal Diagnosis Diagnostic Aids A loose or improper installation of a body, or suspension component, or other item(s) on the vehicle may cause the squeal noise. If the squeal is intermittent, verify that it is not the accessory drive component(s) by varying their load(s), making sure they are operating to their maximum capacity. An overcharged air conditioning (A/C) system, a power steering system restriction or the incorrect fluid, or a failing generator are suggested items to inspect. Test Description Steps 1 - 9 The number(s) below refer to the step(s) in the diagnostic table. 2. The squeal may not be engine related. This step is to verify that the engine is making the noise. If the engine is not making the noise do not proceed further in this table Page 10327 3. Remove the retaining bolt for the brake hose and the wheel speed sensor brackets. 4. Remove the nut at the upper ball joint. Discard the nut. 5. Disconnect the upper control arm from the steering knuckle using the J 42188-B. 6. Remove the upper control arm nuts and the adjustment cams. 7. Remove the upper control arm. Installation Procedure 1. Install the upper control arm. Note: Refer to Fastener Notice in Cautions and Notices. 2. Install the upper control arm bolts. Tighten Tighten the nuts to 190 N.m (140 lb ft). 3. Connect the upper control arm to the steering knuckle. 4. Install the new nut to the upper ball joint stud. Tighten Tighten the nut to 50 N.m (39 lb ft). 5. Install the retaining bolts for the brake hose and wheel speed sensor brackets. Tighten Tighten the bolts to 9 N.m (80 lb in). 6. Install the tire and wheel. Refer to Tire and Wheel Removal and Installation in Tires and Wheels. 7. Lower the vehicle. Page 13565 Body Control Module (BCM) - C4 Part 1 Page 325 ^ SP303 The following modules, components, and splice pack are connected to the star portion of the class 2 serial data circuit: ^ SP300 ^ Audio amplifier ^ Driver door module (DDM) ^ Driver door switch assembly (DDSA) ^ Memory seat module (MSM) ^ Left rear door module (LRDM) AND ^ SP303 ^ Antenna module ^ Front passenger door module (FPDM) ^ Rear integration module (RIM) ^ Right rear door module (RRDM) ^ Theft deterrent module (TDM) ^ Vehicle communication interface module (VCIM). Refer to Data Communication Schematics and Data Link Communications Description and Operation in SI. Part 2 Conditions for Running the DTC Voltage supplied to the module is in the normal operating voltage range of 9 - 16 volts. DTCs B1327, B1328, U1300, U1301, U1305 are not set as current. The vehicle power mode requires serial data communication to occur. Conditions for Setting the DTC A message containing a critical operating parameter has not been received within the last 5 seconds after establishing class 2 serial data communication. Action Taken When the DTC Sets The module uses a default value for the missing parameter. Conditions for Clearing the DTC A current DTC clears when the malfunction is no longer present. A history DTC clears when the module ignition cycle counter reaches the reset threshold, without a repeat of the malfunction. Diagnostic Aids When a malfunction such as an open fuse to a module occurs while modules are communicating, a DTC U1001-1254 Loss of XXX Communications is set current. When the modules stop communicating the current DTC U1001-1254 Loss of XXX Communications is cleared but the history DTC remains. When the modules begin to communicate again, the module with the open fuse will not be learned by the other modules so U1000 or U1255 is set current by the other modules. If the malfunction occurs when the modules are not communicating, only U1000 or U1255 is set. Page 11682 Inflatable Restraint Seat Position Switch - Right ((With RPO Code AL0) Page 7026 ^ Dry or brittle ^ Compression set Installation Procedure 1. Clean all corrosion or contaminates from the steering knuckle bore and the hub and bearing assembly. 2. Lubricate the steering knuckle bore with wheel bearing grease or the equivalent. 3. Install the O-ring (7) to the steering knuckle, the 25/35 series. 4. Notice: Refer to Fastener Notice in Service Precautions. Install the wheel speed sensor mounting bolt to the wheel hub and bearing. ^ Tighten the sensor mounting bolt to 18 Nm (13 ft. lbs.). 5. Install the wheel hub and bearing and splash shield to the vehicle, 25/35 series. 6. Install the wheel hub and bearing (5) and splash shield (6) to the vehicle, 15 series. 7. Install the wheel hub and bearing mounting bolts, the 15 series. 8. Install the wheel hub and bearing mounting bolts, 25/35 series. ^ Tighten the wheel hub to knuckle bolts to 180 Nm (133 ft. lbs.). HVAC System - Manual A/C Low Pressure Switch Page 7264 PTO - Variable Mode Function Chart PTO - Variable Mode Function Chart PTO COMPONENTS PTO Switch The PTO Switch is mounted in the center of the Instrument Panel. The PTO Switch has three positions: OFF, ON and SET. When the PTO switch is in ON voltage will be present on the PTO On Switch Signal circuit at the relay and the PCM. When the switch is held to the SET position, voltage will be present on the PTO Engage Signal circuit at the PCM. The PTO indicator light is integral with the switch and will illuminate when the switch is turned ON. The presence of the indicator being on does not mean that the PTO Solenoid is engaged. The Cruise Control Multi-Function Switch may be used in conjunction with the PTO Switch. Illumination of the switch is provided through the dimming circuit and controlled in part by internal switch logic. Cruise Control Multi-Function Switch The operation of the PTO system may be through the function control switches located on the multifunction turn signal lever. The cruise control function control switches includes the ON/OFF, SET/COAST, and R/A. The switch assembly provides driver control of the PTO as well as the cruise control system. The SET/COAST and R/A switches may be used to increase and decrease engine RPM in increments of 100 RPM. See the chart below for recommended speeds. PTO Relay The PTO Relay is located on the side of the underhood fuse block. The secondary side of the relay is supplied with voltage at all times through the Fog Lamp fuse. The PTO switch controls the voltage to the primary side of the PTO relay while the PCM controls the ground. PTO Solenoid The solenoid is an upfitter supplied part and is replaceable on most PTOs. The PTO solenoid is used on clutch activated PTOs. The PTO relay supplies the solenoid with voltage when the relay is energized. PCM The powertrain control module (PCM) is the control center of the PTO system. Applications with a 6.6L diesel use an ECM. The PCM monitors numerous engine and vehicle functions. To engage the PTO, the PCM must see the following conditions: - PTO switch is ON - Engine must be running - Transmission must be in PARK or NEUTRAL - Park Brake must be set for manual transmission only - Vehicle speed must be zero in Preset Mode only - Brake or Clutch must not be depressed The PCM constantly looks at the information from various sensors and other inputs, and controls the systems that affect vehicle performance. The PCM also performs a diagnostic test on the Electronic Throttle Control system. TAC Module The TAC module is the control center for the electronic throttle system. The TAC module and the PCM communicate through a dedicated redundant serial data circuit. The TAC module and the PCM monitor the commanded throttle position and compare the commanded position to the actual throttle position. This is accomplished by monitoring the APP and the throttle position (TP) sensor. These 2 values must be within a calibrated value of each other or a DTC may be set. The TAC module also monitors each individual circuit of the TP sensor and the APP to verify proper operation. The TAC Page 15270 Door Latch Assembly (Door Jamb Switch) - Front Passenger - C2 Cooling System - DEX-COOL(R) Coolant Leak Detection Dye Coolant: Technical Service Bulletins Cooling System - DEX-COOL(R) Coolant Leak Detection Dye Bulletin No.: 05-06-02-002B Date: January 18, 2008 INFORMATION Subject: DEX-COOL(R) Coolant - New Leak Detection Dye J 46366 - Replaces J 29545-6 Models: 1996-2008 GM Passenger Cars and Light/Medium Duty Trucks* (including Saturn) 1997-2008 Isuzu T-Series Medium Duty Tilt Cab Models Built in Janesville and Flint 1999-2008 Isuzu N-Series Medium Duty Commercial Models with 5.7L or 6.0L Gas Engine 2003-2008 HUMMER H2 2006-2008 HUMMER H3 2005-2008 Saab 9-7X *EXCLUDING 2006 and Prior Chevrolet Aveo, Epica, Optra, Vivant and Pontiac Matiz, Wave Supercede: This bulletin is being revised to include additional model years. Please discard Corporate Bulletin Number 05-06-02-002A (Section 06 - Engine/Propulsion System). Leak detection dye P/N 12378563 (J 29545-6) (in Canada P/N 88900915) may cause DEX-COOL(R) coolant to appear green in a black vessel making it appear to be conventional (green) coolant. This may cause a technician to add conventional coolant to a low DEX-COOL(R) system thus contaminating it. The green DEX-COOL(R) appearance is caused by the color of the leak detection dye which alters the color of the DEX-COOL(R) coolant. A new leak detection dye P/N 89022219 (J 46366) (in Canada P/N 89022220) has been released that does not alter the appearance of the DEX-COOL(R) coolant. When adding the new leak detection dye the color of the DEX-COOL(R) coolant will not change. For detecting leaks on any system that uses DEX-COOL(R) leak detection dye P/N 89022219 (in Canada P/N 89022220) should be used. The new leak detection dye can be used with both conventional and DEX-COOL(R) coolant. Disclaimer Page 14620 Seat Front Vertical Position Sensor - Driver (With RPO Code AN3) Front Propeller Shaft Page 16295 2. Position the wiper blade pivot in the inside radius of the wiper arm hook. 3. Pull the wiper blade pivot into the wiper arm hook until the pivot locks into the hook. 4. Operate the wipers and inspect for proper operation. Page 10065 1. Notice: Refer to Fastener Notice in Service Precautions. Install the power steering cooler (1) to the radiator support. ^ Tighten the bolts retaining the power steering cooler to 5 Nm (44 inch lbs.). 2. Install the power steering cooler outlet hose (3) to the power steering pump (2). 3. Install the retaining clamp. 4. Install the power steering inlet hose (5) to the power steering gear (1). 5. Install the retaining clamp. 6. Fill and bleed the power steering system. Refer to Bleeding the Power Steering System. 7. Inspect all the hose connections for leaks. 8. Install the front grille. Refer to Grille Replacement (GMC) Grille Replacement (Chevrolet) in Exterior Trim. (Without Hydroboost) Power Steering Cooler Pipe/Hose Replacement (Without Hydroboost) Removal Procedure 1. Remove the front grille. Refer to Grille Replacement (GMC) Grille Replacement (Chevrolet) in Exterior Trim. 2. Notice: Refer to Power Steering Hose Disconnected Notice in Service Precautions. Remove the clamp retaining the power steering outlet hose (3) from the power steering gear (4). 3. Remove the clamp retaining the power steering inlet hose from the power steering pump (5). Electrical - Trailer Brakes Apply With Headlamps ON Trailer Lighting Module: Customer Interest Electrical - Trailer Brakes Apply With Headlamps ON Bulletin No.: 02-05-22-004C Date: April 05, 2005 TECHNICAL Subject: Trailer Brakes Applied When Headlights/Park Lamps Are On, Brake Controller Illumination (Modify Brake Controller Wiring Harness) Models: 2002-2005 Cadillac Escalade, Escalade EXT 1999-2005 Chevrolet Silverado 2000-2005 Chevrolet Suburban, Tahoe 2002-2005 Chevrolet Avalanche 1999-2005 GMC Sierra 2000-2005 GMC Yukon, Yukon XL 2003-2005 HUMMER H2 Supercede: This bulletin is being revised to add additional model years. Please discard Corporate Bulletin Number 02-05-22-004B (Section 05 - Brakes). Condition Some customers may comment that when the headlamps or park lamps are on, the brakes on the trailer are always applied, or that the back lighting for the trailer brake controller only illuminates when the brakes are applied. Cause The cause of this condition may be due to wiring changes within the vehicle electrical system for the 2003 model year. Correction Inspect the brake controller wiring harness jumper that is plugged into the vehicle relay block-body. The relay block-body is located under the left side of the instrument panel near the left kick panel, behind a plastic cover. Page 8200 Brake Rotor/Disc: Service and Repair Brake Rotor Replacement - Front Brake Rotor Replacement - Front ^ Tools Required J 41013 Rotor Resurfacing Kit - J 42450-A Wheel Hub Resurfacing Kit Caution: Refer to Brake Dust Caution in Service Precautions. Removal Procedure 1. Notice: Any new rotor must have the protective coating removed from the friction surfaces before being placed in service. Remove the protective coating using denatured alcohol or an equivalent, and wipe the surface clean with clean cloths. Do not use gasoline, kerosene, or other oil base solvents which may leave an oily residue. This residue is damaging to the brake lining and is flammable. Raise and support the vehicle. Refer Vehicle Lifting 2. Remove the tire and wheel assembly. 3. Remove the front wheel hub extension, dual wheel vehicles only. 1. Insert a drift or large screwdriver through the brake caliper into one of the brake rotor vanes in order to prevent the rotor from turning. 2. Mark the relationship of the front wheel hub extension to the hub. 3. Remove the front wheel hub extension bolts. 4. Remove the front wheel hub extension from the vehicle. It may be necessary to tap around the perimeter of the hub extension with a rubber mallet to loosen it from the hub. 4. Mark the relationship of the rotor to the hub. 5. Install a C-clamp over the body of the brake caliper, with the C-clamp ends against the rear of the caliper body and the outboard disc brake pad. Page 4669 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves SPLICING COPPER WIRE USING SPLICE SLEEVES TOOLS REQUIRED J 38125-D Terminal Repair Kit IMPORTANT: Use only GM splice sleeves, other splice sleeves may not protect the splice from moisture or a provide good electrical connection. Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. Service and Repair Oil Pressure Sensor: Service and Repair Engine Oil Pressure Sensor and/or Switch Replacement ^ Tools Required J 41712 Oil Pressure Switch Socket Removal Procedure 1. If necessary, remove the engine sight shield. 2. Disconnect the oil pressure sensor electrical connector (1). 3. Using J 41712 or equivalent, remove the oil pressure sensor. Installation Procedure Page 9642 4. Connect the wiring connectors to the fuse block. Refer to Electrical Center Identification Views to ensure the right connections are made. 5. Install the right side end panel. Page 6748 Extended Cab Short Box Shown Below, Other Configurations Similar 6. Install the new canister vent valve solenoid to the fuel tank clip or mounting bracket as shown above. The valve port closest to the electrical connector must point towards the canister. 7. Cut bulk 5/8" heater hose to a length of approximately 76 mm (3 in). Install the hose between the solenoid and the canister pipe and secure using clamps. 8. Attach bulk 5/8" heater hose to the vent port and secure using a clamp. Run a length as needed along the frame rail routing to the area above the transmission. 9. Cut the hose to determined length and install the supplied filter box. Secure using a clamp. 10. Remove the transmission support and lower the transmission assembly as necessary to allow for access to the new filter box location. 11. Secure the filter box to the transmission vent hose just forward of the hose tee-section using a tie strap. DO NOT pinch or restrict the transmission vent hose. The filter box opening should be pointing downward. 12. Raise the transmission and reinstall the transmission support. 13. Connect the EVAP canister vent valve electrical connector. 14. Tie strap the hose as needed along the frame rail in order to keep the hose away from pinch-points and heat sources. 15. Lower the vehicle. Correction (2007-2010 New Style Models) After following the published SI diagnostics and determining that the EVAP canister vent valve is the cause of the MIL light, replace the EVAP canister vent valve assembly and relocate the remote filter box. To ensure correct installation, follow the procedures below. Important DO NOT replace the EVAP canister assembly for this concern unless it fails the leak test. Use Service Kit P/N 19207763 1. Raise the vehicle. Suitably support the vehicle. 2. Disconnect the EVAP canister vent valve electrical connector. Page 13534 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the cover up until the dress cover releases. Repeat this procedure for the other locking tab. 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. 5. If the connector has a nose piece, use a small flat-blade tool to remove the nose piece by inserting the blade into the slot on the front of the connector and prying up on the nose piece. IMPORTANT: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 6. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. IMPORTANT: Be careful not to angle or rock the J 38125-13A tool when inserting it into the connector or the tool may break. Page 13717 Rear Door Panel: Service and Repair Water Deflector Water Deflector Replacement - Rear Door (Crew Cab) Water Deflector Replacement - Rear Door (Crew Cab) Removal Procedure 1. Remove the trim panel. 2. Using a flat-bladed tool, separate the bond between the sealer and the door. 3. Pull the waterproof sealing tape from the deflector. 4. Remove the water deflector. Installation Procedure 1. Position the electrical connectors through the water deflector. 2. Using waterproof tape, or 3M(R) 777, or equivalent, install the water deflector to the door. 3. Install the trim panel to the door. Water Deflector Replacement - Side Access Water Deflector Replacement - Side Access Removal Procedure Important: Water deflectors seal the inner panel. Water deflectors prevent water from entering into the body. A strip of adhesive between the deflector and the door secures the deflector. 1. Remove the trim panel. Page 9054 Relay Block - I/P C1 Part 5 Page 13804 3. Install the hood latch (1) to the radiator support (3). 4. Install the hood latch bolts (2) loosely. 5. Adjust the hood latch height so that when the hood is closed, the hood is held securely against the front hood bumpers. Notice: Refer to Fastener Notice in Service Precautions. 6. Raise the hood. Tighten the hood latch bolts to 9 N.m (80 lb in). 7. Adjust the front hood bumpers so that the top of the hood is flush with the fenders. 8. Install the upper radiator support baffle. Page 15018 1. Open the rear tailgate and support it as necessary. 2. Release (unhook) the right side tailgate support cable from the pickup box. Important: If the support cable (2) has NOT been replaced previously, there will be a toothed nut or plastic nut (1) located between the latch (4) and the tailgate that MAY prevent the bolt (3) from being removed in the next step. The nut is an assembly aid used in the assembly plant. Do not reinstall or replace the toothed or plastic nut when installing the new support cable. 3. Loosen the bolt (3) that attaches the opposite end of the support cable to the latch assembly (2). - If the toothed or plastic nut IS present, you will only be able to loosen the bolt partially from the latch. If this condition is encountered, proceed to the next step. - If the toothed or plastic nut is NOT present, proceed to Step 8. Page 15001 Page 13946 3. Connect the trailer wiring harness. Fuel Level Sensor Replacement - 1 Fuel Gauge Sender: Service and Repair Fuel Level Sensor Replacement - 1 FUEL LEVEL SENSOR REPLACEMENT REMOVAL PROCEDURE 1. Remove the sending unit. 2. Disconnect the fuel pump electrical connector. 3. Remove the fuel lever sensor electrical connector retaining clip. 4. Disconnect the fuel level sensor electrical connector. 5. Remove the fuel level sensor retaining clip. 6. Remove the fuel level sensor (1). INSTALLATION PROCEDURE 1. Install the fuel level sensor (1). 2. Install the fuel level sensor retaining clip. 3. Connect the fuel level sensor electrical connector. 4. Install the fuel lever sensor electrical connector retaining clip. 5. Connect the fuel pump electrical connector. 6. Install the sending unit. Page 15996 Steps 12-17 Page 5863 3. Remove the right rear speed sensor. Installation Procedure 1. Notice: Refer to Fastener Notice in Service Precautions. Install the right rear speed sensor. ^ Tighten the speed sensor to 15 Nm (11 ft. lbs.). 2. Connect the right rear speed sensor electrical connector (3). 3. Lower the vehicle. Page 3608 1. Install the fan clutch bolts from the rear of the fan blade. 2. Notice: Refer to Fastener Notice in Service Precautions. Install the fan clutch bolts. Tighten the bolts to 23 Nm (17 ft. lbs.). 3. Install the fan assembly. 4. Install the J 46406 to the fan clutch. Tighten the nut clockwise to 56 Nm (41 ft. lbs.). 5. Install the upper fan shroud. Page 4698 Body Control Module: Removal and Replacement BODY CONTROL MODULE REPLACEMENT REMOVAL PROCEDURE CAUTION: Refer to Battery Disconnect Caution in Service Precautions. 1. Disconnect the negative battery cable(s). 2. Remove the knee bolster. 3. Disconnect the brown connector. 4. Disconnect all other connectors (1). 5. Remove the BCM from the sliding bracket. INSTALLATION PROCEDURE Page 1342 Low Pressure Sensor / Switch: Locations Right Side Of The Engine Compartment Page 9926 Figure 1: Full Tread View - "NORMAL" Tire "Feathering" Wear on the Shoulder/Adjacent/Center Ribs Figure 2: Tire Shoulder View Example 1 - "NORMAL" Tire "Feathering" Wear on the Shoulder Figure 3: Tire Shoulder View Example 2 - "NORMAL" Tire "Feathering" Wear Figure 4: Detail Side View of Tire Shoulder Area - "NORMAL" Tire "Feathering" Wear Important When a wheel alignment is deemed necessary for tire wear, be sure to document on the repair order, in as much detail as possible, the severity and type of tire wear (e.g., severe center wear or severe inside or outside shoulder wear) and the position of the tire on the vehicle (RF, LF, LR, RR). Please note the customer's concern with the wear such as, noise, appearance, wear life, etc. A field product report with pictures of the tire wear condition is recommended. Refer to Corporate Bulletin Number 02-00-89-002J and #07-00-89-036C. 4. Other repairs that affect wheel alignment; e.g., certain component replacement such as suspension control arm replacement, engine cradle adjustment/replace, steering gear replacement, steering tie rod replace, suspension strut/shock, steering knuckle, etc. may require a wheel alignment. Important If other components or repairs are identified as affecting the wheel alignment, policy calls for the wheel alignment labor time to be charged to the replaced/repaired component's labor operation time rather than the wheel alignment labor operations. Important Vibration type customer concerns are generally NOT due to wheel alignment except in the rare cases; e.g., extreme diagonal wear across the tread. In general, wheel alignments are NOT to be performed as an investigation/correction for vibration concerns. "Normal Operation" Conditions Vehicle Lead/Pull Due to Road Crown or Slope: As part of "Normal Operation," vehicles will follow side-to-side or left to right road crown or slope. Be sure to verify from the customer the types of roads they are driving as they may not recognize the influence of road crown on vehicle lead/pull and steering wheel angle. If a vehicle requires significant steering effort to prevent it from "climbing" the road crown there may be an issue to be looked into further. Important Page 1587 Fuel Tank Pressure Sensor: Description and Operation FUEL TANK PRESSURE SENSOR The FTP sensor measures the difference between the pressure or vacuum in the fuel tank and outside air pressure. The control module provides a 5-volt reference and a ground to the FTP sensor. The FTP sensor provides a signal voltage back to the control module that can vary between 0.1-4.9 volts. A high FTP sensor voltage indicates a low fuel tank pressure or vacuum. A low FTP sensor voltage indicates a high fuel tank pressure. Page 2004 9. Use J 38125-12A to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. REPAIR PROCEDURE The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. 1. Cut the wire as close to the terminal as possible. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. Page 13560 Body Control Module (BCM) - C2 Part 1 Page 7428 1. Notice: Refer to Fastener Notice in Service Precautions. Install the left rear speed sensor. ^ Tighten the speed sensor to 15 Nm (11 ft. lbs.). 2. Connect the left rear speed sensor electrical connector (4) 3. Lower the vehicle. Transfer Case Speed Sensor Replacement - Right Rear Transfer Case Speed Sensor Replacement - Right Rear Removal Procedure 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. Disconnect the right rear speed sensor electrical connector (3). Page 4371 Coolant Temperature Sensor/Switch (For Computer): Service and Repair ENGINE COOLANT TEMPERATURE (ECT) SENSOR REPLACEMENT REMOVAL PROCEDURE NOTE: Use care when handling the coolant sensor. Damage to the coolant sensor will affect the operation of the fuel control system. 1. Drain the cooling system to a level below the engine cooling temperature (ECT) sensor. Refer to Draining and Filling Cooling System in Cooling System. 2. Disconnect the ECT sensor electrical connector (5). 3. Remove the ECT sensor. INSTALLATION PROCEDURE NOTE: Replacement components must be the correct part number for the application. Components requiring the use of the thread locking compound, lubricants, corrosion inhibitors, or sealants are identified in the service procedure. Some replacement components may come with these coatings already applied. Do not use these coatings on components unless specified. These coatings can affect the final torque, which may affect the operation of the component. Use the correct torque specification when installing components in order to avoid damage. - Use care when handling the coolant sensor. Damage to the coolant sensor will affect the operation of the fuel control system. Page 5502 Accelerator Pedal Position Sensor: Service and Repair ACCELERATOR PEDAL POSITION (APP) SENSOR REPLACEMENT REMOVAL PROCEDURE NOTE: Handle the electronic throttle control components carefully. Use cleanliness in order to prevent damage. Do not drop the electronic throttle control components. Do not roughly handle the electronic throttle control components. Do not immerse the electronic throttle control components in cleaning solvents of any type. 1. Remove the connector position assurance (CPA) retainer. 2. Disconnect the accelerator pedal position (APP) sensor electrical connector. 3. Reposition the carpet to access the lower nut. 4. Remove the accelerator pedal nuts. 5. Remove the accelerator pedal assembly. INSTALLATION PROCEDURE Page 7379 Page 10912 If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Sir/SRS Wiring Repairs SIR/SRS WIRING REPAIRS TOOLS REQUIRED J 38125-D Terminal Repair Kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-D contains the following items: - Special sealed splices - in order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping tool - A heat torch - An instruction manual The sealed splices have the following 2 critical features: - A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-D also serves as a generic terminal repair kit. The kit contains the following items: - A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors Fuel System - Fuel Cap Retention When Refueling Fuel Filler Cap: All Technical Service Bulletins Fuel System - Fuel Cap Retention When Refueling Bulletin No.: 04-06-04-032 Date: April 28, 2004 INFORMATION Subject: Proper Method to Secure Fuel Cap During Refueling Models: 2004 Cadillac Escalade, Escalade ESV, Escalade EXT 2004 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2004 GMC Sierra, Yukon, Yukon XL This bulletin is being issued to inform dealers that there are two different types of fuel caps used on all 2004 full-size pick-ups and utilities with gasoline engines. A threaded design is used with the E-85 5.3L (VIN Z - RPO L59) engine. A 1/4 turn design is used with all other gas engines. The 1/4 turn design has a shorter tether strap and will not allow the customer to drape the fuel cap over the hook on the filler door. However, as designed and per the vehicle's Owners Manual, the cap can be retained in the hook by the lip of the fuel cap. Disclaimer Page 14194 6. Remove the door module from the switch panel bezel. INSTALLATION PROCEDURE 1. Install the door module into the switch panel bezel until it snaps into place. 2. Install the switch panel bezel and module to the door panel. NOTE: Refer to Fastener Notice in Service Precautions. 3. Install the screw that retains the switch panel bezel (1) to the front door panel. Tighten Tighten the screw to 2 N.m (18 lb in). Page 7171 Seals and Gaskets: Service and Repair NV 4500 Transmission Housing Oil Seal Replacement - Front Removal Procedure ^ Tools Required J 38801 Input Shaft Seal Installer 1. Remove the transmission. 2. Remove the clutch actuator cylinder bolts. 3. Remove the clutch actuator cylinder. 4. Remove the input shaft bearing retainer bolts.Remove the input shaft bearing retainer. Screw 2 of the removed bolts into the threaded holes in the retainer in order to remove the retainer. 5. Using a hammer and a punch, remove the transmission housing front oil seal from the input shaft bearing retainer. 6. Remove the old gasket material from the input shaft bearing retainer. Installation Procedure Important: Inspect the input shaft bearing retainer for any nicks or cracks that may result in a leak. Replace as necessary. Page 13419 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. REPLACEMENT PROCEDURE After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Insure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the Terminal Removal Procedure. Repairing Connector Terminals REPAIRING CONNECTOR TERMINALS TOOLS REQUIRED J 38125-D Terminal Repair Kit Use the following repair procedures in order to repair the following: - Push to Seat terminals - Pull to Seat terminals - Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-D contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100 World terminals. Soldering Micro-Pack 100 World terminals may damage the terminal. Circuit Protection - Circuit Breakers CIRCUIT PROTECTION - CIRCUIT BREAKERS A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Page 8159 4. Remove the brake caliper bracket mounting bolts (2). 5. Remove the brake caliper bracket (1). 6. Remove any contaminants or foreign material from the inside ends of the brake caliper bracket. 7. Clean the mounting surface and threads of the brake caliper bracket. Installation Procedure 1. Install the brake caliper bracket (1). 2. Perform the following procedure before installing the brake caliper bracket mounting bolts. 1. Remove all traces of the original adhesive patch. 2. Clean the threads of the bolt with denatured alcohol or equivalent and allow to dry. 3. Apply Threadlocker GM P/N 12345493 (Canadian P/N 10953488) to the threads of the bolt. 3. Notice: Refer to Fastener Notice in Service Precautions. Install the caliper bracket mounting bolts (2). ^ Tighten the brake caliper bracket mounting bolts to 175 Nm (121 ft. lbs.) (15 Series). ^ Tighten the brake caliper bracket mounting bolts to 300 Nm (221 ft. lbs.) (25 and 35 Series). 4. Install the anti-rattle clips to the brake caliper bracket. 5. Install the brake pads to the brake caliper bracket. 6. Slide the brake pads in until they contact the rotor. 7. Install the brake caliper. Refer to Brake Caliper Replacement - Front. 8. Install the tire and wheel assembly. 9. Lower the vehicle. 10. With the engine OFF, gradually apply the brake pedal to approximately 2/3 of it's travel distance. 11. Slowly release the brake pedal. Page 9780 C399 Body Harness To Passenger Seat Harness Part 2 Page 5861 2. Connect the front speed sensor electrical connector (5). 3. Install the transfer case shield, if equipped. Transfer Case Speed Sensor Replacement - Left Rear Transfer Case Speed Sensor Replacement - Left Rear Removal Procedure 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. Disconnect the left rear speed sensor electrical connector (4). 3. Remove the left rear speed sensor. Installation Procedure Page 1363 Door Switch: Diagrams Door Latch Assembly (Door Jamb Switch) - LR C2 (Crew Cab Only) Door Latch Assembly (Door Jamb Switch) - LR C2 (Crew Cab Only) Page 14107 Control Module References Part 5 Page 12286 analyzed. Therefore, technicians should be checking for loose connections and installing cable connector clamps to ensure a positive and robust connection. Technicians are to install a video cable connector clamp on each cable connector located under each front seat. A total of four cable connector clamps, P/N 19159659, are required for each vehicle. The illustration above shows a pair of display monitor cable connectors without the cable clamps installed. The illustration above shows the display monitor cable connectors with the cable connector clamps. The lower cable connector clamp is installed but not locked together. The upper cable connector clamp is closed and locked. The cable connector clamps have now been added as a permanent component to all GM Accessories Headrest DVD Systems installation kits. Parts Information Warranty Information (excluding Saab U.S. Models) Engine Controls - MIL ON/Rough Idle/Misfire/DTC's Set Oxygen Sensor: All Technical Service Bulletins Engine Controls - MIL ON/Rough Idle/Misfire/DTC's Set Bulletin No.: 05-06-04-063 Date: October 12, 2005 TECHNICAL Subject: LM7, L59 or L33 Engines with Cold Start Rough or Incorrect Idle, Misfire, Malfunction Indicator Lamp (MIL) or Flashing Requiring 02 Sensor Replacement (Reprogram PCM) Models: 2004-2005 Cadillac Escalade 2004-2005 Chevrolet Avalanche, Silverado 1500, Suburban, Tahoe 2005 Chevrolet Silverado Hybrid (HP2) 2004-2005 GMC Sierra 1500, Yukon, Yukon XL 2005 GMC Sierra Hybrid (PH2) with Vortec 5300 5.3L V-8 Engine (VINs T, Z, B - RPOs LM7, L59, L33) Condition Some customers may comment on a Malfunction Indicator Lamp (MIL) On or that the MIL is flashing. An actual engine misfire may or may not be felt along with an incorrect idle speed. Typically this occurs during cold winter months, on cold engine starts. Some vehicles may have been previously serviced for the same condition. Technicians may also find the following DTCs stored with the Tech 2(R) P0131, P0133, P0134, P0137, P0138, P0140, P0151, P0153, P0154, P0157, P1133, which may be in conjunction with P0171, P0174, P0300 and P1138. Cause Water shock occurs when water droplets are present in the exhaust. The water in the exhaust contacts the sensor element inside the H02 sensor, causing the H02 sensor element to crack. Correction Upon diagnostic investigation, the technician may find that the H02 sensor requires replacement. In addition to replacing the affected H02 sensor, these vehicles should also be reflashed with the latest PCM calibration. An updated PCM calibration will be available to dealerships as part of TIS 2000 incremental satellite update 11.0 (NAO version 25.010) or greater. Always, make sure your Tech 2 is updated with the latest software version. Important: If a DTC P0420 or P0430 is stored along with DTC(s) P0300, the catalytic converter diagnostics in Service Information (SI) must be followed to determine if the catalytic converters are operating properly. Warranty Information For vehicles repaired under warranty, use the table. Page 6056 13. Important: RPO M33 transmissions do not use a 1-2 accumulator spring inner (104). Assemble the 1-2 accumulator assembly (54, 56, 57, 104). Ensure that the piston legs face the accumulator cover. 14. Install the 1-2 accumulator cover (57) and pin. 15. Install the 1-2 accumulator cover and the accumulator cover bolts. ^ Tighten the bolts to 11 Nm (97 inch lbs.). 16. Remove the J 25025-B from the transmission case. 17. Install the valve body. 18. Install the transmission filter. Page 4776 Camshaft Position Sensor: Service and Repair CAMSHAFT POSITION (CMP) SENSOR REPLACEMENT REMOVAL PROCEDURE IMPORTANT: Clean the area around the CMP sensor before removal in order to prevent debris from entering the engine. 1. Remove the camshaft position (CMP) sensor bolt. 2. Remove the CMP sensor. INSTALLATION PROCEDURE 1. Install the CMP sensor. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the CMP sensor bolt. Tighten Tighten the bolt to 29 N.m (21 lb ft). Page 2501 7. If the level is low, add lubricant until the level is even with the bottom edge of the fill plug opening. Use the proper fluid. 8. Notice: Refer to Fastener Notice in Service Precautions. Install the rear axle fill plug. ^ Tighten the rear axle fill plug to 33 Nm (24 ft. lbs.). 9. Lower the vehicle. 9.75 Inch Axle Lubricant Level Inspection - Rear Drive Axle (9.75 Inch Axle) 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Ensure the vehicle is level. 3. Inspect the rear axle for leaks. Repair as necessary. 4. Clean the area around the rear axle fill plug. 5. Remove the rear axle fill plug. 6. Inspect the lubricant level. The lubricant level should be between 0-4 mm (0-0.16 inch) below the fill plug opening. 7. If the level is low, add lubricant until the level is even with the bottom edge of the fill plug opening. Use the proper fluid. 8. Notice: Refer to Fastener Notice in Service Precautions. Install the rear axle fill plug. ^ Tighten the rear axle fill plug to 21 Nm (15 ft. lbs.). 9. Lower the vehicle. 11.5 Inch Axle Lubricant Level Inspection - Rear Drive Axle (11.5 Inch Axle) 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Make sure the vehicle is level. 3. Inspect the rear axle for leaks. Repair as necessary. 4. Clean the area around the rear axle fill plug. 5. Remove the rear axle fill plug and the seal. 6. Inspect the lubricant level. The lubricant level should be between 17-21 mm (0.6-0.8 inch) below the fill plug opening. Drivetrain - Updated Transfer Case Speed Sensor Conn. Speed Sensor: All Technical Service Bulletins Drivetrain - Updated Transfer Case Speed Sensor Conn. Bulletin No.: 06-04-21-001 Date: May 17, 2006 INFORMATION Subject: Updated Transfer Case Connector Service Kit Now Available For Transfer Case Speed Sensor Wire Harness Connector that Comes Loose Or Connector Retainer Clip Breaks Models: 2007 and Prior GM Light Duty Trucks 2007 and Prior HUMMER H2, H3 2005-2007 Saab 9-7X with Four-Wheel Drive or All-Wheel Drive Technicians may find that when the transfer case speed sensor wire harness connector is removed, the connector lock flexes/bends and does not return to the original position. The transfer case speed sensor wire harness connector then has no locking device. On older vehicles, the plastic connector retainer becomes brittle and the clip may break as soon as it is flexed. In the past, the only service fix was to install a wire harness connector service pack, P/N 88987183. This repair procedure involved splicing a new service connector with an integral connector lock. This connector service kit is of the same design and was still prone to failure over time. A new connector service repair kit is now available, P/N 15306187, that is an updated design. This new kit should be used whenever the speed sensor wire harness connector requires replacement. Parts Information Disclaimer Page 8156 5. Install the caliper guide pin bolts. 6. Notice: Refer to Fastener Notice in Service Precautions. ^ Tighten the caliper guide pin bolts. ^ Tighten the caliper guide pin bolts to 42 Nm (31 ft. lbs.). 7. Remove the rubber cap or plug from the exposed brake hose fitting end. 8. Important: Install 2 new copper brake hose gaskets. Assemble the 2 new copper brake hose gaskets and the brake hose to caliper bolt to the brake hose. 9. Connect the brake hose at the caliper by installing the brake hose to caliper bolt. ^ Tighten the bolt to 40 Nm (30 ft. lbs.). 10. Bleed the hydraulic brake system. 11. Install the tire and wheel assembly. 12. Lower the vehicle. 13. Fill the master cylinder reservoir to the proper level with clean brake fluid. Refer to Master Cylinder Reservoir Filling in Hydraulic Brakes. Brake Caliper Overhaul - Rear Brake Caliper Overhaul - Rear (15 Series) Caution: Refer to Brake Dust Caution in Service Precautions. Caution: Refer to Brake Fluid Irritant Caution in Service Precautions. Disassembly Procedure Important: Page 14013 1. With the aid of an assistant, install the headliner to the vehicle. 2. Install the rear window into the vehicle, if removed. 3. Install the assist handles, if equipped. 4. Install the interior dome lamp. 5. Install the rear coat hook, if equipped. 6. Install both front sunshades. 7. Install the DVD player, if equipped. 8. Install the overhead console, if equipped. 9. Install the rear quarter trim panels, if needed. Important: Ensure that all of the wire harness retainers in the I/P and the windshield pillar are all pressed into place in order to prevent rattling during driving. 10. Connect the headliner electrical connector to the junction block located next to the clutch or brake pedal. 11. Connect the electrical connectors to the drivers side accessory housing. 12. Install the hinge pillar trim. 13. Install the I/P top trim panel. Input Shaft Speed Sensor Replacement Transmission Speed Sensor: Service and Repair Input Shaft Speed Sensor Replacement Input Shaft Speed Sensor Replacement Removal Procedure 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. Disconnect the input speed sensor electrical connector (1). 3. Remove the input speed sensor bolt. 4. Remove the input speed sensor (1). 5. Inspect the input speed sensor (1) for any evidence of damage. Installation Procedure Page 13392 Electrical Symbols Part 4 Front Suspension Stabilizer Bushing: Service and Repair Front Suspension Stabilizer Shaft Insulator Replacement Removal Procedure 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Remove the tire and wheel assembly. 3. Remove the oil pan skid plate, if equipped. 4. Remove the stabilizer shaft insulator bracket bolts (3). 5. Remove the stabilizer shaft bracket (2). 6. Lower the stabilizer bar to remove the stabilizer shaft insulators (1). 7. Inspect all of the parts for wear and damage. Installation Procedure 1. Install the stabilizer shaft insulators (1) to the stabilizer shaft (4). Important: Place the insulators on the stabilizer shaft with the slits facing toward the front of the vehicle. 2. Install the stabilizer shaft (4) brackets (2) over the insulators. 3. Install stabilizer shaft insulator bracket bolts (3). Page 7068 21. With the trunnion seated in the bearing cup, press the bearing cup into the yoke until the bearing cup is flush with the yoke ear. 22. Install the opposite bearing cup part way into the yoke ear. 23. Ensure that the trunnions start straight and true into both bearing cups. 24. Press the opposite bearing cup into the yoke ear while working the cross all the time in order to inspect for free unbinding movement of the trunnions in the bearing cups. Important: If there seems to be a hang up or binding, stop pressing. Inspect the needle bearings for misalignment in the bearing cup. 25. Press the bearing cup into the yoke until the bearing cup retainer groove is visible over the top of the bearing cup. 26. Assemble the bearing retainer in the retainer groove. 27. Continue pressing until both retainers can be snapped into place. 28. If the retainer is difficult to seat, the yoke can be sprung slightly with a firm blow from a soft-faced dead blow hammer. 29. It may be necessary to lubricate the snap ring with a slight amount of chassis grease so that the snap ring seats in the bearing cup groove. 30. Install the slip yoke onto the output shaft in the transfer case. 31. Align the reference marks on the pinion flange and the propeller shaft. 32. Install the yoke retainers and bolts. Tighten Tighten the yoke retainer bolts to 25 N.m (19 lb ft). 33. Lower the vehicle. Page 8299 4. Remove the brake caliper bracket mounting bolts (2). 5. Remove the brake caliper bracket (1). 6. Remove any contaminants or foreign material from the inside ends of the brake caliper bracket. 7. Clean the mounting surface and threads of the brake caliper bracket. Installation Procedure 1. Install the brake caliper bracket (1). 2. Perform the following procedure before installing the brake caliper bracket mounting bolts. 1. Remove all traces of the original adhesive patch. 2. Clean the threads of the bolt with denatured alcohol or equivalent and allow to dry. 3. Apply Threadlocker GM P/N 12345493 (Canadian P/N 10953488) to the threads of the bolt. 3. Notice: Refer to Fastener Notice in Service Precautions. Install the caliper bracket mounting bolts (2). ^ Tighten the brake caliper bracket mounting bolts to 175 Nm (121 ft. lbs.) (15 Series). ^ Tighten the brake caliper bracket mounting bolts to 300 Nm (221 ft. lbs.) (25 and 35 Series). 4. Install the anti-rattle clips to the brake caliper bracket. 5. Install the brake pads to the brake caliper bracket. 6. Slide the brake pads in until they contact the rotor. 7. Install the brake caliper. Refer to Brake Caliper Replacement - Front. 8. Install the tire and wheel assembly. 9. Lower the vehicle. 10. With the engine OFF, gradually apply the brake pedal to approximately 2/3 of it's travel distance. 11. Slowly release the brake pedal. OnStar(R) - System Inoperative/No LED Lamp ON Fuse: All Technical Service Bulletins OnStar(R) - System Inoperative/No LED Lamp ON Bulletin No.: 04-08-46-005 Date: December 21, 2004 TECHNICAL Subject: OnStar(R) Generation 6 (Digital) System Inoperative/Has No Power, LED Light Not On (Remove/Reinstall OnStar(R) Fuse and Replace VCIM or Follow SI Diagnostics) Models: 2004-2005 Buick Rainier, Rendezvous 2005 Buick Allure (Canada), LaCrosse, LeSabre, Terrazza 2004-2005 Cadillac Escalade, Escalade ESV, Escalade EXT 2005 Cadillac CTS, DeVille 2004-2005 Chevrolet Avalanche, Silverado, Suburban, Tahoe, TrailBlazer, TrailBlazer EXT 2005 Chevrolet Colorado, Express, Impala, Monte Carlo, Uplander 2004-2005 GMC Denali, Denali XL, Envoy, Envoy XL, Envoy XUV, Sierra, Yukon, Yukon XL 2005 GMC Canyon, Savana 2004-2005 Pontiac Aztek 2005 Pontiac Bonneville, Grand Prix, Montana SV6, Vibe with Digital Gen 6 OnStar(R) (RPO UE1) Condition Some customers may comment any or all of the following conditions: ^ The OnStar(R) system may be inoperative. ^ The OnStar(R) system may have no power. ^ The OnStar(R) LED light may not be on. The technician may also not be able to communicate with the OnStar(R) Vehicle Communication Interface Module VCIM) with a Tech 2(R). Correction Remove the OnStar(R) fuse from the fuse box, wait five minutes and reinstall the fuse. If the OnStar(R) system DOES NOT return to normal functionality, then follow the diagnostics in SI for this condition. If the OnStar(R) system DOES return to normal functionality, you will need to replace the VCIM. If the VCIM is not replaced, there is the possibility that the customer will return to the dealership with the same conditions at a later date. Please contact the GM Technical Assistance Center (TAC), to obtain a new VCIM. The TAC consultant will verify your diagnosis and, if appropriate, order a replacement part. Replacement parts are usually shipped out within 24 hours, and a pre-paid return package label will be included for returning the faulty part. By returning the faulty part, you will avoid a significant non-return core charge. After the VCIM has been replaced, press the blue OnStar(R) button and request a full reconfiguration. When contacting TAC regarding this concern, the availability of certain information from the vehicle will streamline the process for the dealership technician as well as minimize the time necessary for TAC to provide the correct diagnosis. Please refer to Corporate Bulletin Number 01-00-89-011B for further information concerning the information necessary before contacting TAC. Dealers in Canada should refer to GM Service Policies & Procedures Section 5.3.1 "DEALER REQUIREMENTS FOR ASSISTANCE". Warranty Information Page 979 Conditions for Setting the DTC occur, the PCM executes the Action Taken When the DTC Sets. Some DTCs alert the driver via the MIL or a message. Other DTCs do not trigger a driver warning, but are stored in memory. The PCM also saves data and input parameters when most DTCs are set. This data is stored in the Freeze Frame and/or Failure Records. The DTCs are categorized by type. The DTC type is determined by the MIL operation and the manner in which the fault data is stored when a particular DTC fails. In some cases there may be exceptions to this structure. Therefore, when diagnosing the system it is important to read the Action Taken When the DTC Sets and the Conditions for Clearing the DTC in the supporting text. There are different types of DTCs and different actions taken when the DTCs set. Refer to Diagnostic Trouble Code (DTC) Type Definitions for a description of the general characteristics of each DTC type. DTC STATUS When the scan tool displays a DTC, the status of the DTC is also displayed. The following DTC statuses are indicated only when they apply to the DTC that is set. Fail This Ign. (Fail This Ignition): Indicates that this DTC failed during the present ignition cycle. Last Test Fail: Indicates that this DTC failed the last time the test ran. The last test may have run during a previous ignition cycle if an A or B type DTC is displayed. For type C DTCs, the last failure must have occurred during the current ignition cycle to appear as Last Test Fail. MIL Request: Indicates that this DTC is currently requesting the MIL. This selection will report type B DTCs only when they have requested the MIL (failed twice). Test Fail SCC (Test Failed Since Code Clear): Indicates that this DTC that has reported a failure since the last time DTCs were cleared. History: Indicates that the DTC is stored in the PCM History memory. Type B DTCs will not appear in History until they have requested the MIL (failed twice). History will be displayed for all type A DTCs and type B DTCs (which have requested the MIL) that have failed within the last 40 warm-up cycles. Type C DTCs that have failed within the last 40 warm-up cycles will also appear in History. Not Run SCC (Not Run Since Code Clear): DTCs will be listed in this category if the diagnostic has not run since DTCs were last cleared. This status is not included with the DTC display since the DTC can not be set if the diagnostic has not run. This information is displayed when DTC Info is requested using the scan tool. Page 2178 Disclaimer Page 2818 Oil Change Reminder Lamp: Description and Operation GM OIL LIFE SYSTEM When the "CHANGE ENGINE OIL" light comes on, it means that service is required for your vehicle. Have your vehicle serviced as soon as possible within the next 1 000 km (600 miles). It is possible that, if you are driving under the best conditions, the engine oil life system may not indicate that vehicle service is necessary for over a year. However, your engine oil and filter must be changed at least once a year and at this time the system must be reset. If the engine oil life system is ever reset accidentally, you must service your vehicle within 5 000 km (3,000 miles) since your last service. Remember to reset the oil life system whenever the oil is changed. Refer to GM Oil Life System - Resetting for information on the engine Oil Life System and resetting the system. When the "CHANGE ENGINE OIL" light appears, certain services, checks and inspections are required. Required services are described in the following for "Maintenance I" and "Maintenance II." Generally, it is recommended that your first service be Maintenance I, your second service be Maintenance II and that you alternate Maintenance I and Maintenance II thereafter. However, in some cases, Maintenance II may be required more often. The engine oil life monitor will indicate when to change the engine oil - usually between 5,000 km (3,000 miles) and 16,000 km (10,000 miles) since the last oil change. Under severe conditions, the "CHANGE OIL SOON" light may be displayed before 5,000 km (3,000 miles). The vehicle must not be driven more than 16,000 km (10,000 miles) or 12 months without an oil change. The engine oil life monitor will not detect dust in the oil. If the vehicle is driven in a dusty area, be sure to change the oil every 5,000 km (3,000 miles) or sooner if the "CHANGE OIL SOON" light is displayed. Page 7053 8. Install the boot (3) and two new clamps (2) onto the front propeller shaft stub shaft (4), if applicable. 9. Install the rear propeller shaft slip yoke onto the front propeller shaft stub shaft.Mate the missing tooth in the yoke with the bridged tooth on the splined shaft. 10. Install the rear propeller shaft onto the rear axle pinion yoke.Align the reference marks made during removal. 11. Install the yoke retainers (2) and the bolts (1). ^ Tighten the yoke retainer bolts to 25 Nm (18 ft. lbs.). 12. Using the J 43218, crimp the boot clamps until the dimensions shown are obtained. 13. Lower the vehicle. Electrical - Information For Electrical Ground Repair Grounding Point: All Technical Service Bulletins Electrical - Information For Electrical Ground Repair INFORMATION Bulletin No.: 10-08-45-001B Date: October 25, 2010 Subject: Information for Electrical Ground Repair - Use New Replacement Fasteners with Conductive Finish Models: 2011 and Prior GM Passenger Cars and Trucks (including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X Supercede: This bulletin is being revised to add the 2011 model year and update the Warranty Information. Please discard Corporate Bulletin Number 10-08-45-001A (Section 08 - Body and Accessories). Electrical Ground Repair Overview Proper electrical system function relies on secure, stable and corrosion-free electrical ground connections. Loose, stripped, or corroded connections increase the possibility of improper system function and loss of module communication. These conditions may also lead to unnecessary repairs and component replacement. In general, electrical ground connections are accomplished using one, or a combination of the following attachment methods: - Welded M6 stud and nut - Welded M6 nut and bolt - Welded M8 nut and bolt Determine which attachment method is used and perform the appropriate or alternative repair as described in this bulletin. M6 Weld Stud Replacement Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. Select a location adjacent the damaged or missing M6 ground stud having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the M6 conductive rivet stud flange. 2. Using GM approved residue-free solvent or equivalent, remove any grease from the repair site and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 3. Drill a 10 mm (0.40 in) diameter hole through the panel. 4. Remove paint and primer from the area surrounding the 10 mm (0.40 in) hole until bare metal is visible. Page 4825 Manifold Pressure/Vacuum Sensor: Service and Repair MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR REPLACEMENT REMOVAL PROCEDURE 1. Remove the engine sight shield. 2. Disconnect the manifold absolute pressure (MAP) sensor electrical connector (1). 3. Remove the MAP sensor (1). INSTALLATION PROCEDURE IMPORTANT: Lightly coat the MAP sensor seal with clean engine oil before installing the sensor. 1. Install the MAP sensor (1). Page 9611 Application Tabel Part 2 Location View Page 9881 - HVAC Actuator - Inflatable Restraint Sensing and Diagnostic Module (SDM) - Any AIR BAG module - Seatbelt Lap Anchor Pretensioner - Seatbelt Retractor Pretensioner - An SIR system connection or connector condition resulting in the following DTCs being set: B0015, B0016, B0019, B0020, B0022, or B0023 - Powertrain Control Module (PCM) - Remote Control Door Lock Receiver (RCDLR) - Transmission Control Module (TCM) Correction Important DO NOT replace the control module, wiring or component for the following conditions: - The condition is intermittent and cannot be duplicated. - The condition is present and by disconnecting and reconnecting the connector the condition can no longer be duplicated. Use the following procedure to correct the conditions listed above. 1. Install a scan tool and perform the Diagnostic System Check - Vehicle. Retrieve and record any existing history or current DTCs from all of the control modules (refer to SI). ‹› If any DTC(s) are set, refer to Diagnostic Trouble Code (DTC) List - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). ‹› If DTCs are not set, refer to Symptoms - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). 2. When identified, use the appropriate DTC Diagnostics, Symptoms, Schematics, Component Connector End Views and Component Locator documents to locate and disconnect the affected harness connector(s) which are causing the condition. Note Fretting corrosion looks like little dark smudges on electrical terminals and appear where the actual electrical contact is being made. In less severe cases it may be unable to be seen or identified without the use of a magnifying glass. Important DO NOT apply an excessive amount of dielectric lubricant to the connectors as shown, as hydrolock may result when attempting to mate the connectors. Use ONLY a clean nylon brush that is dedicated to the repair of the conditions in this bulletin. 3. With a one-inch nylon bristle brush, apply dielectric lubricant to both the module/component side and the harness side of the affected connector(s). 4. Reconnect the affected connector(s) and wipe away any excess lubricant that may be present. 5. Attempt to duplicate the condition by using the following information: - DTC Diagnostic Procedure - Circuit/System Description - Conditions for Running the DTC - Conditions for Setting the DTC - Diagnostic Aids - Circuit/System Verification ‹› If the condition cannot be duplicated, the repair is complete. ‹› If the condition can be duplicated, then follow the appropriate DTC, Symptom or Circuit/System Testing procedure (refer to SI). Repair Order Documentation Page 9574 Fuse Block- I/P C3 Part 1 Page 14077 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors USING CONNECTOR TEST ADAPTERS IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-B Connector Test Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Page 5110 12. If vehicle is a regular cab, remove the fuel and EVAP bundle nuts. 13. If vehicle is a crew cab or extended cab, remove the fuel and EVAP bundle nuts. 14. Remove the fuel and EVAP bundle. INSTALLATION PROCEDURE 1. Install the fuel and EVAP bundle. NOTE: Refer to Fastener Notice in Service Precautions. 2. If vehicle is a crew cab or extended cab, install the fuel and EVAP bundle nuts. Tighten Tighten the nuts to 12 N.m (106 lb in). Page 4513 SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-D. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: - The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair Tools Required J 38125-D Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-D. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Page 368 7.1. Remove the console (A) together with the OnStar(R) control modules. 7.2. Remove the connectors (B). Important: The optic cable must not be bent with a radius less than 25 mm (1 in). Important: Secure the wiring harness so that there is no risk of chafing and rattling. 7.3. Fold back the wiring harness and tape over the connectors (C). Fold back the wiring harness once more and secure with cable ties (D). 7.4. Fit the parcel shelf trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 8. CV: Removing the OnStar(R) control modules and securing the wiring: Adjustment/Replacement. 8.1. Open the luggage compartment floor. Page 13907 Installation Procedure 1. Use the following procedure in order to install the fender to the vehicle: 1. Position the locating notch in the fender to the vehicle. 2. Rotate the fender up 90 degrees. 3. Slide the fender under the retainers. 4. Rotate the fender down 90 degrees into the body position. 2. Install the rear retaining screws. 3. Install the fender to the rear pillar retaining bolts through the tail lamp opening. 4. Install the tail lamp assembly. 5. Install the fender step bolts. 6. Install the step pad. 7. Install the front filler bolts. 8. Install the lower fender brace rods bolts. 9. Install the top fender molding. 10. Install the top molding rear push-pin retainer. Page 969 Engine Controls - Aftermarket Accessory Usage Engine Control Module: All Technical Service Bulletins Engine Controls - Aftermarket Accessory Usage INFORMATION Bulletin No.: 04-06-04-054B Date: November 18, 2010 Subject: Info - Non-GM Parts and Accessories (Aftermarket) Models: 2011 and Prior GM Passenger Cars and Trucks Supercede: This bulletin is being revised to add model years and update to the new U.S. Fixed Operation Manager (FOM) and Canada Warranty Manager (WM) names. Please discard Corporate Bulletin Number 04-06-04-054A (Section 06 - Engine/Propulsion System). The recent rise and expansion of companies selling non-GM parts and accessories has made it necessary to issue this reminder to dealers regarding GM's policy on the use and installation of these aftermarket components. When a dealer is performing a repair under the New Vehicle Limited Warranty, they are required to use only genuine GM or GM-approved parts and accessories. This applies to all warranty repairs, special policy repairs or any repairs paid for by GM. Parts and accessories advertised as being "the same" as parts manufactured by GM, but not sold through GM, do not qualify for use in warranty repairs, special policy repairs or any repairs paid for by GM. During a warranty repair, if a GM original equipment part is not available through GM Customer Care and Aftersales (GM CC&A;), ACDelco(R) distributors, other GM dealers or approved sources, the dealer is to obtain comparable, non-GM parts and clearly indicate, in detail, on the repair order the circumstances surrounding why non-GM parts were used. The dealer must give customers written notice, prior to the sale or service, that such parts or accessories are not marketed or warranted by General Motors. It should also be noted that dealers modifying new vehicles and installing equipment, parts and accessories obtained from sources not authorized by GM are responsible for complying with the National Traffic and Motor Vehicle Safety Act. Certain non-approved parts or assemblies, installed by the dealer or its agent not authorized by GM, may result in a change to the vehicle's design characteristics and may affect the vehicle's ability to conform to federal law. Dealers must fully understand that non-GM approved parts may not have been validated, tested or certified for use. This puts the dealer at risk for potential liability in the event of a part or vehicle failure. If a GM part failure occurs as the result of the installation or use of a non-GM approved part, the warranty will not be honored. A good example of non-authorized modification of vehicles is the result of an ever increasing supply of aftermarket devices available to the customer, which claim to increase the horsepower and torque of the Duramax(TM) Diesel Engines. These include the addition of, but are not limited to one or more of the following modifications: - Propane injection - Nitrous oxide injection - Additional modules (black boxes) that connect to the vehicle wiring systems - Revised engine calibrations downloaded for the engine control module - Calibration modules which connect to the vehicle diagnostic connector - Modification to the engine turbocharger waste gate Although the installation of these devices, or modification of vehicle components, can increase engine horsepower and torque, they may also negatively affect the engine emissions, reliability and/or durability. In addition, other powertrain components, such as transmissions, universal joints, drive shafts, and front/rear axle components, can be stressed beyond design safety limits by the installation of these devices. General Motors does not support or endorse the use of devices or modifications that, when installed, increase the engine horsepower and torque. It is because of these unknown stresses, and the potential to alter reliability, durability and emissions performance, that GM has adopted a policy that prevents any UNAUTHORIZED dealer warranty claim submissions to any remaining warranty coverage, to the powertrain and driveline components whenever the presence of a non-GM (aftermarket) calibration is confirmed - even if the non-GM control module calibration is subsequently removed. Refer to the latest version of Bulletin 09-06-04-026 (V8 Gas Engines) or 06-06-01-007 (Duramax(TM) Diesel Engines) for more information on dealer requirements for calibration verification. These same policies apply as they relate to the use of non-GM accessories. Damage or failure from the use or installation of a non-GM accessory will not be covered under warranty. Failure resulting from the alteration or modification of the vehicle, including the cutting, welding or disconnecting of the vehicle's original equipment parts and components will void the warranty. Additionally, dealers will NOT be reimbursed or compensated by GM in the event of any legal inquiry at either the local, state or federal level that Page 7640 Remote Programming Feature 1. Connect the scan tool to the vehicle. 2. Power-up the scan tool and select the Service Programming feature. 3. Select the appropriate vehicle. 4. Press the Request Info button on the scan tool. 5. Connect the scan tool to the computer station. 6. Follow the menu select items for reprogramming and provide information about the type of device you are programming and whether you are reprogramming or replacing the electronic control unit (ECU). 7. Select "vehicle" from the selection menu. 8. Select the module you wish to program. 9. Select "Normal" for Programming Type. 10. Select the applicable software calibrations. 11. Transfer data file to the scan tool. 12. Connect the scan tool to the vehicle. 13. Turn ON the ignition, with the engine OFF. 14. Select the Service Programming feature on the scan tool. 15. Press the Program button on the scan tool. Programming Using Scan Tool Pass-Through Connection 1. Connect the scan tool to vehicle and power it up. 2. Connect the computer station to the scan tool. 3. Select "PC Using Scan Tool Connection" from the programming menu on the computer station. 4. Follow the menu select items for reprogramming and provide information about the type of device you are programming and whether you are reprogramming or replacing the electronic control unit (ECU). 5. Select "vehicle" from the selection menu. 6. Select the module you wish to program. 7. Select "Normal" for Programming Type. 8. Select the applicable software calibrations. 9. Transfer data file to the scan tool. Page 9200 C201 Steering Column Harness To I/P Harness Part 2 Page 15291 3. Locate the auxiliary fuel tank vent hose. The vent hose is the smaller diameter of the two hoses that comes from the auxiliary fuel tank and feeds into the main tank vent hose. 4. Disconnect the auxiliary tank vent hose from the main tank vent hose connection. 5. Install the cap supplied with kit, P/N 15213990, to the main tank vent hose connector where the auxiliary tank vent hose was just removed. 6. Locate the section of vent hose on the main tank between the fuel filler neck and the metal pipe. The smaller of the two hoses on the filler neck. 7. Cut the main tank vent hose between the filler neck and the metal pipe using an appropriate cutting tool. 8. Install the "T" and the two hose clamps supplied with kit, P/N 15213990, into the main tank vent hose. Tighten Tighten the hose clamps to 2.5 N.m (22 lb in). 9. Install the new auxiliary tank vent hose and clamp supplied with kit, P/N 15213990, to the "T" that was just installed. Tighten Tighten the hose clamp to 2.5 N.m (22 lb in). 10. Connect the new vent hose to the original auxiliary tank hose. 11. Secure the newly installed vent hose and the original auxiliary tank vent hose with plastic ties supplied in kit, P/N 15213990. 12. If necessary, reinstall the left rear tires/wheels assemblies. Page 13276 10.4. Remove the end cap from the new optic cable, connect to the connector and refit the secondary catch (D). Fit the terminal housing (C) to the connector and refit the locking strip (B). 10.5. Secure the old optic cable together with the new one (E). Important: The optic cable must not be bent with a radius less than 25 mm (1 in). Important: Secure the wiring harness so that there is no risk of chafing and rattling. 11. CV: Remove the rear seat in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. The O-bus connector H2-9 is located behind the left speaker. 12. M04-05: Disconnect the optic cables on the OnStar(R) control modules and join the cables: 12.1. Cut off the cable tie holding the connector (H2-9) against REC. Page 523 Front Passenger Door Module (FPDM) - C2 (With RPO Code YE9) Part 2 Page 14117 Driver Door Module (DDM) - C5 (With RPO Code AN3) Part 1 Page 14365 7. Insert the J 38125-13A (GM P/N 12031876-1) tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the Terminal Repair Kit to ensure that the correct release tool is used. 8. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. REPAIR PROCEDURE Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. A/T - 4T65-E Fluid Leaks From Reverse Servo Cover Band Apply Servo: Customer Interest A/T - 4T65-E Fluid Leaks From Reverse Servo Cover Bulletin No.: 04-07-30-028A Date: January 12, 2006 TECHNICAL Subject: 4T65-E Automatic Transmission Fluid Leak From Reverse Servo Cover (Replace Reverse Servo Cover Seal) Models: 2005 and Prior Cars and Light Duty Trucks with Automatic Transmission 4T65-E (RPOs MN3, MN7, M15, M76) Supercede: This bulletin is being revised to announce an improved reverse servo cover seal is available from GMSPO and to advise technicians that it is no longer necessary to replace the reverse servo cover when replacing the seal. The 2005 model year vehicles are also being added. Please discard Corporate Bulletin Number 04-07-30-028 (Section 07 - Transmission/Transaxle). Condition Some customers may comment on a fluid leak under the vehicle. A transmission fluid leak may be noted during the Pre-delivery Inspection (PDI). Cause A possible cause of a transmission fluid leak usually only during cold ambient temperatures below -6.7°C (20°F) may be the reverse servo cover seal. The reverse servo cover seal may shrink in cold ambient temperatures causing a transmission fluid leak. Correction Follow the diagnosis and repair procedure below to correct this condition. 1. Diagnose the source of the fluid leak. 2. If the source of the transmission fluid leak is the reverse servo cover, replace the reverse servo cover seal with P/N 24235894. Refer to Reverse Servo Replacement in the appropriate Service Manual. Page 4670 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-8 (12085115) crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-8 (12085115) until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes SPLICING INLINE HARNESS DIODES Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate Service Data wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. 9. Tape the diode to the harness or connector using electrical tape. Page 12298 DVD Player: Service and Repair DVD Player Replacement (2ND Row) DVD PLAYER REPLACEMENT (2ND ROW) TOOLS REQUIRED J 38778 Door Trim Pad Clip Remover REMOVAL PROCEDURE IMPORTANT: Components of the DVD player cannot be serviced separately. Replace as an assembly. 1. Move the screen to the open position. 2. Remove the rear screw cover using a flat bladed tool. 3. Remove the four retaining bolts (2). 4. Insert the J 38778 between the headliner and the DVD player assembly. 5. With 1 hand holding the DVD player assembly, pry the retainer from the bracket. 6. Allow the DVD player assembly to come to rest on the hook. IMPORTANT: Observe the routing of the wiring harness (2). Page 10306 1. Connect the outer tie rod assembly (3) to the inner tie rod (1). Do not tighten the jam nut (2). 2. Install the tie rod seal (2) to the outer tie rod assembly (1). 3. Connect the outer tie rod assembly (1) to the steering knuckle (2). Notice: Refer to Fastener Notice in Service Precautions. 4. Install the torque prevailing nut (3) to the outer tie rod stud (1). ^ Tighten the torque prevailing nut (3) to 50 Nm (37 ft. lbs.). 5. Important: Be sure the rack and pinion boot is not twisted after the toe adjustment. Check the wheel alignment. Page 2492 Disclaimer Page 595 Power Seat Control Module: Diagrams Memory Seat Module - C1 Page 5124 1. Install the rear fuel line bundle. 2. Install the rear fuel line bundle clip nuts. 3. Remove the caps from the fuel and balance lines at the fuel tank. 4. Connect the fuel feed and pressure balance lines from the rear tank. 5. Remove the caps from the fuel and balance lines at the fuel tank. 6. Connect the fuel feed and pressure balance lines from the front tank. 7. Install the fuel fill cap. 8. Connect the negative battery cable. 9. Perform the following procedure in order to inspect for leaks. 9.1. Turn the ignition ON, with the engine OFF, for 2 seconds. 9.2. Turn the ignition OFF for 10 seconds. 9.3. Turn the ignition ON, with the engine OFF. 9.4. Inspect for fuel leaks. EVAP Hoses/Pipes Replacement - Canister/Fuel Tank (Cab/Chassis) Page 487 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the cover up until the dress cover releases. Repeat this procedure for the other locking tab. 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. 5. If the connector has a nose piece, use a small flat-blade tool to remove the nose piece by inserting the blade into the slot on the front of the connector and prying up on the nose piece. IMPORTANT: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 6. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. IMPORTANT: Be careful not to angle or rock the J 38125-13A tool when inserting it into the connector or the tool may break. Page 425 ^ Reinstall the fuse and fuse panel cover. ^ Press the "Enter" button to perform the "Refresh" function. ^ "Test in Progress" will be displayed and the right front passenger door lock will cycle once. ^ The screen will display "Procedure Completed". ^ Press the "Exit" button as necessary to return to the main menu screen. 3. Using the switches in the right front passenger door, verify that the power window and power door lock located in that door function properly. Important: The calibrations required for performing SPS reprogram in the next step are based on the type of exterior rearview mirror the vehicle has. To determine the correct calibration, check the Service Parts Identification Label on the vehicle for the RPO code for exterior mirrors. 4. Follow normal Service Programming System (SPS) to reprogram the passenger door module with the current calibration available in TIS 2000. 5. After reprogramming is complete, using the switches in the right front passenger door, verify that the power window and power door lock located in that door function properly. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 14121 Front Passenger Door Module (FPDM) - C2 (With RPO Code YE9) Part 2 Page 11987 Conditions for Running the DTC Ignition is in RUN or ACC position System voltage is between 9.5 - 15.5 volts. The above conditions are met for more than 1 second. Conditions for Setting the DTC The VCIM does not detect the presence of a cellular antenna for more than 1 second. Action Taken When the DTC Sets The vehicle is unable to connect to the OnStar(R) Call Center. The OnStar(R) status LED turns red. Conditions for Clearing the DTC The VCIM detects the presence of a cellular antenna. A history DTC clears after 50 malfunction-free ignition cycles. Circuit/System Testing Perform a visual inspection as shown above in order to verify that the cellular antenna and the cellular antenna coupling assembly are not damaged. If any components are damaged replace the assembly. DTC B2476 or B2482 DTC Descriptors Page 5204 Repairs to non-FlexFuel vehicles that have been fueled with E85 are not covered under the terms of the New Vehicle Warranty. A complete list of GM's FlexFuel vehicles can be found in this Service Bulletin, or at www.livegreengoyellow.com. E85 Compatible Vehicles The only E85 compatible vehicles produced by General Motors are shown. Only vehicles that are listed in the E85 Compatible Vehicles section of this bulletin and/or www.livegreengoyellow.com are E85 compatible. All other gasoline and diesel engines are NOT E85 compatible. Use of fuel containing greater than 10% ethanol in non-E85 designated vehicles can cause driveability issues, service engine soon indicators as well as increased fuel system corrosion. Repairs to non-FlexFuel vehicles that have been fueled with E85 are not covered under the terms of the New Vehicle Warranty. Disclaimer Page 10178 7. From inside the vehicle remove the upper bolt from the upper intermediate steering shaft (1) to the steering column connection. 8. Remove the upper intermediate steering shaft assembly. 1. From inside the vehicle slide the shaft down and off the steering column. 2. From inside the vehicle slide the upper intermediate shaft through the dash boot seal and remove the shaft from the vehicle. 9. Replace the upper intermediate shaft. 10. Install the upper intermediate steering shaft through the dash boot seal and slide the lower end into the steering gear coupling shaft. 11. Raise the upper end of the intermediate steering shaft and install into the steering column shaft. 12. Install the upper bolt and nut. Tighten Tighten the bolt to 47 N.m (35 lb ft). 13. Install the lower bolt and nut. Tighten Tighten the bolt to 50 N.m (37 lb ft). 14. For vehicles equipped with adjustable foot pedals perform the following steps: 1. Reposition the accelerator pedals into position on the bulkhead. 2. Install the two retaining nuts. Tighten Tighten the nuts to 20 N.m (15 lb ft). 3. Reposition the carpet into place. Parts Information Warranty Information For vehicles repaired under warranty use, the table. Page 13025 Models The service procedure in this bulletin has been revised. Step 11 in the procedure for the 2004-2005 Saab 9-3 (9440) Convertible has been revised. Discard all copies of bulletin 08089B, issued September 2008. Condition In November 2002, the U.S. Federal Commissions (FCC) ruled that wireless carriers would no longer be required to support the analog wireless network beginning in 2008. As a result, On Star(R) is unable to continue analog service. OnStar(R) has deactivated most of the systems operating in the analog mode; however, there are some vehicles that OnStar(R) could not deactivate. Although the analog OnStar(R) hardware in these vehicles can no longer communicate with OnStar(R), the hardware in the vehicle is still active. If the OnStar(R) emergency button is pressed, or in the case of an airbag deployment, or near deployment, the customer may hear a recording that OnStar(R) is being contacted. However, since analog service is no longer available, the call will not connect to OnStar(R). To end the call, the customer must press the white phone or white dot button. If the call is not ended, the system will continue to try to connect to OnStar(R) until the vehicle battery is drained. Special Policy Adjustment At the customer's request, dealers/retailers are to deactivate the OnStar(R) system. The service will be made at no charge to the customer. This special coverage covers the condition described above until December 31, 2008 for all non-Saab vehicles; April 30, 2009 for all Saab vehicles. Vehicles Involved Page 3312 2. Hook one of the open ends of the retaining ring in one of the slots in the quick connector. 3. Rotate the retaining ring around the connector until the retaining ring is positioned with all 3 ears through the 3 slots. 4. Ensure the 3 retaining ring ears can be seen from the inside of the connector and the retaining ring can move freely in the slots. 5. Install the engine oil cooler line into the quick connector fitting until a click is heard or felt.Pull back on the engine oil cooler lines to ensure a proper connection. Page 8043 5. Remove the mounting screws (1) that fasten the EBCM (2) to the BPMV (3). 6. Remove the EBCM (2) from the BPMV (3). Removal may require a light amount of force. Notice: Do not use a tool to pry the EBCM or the BPMV. Excessive force will damage the EBCM. Page 2743 Junction Block - I/P Wire Entry Part 2 Page 11350 Ambient Temperature Sensor / Switch HVAC: Description and Operation AIR TEMPERATURE SENSORS The air temperature sensors are a 2-wire negative temperature co-efficient thermistor. The vehicle uses the following air temperature sensors: Ambient Air Temperature Sensor - Inside Air Temperature Sensor Assembly - Upper Left Air Temperature Sensor - Upper Right Air Temperature Sensor - Lower Left Air Temperature Sensor - Lower Right Air Temperature Sensor A signal and a low-reference circuit enables the sensor to operate. As the air temperature surrounding the sensor increases, the sensor resistance decreases. The sensor signal voltage decreases as the resistance decreases. The sensor operates within a temperature range between -40°C (-40°F) to 101°C (215°F). The sensor signal varies between 0.5 volts. The input of the duct air temperature sensors are different from the ambient and inside sensors. The HVAC control module converts the signal to a range between 0-255 counts. As the air temperature increases the count value will decrease. If the HVAC control module detects a malfunctioning sensor, then the control module software will use a defaulted air temperature value. The default value for the ambient and inside air temperature sensors will be displayed on the scan tool. The default value for the duct air temperature sensors will not be displayed on the scan tool. The scan tool parameter for the duct air temperature sensors are the actual state of the signal circuit. The default action ensures that the HVAC system can adjust the inside air temperature near the desired temperature until the condition is corrected. The ambient air temperature sensor mounts underhood and can be affected by city traffic, by idling, and by restarting a hot engine. Therefore, the HVAC control module filters the value of the ambient air temperature sensor for temperature display. The ambient air temperature value is updated under the above conditions. The scan tool has the ability to update the displayed ambient air temperature. To update the ambient air temperature display on the HVAC control module, perform the following procedure: Simultaneously press the MODE, FRONT DEFROST and REAR DEFROST switches. 1. Turn ON the ignition. 2. Simultaneously press the MODE, FRONT DEFROST and REAR DEFROST switches. Page 1472 Door Switch: Diagrams Door Latch Assembly (Door Jamb Switch) - Front Passenger C2 Door Latch Assembly (Door Jamb Switch) - Front Passenger C2 Air Bag System Repairs and Inspections Required After a Collision: Service and Repair Air Bag System REPAIRS AND INSPECTIONS REQUIRED AFTER A COLLISION ACCIDENT WITH OR WITHOUT AIR BAG DEPLOYMENT - COMPONENT INSPECTIONS CAUTION: Proper operation of the SIR sensing system requires that any repairs to the vehicle structure return the vehicle structure to the original production configuration. Not properly repairing the vehicle structure could cause non-deployment in a collision or deployment for conditions less severe than intended. After any collision, inspect the following components as indicated. If you detect any damage, replace the component. If you detect any damage to the mounting points or mounting hardware, repair or replace the mounting points and mounting hardware as needed. Steering column.Perform the steering column accident damage checking procedures. Refer to Steering Column Accident Damage Inspection in Steering Wheel and Column. - I/P Knee Bolsters and Mounting Points.Inspect the knee bolsters for bending, twisting, buckling, or any other type of damage. - I/P brackets, braces, etc..Inspect for bending, twisting, buckling, or any other type of damage. - Seat Belts.Perform the seat belt operational and functional checks. Refer to Operational and Functional Checks in Seat Belts. - Seats and Seat Mounting Points. Inspect for bending, twisting, buckling, or any other type of damage. Page 3249 Steps 1 - 12 The number(s) below refer to the step(s) in the diagnostic table. 2. This inspection is to verify the condition of the drive belt(s). Damage may have occurred to the drive belt(s) when the drive belt(s) fell off the pulley. Inspect the drive belt(s) for cuts, tears, sections of ribs missing, or damaged belt plys. 4. Misalignment of the accessory drive pulley(s) may be caused from improper mounting or incorrect installation of a accessory drive component, or the pulley may be bent inward or outward from a previous repair. Test for a misaligned pulley using a straight edge in the pulley grooves across two or three pulleys. If a misaligned pulley is found, refer to that accessory drive component for the proper removal and installation procedure of that pulley. 5. Inspection of the accessory drive pulley(s) should include inspecting for bends, dents, or other damage that would prevent the drive belt from seating properly in the pulley grooves or on the smooth surface of a pulley when the back side of the drive belt(s) is used to drive the pulley. 6. Accessory drive component brackets that are bent or cracked will also cause the drive belt(s) to fall off. 7. Inspection of the fasteners can eliminate the possibility that a incorrect bolt, nut, spacer, or washer was installed. Missing, loose, or incorrect fasteners may cause pulley misalignment from the accessory drive bracket(s) moving under load. Over tightening the fasteners may cause misalignment of the accessory component bracket(s). Drive Belt Rumbling Drive Belt Rumbling Diagnosis Door Hinge Pin and Bushing Replacement - Rear Door Rear Door Hinge: Service and Repair Door Hinge Pin and Bushing Replacement - Rear Door Door Hinge Pin and Bushing Replacement - Rear Door The door hinge pins and bushings are not replaceable. If the hinge pins or bushings are damaged, replace the door hinge as an assembly. Refer to Hinge Replacement - Front Door - Door Side and Hinge Replacement - Front Door - Body Side. Description and Operation Keyless Entry Receiver: Description and Operation REMOTE CONTROL DOOR LOCK RECEIVER MODULE SYSTEM The remote control door lock receiver module system may also arm and disarm the CTD system. When the remote control door lock receiver receives a door lock or an unlock signal from the key fob, the remote control door lock receiver sends a message to the BCM. The message orders the BCM to perform the appropriate door lock/unlock command. The BCM detects the message and performs one of the following functions: - Locks the doors and enters the armed initiated mode - Unlocks the doors and enters the ready-to-arm mode Page 5507 Air Induction Components Recall 04V045000: Possible Hydro-Boost Defect Hydraulic Brake Booster: Recalls Recall 04V045000: Possible Hydro-Boost Defect DEFECT: Certain sport utility vehicles, pickup trucks, and passenger vans fail to comply with the requirements of Federal Motor Vehicle Safety Standard No. 135, "Passenger Car Brake Systems." Some of these vehicles were produced with an out-of-specification brake hydro-boost housing relief valve bore. Consequently, the valve O-ring seal may fracture. Steering efforts may be slightly increased while braking or parking. Under certain driving conditions, a fractured seal may also require an increase in the applied brake pedal effort to achieve the same vehicle deceleration. REMEDY: Dealers are to replace the hydro-boost relief valve. The manufacturer has reported that owner notification is expected to begin during the second quarter of 2004. Owners may contact Cadillac at 1-866-982-2339; Chevrolet at 1-800-630-2438; GMC at 1-866-996-9463; or Hummer at 1-866-486-6376. Page 1521 Upper Steering Column Page 7637 1. If a NEW control module is being installed, program the new module. 2. Install the shift control module to the bracket. 3. Connect the shift control module electrical connectors. 4. Start the engine and test the automatic transfer case system for proper shift operation. Page 14400 Front Passenger Door Module (FPDM) - C2 (With RPO Code YE9) Part 2 Page 9091 Junction Block - I/P Wire Entry Part 3 Page 7228 IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections TESTING FOR INTERMITTENT AND POOR CONNECTIONS TOOLS REQUIRED - J 35616-C GM-Approved Terminal Test Kit - J 38125-D Terminal Repair Kit - J 42675 Flat-Wire Probe Adapter Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector. - Poor terminal to wire connection - Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. - Wire insulation which is rubbed through - This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. - Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. Testing For Proper Terminal Contact It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-D or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-D, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. Page 4898 3. Connect the VSS electrical connector (3). Lower the vehicle. Page 6034 Vehicle Speed Sensor (VSS) Tow/Haul Switch Location Page 13026 Page 11969 OnStar(R) Microphone The OnStar(R), or cellular microphone, can be a part of the rearview mirror assembly, or on some vehicle lines, a separate, stand alone unit. In either case, the VCIM supplies approximately 10 volts to the microphone on the cellular microphone signal circuit, and voice data from the user is sent back to the VCIM over the same circuit. A cellular microphone low reference circuit or a drain wire provides a ground for the microphone. Cellular and GPS Antennas The vehicle will be equipped with one of the following types of antennas: ^ Separate, stand-alone cellular and navigation (GPS) antennas. ^ A combination cellular and navigation (GPS) antenna, which brings the functions of both into a single part. ^ A cellular, GPS, and digital radio receiver (DRR) antenna, which also incorporates the functionality of the DRR satellite antenna (XM). The cellular antenna is the component that allows the OnStar(R) system to send and receive data using electromagnetic waves by means of cellular technology. The antenna is connected at the base to a coax cable that plugs directly into the VCIM. The GPS antenna is used to collect the signals of the orbiting GPS satellites. Within the antenna is housed a low noise amplifier that allows for a more broad and precise reception of this data. The antenna is connected at the base to a coax cable that plugs directly into the VCIM. The cable also provides a path for DC current for powering the antenna. The OnStar(R) Call Center also has the capability of communicating with the vehicle during an OnStar(R) call to retrieve the latest GPS location and transmit it to the OnStar(R) Call Center. A history location of the last recorded position of the vehicle is stored in the module and marked as aged, for as long as the module power is not removed. Actual GPS location may take up to 10 minutes to register in the event of a loss of power. Audio System Interface When the OnStar(R) requires audio output, a serial data message is sent to the audio system to mute all radio functions and transmit OnStar(R) originated audio. The OnStar(R) audio is transmitted to the vehicle audio system by a dedicated signal circuit and a low reference circuit. The audio system will mute and an audible ring will be heard though the speakers if the vehicle receives a call with the radio ON. On some vehicles, the HVAC blower speed may be reduced when the OnStar(R) system is active to aid in reducing interior noise. When the system is no longer active, the blower speed will return to its previous setting. OnStar(R) Steering Wheel Controls Some vehicles may have a button on the steering wheel, that when pushed can engage the OnStar(R) system. The button may be a symbol of a face with sound waves, or may say MUTE, or be a symbol of a radio speaker with a slash through it. By engaging the OnStar(R) system with this feature, the user can interact with the system by use of voice commands. A complete list of these commands is supplied in the information provided to the customer. If the information is not available for reference, at any command prompt, the user can say "HELP" and the VCIM will return an audible list of available commands. The steering wheel controls consist of multiple momentary contact switches and a resistor network. The switches and resistor network are arranged so that each switch has a different resistance value. When a switch is pressed, a voltage drop occurs in the resistor network. This produces a specific voltage value unique to the switch selected, to be interpreted by the radio or the body control module (BCM). OnStar(R) Power Moding (DRX or Sleep Cycle) The OnStar(R) system uses a unique sleep cycle to allow the system to receive cellular calls while the ignition is in the OFF position and retained accessory power (RAP) mode has ended. A green status LED on the OnStar(R) keypad normally indicates an active OnStar(R) account. The OnStar(R) system will stay powered up after ignition off for an extended time in order to allow for remote services like door unlock, horn honk, light flash, etcetera to take place as requested by the customer. Power cycle (also referred to as DRX) times vary depending on the generation of the OnStar(R) system. Technicians may identify the OnStar(R) system generation by using a Tech 2 and following this menu path: (Body>VCIM>Module ID Information>Module Information 2) or by accessing www.onstarenrollment.com All Generation 6 digital systems are powered up continuously for 48 hours from ignition OFF. After 48 hours, the Generation 6 systems will enter a 9 minute OFF, 1 minute ON power cycle for an additional 72 hours. At the beginning and end of the 1 minute ON stage, you may or may not experience a short spike of current at the beginning and at the end. This allows for calls from OnStar to be received by the system. After 120 hours from ignition OFF, Page 13042 5.2 Cut off the cable tie (B), detach the connector's rear end face (C) and pull out the connecting rail (D). 5.3. Remove pin 39, cut off the cable terminal and insulate the end with tape (E). Fold back the cable and secure it with tape (F). 5.4. Fit the connecting rail and end face. 5.5. Plug in the connector (A) and secure the cables with cable ties (B). 6. Install the floor console over the handbrake. Do not press the console down into place, but instead allow it to fit loosely. 7. Install the switch: 7.1. Install the switch for the roof lighting (B) and plug in its connector. 7.2. Guide the connectors for the window lift module and rear seat heater, if equipped, through the hole for each respective unit. Plug in the window lift module's connector and install the module (A). Page 9558 Fuse Block - Underhood C3 Part 1 Page 11547 Knee Diverter: Service and Repair KNEE BOLSTER REPLACEMENT REMOVAL PROCEDURE 1. Remove the I/P cluster trim plate bezel. 2. Remove the knee bolster screws. 3. Unsnap the top of the knee bolster from the I/P assembly. INSTALLATION PROCEDURE Page 7075 For vehicles repaired under warranty, use the table. Disclaimer Page 13108 Page 529 Door Module: Electrical Diagrams Door Control Module Diagram 1 Page 921 Body Control Module (BCM) - C5 Page 11999 A/C - Control Knob Replacement Availability Control Assembly: Technical Service Bulletins A/C - Control Knob Replacement Availability Bulletin No.: 04-01-37-001 Date: January 06, 2004 INFORMATION Subject: HVAC Control Knob Replacement Models: 2000-2004 All Passenger Cars and Light Duty Trucks 2003-04 HUMMER H2 HVAC Control Knob Availability Important: If a knob becomes loose or broken, you MUST first check for availability of the control knob before attempting to replace the entire HVAC controller. The various knobs used on the HVAC controls of most GM vehicles are available for purchase separately from the HVAC head units. If a knob becomes loose or broken, you MUST first check for availability of the control knob before attempting to replace the entire HVAC controller. Please use only the labor operation code listed below when replacing an HVAC control knob. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 8249 Brake Bleeding: Service and Repair Master Cylinder Bench Bleeding Master Cylinder Bench Bleeding Caution: Refer to Brake Fluid Irritant Caution in Service Precautions. Notice: When adding fluid to the brake master cylinder reservoir, use only Delco Supreme 11, GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. The use of any type of fluid other than the recommended type of brake fluid, may cause contamination which could result in damage to the internal rubber seals and/or rubber linings of hydraulic brake system components. 1. Secure the mounting flange of the brake master cylinder in a bench vise so that the rear of the primary piston is accessible. 2. Remove the master cylinder reservoir cap and diaphragm. 3. Install suitable fittings to the master cylinder ports that match the type of flare seat required and also provide for hose attachment. 4. Install transparent hoses to the fittings installed to the master cylinder ports, then route the hoses into the master cylinder reservoir. 5. Fill the master cylinder reservoir to at least the half-way point with Delco Supreme 11® (GM P/N 12377967) or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. 6. Ensure that the ends of the transparent hoses running into the master cylinder reservoir are fully submerged in the brake fluid. 7. Using a smooth, round-ended tool, depress and release the primary piston as far as it will travel, a depth of about 25 mm (1 inch), several times. Observe the flow of fluid coming from the ports.As air is bled from the primary and secondary pistons, the effort required to depress the primary piston will increase and the amount of travel will decrease. 8. Continue to depress and release the primary piston until fluid flows freely from the ports with no evidence of air bubbles. 9. Remove the transparent hoses from the master cylinder reservoir. 10. Install the master cylinder reservoir cap and diaphragm. 11. Remove the fittings with the transparent hoses from the master cylinder ports. Wrap the master cylinder with a clean shop cloth to prevent brake fluid spills. 12. Remove the master cylinder from the vise. Page 14377 Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips SPLICING COPPER WIRE USING SPLICE CLIPS IMPORTANT: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. TOOLS REQUIRED J 38125-D Terminal Repair Kit 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-D in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. Page 9737 C214 Infotainment Harness To Headliner Harness (With RPO Code UE1) Oil Pan Replacement Oil Pan: Service and Repair Oil Pan Replacement Oil Pan Replacement Removal Procedure 1. If equipped with regular production option (RPO) HP2, it is necessary to drain the cooling system and engine block. 2. If equipped with four wheel drive (4WD), remove the inner axle housing nuts and washers from the bracket. 3. Support the front drive axle with a suitable jack. 4. If equipped with 4WD, remove the differential carrier lower mounting bolt and nut. 5. If equipped with 4WD, remove the differential carrier upper mounting bolt and nut. 6. Lower the front drive axle. Page 15756 Brake Light Switch: Service and Repair STOP LAMP SWITCH REPLACEMENT REMOVAL PROCEDURE 1. Disconnect the electrical connector from the stop lamp switch (2). 2. Remove the pushrod retaining clip (4). 3. Remove the stop lamp switch (2). INSTALLATION PROCEDURE 1. Install the stop lamp switch (2). 2. Install the pushrod retaining clip (4). 3. Connect the electrical connector to the stop lamp switch (2). Page 8431 2. Align the slots in both the adjusting screw (1) and tappet to be parallel with the backing plate face. 3. Install the park brake shoe assembly to the vehicle by placing one of the open ends of the shoe (2) over the axle flange and rotating the shoe until it is behind the flange. 4. Position the park brake shoe (2) on the inboard side of the actuator. 5. Slide the park brake shoe (2) into position and seat into the retaining spring (3). 6. Inspect the shoe assembly position. The shoe must be central on the backing plate with both tips located in the slots. 7. Adjust the park brake shoe. Refer to Park Brake Adjustment See: Adjustments. 8. Install the rotor. Refer to Rear Brake Rotor Replacement in Disc Brakes See: Disc Brake System/Brake Rotor/Disc/Service and Repair. 9. Install the park brake cable to the park brake actuator lever. Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems. 10. Tighten the nut to the intermediate cable at the equalizer. Tighten Tighten the nut to 3.5 Nm (31 lb in). 11. Install the tire and wheel. 12. Remove the safety stands. 13. Lower the vehicle. 14. Adjust park brake cable. Refer to Park Brake Adjustment See: Adjustments. Page 13535 7. Insert the J 38125-13A (GM P/N 12031876-1) tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the Terminal Repair Kit to ensure that the correct release tool is used. 8. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. REPAIR PROCEDURE Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. Page 5170 Disclaimer Page 6372 into the bore until it is seated at the bottom of the bore. 4. Install the PNP switch. 5. Fill the transmission to the proper level with DEXRON® III transmission fluid. Transmission Extension Housing Rear Oil Seal Replacement Transmission Extension Housing Rear Oil Seal Replacement ^ Tools Required J 21426 Extension Housing Seal Installer - J 36850 Transjel Lubricant Removal Procedure 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Place a drain pan under the vehicle. 3. Remove the propeller shaft. 4. Remove the case extension housing rear oil seal. Use a flat bladed tool and carefully pry the seal from the housing. 5. Inspect the case extension housing for damage. Replace the extension housing if necessary. Installation Procedure 1. Lubricate the inside diameter of the new seal with J 36850. 2. Use the J 21426 with a soft faced mallet to install the seal. 3. Install the seal to the extension housing. 4. Install the propeller shaft. 5. Remove the drain pan and lower the vehicle. 6. Fill the transmission to the proper level with DEXRON® III transmission fluid. Service and Repair Steering Angle Sensor: Service and Repair Rear Position Sensor Replacement Removal Procedure 1. Notice: Refer vehicle Lifting. Raise the vehicle. Refer to Vehicle Lifting. 2. Remove the steering gear protection shield (1) retaining bolts (3). 3. Disconnect the electrical connector (1). 4. Notice: When removing the rear position cover from the steering gear be careful not to damage to the rear position sensor. Remove the rear wheel position sensor cover (4) from the steering gear by prying on the cover using the slot. 5. Remove the rear wheel position sensor retaining bolts (3). 6. Important: Check the inner tie rod boot for wear or damage. If the boots are damaged replace the steering gear actuator. 7. Important: Page 4861 Tighten Tighten the sensor to 42 N.m (31 lb ft). 3. If equipped with a 6.0L engine, connect the HO2S electrical connector (2). 4. If equipped with a 4.8L or 5.3L engine, connect the HO2S electrical connector (2). 5. If equipped with a fuel composition sensor, install the HO2S electrical connector to the fuel line clip. 6. Disconnect the CPA retainer. 7. If equipped, connect the fuel composition sensor electrical connector. 8. Lower the vehicle. Page 10305 Tie Rod End: Service and Repair Outer Rack and Pinion Outer Tie Rod End Replacement ^ Tools Required J 24319-01 Universal Steering Linkage Puller Removal Procedure 1. Raise the vehicle. Support the vehicle with suitable safety stands. Refer to Vehicle Lifting. 2. Remove the tire and wheel assembly. 3. Remove the torque prevailing nut from outer tie rod stud. 4. Loosen the jam nut (2) on the inner tie rod assembly (1). 5. Remove the outer tie rod assembly (2) from the steering knuckle (1) using J 24319-01. 6. Remove the outer tie rod assembly (3) from the inner tie rod assembly (1). Installation Procedure Page 9742 C221 I/P Harness To Body Harness (With Dual Stage Air Bag) Page 16074 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors USING CONNECTOR TEST ADAPTERS IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-B Connector Test Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Page 1444 Backup Lamp Switch: Service and Repair ZF S6-650 Backup Lamp Switch Replacement Removal Procedure 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. If equipped with a 6.6L engine, disconnect the backup lamp switch electrical connector (3). 2. If equipped with a 8.1L engine, disconnect the backup lamp switch electrical connector (4). 3. Remove the backup lamp switch. Installation Procedure Page 3272 Engine Mount: Service and Repair Engine Mount Replacement Left Engine Mount Replacement - Left Removal Procedure Notice: When raising or supporting the engine for any reason, do not use a jack under the oil pan, any sheet metal, or the crankshaft pulley. Due to the small clearance between the oil pan and the oil pump screen, jacking against the oil pan may cause the pan to be bent against the pump screen. This will result in a damaged oil pickup unit. 1. Remove the engine mount heat shield, if equipped. 2. Remove the engine mount-to-engine mount bracket bolts. (Right side shown, left side similar). Interior - Intermittent Seat Heater Operation Seat Heater Control Module: Customer Interest Interior - Intermittent Seat Heater Operation Bulletin No.: 05-08-50-008 Date: August 19, 2005 TECHNICAL Subject: Intermittent Heated Seats Inoperative, DTC B3941 Set (Reprogram Driver Seat Module) Models: 2003-2005 Cadillac Escalade, Escalade ESV, Escalade EXT 2003-2005 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2003-2005 GMC Sierra, Yukon, Yukon XL, Yukon Denali All with Seat FRT, Individual (Non BKT) (RPO AN3) 2003-2005 HUMMER H2 with Seat, Front Bucket Deluxe (RPO AR9) Condition Some customers may comment that occasionally the seat heater will not operate when activated. If the ignition key is cycled OFF and back ON again, the heated seat will operate correctly. Also, on some LB7 diesel engine vehicles, the seat heater may turn itself off during the first 10 minutes of operation. This occurs only with the first activation for the day and works correctly with subsequent activations immediately after the event. These conditions are intermiffent and DTC B3941 may be set. Correction Technicians are to reprogram the driver seat module with an updated software calibration. This new service calibration was released with TIS satellite data update version 6.5 available June 13, 2005. As always, make sure your Tech 2(R) is updated with the latest software version. Warranty Information Page 11981 The number above refers to the step number on the diagnostic table. DTC U0073 or U2100 DTC Descriptors DTC U0073 00: Control Module Communication Bus Off DTC U0073 71: ECU HS Bus Off DTC U0073 72: ECU LS Bus Off DTC U2100 00: Controller Area Network (CAN) Bus Communication DTC U2100 47: Controller Area Network (CAN) Bus Communication Circuit/System Description The serial data circuits are serial data buses used to communicate information between the control modules. The serial data circuits also connect directly to the data link connector (DLC). Conditions for Running the DTCs Supply voltage at the modules are in the normal operating range. The vehicle power mode requires serial data communications. Conditions for Setting the DTC The module setting the DTC has attempted to establish communications on the serial data circuits more than 3 times. Page 12794 Test Description DTC U1001 and U1254 Circuit/System Description Modules connected to the Class 2 serial data circuit monitor for serial data communications during normal vehicle operation. Operating information and commands are exchanged among the modules. When a module receives a message for a critical operating parameter, the module records the identification number of the module which sent the message for State of Health monitoring. A critical operating parameter is one which, when not received, requires that the module use a default value for that parameter. Once an identification number is learned by a module, it will monitor for that module's Node Alive message. Each module on the class 2 serial data circuit which is powered and performing functions that require detection of a communications malfunction is required to send a Node Alive message every 2 seconds. When no message is detected from a learned identification number for 5 seconds, a DTC U1XXX where XXX is equal to the 3-digit identification number is set. Page 4632 Electrical Symbols Part 2 Page 13275 8.5. Close the luggage compartment floor. 9. Fold down the left-hand rear side hatch in the luggage compartment. 10. M03: Replace the optic cable on the left-hand rear side: 10.1. Place the optic cable so that it is positioned behind the terminal housing on top of REC (A). 10.2. Remove the locking strip (B) on the 2-pin connector (H2-9) for the optic cable. 10.3. Open the terminal housing (C) with a screwdriver. Remove the secondary catch (D) on the connector and disconnect the optic cable coming from the OnStar(R) control modules. Page 2496 Grade ................................................................................................................................................... .................................................................... Synthetic Viscosity .......................................................... ......................................................................................................................................................... 75W-90 Locations Door Module: Locations Driver Door Page 12221 7.1. Remove the console (A) together with the OnStar(R) control modules. 7.2. Remove the connectors (B). Important: The optic cable must not be bent with a radius less than 25 mm (1 in). Important: Secure the wiring harness so that there is no risk of chafing and rattling. 7.3. Fold back the wiring harness and tape over the connectors (C). Fold back the wiring harness once more and secure with cable ties (D). 7.4. Fit the parcel shelf trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 8. CV: Removing the OnStar(R) control modules and securing the wiring: Adjustment/Replacement. 8.1. Open the luggage compartment floor. Page 12125 ^ For U.S. Saturn retailer claim submission, use Net Item code "M" and Case Type VW. Page 5338 7. Use the following procedure in order to inspect for leaks: 7.1. Turn the ignition ON, with the engine OFF, for 2 seconds. 7.2. Turn the ignition OFF for 10 seconds. 7.3. Turn the ignition ON, with the engine OFF. 7.4. Inspect for fuel leaks. Page 5159 Accelerator Pedal Position Sensor: Service and Repair ACCELERATOR PEDAL POSITION (APP) SENSOR REPLACEMENT REMOVAL PROCEDURE NOTE: Handle the electronic throttle control components carefully. Use cleanliness in order to prevent damage. Do not drop the electronic throttle control components. Do not roughly handle the electronic throttle control components. Do not immerse the electronic throttle control components in cleaning solvents of any type. 1. Remove the connector position assurance (CPA) retainer. 2. Disconnect the accelerator pedal position (APP) sensor electrical connector. 3. Reposition the carpet to access the lower nut. 4. Remove the accelerator pedal nuts. 5. Remove the accelerator pedal assembly. INSTALLATION PROCEDURE Page 1392 3. Disconnect the vent valve pipe quick connect from the canister. 4. Either cut the existing valve vent pipe and leave the remaining section of pipe in the vehicle or remove along with the valve. 5. Push in the retainer and remove the existing canister vent valve from the fuel tank clip or mounting bracket. 6. Cut back the existing canister pipe approximately 51 mm (2 in) and retain the pipe for use with new valve. 7. Connect the canister pipe quick connect to the canister. 2500 Crew Cab Short Box Shown Below, Other Configurations Similar 1500 Extended Cab Short Box Shown Below, Other Configurations Similar 8. Install the new canister vent valve solenoid to the fuel tank clip or mounting bracket as shown above. The valve port closest to the electrical connector must point towards the canister. 9. Cut bulk 5/8" heater hose to a length of approximately 76 mm (3 in). Install the hose between the solenoid and the canister pipe and secure using clamps. 10. Attach bulk 5/8" heater hose to the vent port and secure using a clamp. Run a length as needed along the frame rail routing to the passenger side area above the transmission. 11. Cut the hose to determined length and install the supplied filter box. Secure using a clamp. 12. Remove the transmission heat shield, if necessary. 13. Remove the transmission support and lower the transmission assembly as necessary to allow for access to the new filter box location. 14. Secure the filter box to the transmission vent hose just forward of the hose tee-section using a tie strap. DO NOT pinch or restrict the transmission vent hose. The filter box opening should be pointing downward. 15. Raise the transmission and reinstall the transmission support. 16. Reinstall the transmission heat shield. 17. Connect the EVAP canister vent valve electrical connector. 18. Tie strap the hose as needed along the frame rail in order to keep the hose away from pinch-points and heat sources. 19. Lower the vehicle. Parts Information Page 2154 3. The squeal may be an internal engine noise. Remove the drive belt(s) and operate the engine for a few seconds, this will verify if the squealing noise is related to the drive belt(s) or an accessory drive component. With the drive belt(s) removed the water pump will not operate and the engine may overheat. Also diagnostic trouble codes (DTCs) may set when the engine is operated with the drive belt(s) removed. 4. This test is to verify that an accessory drive component(s) does not have a seized bearing. With the belt(s) removed, test the bearings in the accessory drive component(s) for smooth operation. Also test the accessory drive component(s) with the engine operating by varying the load on the accessory drive component(s) to verify that the component(s) is operating properly. 5. This test is to verify that the drive belt(s) tensioner(s) are not operating properly. If the drive belt tensioner(s) are not operating properly, proper belt tension may not be achieved to keep the drive belt(s) from slipping which could cause a squealing noise. 6. This test is to verify that the drive belt(s) is not too long, which would prevent the drive belt tensioner(s) from operating properly. Also if the incorrect length drive belt(s) was installed, it may not be routed correctly and may be turning an accessory drive component in the incorrect direction. 7. Misalignment of the accessory drive pulley(s) may be caused from improper mounting or incorrect installation of a accessory drive component, or the pulley may be bent inward or outward from a previous repair. Test for a misaligned pulley using a straight edge in the pulley grooves across two or three pulleys. If a misaligned pulley is found, refer to that accessory drive component for the proper removal and installation procedure for that pulley. 8. Inspect the accessory drive pulley(s) to verify that they are the correct diameter or width. Using a known good vehicle, compare the accessory drive pulleys. Drive Belt Vibration Drive Belt Vibration Diagnosis Diagnostic Aids The accessory drive components may have an affect on engine vibration. An overcharged air conditioning (A/C) system, a power steering system restriction, or the incorrect fluid, or an extra load placed on the generator are suggested items to inspect. To help identify an intermittent or an improper condition, vary the loads on the accessory drive components. Test Description Page 11087 HVAC Control Module - C2 Part 2 Page 13367 Important The following information MUST be documented on the repair order. Failure to do so may result in a chargeback. - Customer vehicle condition. - Was a Service Lamp or Service Message illuminated? If yes, specify which Service Lamp or Service Message. - Was a DTC(s) set? If yes, specify which DTC(s) were set. - After following the procedure contained within this bulletin, could the condition be duplicated? ‹› If the condition was not duplicated, then document the affected module/component connector name and number on the repair order. - If the condition was duplicated after the procedure contained within this bulletin was followed, and additional diagnosis led to the replacement of a module or component, the SI Document ID Number MUST be written on the repair order. Parts Information Alternate Distributor For All of North America Note NyoGel(R) 760G Lubricant* is equivalent to GMSPO P/N 12377900, and P/N 10953529 (Canada), specified for use to correct the condition in this bulletin. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to: Warranty Information (Saab Models) Page 6535 6. Install the cooler line into the quick connect fitting. 7. Insert the cooler line end into the quick connect fitting until a click is either heard or felt. 8. Do not use the plastic cap on the cooler line in order to install the cooler line into the fitting. 9. Pull back sharply on the cooler line in order to ensure that the cooler line is fastened into the quick connect fitting. 10. Important: Do not manually depress the retaining clip when installing the plastic cap. Position (snap) the plastic cap onto the fitting. Do not manually depress the retaining ring when installing the plastic cap onto the quick connect fitting. 11. Ensure that the plastic cap is fully seated against the fitting. 12. Ensure that no gap is present between the cap and the fitting. Automatic Transmission - 4L60-E/4L65-E Fluid Pan: Specifications Automatic Transmission - 4L60-E/4L65-E Tighten the Pan bolts alternately and evenly to ..................................................................................................................................... 11 Nm (97 inch lbs.) Page 8295 13. Remove the caliper guide pin bolts. 14. Remove the brake caliper from the vehicle. 15. Inspect the caliper assembly. Refer to Brake Caliper Inspection. Installation Procedure 1. Important: Use denatured alcohol to clean the outside surface of caliper boot before installing new brake pads. If you are installing new brake pads, use a C-clamp in order to compress the piston to the bottom of the caliper bore. Use the old brake pad, a metal plate or a wooden block across the face of the piston in order to protect the piston and the caliper boot. 2. Important: Use a small flat-bladed tool and lift the inner edge caliper boot next to the piston to release any trapped air. Ensure that the piston boot is below the level of the piston face. 3. Install the caliper to the caliper mounting bracket. 4. Perform the following procedure before installing the caliper guide pin bolts (15 Series pickups only). 1. Remove all traces of the original adhesive patch. 2. Clean the threads of the bolt with brake parts cleaner or the equivalent and allow to dry. 3. Apply Threadlocker GM P/N 12345493 (Canadian P/N 10953488) to the threads of the bolt. Campaign - Deactivation Of Analog OnStar(R) Technical Service Bulletin # 08089C Date: 081118 Campaign - Deactivation Of Analog OnStar(R) # 08089C: Special Coverage Adjustment - Analog OnStar Deactivation (Nov 18, 2008) Subject: 08089C -- SPECIAL COVERAGE ADJUSTMENT - ANALOG ONSTAR(R) DEACTIVATION Page 4400 Electronic Throttle Control Module: Service and Repair THROTTLE ACTUATOR CONTROL (TAC) MODULE REPLACEMENT REMOVAL PROCEDURE 1. Disconnect the instrument panel (I/P) harness electrical connector (2). 2. Release the red connector position assurance (CPA) retainer. 3. Disconnect the engine wiring harness electrical connector (1). 4. Remove the throttle actuator control (TAC) module nuts. 5. Remove the TAC module. INSTALLATION PROCEDURE Service and Repair Towing Hook / Bracket: Service and Repair Tow Hook Replacement (15 Series) Removal Procedure 1. Remove the front bumper. 2. Remove the tow hook bolts from the frame rail. 3. Remove the tow hook from the vehicle. Installation Procedure 1. Install the tow hook to the frame rail. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the bolts to the tow hook through the frame rail. Tighten the bolts to 85 N.m (63 lb ft). 3. Install the front bumper. Page 13241 DTC B2483: Global Positioning System (GPS) Antenna Malfunction Short to Ground DTC B2484: Global Positioning System (GPS) Antenna Malfunction Open Circuit Conditions for Running the DTCs The ignition is in RUN or ACC position System voltage is between 9.5 - 15.5 volts. The above conditions are met for more than 1 second. Conditions for Setting the DTCs B2462 02: The CIM detects a short to ground on the navigation antenna signal circuit. B2462 04: The CIM detects an open/high resistance on the navigation antenna signal circuit. B2483: The CIM detects a short to ground on the navigation antenna signal circuit. B2484: The CIM detects an open/high resistance on the navigation antenna signal circuit. Action Taken When the DTCs Set The OnStar(R) status LED turns red. The OnStar(R) Call Center cannot locate the vehicle. Conditions for Clearing the DTCs The condition responsible for setting the DTC no longer exists. A history DTC will clear once 50 consecutive malfunction-free ignition cycles have occurred. Circuit/System Testing Turn OFF the ignition. 1. Disconnect the navigation antenna coax cable from the VCIM. 2. Ignition ON, test for 4.5-5.5 volts between the VCIM coax cable center conductor terminal at the VCIM and ground. ^ If not within the specified range, replace the VCIM. Refer to the appropriate vehicle in SI. 3. Reconnect the coax cable to the VCIM. 4. Disconnect the coax cable from the navigation antenna. 5. Test for 4.55.5 volts between the coax cable center conductor and the outer shield. ^ If not within the specified range, replace the coax cable. 6. If all circuits test normal, replace the navigation antenna. Refer to the appropriate vehicle in SI. DTC B2470 DTC Descriptor DTC B2470 04: Cellular Phone Antenna Circuit Malfunction Open Circuit Circuit/System Description The cellular antenna is connected to the vehicle communication interface module (VCIM) with an RG-58 coax cable. The VCIM collects the data from the cellular antenna once every second. Page 8346 1. Disconnect the electrical connector from the fluid level sensor. 2. Using needle nose pliers, compress the locking tabs at the opposite side of the master cylinder. 3. Remove the fluid level sensor. Installation Procedure Page 3599 7. Reposition the surge tank inlet hose clamp from the surge tank. 8. Remove the surge tank inlet hose (1) from the surge tank. 9. Reposition the surge tank outlet hose clamp from the surge tank. 10. Remove the surge tank outlet hose (2) from the surge tank. 11. Remove the bolt from the surge tank. 12. Remove the nut from the surge tank. 13. Remove the surge tank. Installation Procedure 1. Install the surge tank. Panel Replacement Rear Door Panel: Service and Repair Panel Replacement Trim Panel Replacement - Side Access Door Trim Panel Replacement - Side Access Door Removal Procedure 1. Remove the door handle bezel. 2. Remove the screws that retain the trim panel armrest. 3. Insert a flat-bladed tool between the trim panel and the door in order to carefully pry the panel from the door. Installation Procedure 1. Install the trim panel to the door by pressing the panel edges until the panel is in place. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the screws that retain the trim panel armrest. Page 13699 Rear Door Hinge: Service and Repair Hinge Replacement - Rear Side Access Door Hinge Replacement - Rear Side Access Door Removal Procedure 1. Remove the door from the body. 2. Remove any excess sealer surrounding the hinge and scribe the location of the hinge on the body. 3. Lightly hand-sand existing body hinge with 100 grit or finer sandpaper to locate each weld attaching hinge to door. Important: Original punch marks may not necessarily indicate the center of the welds. 4. Center punch each of the 4 weld marks on the original hinge base. It is critical to punch the center of the weld so that as much of the weld is removed during drilling as possible. Important: Do not drill into the hinge pillar (3). Drill through hinge (2) only. If necessary, use a chisel to separate the hinge from pillar. 5. At each punch location, drill through hinge base only using a 13 mm (1/2 in) rotabroach hole saw (4), or equivalent. 6. Remove the hinge from the pillar (3). 7. Remove all remaining weld from the pillar surface to ensure a flush fit of service hinge. Installation Procedure 1. Repair any damage done to the pillar during drilling or removal. 2. Position the hinge within the scribe marks on the hinge pillar. 3. Center punch each stud location on the pillar according to the service hinge. 4. Drill a 3 mm (1/8 in) pilot hole at each center punch location. Page 9638 4. Connect the wire connectors to the lower portion of the electrical center block. 5. Connect the wire connectors with the bolts to the electrical center block. Tighten Tighten all connector bolts (1) to 9 N.m (80 lb in). 6. Ensure all wire connectors are securely connected. 7. Set the electrical center block in its resting position till the tabs (3) locks in place. 8. Install the lower part of the cover (1). 9. With the cover (2) off, use the fuse location information to install all fuses and relays. 10. Install the cover. 11. Install the fender upper brace. 12. Install the 4 fender upper brace bolts. Tighten Tighten the 4 retaining bolts to 25 N.m (18 lb ft). 13. Connect the negative battery cable. 14. Start vehicle and ensure all components function properly. Navigation Radio - Diagnostic Tips Navigation System: All Technical Service Bulletins Navigation Radio - Diagnostic Tips INFORMATION Bulletin No.: 08-08-44-010F Date: March 09, 2009 Subject: Navigation Radio Diagnostic Tips Models: 2008 and Prior GM Passenger Cars and Trucks (Including Saturn) 2008 and Prior HUMMER H2, H3 2008 and Prior Saab 9-7X All Equipped with Navigation Radio Supercede: This bulletin is being revised to update the model years involved, the radio part number list, remove the PQC parts restriction and revise the diagnostic information. Please discard Corporate Bulletin Number 08-08-44-010E (Section 08 - Body and Accessories). Recent part reviews indicate that the majority of Navigation Radios returned for analysis do not test as defective. In many cases, published SI documents were available to correct the condition without the need for an exchange unit. The following Diagnostic Tips may assist with the proper diagnosis and repair of Navigation Radio Concerns. Note For U.S. dealers the 2009 and 2010 Model Year Navigation Radios are currently on restriction through the Technical Assistance Center (TAC). Refer to PI PIC5102. To order Radios and Instrument Panel Clusters (IPC) for 2008 and prior model year vehicles, please continue to follow the normal process and contact an authorized Electronic Service Center (ESC) for assistance. For any Navigation Radio replaced, a copy of the Repair Order (RO) must be included with the returned radio. Be sure to document the customer's concern in detail, including unusual noises and what functions are affected. List any Diagnostic Trouble Codes (DTCs) on the RO. Ensure the radio is sufficiently protected during shipping to prevent damage to the radio assembly. Note Navigation Radios with physical damage (for example: shattered displays, impact damage to the radio face and fluid damage) must be reviewed with the District Service Manager for appropriate coverage prior to replacing the radio. The dealership must note the District Service Manager's approval on the Repair Order, along with the reason for the goodwill assistance. Do NOT disassemble the radio to try and retrieve stuck CDs/DVDs as this may result in a debit to the dealership. Refer to Corporate Bulletin Number 08-08-44-015, Information on Inappropriate Warranty Claims submitted for Damaged Radios and Instrument Panel Clusters. Getting Started Retrieve the Navigation Radio part number using the Tech 2(R). Refer to Corporate Bulletin Number 04-08-44-005C - Utilizing Tech 2 to Retrieve Part Numbers for Radios, Compact Disc (CD) Changers and Instrument Panel Clusters (IPC). Use the table below to determine the appropriate Diagnostic Tips Review to follow based on the radio part number. Scroll down the bulletin to find the corresponding Diagnostic Tips Review. Printing This Document To print the applicable Diagnostic Tips Review pages, select File then Print Preview. Use the arrows at the top of the screen to scroll left and right through the bulletin to identify the correct pages containing the questions. With the pages identified, click on the Print button at the top left. In the pop-up box, select "Pages" in the "Print Range" and type in the pages. For example, to print pages 19 through 22, type in the box provided "19-22". Once the page range has been filled in, click the Print box at the bottom of the pop-up box. Trim Height Specifications Alignment: Specifications Trim Height Specifications Trim Height Specifications Page 14994 4. Important: DO NOT loosen the other bolt completely in the next step. Leave two or three threads of the bolt engaged in the tailgate. Removing this bolt completely may allow the linkage inside the tailgate to separate from the latch. 5. If the toothed or plastic nut is present, loosen the other two bolts (1) attaching the latch (2) to the tailgate. DO NOT remove these bolts. 6. Finish loosening the bolt that attaches the support cable. The bolt will NOT be removable even though the threads are completely out. 7. Place an interior trim removal type tool (2) between the support cable end (3) and the latch (1), and pry the two apart. As the two spread apart, the toothed or plastic nut on the other side of the latch will begin to move towards the end of the bolt. 8. Once the toothed or plastic nut has moved away from the backside of the latch, use long nose pliers to grasp and twist it off of the bolt. Discard the toothed nut. 9. Remove the bolt and support cable. Important: Do not reinstall the toothed or plastic nut when installing the new support cable. Also, the support cables used on these vehicles are interchangeable from side to side, and no washers are to be installed like those used on the new style trucks (GMT800). 10. Install the new support cable to the latch and reinstall the original bolt. Tighten Tighten the bolt to 30 Nm (22 lb-ft). 11. If the other bolts were loosened earlier, Tighten Tighten the other loose bolts to 30 Nm (22 lb-ft). 12. Attach the opposite end of the support cable to the pickup box. 13. Repeat this procedure on the other support cable. Important: Depending on the condition of the tailgate and related parts, one of the two new support cables (either left or right) may NOT be tight (taut) when the tailgate is fully open. This condition may be caused by several factors including a damaged hinge, pickup box, or the tailgate itself may be slightly bent due to overloading at some previous time. Replacing either or both support cables a second time will NOT correct this condition. Replacement of any additional parts to correct this condition will NOT be covered under this recall. 14. Remove the tailgate support, close, open and re-close the tailgate. Verify that the support cables fold properly. Escalade EXT, Avalanche, New Style Silverado and Sierra (GMT800), Kodiak, TopKick The following procedures provides instructions for inspecting, and if necessary, replacing the rear endgate (tailgate) support cables and inspecting the right side tailgate hinge for damage, and replacing if necessary. Page 348 Page 6006 1. The shift lock control actuator must lock the shift lever clevis when the shift lever clevis is put into the park position. 2. Depress the brake pedal to move the shift lever out of the park position. 3. The actuator will be energized. 4. Readjust the shift lock control actuator if needed. 5. Install the BCM. 6. Enable the SIR system. Page 2950 longer. Important Whenever a wheel is refinished, the mounting surface and the wheel nut contact surfaces must not be painted or clearcoated. Coating these surfaces could affect the wheel nut torque. When re-mounting a tire on an aluminum wheel, coated balance weights must be used in order to reduce the chance of future cosmetic damage. Disclaimer Page 6972 Date: May 01, 2008 Subject: HYDRA-MATIC(R) Front Wheel Drive 4T80-E (MH1) Left Front Axle Seal Leak, Transmission Slips in Gear (Replace Third Clutch Housing with Revised Service Part) Models: 2001-2008 GM Passenger Cars with HYDRA-MATIC(R) Front Wheel Drive 4T80-E Automatic Transmission (RPO - MH1) Supercede: This bulletin is being updated to revise the Warranty Information. Please discard Corporate Bulletin Number 08-07-30-009A (Section 07 - Transmission/Transaxle). Condition Some customers may comment on a transmission oil leak and/or that the transmission slips in gear. Cause An oil leak may be caused by bushing wear in the third clutch housing, causing excessive fluid build-up at axe sea. Correction Important: DO NOT replace the transmission for above concerns. Replace the third clutch housing with service P/N 8682114, which has revised bushing material to extend life and reduce left front axle seal leaks. Refer to Automatic/Transaxle - 4T80-E Transmission Off-Vehicle Repair Instructions for the replacement of the third clutch housing in SI. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 15275 Door Switch: Description and Operation DOOR LATCH (DOOR JAMB) SWITCHES The theft deterrent system uses the door key switch as one method in order to activate the alarm. If the BCM detects any door opening before the BCM receives a disarm input, the alarm mode activates. DOOR KEY SWITCH The BCM monitors the door key switches in order to disarm the CTD system. When the lock cylinder turns in order to unlock the door, the switch grounds the disarm input to the BCM. Page 7295 For vehicles repaired under warranty, use the table. Disclaimer Page 9475 5. If J 42059 tool fails to release the power port/lighter socket from the retainer, perform the following alternate method: 5.1. Insert a small grinding tool with a cutoff wheel into the socket. 5.2. Remove the plastic latches in the 3 mm (0.11 in) square windows. 5.3. Use the J 42059 as directed above to remove the socket. 6. Remove the electrical connector from the socket. INSTALLATION PROCEDURE 1. Insert the plastic ring into the opening and snap the plastic ring into place. 2. Connect the electrical connector to the receptacle. 3. Insert the receptacle through the plastic ring gently by hand until the receptacle ring is sealed. 4. Install the power supply fuse. Service and Repair Wiper Gear Box: Service and Repair WIPER TRANSMISSION REPLACEMENT TOOLS REQUIRED - J 39232 Wiper Transmission Separator - J 39529 Wiper Transmission Installer REMOVAL PROCEDURE 1. Remove the wiper arms. 2. Remove the air inlet grille panel. 3. Remove the 4 bolts and the reinforcement panel. 4. Disconnect the electrical connector from the wiper motor. 5. Remove the 2 bolts from the wiper transmission assembly. 6. Remove the wiper transmission assembly from the vehicle. Page 3825 Body Control Module (BCM) - C2 Part 3 Engine, A/T - Shift/Driveability Concerns/MIL ON Air Filter Element: All Technical Service Bulletins Engine, A/T - Shift/Driveability Concerns/MIL ON Bulletin No.: 04-07-30-013B Date: February 01, 2007 INFORMATION Subject: Automatic Transmission Shift, Engine Driveability Concerns or Service Engine Soon (SES) Light On as a Result of the Use of an Excessively/Over-Oiled Aftermarket, Reusable Air Filter Models: 2007 and Prior GM Cars and Light Duty Trucks 2007 and Prior Saturn Models 2003-2007 HUMMER H2 2006-2007 HUMMER H3 2005-2007 Saab 9-7X Supercede: This bulletin is being revised to add models and model years. Please discard Corporate Bulletin Number 04-07-30-013A (Section 07 - Transmission/Transaxle). The use of an excessively/over-oiled aftermarket, reusable air filter may result in: Service Engine Soon (SES) light on Transmission shift concerns, slipping and damaged clutch(es) or band(s) Engine driveability concerns, poor acceleration from a stop, limited engine RPM range The oil that is used on these air filter elements may be transferred onto the Mass Air Flow (MAF) sensor causing contamination of the sensor. As a result, the Grams per Second (GPS) signal from the MAF may be low and any or all of the concerns listed above may occur. When servicing a vehicle with any of these concerns, be sure to check for the presence of an aftermarket reusable, excessively/over-oiled air filter. The MAF, GPS reading should be compared to a like vehicle with an OEM air box and filter under the same driving conditions to verify the concern. The use of an aftermarket reusable air filter DOES NOT void the vehicle's warranty. If an aftermarket reusable air filter is used, technicians should inspect the MAF sensor element and the air induction hose for contamination of oil prior to making warranty repairs. Transmission or engine driveability concerns (related to the MAF sensor being contaminated with oil) that are the result of the use of an aftermarket reusable, excessively/over-oiled air filter are not considered to be warrantable repair items. Page 7394 6. With the output gear encoder assembly in hand, carefully align the casting and output gear timing marks (1). 7. At the same time, be sure to align the encoder phasing post (1) with the phasing slot (2) in the casting and insert the shaft into the bushing. 8. Verify that the output gear and idler are engaged properly. 9. Seat the harness wires on the casting channel. 10. Place the shim on the output shaft gear. 11. Press a NEW seal into the cover. Automatic Transmission - 4L60-E/4L65-E Fluid - A/T: Service and Repair Automatic Transmission - 4L60-E/4L65-E Automatic Transmission Fluid/Filter Replacement Removal Procedure Caution: When the transmission is at operating temperatures, take necessary precautions when removing the drain plug, to avoid being burned by draining fluid. 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. Place a drain pan under the transmission oil pan. 3. Remove the oil pan drain plug, if equipped. 4. If necessary, remove the bolts and position aside the range selector cable bracket for clearance while lowering the pan. It is not necessary to remove the cable from the lever or bracket. 5. Remove the oil pan bolts from the front and sides of the pan only. 6. Loosen the rear oil pan bolts approximately 4 turns. 7. Lightly tap the oil pan with a rubber mallet in order to loosen the pan to allow the fluid to drain. 8. Remove the remaining oil pan bolts. 9. Remove the oil pan and the gasket. Page 11911 5.2 Cut off the cable tie (B), detach the connector's rear end face (C) and pull out the connecting rail (D). 5.3. Remove pin 39, cut off the cable terminal and insulate the end with tape (E). Fold back the cable and secure it with tape (F). 5.4. Fit the connecting rail and end face. 5.5. Plug in the connector (A) and secure the cables with cable ties (B). 6. Install the floor console over the handbrake. Do not press the console down into place, but instead allow it to fit loosely. 7. Install the switch: 7.1. Install the switch for the roof lighting (B) and plug in its connector. 7.2. Guide the connectors for the window lift module and rear seat heater, if equipped, through the hole for each respective unit. Plug in the window lift module's connector and install the module (A). Engine Controls - MIL ON/Misfire/Misfire DTC's Set Ground Strap: All Technical Service Bulletins Engine Controls - MIL ON/Misfire/Misfire DTC's Set Bulletin No.: 06-06-04-046 Date: September 12, 2006 INFORMATION Subject: Information on Engine Misfire MIL/SES Light Illuminated or Flashing DTC P0300, P0301, P0302, P0303, P0304, P0305, P0306, P0307, P0308, P0420 or P0430 Models: 1999-2007 Cadillac, Chevrolet, GMC Full-Size Pickup and/or Utility Trucks with 4.8L, 5.3L, 5.7L, 6.0L or 6.2L VORTEC GEN III, GEN IV, V-8 Engine (VINs V, C, T, Z, B, 3, M, 0, J, R, U, N, Y, K, 8 - RPOs LR4, LY2, LM7, L59, L33, LC9, LH6, LMG, LY5, L31, LQ4, LQ9, L76, LY6, L92) with Active Fuel Management(TM) and E85 Flex Fuel If you encounter vehicles that exhibit the above conditions, refer to SI for the appropriate DTC(s) set. If no trouble is found, the cause may be due to an ECM ground terminal that has corroded with rust over time. Inspect the main engine wiring harness ground terminal (G103) for this condition. The wire terminal (G103) attaches either to the front or to the rear of the right side cylinder head, depending on the model year of the Full Size Pickup and/or Utility Trucks. If the ECM ground terminal has been found to be corroded, then follow the service procedure outlined in this bulletin to correct the corrosion issue. Remove either the nut or bolt securing the main engine wiring harness ground terminal (G103) to the right cylinder head. Refer to the above illustration to determine where the ground is located on the vehicle (1). Page 2409 For vehicles repaired under warranty, use the table. Disclaimer TPMS System - Service And Re-Learning Sensor IDs Tire Pressure Sensor: Technical Service Bulletins TPMS System - Service And Re-Learning Sensor IDs INFORMATION Bulletin No.: 10-03-16-001 Date: July 19, 2010 Subject: TPMS System Service and Re-Learning Sensor IDs Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks 2010 and Prior HUMMER H2 2009 and Prior HUMMER H3 2010 and Prior Saturn Models 2009 and Prior Saab 9-7X with Wheel-Mounted Tire Pressure Sensors In the event that the spare tire, which is normally not equipped with a tire pressure monitor (TPM) sensor, is installed in place of one of the road tires and the vehicle is driven above 40 km/h (25 mph) for 20 minutes or more, the TPM indicator icon on the instrument panel cluster (IPC) will flash for approximately one minute and then remain on steady each time the ignition is turned ON, indicating a diagnostic trouble code (DTC) has been set. The driver information center (DIC), if equipped, will also display a SERVICE TIRE MONITOR type message. When the road tire is repaired and reinstalled in the original location, the TPM indicator icon illumination and DIC message may remain displayed until the DTC is cleared. To ensure that the TPM indicator and the DIC message are cleared after service, it is necessary to clear any TPM DTCs using a scan tool. If a scan tool is unavailable, performing the TPM relearn procedure using a TPM diagnostic tool will provide the same results. It is advised to perform the relearn procedure away from other vehicles to prevent picking up a stray sensor signal. If one or more of the TPM sensors are missing or damaged and have been replaced, then the relearn procedure must be performed. Disclaimer Page 2011 Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips SPLICING COPPER WIRE USING SPLICE CLIPS IMPORTANT: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. TOOLS REQUIRED J 38125-D Terminal Repair Kit 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-D in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. Page 2772 8. Install the left side end panel. Page 9834 Location View Location View Restraints - Passenger Presence System Information Seat Occupant Sensor: All Technical Service Bulletins Restraints - Passenger Presence System Information INFORMATION Bulletin No.: 06-08-50-009F Date: December 23, 2010 Subject: Information on Passenger Presence Sensing System (PPS or PSS) Concerns With Custom Upholstery, Accessory Seat Heaters or Other Comfort Enhancing Devices Models: 2011 and Prior GM Passenger Cars and Trucks Equipped with Passenger Presence Sensing System Supercede: This bulletin is being revised to update the model years. Please discard Corporate Bulletin Number 06-08-50-009E (Section 08 - Body and Accessories). Concerns About Safety and Alterations to the Front Passenger Seat Important ON A GM VEHICLE EQUIPPED WITH A PASSENGER SENSING SYSTEM, USE THE SEAT COVERS AND OTHER SEAT-RELATED EQUIPMENT AS RELEASED BY GM FOR THAT VEHICLE. DO NOT ALTER THE SEAT COVERS OR SEAT-RELATED EQUIPMENT. ANY ALTERATIONS TO SEAT COVERS OR GM ACCESSORIES DEFEATS THE INTENDED DESIGN OF THE SYSTEM. GM WILL NOT BE LIABLE FOR ANY PROBLEMS CAUSED BY USE OF SUCH IMPROPER SEAT ALTERATIONS, INCLUDING ANY WARRANTY REPAIRS INCURRED. The front passenger seat in many GM vehicles is equipped with a passenger sensing system that will turn off the right front passenger's frontal airbag under certain conditions, such as when an infant or child seat is present. In some vehicles, the passenger sensing system will also turn off the right front passenger's seat mounted side impact airbag. For the system to function properly, sensors are used in the seat to detect the presence of a properly-seated occupant. The passenger sensing system may not operate properly if the original seat trim is replaced (1) by non-GM covers, upholstery or trim, or (2) by GM covers, upholstery or trim designed for a different vehicle or (3) by GM covers, upholstery or trim that has been altered by a trim shop, or (4) if any object, such as an aftermarket seat heater or a comfort enhancing pad or device is installed under the seat fabric or between the occupant and the seat fabric. Aftermarket Seat Heaters, Custom Upholstery, and Comfort Enhancing Pads or Devices Important ON A GM VEHICLE EQUIPPED WITH A PASSENGER SENSING SYSTEM, USE ONLY SEAT COVERS AND OTHER SEAT-RELATED EQUIPMENT RELEASED AS GM ACCESSORIES FOR THAT VEHICLE. DO NOT USE ANY OTHER TYPE OF SEAT COVERS OR SEAT-RELATED EQUIPMENT, OR GM ACCESSORIES RELEASED FOR OTHER VEHICLE APPLICATIONS. GM WILL NOT BE LIABLE FOR ANY PROBLEMS CAUSED BY USE OF SUCH IMPROPER SEAT ACCESSORIES, INCLUDING ANY WARRANTY REPAIRS MADE NECESSARY BY SUCH USE. Many types of aftermarket accessories are available to customers, upfitting shops, and dealers. Some of these devices sit on top of, or are Velcro(R) strapped to the seat while others such as seat heaters are installed under the seat fabric. Additionally, seat covers made of leather or other materials may have different padding thickness installed that could prevent the Passenger Sensing System from functioning properly. Never alter the vehicle seats. Never add pads or other devices to the seat cushion, as this may interfere with the operation of the Passenger Sensing System and either prevent proper deployment of the passenger airbag or prevent proper suppression of the passenger air bag. Disclaimer Page 9192 C152 Chassis Harness To Engine Harness Part 1 Page 12607 6. See wiring diagram shown above for details. 5. Replace the OnStar(R) Vehicle Communication Interface Module (VCIM) in the vehicle with the provided Digitally-Capable VCIM. Refer to the Communication Interface Module Replacement procedure in the Cellular Communication section of SI. This kit may include a new VCIM bracket. If it does, use this new bracket on the vehicle and discard the original bracket. The kit may also include a small wiring jumper cable. If it does, plug the wiring jumper cable into the connector on the VCIM and the other end to the corresponding vehicle wiring harness connector. ^ For 2001, 2002 and 2003 Chevrolet Impala and Monte Carlo, do not reinstall the black plastic OnStar(R) module cover onto the vehicle after the VCIM and module bracket have been installed. This black plastic cover will no longer fit on the vehicle. ^ The upgrade kit for 2002 Sevilles and DeVilles, and some 2003 Sevilles and DeVilles, will contain a large bracket. To install the new VCIM into this bracket you'll need to carefully line up the notch in the VCIM with the tab in the bracket. Page 2328 Power Steering Line/Hose: Service and Repair Power Steering Gear Outlet Pipe/Hose (Recirculating Ball) Power Steering Gear Outlet Pipe/Hose Replacement (Recirculating Ball) Removal Procedure 1. Notice: Refer to Power Steering Hose Disconnected Notice in Service Precautions. Install a drain pan under the vehicle. 2. Remove the power steering gear outlet hose (3) from the steering gear (2). 3. Remove the clamp retaining the power steering gear outlet hose (3) to the power steering pump (1).Remove the power steering gear outlet hose from the power steering pump. 4. Remove the power steering gear outlet hose from the vehicle. Installation Procedure 1. Notice: Refer to Installing Hoses Without Twists or Bends Notice in Service Precautions. Route the hose in the same position the hose occupied prior to removal. 2. Install the power steering gear outlet hose (3) to the power steering pump (1).Position the clamp at the end of the hose. 3. Notice: Refer to Fastener Notice in Service Precautions. Install the power steering gear outlet hose to the power steering gear. ^ Tighten the outlet hose fitting to 28 Nm (20 ft. lbs.). 4. Remove the drain pan from under the vehicle. 5. Bleed the power steering system. Refer to Bleeding the Power Steering System. (Rack and Pinion) Power Steering Gear Outlet Pipe/Hose Replacement (Rack and Pinion) Page 4237 Spark Plug: Service and Repair SPARK PLUG REPLACEMENT REMOVAL PROCEDURE 1. Remove the spark plug wire. 2. Loosen the spark plug 1 or 2 turns. 3. Brush or using compressed air, blow away any dirt from around the spark plug. 4. Remove the spark plug. If removing more than one plug, place each plug in a tray marked with the corresponding cylinder number. INSTALLATION PROCEDURE 1. Correctly position the spark plug washer. 2. Inspect the spark plug gap. Adjust the gap as needed. Specification Spark plug gap: 1.01 mm (0.040 in) 3. Hand start the spark plug in the corresponding cylinder. NOTE: Refer to Fastener Notice in Service Precautions. 4. Tighten the spark plug. Tighten Tighten the plug to 15 N.m (11 lb ft) for used heads. - Tighten the plug to 20 N.m (15 lb ft) for NEW heads. 1. Install the spark plug wire. Page 12958 Speaker - RF Door - With RPO Code UQ3/UQ7 Page 10103 3. Important: The lower connector will not go on if the upper connector is already installed. Connect the lower electrical connector (4) to the power steering pump. 4. Connect the upper electrical connector (3) to the power steering pump. Page 13418 9. Use J 38125-12A to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. REPAIR PROCEDURE The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. 1. Cut the wire as close to the terminal as possible. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. Locations Knock Sensors Page 16156 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. REPLACEMENT PROCEDURE After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Insure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the Terminal Removal Procedure. Repairing Connector Terminals REPAIRING CONNECTOR TERMINALS TOOLS REQUIRED J 38125-D Terminal Repair Kit Use the following repair procedures in order to repair the following: - Push to Seat terminals - Pull to Seat terminals - Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-D contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100 World terminals. Soldering Micro-Pack 100 World terminals may damage the terminal. Circuit Protection - Circuit Breakers CIRCUIT PROTECTION - CIRCUIT BREAKERS A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Page 8769 Generator Page 11241 Refrigerant Filter: Service and Repair Replacement AIR CONDITIONING (A/C) REFRIGERANT FILTER REPLACEMENT TOOLS REQUIRED J 39400-A Halogen Leak Detector REMOVAL PROCEDURE 1. Recover the refrigerant from the system. Refer to Refrigerant Recovery and Recharging. 2. Remove the air cleaner. IMPORTANT: The nuts (4) and the ferrules (3) will remain on the evaporator tube. Do not try to remove. 3. Remove the nuts (4) from the A/C refrigerant filter (1). 4. Remove the A/C refrigerant filter (3) from the evaporator tube (2). INSTALLATION PROCEDURE Page 5583 Steps 15 - 18 Page 5572 12. Remove the ignition coil. INSTALLATION PROCEDURE 1. Install the ignition coil. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the ignition coil bolts. Page 13697 Rear Door Hinge: Service and Repair Hinge Replacement - Rear Door - Door Side Hinge Replacement - Rear Door - Door Side Removal Procedure 1. Remove all of the related panels and components. 2. Remove any excess sealer surrounding the existing hinge and scribe the location of the hinge on the hinge pillar. 3. Lightly hand-sand the existing hinge with 100 grit or finer sandpaper in order to locate the 4 welds that attach the hinge to the pillar. Important: It is critical to punch the center of the weld so that as much of the weld as possible is removed during the drilling. 4. Center punch each of the 4 weld marks on the original hinge. Important: Do not drill into the door (1). 5. Drill through the hinge (2), at each punch location. Use a 13 mm (1/2 in) rotabroach hole saw (3) or equivalent. 6. Remove the hinge. If necessary, use a chisel in order to separate the hinge from the door. 7. Remove all of the remaining welds from the door surface in order to ensure a flush fit of the service hinge. Installation Procedure 1. Repair any damage done to the door during the drilling or the removal of the hinge. 2. Clean and prepare the backing plate mounting surfaces in order to ensure a flush fit of the backing plate. 3. Position the service hinge within the scribe marks on the door. 4. Center punch each hole location on the door according to the service hinge. Page 5462 3. Using J 45722 install the sending unit lock ring. 4. Connect the EVAP line to the sending unit. 5. Connect the fuel line to the sending unit. 6. Install the fuel tank. I/P Fuse Block Fuse Block: Locations I/P Fuse Block Body Control Module (BCM) Page 374 1. Remove the ground cable from the battery's negative cable. 2. Remove the center console, see WIS - Body - Interior. 3. Loosen the gear shift housing (A). AUT: Disconnect the 6-pin connector (B) to improve access to the gear shift housing screws. 4. Disconnect the signal cable from the SRS control module to the OnStar(R) control module and secure the cable. 4.1. Disconnect the connector (A) from the SRS control module and cut the cable tie (B). Heated Oxygen Sensor (HO2S) Bank 1 Sensor 1 Heated Oxygen Sensor (HO2S) Bank 1 Sensor 1 Locations Door Module: Locations Driver Door Page 14624 Seat Front Vertical Position Sensor - Driver (With RPO Code AN3) Page 11750 Steps 1-5 Page 2711 Location View Page 5993 Park Neutral Position (PNP) Switch C175 Page 2335 1. Notice: Refer to Power Steering Hose Disconnected Notice in Service Precautions. Install a drain pan under the vehicle. 2. Remove the power steering gear outlet hose (3) from the steering gear (2). 3. Remove the clamp retaining the power steering gear outlet hose (3) to the power steering pump (1).Remove the power steering gear outlet hose from the power steering pump. 4. Remove the power steering gear outlet hose from the vehicle. Installation Procedure 1. Notice: Refer to Installing Hoses Without Twists or Bends Notice in Service Precautions. Route the hose in the same position the hose occupied prior to removal. 2. Install the power steering gear outlet hose (3) to the power steering pump (1).Position the clamp at the end of the hose. 3. Notice: Refer to Fastener Notice in Service Precautions. Install the power steering gear outlet hose to the power steering gear. ^ Tighten the outlet hose fitting to 28 Nm (20 ft. lbs.). 4. Remove the drain pan from under the vehicle. 5. Bleed the power steering system. Refer to Bleeding the Power Steering System. (Rack and Pinion) Power Steering Gear Outlet Pipe/Hose Replacement (Rack and Pinion) Removal Procedure Notice: Refer to Power Steering Hose Disconnected Notice in Service Precautions. Page 12323 Electrical Symbols Part 14 Page 13209 Disclaimer Page 12670 OnStar(R) Microphone The OnStar(R), or cellular microphone, can be a part of the rearview mirror assembly, or on some vehicle lines, a separate, stand alone unit. In either case, the VCIM supplies approximately 10 volts to the microphone on the cellular microphone signal circuit, and voice data from the user is sent back to the VCIM over the same circuit. A cellular microphone low reference circuit or a drain wire provides a ground for the microphone. Cellular and GPS Antennas The vehicle will be equipped with one of the following types of antennas: ^ Separate, stand-alone cellular and navigation (GPS) antennas. ^ A combination cellular and navigation (GPS) antenna, which brings the functions of both into a single part. ^ A cellular, GPS, and digital radio receiver (DRR) antenna, which also incorporates the functionality of the DRR satellite antenna (XM). The cellular antenna is the component that allows the OnStar(R) system to send and receive data using electromagnetic waves by means of cellular technology. The antenna is connected at the base to a coax cable that plugs directly into the VCIM. The GPS antenna is used to collect the signals of the orbiting GPS satellites. Within the antenna is housed a low noise amplifier that allows for a more broad and precise reception of this data. The antenna is connected at the base to a coax cable that plugs directly into the VCIM. The cable also provides a path for DC current for powering the antenna. The OnStar(R) Call Center also has the capability of communicating with the vehicle during an OnStar(R) call to retrieve the latest GPS location and transmit it to the OnStar(R) Call Center. A history location of the last recorded position of the vehicle is stored in the module and marked as aged, for as long as the module power is not removed. Actual GPS location may take up to 10 minutes to register in the event of a loss of power. Audio System Interface When the OnStar(R) requires audio output, a serial data message is sent to the audio system to mute all radio functions and transmit OnStar(R) originated audio. The OnStar(R) audio is transmitted to the vehicle audio system by a dedicated signal circuit and a low reference circuit. The audio system will mute and an audible ring will be heard though the speakers if the vehicle receives a call with the radio ON. On some vehicles, the HVAC blower speed may be reduced when the OnStar(R) system is active to aid in reducing interior noise. When the system is no longer active, the blower speed will return to its previous setting. OnStar(R) Steering Wheel Controls Some vehicles may have a button on the steering wheel, that when pushed can engage the OnStar(R) system. The button may be a symbol of a face with sound waves, or may say MUTE, or be a symbol of a radio speaker with a slash through it. By engaging the OnStar(R) system with this feature, the user can interact with the system by use of voice commands. A complete list of these commands is supplied in the information provided to the customer. If the information is not available for reference, at any command prompt, the user can say "HELP" and the VCIM will return an audible list of available commands. The steering wheel controls consist of multiple momentary contact switches and a resistor network. The switches and resistor network are arranged so that each switch has a different resistance value. When a switch is pressed, a voltage drop occurs in the resistor network. This produces a specific voltage value unique to the switch selected, to be interpreted by the radio or the body control module (BCM). OnStar(R) Power Moding (DRX or Sleep Cycle) The OnStar(R) system uses a unique sleep cycle to allow the system to receive cellular calls while the ignition is in the OFF position and retained accessory power (RAP) mode has ended. A green status LED on the OnStar(R) keypad normally indicates an active OnStar(R) account. The OnStar(R) system will stay powered up after ignition off for an extended time in order to allow for remote services like door unlock, horn honk, light flash, etcetera to take place as requested by the customer. Power cycle (also referred to as DRX) times vary depending on the generation of the OnStar(R) system. Technicians may identify the OnStar(R) system generation by using a Tech 2 and following this menu path: (Body>VCIM>Module ID Information>Module Information 2) or by accessing www.onstarenrollment.com All Generation 6 digital systems are powered up continuously for 48 hours from ignition OFF. After 48 hours, the Generation 6 systems will enter a 9 minute OFF, 1 minute ON power cycle for an additional 72 hours. At the beginning and end of the 1 minute ON stage, you may or may not experience a short spike of current at the beginning and at the end. This allows for calls from OnStar to be received by the system. After 120 hours from ignition OFF, Page 4171 Crankshaft Position Sensor: Description and Operation CRANKSHAFT POSITION (CKP) SENSOR The crankshaft position (CKP) sensor is a three wire sensor based on the magneto resistive principle. A magneto resistive sensor uses two magnetic pickups between a permanent magnet. As an element such as a reluctor wheel passes the magnets the resulting change in the magnetic field is used by the sensor electronics to produce a digital output pulse. The PCM supplies a 12-volt, low reference, and signal circuit to the CKP sensor. The sensor returns a digital ON/OFF pulse 24 times per crankshaft revolution. Page 10613 service operation. A simple distraction or time constraint that rushes the job may result in personal injury if the greatest of care is not exercised. Make it a habit to double check your work and to always side with caution when installing wheels. Disclaimer Page 10569 of vibration is normally felt more in the "seat of the pants" than the steering wheel. 5. Next, record the Hertz (Hz) reading as displayed by the EVA onto the tire data worksheet found at the end of this bulletin. This should be done after a tire break-in period of at least 16 km (10 mi) at 72 km/h (45 mph) or greater, in order to eliminate any possible tire flat-spotting. This reading confirms what the vehicle vibration frequency is prior to vehicle service and documents the amount of improvement occurring as the result of the various steps taken to repair. Completing the Steering Wheel Shake Worksheet below is required. A copy of the completed worksheet must be saved with the R.O. and a copy included with any parts returned to the Warranty Parts Center for analysis. A reading of 35 to 50 Hz typically indicates a first order propshaft vibration. If this is the situation, refer to Corporate Bulletin Number 08-07-30-044D. Generally, a reading between 10 and 20 Hz indicates a tire/wheel vibration and if this is the reading obtained, continue using this bulletin. If the tire 1st order vibration goes away and stays away during this evaluation, the cause is likely tire flat-spotting. Tire flat-spotting vibration may come and go at any speed over 72 km/h (45 mph) during the first 10 minutes of operation, if vibration continues after 10 minutes of driving at speeds greater than 72 km/h (45 mph), tire flat-spotting can be ruled out as the cause for vibration. 6. If flat-spotting is the cause, provide the explanation that this has occurred due to the vehicle being parked for long periods of time and that the nature of the tire is to take a set. Refer to Corporate Bulletin Number 03-03-10-007E: Information on Tire/Wheel Characteristics (Vibration, Balance, Shake, Flat Spotting) of GM Original Equipment Tires. 7. If the road test indicates a shake/vibration exists, check the imbalance of each tire/wheel assembly on a known, calibrated, off-car dynamic balancer.Make sure the mounting surface of the wheel and the surface of the balancer are absolutely clean and free of debris. Be sure to chose the proper cone/collet for the wheel, and always use the pilot bore for centering. Never center the wheel using the hub-cap bore since it is not a precision machined surface. If any assembly calls for more than 1/4 ounce on either rim flange, remove all balance weights and rebalance to as close to zero as possible. If you can see the vibration (along with feeling it) in the steering wheel (driving straight without your hands on the wheel), it is very likely to be a tire/wheel first order (one pulse per revolution) disturbance. First order disturbances can be caused by imbalance as well as non-uniformities in tires, wheels or hubs. This first order frequency is too low for a human to hear, but if the amplitude is high enough, it can be seen. If a vibration or shake still exists after balancing, any out of round conditions, of the wheel, and force variation conditions of the tire, must be addressed. Equipment such as the Hunter GSP9700 can address both (it is also a wheel balancer). Tire radial force vibration (RFV) can be defined as the amount of stiffness variation the tire will produce in one revolution under a constant load. Radial force variation is what the vehicle feels because the load (weight) of the vehicle is always on the tires. Although free runout of tires (not under load) is not always a good indicator of a smooth ride, it is critical that total tire/wheel assembly runout be within specification. Equipment such as the Hunter GSP9700 loads the tire, similar to on the vehicle, and measures radial force variation of the tire/wheel assembly. Note that the wheel is affecting the tire's RFV measurement at this point. To isolate the wheel, its runout must be measured. This can be easily done on the Hunter, without the need to set up dial indicators. If the wheel meets the runout specification, the tire's RFV can then be addressed. After measuring the tire/wheel assembly under load, and the wheel alone, the machine then calculates (predicts) the radial force variation of the tire. However, because this is a prediction that can include mounting inaccuracies, and the load wheel is much smaller in diameter than used in tire production, this type of service equipment should NOT be used to audit new tires. Rather, it should be used as a service diagnostic tool to minimize radial force variation of the tire/wheel assembly. Equipment such as the Hunter GSP9700 does an excellent job of measuring wheel runout, and of finding the low point of the wheel (for runout) and the high point of the tire (for radial force variation). This allows the tire to be matched mounted to the wheel for lowest tire/wheel assembly force variation. The machine will simplify this process into easy steps. The following assembly radial force variation numbers should be used as a guide: When measuring RFV and match mounting tires perform the following steps. Measuring Wheel Runout and Assembly Radial Force Variation Important The completed worksheet at the end of this bulletin must be attached to the hard copy of the repair order. - Measure radial force variation and radial runout. - If a road force/balancing machine is used, record the radial force variation (RFV) on the worksheet at the end of this bulletin. It may be of benefit to have the lowest RFV assembly to the front left corner. If the machine is not available and the EVA data suggests there is an issue, swap the tire and wheel assemblies from the front to the back. Re-check on the EVA and if the problem still exists, test another vehicle to find tires that do not exhibit the same frequency and swap those tires onto the subject vehicle. - If a runout/balancing machine is used, record the radial runout of the tire/wheel assemblies on the worksheet at the end of this bulletin. If one or more of the tire/wheel assemblies are more than.040 in (1.02 mm), match mount the tire to the wheel to get below.040 in (1.02 mm). For sensitive customers, readings of 0.030 inch (0.76 mm) or less are preferable, it may also be of benefit to have the lowest runout assembly to the front left corner. If the machine is not available and the EVA data suggests there is an issue, swap the tire and wheel assemblies from the front to the back. Re-check on the EVA and if the problem still exists, test another vehicle to find tires that do not exhibit the same frequency and swap those tires Page 3251 the noise. Belt separation is identified by the plys of the belt separating, this may be seen at the edge of the belt or felt as a lump in the belt. 5. Small amounts of pilling is a normal condition and acceptable. When the pilling is severe the drive belt(s) does not have a smooth surface for proper operation. Drive Belt Squeal Drive Belt Squeal Diagnosis Diagnostic Aids A loose or improper installation of a body, or suspension component, or other item(s) on the vehicle may cause the squeal noise. If the squeal is intermittent, verify that it is not the accessory drive component(s) by varying their load(s), making sure they are operating to their maximum capacity. An overcharged air conditioning (A/C) system, a power steering system restriction or the incorrect fluid, or a failing generator are suggested items to inspect. Test Description Steps 1 - 9 The number(s) below refer to the step(s) in the diagnostic table. 2. The squeal may not be engine related. This step is to verify that the engine is making the noise. If the engine is not making the noise do not proceed further in this table Page 2003 6. Use fingers to squeeze the 2 locking legs of the cover. 7. Apply pressure and gently rock the cover until one locking leg is unseated. 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. Page 14243 Memory/Heated Seat Switch - Driver (DDM C5) Part 2 Page 8905 Control Module References Part 2 Page 5090 7. If the vehicle is equipped with a 8 ft box, disconnect the EVAP CVS line from the canister. 8. Remove the CVS clip from the frame crossmember. 9. Push in the retainer and remove the CVS from the fuel tank clip. INSTALLATION PROCEDURE 1. If the vehicle is equipped with a 8 ft box, install the CVS to the fuel tank until the clip engages. IMPORTANT: On vehicles equipped with a 8 ft box, the CVS line is routed below the frame crossmember. 2. Install the CVS clip to the frame crossmember. 3. Connect the EVAP CVS line to the canister. 4. If the vehicle is equipped with a 6 ft box, install the CVS to the fuel tank until the clip engages. IMPORTANT: On vehicles equipped with a 6 ft box, the CVS line is routed above the frame crossmember. Page 12726 Page 6351 Phase three will eliminate the oil pump body 0-ring seal groove and the 0-ring seal. Beginning March 2004, a new stamped carrier molded rubber seal (2) will be used to seal the pump assembly to the transmission case. The pump sealing surface is now the outer diameter of the pump and the inner diameter (1) of the transmission case bore. Unlike the current 0-ring seal, which is installed on the oil pump body, the new seal is installed after the pump assembly is properly positioned and torqued in place. Seating the seal is accomplished when the torque converter housing is installed, which presses the seal (3) into position between the pump and the case bore (1). As a result of the modified casting and the deeper pump bore machining, the area between the oil pan mounting surface and the pump bore has decreased. Because of the reduced material in this area (1) it is necessary to use the shorter oil pan attaching bolts (2). Early pan bolts (3), before November 2002, should not be used with the modified case design, since they are 1.0 mm (0.39 in) longer and could deform the chamfer surface (4). Service Information Page 3889 Engine Control Module: Description and Operation Electronic Ignition (EI) System POWERTRAIN CONTROL MODULE (PCM) The PCM controls all ignition system functions, and constantly corrects the basic spark timing. The PCM monitors information from various sensor inputs that include the following: - The throttle position (TP) sensor - The engine coolant temperature (ECT) sensor - The mass air flow (MAF) sensor - The intake air temperature (IAT) sensor - The vehicle speed sensor (VSS) - The transmission gear position or range information sensors - The engine knock sensors (KS) Page 13298 Labor Time Information Page 10100 Power Steering Pump: Service and Repair Power Steering Pump Replacement (Parallel Hybrid Truck) Power Steering Pump Replacement (Parallel Hybrid Truck) Removal Procedure 1. Disconnect the energy storage box before servicing the vehicle. 2. Place a drain pan under the vehicle. 3. Disconnect the power steering pump pressure hose from the power steering pump. 4. Remove the clamps (2, 4) retaining the power steering return hoses (1, 5) to the power steering pump and remove the hoses. Page 3057 14. Remove the retaining ring from the wheel hub. 15. Remove the outer hub bearing and bearing cup using the J 24426 (2) and the J 8092 (1). Installation Procedure 1. Lubricate the following with a light coat of high melting point EP bearing lubricant: ^ The outer wheel bearing ^ The inner wheel bearing ^ The outer wheel bearing cup ^ The inner wheel bearing cup ^ The axle housing 2. Install the outer bearing into the wheel hub. 3. Install the outer bearing cup into the wheel hub. Page 7071 Page 10884 Electrical Symbols Part 6 Locations Windshield Washer Reservoir Page 15186 Backup Alarm (With RPO Code 8S3) Page 12214 5.2 Cut off the cable tie (B), detach the connector's rear end face (C) and pull out the connecting rail (D). 5.3. Remove pin 39, cut off the cable terminal and insulate the end with tape (E). Fold back the cable and secure it with tape (F). 5.4. Fit the connecting rail and end face. 5.5. Plug in the connector (A) and secure the cables with cable ties (B). 6. Install the floor console over the handbrake. Do not press the console down into place, but instead allow it to fit loosely. 7. Install the switch: 7.1. Install the switch for the roof lighting (B) and plug in its connector. 7.2. Guide the connectors for the window lift module and rear seat heater, if equipped, through the hole for each respective unit. Plug in the window lift module's connector and install the module (A). Page 9231 C306 Infotainment Jumper Harness To Console Harness (Without RPO Code Y91) Part 3 Page 9277 Junction Block - I/P Wire Entry Part 1 Page 8398 1. Install the new brake cable (2) into the rear brake cable mounting bracket (3) by pushing the cable into place until the locking tabs (1) snap into place. 2. Install the park brake cable to the lever. 3. Notice: Refer to Fastener Notice in Service Precautions. Install the rear park brake cable bracket bolt. ^ Tighten the rear park brake cable bracket bolt to 61 Nm (45 ft. lbs.). 4. Install the park brake cable and the bolt to the lower shock absorber mount. ^ Tighten the park brake cable bolt to 25 Nm (18 ft. lbs.). Page 8604 2. Remove the master cylinder from the booster. Do not remove the pipes from the master cylinder. Set the master cylinder aside in the engine compartment. 3. Disconnect the power brake booster inlet hose, the steering gear inlet hose, and the power brake booster outlet hose from the booster assembly. 4. Disconnect the electrical connector from the stop lamp switch. 5. Remove the retainer from the brake pedal pin. 6. Remove the stop lamp switch and the pushrod to the power brake booster from the brake pedal pin. 7. Unsnap the stop lamp switch from the power brake booster pushrod. 8. Remove the 4 booster to bulkhead nuts. 9. Remove the booster assembly. 10. Remove the gasket. Installation Page 780 The information shown is for the 1999-2002 wiring harnesses and for the 2003-05 wiring harness. To modify a 12171982, 15366255 or 15086884 harness for use in a 2003-05 vehicle, switch the wires in cavities "A" and "D". To modify a 15085418 harness for use in a 1999-2002 vehicle (see model list at the front of this bulletin for applicable models), switch the wires in cavities "A" and "D". Warranty Information When the correct wiring harness P/N is matched to the specific model year of the vehicle, everything works properly. Therefore, conversion of an incorrect wiring jumper to match the vehicle would not be considered a warrantable repair. Disclaimer Service and Repair Compressor Clutch Relay: Service and Repair COMPRESSOR RELAY REPLACEMENT REMOVAL PROCEDURE 1. Remove the cover from the underhood convenience center (1). 2. Remove the compressor relay (2). INSTALLATION PROCEDURE 1. Install the compressor relay (2). 2. Install the cover to the underhood convenience center (1). Page 16166 IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. Splicing Twisted or Shielded Cable SPLICING TWISTED OR SHIELDED CABLE Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. - Rewrap the conductors with the mylar tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with mylar tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Control Module References Page 14676 Page 14809 Driver Door Module (DDM) - C5 (Memory/Heated Seat Switch) Part 2 A/T - Revised Converter Check Valve/Cooler Line Fitting Torque Converter Check Valve: Technical Service Bulletins A/T - Revised Converter Check Valve/Cooler Line Fitting INFORMATION Bulletin No.: 04-07-30-017B Date: November 25, 2008 Subject: Information on 4T65-E MN7, M15, M76, MN3 Automatic Transmission Case, Cooler Fitting and Torque Converter Drain Back Check Ball Change Models: 2008 and Prior GM Passenger Cars and Light Duty Trucks with one of the HYDRA-MATIC(R) Automatic Transmissions shown above. Supercede: This bulletin is being revised to update the Parts Information. Please discard Corporate Bulletin Number 04-07-30-017A (Section 07 - Transmission/Transaxle). Effective with Julian date 4019 (January 19, 2004), the 4T65E transaxle cases and cooler fittings have changed and are not interchangeable with past models. The technician may find that when replacing the inlet or outlet transmission cooler lines, the new lines cannot be connected to the transmission. A change to the transmission cooler line fittings was implemented in production on February 1, 2004. The cooler line fittings were changed to a design with a longer lead in pilot (1). The cooler line fittings with the longer lead in pilot will not fit on models built before February 1, 2004. The longer lead in pilot fittings (1) (9/16-18 UNF) have replaced the shorter lead in pilot fittings (2) (3/8-18 NPSF w/check ball & 1/4-18 NPSF). If the transmission cooler lines will not connect, then replace them with the following cooler line fittings as appropriate with the older, shorter lead in pilot design: ^ For vehicles built prior to February 1, 2004, use Transmission Fluid Cooler Inlet Hose, P/N 20793004. ^ For vehicles built after February 1, 2004, use Transmission Fluid Cooler Inlet Hose, second design P/N 15264588. ^ For vehicles built prior to February 1, 2004, use Transmission Fluid Cooler Outlet Hose, P/N 20793005. ^ For vehicles built after February 1, 2004, use Transmission Fluid Cooler Outlet Hose, second design P/N 15264589. Page 16091 circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links CIRCUIT PROTECTION - FUSIBLE LINKS Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Flat Wire Repairs FLAT WIRE REPAIRS NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Heated Oxygen Sensor (HO2S) Wiring Repairs HEATED OXYGEN SENSOR (HO2S) WIRING REPAIRS TOOLS REQUIRED J 38125-D Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: - Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-D. Repairing Damaged Wire Insulation REPAIRING DAMAGED WIRE INSULATION Page 9279 Junction Block - I/P Wire Entry Part 3 Page 13546 - Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-D in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-D if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Page 12855 Important: The optic cable must not be bent with a radius less than 25 mm (1 in). 6.17. Fold back the wiring harness and tape over the connectors (G). Fold back the wiring harness once more and secure with cable ties (H). 6.18. Secure the new optic cable on the parcel shelf along the existing wiring harness by the ordinary securing points and by the speaker (I). 6.19. Thread the optic cable down next to the old cable from the parcel shelf to the left-hand wheel housing, next to REC. The cable is secured in the existing clips. 6.20. Fit the right-hand C-pillar trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.21. Fit the parcel shelf trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.22. Fit the passenger seat in accordance with WIS - 8. Body - Seats - Adjustment/Replacement. 6.23. Fit the right-hand side bolster in accordance with WIS - 8. Body - Seats Adjustment/Replacement. 6.24. Fold up the rear seat backrest. 6.25. Fit the right-hand B-pillar trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.26. Fit the A-pillar's lower side piece. 7. M04-05, 4D: Removing the OnStar® control modules and securing the wiring: Page 2652 Fuse Block - Underhood C3 Part 2 Body/Frame - Revised Crossmember/Body Bolt Service Cross-Member: Technical Service Bulletins Body/Frame - Revised Crossmember/Body Bolt Service Bulletin No.: 05-08-61-005 Date: April 29, 2005 SERVICE MANUAL UPDATE Subject: Revised Crossmember/Body Mount Bolt Installation Information Models: 1999-2005 Cadillac Full-Size Pickup and Utility Models 1999-2005 Chevrolet Full-Size Pickup and Utility Models 1999-2005 GMC Full-Size Pickup and Utility Models This bulletin is being issued to revise all repair procedures that include reinstalling the front engine crossmember-to-frame bolts or any body mount bolts in the Frame and Underbody sub-section of the Service Manual. Please replace the current information in the Service Manual with the following information. The following information has been updated within SI. If you are using a paper version of this Service Manual, please make a reference to this bulletin on the affected page. Before reinstalling front engine crossmember-to-frame bolts or any body mount bolts, you must do the following: 1. Remove all traces of the original thread locking material. 2. Clean the threads of the bolt with denatured alcohol, or equivalent, and allow to dry. 3. Apply Thread locker, P/N 12345493, (Canadian P/N 10953488). Disclaimer Page 289 Important: This bulletin does NOT apply to 2006 vehicles built AFTER the VIN breakpoints listed above. Refer to applicable diagnostics in SI for those vehicles that exhibit this condition. Remove the OnStar(R) fuse from the fuse box, wait five minutes and reinstall the fuse. (For Saturn VUE vehicles, remove the "INT LTS" fuse from the I/P fuse block for five minutes, then reinstall the fuse.) If the OnStar(R) system DOES NOT return to normal functionality, then follow the diagnostics in SI for this condition. If the OnStar(R) system DOES return to normal functionality, perform the following steps: 1. Install the Tech 2(R) and determine what generation hardware and software ID is in the vehicle. 2. If the vehicle is equipped with Generation 5 hardware and a software version 146, the VCIM should have the B1000 reprogramming performed as described in Corporate Bulletin Number 04-08-46-004A. The system should be tested and if the concern returns, the VCIM should be replaced. 3. If Gen 5 with a software version OTHER than 146 or Gen 6 and above, the VCIM needs to be replaced and the system reconfigured. Refer to the current version of Corporate Bulletin 03-08-46-004 for details on how to order a new VCIM. Important: As with any OnStar(R) VCIM replacement, the OnStar(R) system must be reconfigured after replacement. Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use the table. Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table. Disclaimer Page 9195 C154 I/P Harness To ATC Harness (With RPO Codes NP1/NP8) Page 15178 IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. Splicing Twisted or Shielded Cable SPLICING TWISTED OR SHIELDED CABLE Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. - Rewrap the conductors with the mylar tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with mylar tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Control Module References Page 1015 Inflatable Restraint Sensing And Diagnostic Module: Description and Operation INFLATABLE RESTRAINT SENSING AND DIAGNOSTIC MODULE (SDM) The sensing and diagnostic module (SDM) is a microprocessor and the control center for the SIR system. The SDM contains internal sensors along with several external sensors, if equipped, mounted at various locations on the vehicle. In the event of a collision, the SDM performs calculations using the signals received from the internal and external sensors. The SDM compares the results of the calculations to values stored in memory. When these calculations exceed the stored value, the SDM will cause current to flow through the appropriate deployment loops to deploy the air bags. The SDM records the SIR system status when a deployment occurs and requests the instrument panel cluster (IPC) to turn the AIR BAG indicator ON. The SDM performs continuous diagnostic monitoring of the SIR system electrical components and circuitry when the ignition is turned ON. If the SDM detects a malfunction, a DTC will be stored and the SDM will request the IPC to turn the AIR BAG indicator ON. In the event that ignition 1 voltage is lost during a collision, the SDM maintains a 23-volt loop reserve (23 VLR) for deployment of the air bags. It is important to note, when disabling the SIR system for servicing or rescue operations to allow the 23 VLR to dissipate, which could take up to 1 minute. Page 14932 Memory/Heated Seat Switch - Driver (DDM C5) Part 1 Page 9529 Application Table Part 3 Page 6859 11. If only the left side seal was removed, perform the following step. Install the inner axle shaft into the differential case side gear using a soft-faced mallet until the retaining ring on the inner axle shaft is fully seated within the groove in the differential case side gear. - Pull back on the inner axle shaft to ensure that the inner axle shaft is properly retained in the differential case side gear. 12. If only the left side seal was removed, perform the following step. Install the wheel drive shaft to the inner axle shaft. Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems. 13. If only the left side seal was removed, perform the following step. Install the wheel drive shaft to the inner axle shaft bolts. - Tighten the wheel drive shaft to inner axle shaft bolts to 79 Nm (58 lb ft). 14. Fill the differential carrier assembly. Use the correct fluid. 15. Lower the vehicle. Differential Drive Pinion Flange/Yoke, Seal, and Dust Deflector Replacement Differential Drive Pinion Flange/Yoke, Seal, and Dust Deflector Replacement - Front ^ Tools Required J 8614-01 Flange and Pulley Holding Tool - J 36366 Pinion Oil Seal Installer Removal Procedure 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Remove the tire and wheel assemblies. 3. Remove the brake calipers. 4. Remove the differential carrier assembly shield, if equipped. 5. Reference mark the relationship of the propeller shaft to the front axle pinion yoke. 6. Remove the yoke retainer bolts (6) and the yoke retainers (7) from the front axle pinion yoke (1). 7. Disconnect the propeller shaft universal joint (2) from the front axle pinion yoke (1). Wrap the bearing caps with tape in order to prevent the loss of bearing rollers. Notice: When removing the propeller shaft, do not attempt to remove the shaft by pounding on the yoke ears or using a tool between the yoke and the universal joint. If the propeller shaft is removed by using such means, the injection joints may fracture and lead to premature failure of the joint. 8. Support the propeller shaft and move out of the way as necessary. Description and Operation Shift Indicator: Description and Operation PRNDL DISPLAY The IPC displays the selected gear position as determined by the PCM. The IPC receives a class 2 message from the PCM indicating the gear position. The PRNDL display blanks if: - The IPC receives a class 2 message indicating the park position and the column park switch indicates a position other than park, open input. - The IPC detects a loss of class 2 communications with the PCM. Page 1921 OnStar(R) - Re-establishing OnStar(R) Communications Navigation System: All Technical Service Bulletins OnStar(R) - Re-establishing OnStar(R) Communications Bulletin No.: 00-08-46-004C Date: January 17, 2008 INFORMATION Subject: Re-establishing Communications with OnStar(R) Center After Battery Disconnect Models: 2000-2008 GM Passenger Cars and Trucks (Including Saturn and Saab) with Digital OnStar(R) (RPO UE1) Supercede: This bulletin is being revised to add models and model years. Please discard Corporate Bulletin Number 00-08-46-004B (Section 08 - Body and Accessories). When servicing any of the above models and a battery cable is disconnected or power to the OnStar(R) Vehicle Communication Interface Module (VCIM) is interrupted for any reason the following procedure must be performed to verify proper Global Positioning System (GPS) function. Never swap OnStar(R) Vehicle Communication Interface Modules (VCIM) from other vehicles. Transfer of OnStar(R) modules from other vehicles should not be done. Each OnStar(R) module has a unique identification number. The VCIM has a specific Station Identification (STID). This identification number is used by the National Cellular Telephone Network and OnStar(R) systems and is stored in General Motors Vehicle History files by VIN. After completing ALL repairs to the vehicle you must perform the following procedure: Move the vehicle into an open area of the service lot. Sit in the vehicle with the engine running and the radio turned on for five minutes. Press the OnStar(R) button in the vehicle. When the OnStar(R) advisor answers ask the advisor to verify the current location of the vehicle. If the vehicle location is different than the location the OnStar(R) advisor gives contact GM Technical Assistance (TAC) and choose the OnStar(R) prompt. GM OnStar(R) TAC will assist in the diagnosis of a failed VCIM and, if appropriate, order a replacement part. Replacement parts are usually shipped out within 24 hours, and a pre-paid return package label will be included for returning the faulty part. By returning the faulty part, you will avoid a non-return core charge. Disclaimer Page 9229 C306 Infotainment Jumper Harness To Console Harness (Without RPO Code Y91) Part 1 Page 10997 Tighten Tighten the screws to 1.6 N.m (14 lb in). 6. If equipped, install the sound insulator panel. Page 7869 Pay particular attention to the terminal connections at the module. Spread or open terminal connections may create an intermittent contact. Do a pin drag test. Refer to the terminal testing information in the table shown. ^ After repairs are complete, ALWAYS clear DTCs from the module prior to a system function test. If codes are not cleared first, the system will not function after repair. The technician may erroneously think that the system is still down and that further repairs are needed. Warranty Dealers who unnecessarily replace the TCCM that are found to have No Trouble Found (NTF) at the WPC will be returned to the AVM (Area Service Manager), or the DSM (District Service Manager) in Canada, through the Regional Feedback Process and may be charged back for the repair through the WINS system. Disclaimer Page 16145 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground TESTING FOR SHORT TO GROUND NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting With A Digital Multimeter TROUBLESHOOTING WITH A DIGITAL MULTIMETER NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TROUBLESHOOTING WITH A TEST LAMP Page 4812 Fuel Tank Pressure Sensor: Description and Operation FUEL TANK PRESSURE SENSOR The FTP sensor measures the difference between the pressure or vacuum in the fuel tank and outside air pressure. The control module provides a 5-volt reference and a ground to the FTP sensor. The FTP sensor provides a signal voltage back to the control module that can vary between 0.1-4.9 volts. A high FTP sensor voltage indicates a low fuel tank pressure or vacuum. A low FTP sensor voltage indicates a high fuel tank pressure. Page 1991 Refer to the table as a guide in selecting the correct test adapter for frontprobing connectors: Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure SCAN TOOL SNAPSHOT PROCEDURE Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: - Snapshot - taken from the Snapshot menu choice - Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information Steering - Underhood Clunk Heard/Felt in Steering Wheel Steering Shaft: Customer Interest Steering - Underhood Clunk Heard/Felt in Steering Wheel TECHNICAL Bulletin No.: 00-02-35-003N Date: March 26 2008 Subject: Clunking Noise Under Hood and Can Be Felt in Steering Wheel and/or Steering Column (Replace Upper Intermediate Steering Shaft [I-Shaft] Assembly) Models: 2002-2006 Cadillac Escalade Models 1999-2007 Chevrolet Silverado Models (Classic) 2000-2006 Chevrolet Suburban, Tahoe Models 2002-2006 Chevrolet Avalanche 1999-2007 GMC Sierra Models (Classic) 2000-2006 GMC Yukon, Yukon XL Models 2003-2006 HUMMER H2 Attention: This Service Bulletin DOES NOT include Mid-Size Utilities such as Buick Rainier, Chevrolet TrailBlazer Models, GMC Envoy Models or Oldsmobile Bravada. Refer to Service Bulletin 02-02-35-006A or newer for Mid-Size Utilities. Supercede: This bulletin is being revised to add diagnostic information (refer to Diagnostic Tips) to check the lower steering column bearing as a potential source of the noise. Please discard Corporate Bulletin Number 00-02-35-003M (Section 02-Steering). Condition Some customers may comment on a clunk-type noise coming from under the hood that also can be felt in the steering wheel. These conditions may be more noticeable when turning at low speeds on rough road surfaces. Diagnostic Tips Use the information below to help diagnose the source of the noise. ^ The lower steering column bearing may create the same noise as the intermediate shaft. Before replacing the I-shaft, verify the noise isn't being caused by movement from the lower steering column bearing. Check the bearing for movement by pushing up and down on the I-shaft where it attaches to the steering column. ^ Frame Snap and/or Popping Type Noise - A frame snap or popping type noise can be duplicated on rough or smooth road surfaces with steering wheel input to the left or the right. This type of noise can be HEARD and is typically louder with the windows rolled down. For additional information refer to Corporate Bulletin Number 03-08-61-002F or newer - Snap/Popping Type Noise Coming from Front of Vehicle (Remove Front Crossmember Change Fastener Orientation). ^ Intermediate Shaft Clunk - Intermediate shaft clunk is heard and FELT in the steering wheel and/or steering column area typically while driving on rough road surfaces with steering wheel input. Correction Important: ^ I-shaft P/N 19153614 has been designed to replace previous designed dampened and non-dampened I-shafts. The physical difference in the yoke size will accommodate all vehicles listed in this bulletin. ^ Due to the design of the new I-shaft, it is not possible to lubricate/grease the I-shaft. Replace the steering column upper intermediate shaft with an improved design shaft that will eliminate the clunk noise using the procedure listed below. Wheels - Correct Hub Cap Installation Procedure Wheel Cover: Technical Service Bulletins Wheels - Correct Hub Cap Installation Procedure Bulletin No.: 03-03-10-002B Date: November 02, 2005 INFORMATION Subject: Use of Correct Installation Procedure for Loose Hubcap Assembly Models: 1998-2006 Chevrolet Express Van 1999-2006 Chevrolet Silverado Models 2000-2006 Chevrolet Suburban, Tahoe Models 2002-2006 Chevrolet Avalanche 1998-2006 GMC Savana Van 1999-2006 GMC Sierra Models 2000-2006 GMC Yukon, Yukon XL Models Supercede: This bulletin is being revised to add the 2006 model year. Please discard Corporate Bulletin Number 03-03-10-002A (Section 03 - Suspension). Some hubcap assemblies on the above-listed vehicles are being returned to the Warranty Parts Center (WPC) for loose and/or rattle conditions. Some returned hubcaps have the stand-off insulators removed. Analyses of these parts show no out of specification condition. Hubcap assemblies are placed in the vehicle by the assembly plant for dealer installation. Installation is done by threading the six or eight plastic nut caps, which are part of the hubcap assembly, to the external threads of the wheel (lug) nuts. If over-tightened, these plastic nut caps will jump threads, as designed, causing a loose or rattle condition. Important: ^ DO NOT over-tighten the plastic nut caps. ^ DO NOT use an impact wrench on the plastic nut caps. ^ DO NOT modify or remove the stand-off insulators from the plastic hubcap assembly. The nut cap system is designed to skip a thread if over-tightened. DO NOT replace the hubcap assembly if this happens. Hold hubcap (2) firmly in place on wheel with the plastic wheel nut caps (3) aligned with the steel wheel nuts (1). Hand snug each nut cap (3) (using a hand held deep socket or torque stick) until fully seated against the hubcap (2). You should feel the nut cap (3) ratchet against the hubcap (2) a couple times as the nut cap (3) seats. After all nut caps (3) have been seated, check tightness of each nut cap (3) using the socket or torque stick and tighten any nut cap (3) that may have loosened. If a nut cap (3) jumps thread (a design feature to prevent damage) and becomes loose during tightening, continue to tighten and stop short of thread jump. Follow the installation instruction sheet that is included in each hubcap package. Page 15572 Brake Light Switch: Diagrams Stop Lamp Switch Part 1 Page 4886 Install the parking lock bracket bolts. ^ Tighten the bolts to 24 Nm (18 ft. lbs.). 13. Install the PNP switch. 14. Install the transmission filter. 15. Fill the transmission to the proper level with Dexron® III transmission fluid. Locations Accelerator Pedal Position (APP) Sensor Connector Recall 05V163000: 2nd Row Seat Belt Modification Seat Belt: Recalls Recall 05V163000: 2nd Row Seat Belt Modification MAKE/MODELS: MODEL/BUILD YEARS: CADILLAC / ESCALADE 2003-2005 CHEVROLET / AVALANCHE 2003-2005 CHEVROLET / SILVERADO 2003-2005 CHEVROLET / SUBURBAN 2003-2005 CHEVROLET / TAHOE 2003-2005 GMC / SIERRA 2003-2005 GMC / YUKON 2003-2005 HUMMER / H2 2004-2005 MANUFACTURER: General Motors Corp. NHTSA CAMPAIGN ID NUMBER: 05V163000 RECALL DATE: April 22, 2005 COMPONENT: Seat Belts: Rear POTENTIAL NUMBER OF UNITS AFFECTED: 1359824 SUMMARY: On certain crew cab pickup trucks and sport utility vehicles, the 2nd row center occupant seat belt routing may make it difficult to position the lap portion of the safety belt low around the hips of occupants, especially smaller occupants, seated in this position. Appropriate use of a child seat or booster seat, as recommended for small children, does improve the fit condition for this user group. In addition to instructions on proper infant and young child restraint (with child seats or boosters), special verbiage for restraining older child is included in the owner's manual text. CONSEQUENCE: A lap portion of the seat belt routing that is not low and snug on the hips can allow the lap belt to ride up on an occupant's abdomen instead of fitting low around their hipbones, and therefore, can expose them to more risk of abdominal and internal organ injury. REMEDY: Dealers will cut open the guide loop, remove a portion of the loop, and then the remaining two sides should be folded over and secured with a retainer. The manufacturer has not yet provided an owner notification schedule for this campaign. Owners should contact Cadillac at 1-866-982-2339, Chevrolet at 1-800-630-2438, GMC at 1-866-996-9463, or Hummer at 1-800-732-5493. NOTES: GM recall No. 05037. Customers can also contact The National Highway Traffic Safety Administration's Auto Safety Hotline at 1-888-327-4236. Page 12858 8.5. Close the luggage compartment floor. 9. Fold down the left-hand rear side hatch in the luggage compartment. 10. M03: Replace the optic cable on the left-hand rear side: 10.1. Place the optic cable so that it is positioned behind the terminal housing on top of REC (A). 10.2. Remove the locking strip (B) on the 2-pin connector (H2-9) for the optic cable. 10.3. Open the terminal housing (C) with a screwdriver. Remove the secondary catch (D) on the connector and disconnect the optic cable coming from the OnStar(R) control modules. Page 2956 service operation. A simple distraction or time constraint that rushes the job may result in personal injury if the greatest of care is not exercised. Make it a habit to double check your work and to always side with caution when installing wheels. Disclaimer Page 4933 3. Connect the VSS electrical connector (3). Lower the vehicle. Campaign - HVAC Blower Not Functional Runs Continuously Control Module HVAC: All Technical Service Bulletins Campaign - HVAC Blower Not Functional Runs Continuously SPECIAL COVERAGE Bulletin No.: 11046 Date: April 07, 2011 Subject: 11046 - Special Coverage Adjustment - Heating, Ventilation, and Air Conditioning Blower Not Fully Functional on All Blower Speeds, Inoperative, or Runs Continuously with the Ignition Off Models: 2003-2006 Chevrolet Avalanche, Suburban, Tahoe 2003-2007 Chevrolet Silverado 2003-2006 GMC Yukon, Yukon XL 2003-2007 GMC Sierra Equipped with Manual HVAC (CJ3) or Heavy Duty Heater (C42) Due to part availability, owner letters will be released in phases starting with older model year first. Owners for model year vehicles not included in first phase owner mailing will receive an owner advisory letter. The letter will inform the customer that parts are not yet available and that another letter will be sent to them when parts become available. A copy of this letter will be attached to the dealer message announcing this bulletin. In the meantime, if a customer brings their vehicle to the dealership with the condition described in this bulletin, repair the vehicle using the parts called out in this bulletin. Condition On some 2003-2006 model year Chevrolet Avalanche, Suburban, Tahoe; GMC Yukon, Yukon XL; and 2003-2007 model year Chevrolet Silverado and GMC Sierra vehicles equipped with a manual heating, ventilation, and air conditioning (HVAC) system (CJ3) or heavy duty heater (C42), the interface between the electrical terminals of the relay resistor module and the wiring connector that powers the module may be incapable of conducting higher current levels for sustained periods of blower motor operation. In addition, moisture and other contaminants may enter the fresh air intake plenum and contact the internal circuit of the module or corrode the terminals. Either of the above may cause the relay resistor module or wiring connector to overheat, resulting in one or more of the following symptoms: - The HVAC blower may not function on certain or all blower speed settings - A burning plastic smell or smoke may be present in the vehicle - The HVAC blower may run continually with the ignition in the OFF position In very rare events, if the above symptoms are ignored, a fire could occur. Special Coverage Adjustment This special coverage covers the condition described above for a period of 10 years or 240,000 km, whichever occurs first, from the date the vehicle was originally placed in service, regardless of ownership. Dealers are to install a new blower motor resistor and resistor module connector. The repairs will be made at no charge to the customer. For vehicles covered by Vehicle Service Contracts, all eligible claims with repair orders on or after April 8, 2011 are covered by this special coverage and must be submitted using the labor operation codes provided with this bulletin. Claims with repair orders prior to April 8, 2011 must be submitted to the Service Contract provider. Vehicles Involved Involved are certain 2003-2006 model year Chevrolet Avalanche, Suburban, Tahoe; GMC Yukon, Yukon XL; and 2003-2007 model year Chevrolet Silverado and GMC Sierra vehicles equipped with a manual HVAC (CJ3) or heavy duty heater (C42). Important Dealers are to confirm vehicle eligibility prior to beginning repairs by using the Applicable Warranties section in the Global Warranty Management system. Parts Information Page 9382 Important The M6 conductive rivet stud as shown, can accommodate a panel thickness range of 0.7-4.2 mm (0.03-0.17 in). If there are layers of sheet metal, they should be touching without any air gaps to ensure a good ground. 5. Select a M6 conductive rivet stud. Refer to the Parts Information section of this bulletin. Note Use the GE-50317 rivet stud tool kit. 6. Place the M6 conductive rivet stud (1) in the 10 mm (0.40 in) hole. Assemble the rivet stud tool (2) with the groove and flare side facing the rivet stud, then the washer and the M6 nut (3). 7. Using a wrench on the rivet stud tool, and a socket on the M6 nut, secure the M6 conductive rivet stud. 8. Ensure the rivet stud is securely fastened, WITHOUT ANY detectable movement. 9. Completely wrap the threads of the rivet stud with painters tape or equivalent. Note The rivet stud and surrounding panel area MUST BE properly refinished PRIOR to the installation of the ground wire terminal and conductive nut to maintain a secure, stable and corrosion-free electrical ground. 10. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 11. Allow the refinished repair area to cure sufficiently before removing the protective material applied to the rivet stud threads. 12. Remove the painters tape or equivalent from the rivet stud threads. 13. Using GM approved residue-free solvent or equivalent, thoroughly clean the rivet stud threads to remove any adhesive and allow to dry. 14. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive rivet stud. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. Page 11581 In summary, whenever a vehicle subject to this recall enters your vehicle inventory, or is in your dealership for service in the future, please take the steps necessary to be sure the recall correction has been made before selling or releasing the vehicle. Disclaimer Page 15974 Control Module References Part 5 Page 8205 12. Remove the brake rotor. Do not force the rotor off. If the rotor is difficult to remove, ease it off by gently rotating it as you pull outward. 13. If the brake rotor cannot be removed perform the following: 1. Assemble J-46277 to J 2619-01. 2. Insert J-46277 between the rotor friction surfaces in the vent section of the rotor.DO NOT place the J-46277 on the rotor friction surface. 3. Using J-46277 and J 2619-01 remove the rotor from the hub assembly. 4. Inspect the park brake components for the following conditions: ^ Bent or broken hold down spring ^ Broken, cracked or worn brake shoe lining ^ Bent or damaged brake shoe ^ Worn, bent or damaged backing plate 5. If any of these conditions are found replace the affected parts. Installation Procedure 1. Important: Whenever the brake rotor has been separated from the hub/axle flange, any rust or contaminants should be cleaned from the hub/axle flange and the brake rotor mating surfaces. Failure to do this may result in excessive assembled lateral runout (LRO) of the brake rotor, which could lead to brake pulsation. Use the J 42450-A to clean all rust and contaminants from the mating surface of the hub flange. 2. Use the J 41013 to clean all rust and contaminants from the inside diameter of the hat section of the brake rotor to prevent any foreign material from getting between the brake rotor and the hub flange. 3. Inspect the mating surfaces of the hub/axle flange and the rotor to ensure that there are no foreign particles or debris remaining. 4. Align the rotor to its original position on the hub, if applicable, and install the rotor. 5. If the brake rotor was removed and installed as part of a brake system repair, measure the assembled lateral runout (LRO) of the brake rotor to ensure optimum performance of the disc brakes. Refer to Brake Rotor Assembled Lateral Runout (LRO) Measurement. 6. If the brake rotor assembled LRO measurement exceeds the specification, bring the LRO to within specifications. Refer to Brake Rotor Assembled HVAC System - Manual Control Module HVAC: Description and Operation HVAC System - Manual HVAC CONTROL MODULE The HVAC control module is a class 2 device that interfaces between the operator and the HVAC system to maintain air temperature and distribution settings. The battery positive voltage circuit provides power that the control module uses for keep alive memory (KAM). If the battery positive voltage circuit loses power, all HVAC DTCs and settings will be erased from KAM. The body control module (BCM), which is the vehicle mode master, provides a device on signal. The control module supports the above features. The HVAC control module is a class 2 device that interfaces between the operator and the HVAC system to maintain air temperature and distribution settings. The battery positive voltage circuit provides power that the control module used for keep alive memory (KAM). If the battery positive voltage circuit loses power, all HVAC DTCs and settings will be erased from KAM. The body control module (BCM), which is the vehicle mode master, provides a device on signal. The control module supports the above features. Page 13401 Electrical Symbols Part 14 Page 4021 Disclaimer Page 10693 Parts Information Warranty Information Wheels All GM Accessories sold and permanently installed on a GM vehicle PRIOR to new vehicle delivery will be covered under the provisions of the New Vehicle Limited Warranty. For the U.S., in the event GM Accessories are installed AFTER the New Vehicle Delivery, or are replaced under the New Vehicle Warranty, they will be covered (parts and labor) for the balance of the vehicle warranty, but in no event less than 12 months/12,000 miles. This coverage is only effective for GM Accessories permanently installed by a GM dealer or a GM approved ADI (Accessory Distributor/Installer). For Canada, in the event GM Accessories are installed AFTER the New Vehicle Delivery, they will be covered (parts and labor) for the balance of the vehicle warranty, or up to 12 months/Unlimited kilometers depending on month installed. For replacement after the new vehicle warranty expires, but within the 12 months/unlimited kilometers coverage, refer to claim type "B" guidelines. GM Accessories sold over-the-counter, or those not requiring installation, will continue to receive the standard GM Dealer Parts Warranty of 12 months from the date of purchase (parts only). Tires Any approved tire installed on a GM Vehicle PRIOR to delivery will be covered under the provisions of the New Vehicle Limited Warranty. Tires are covered against defects in material and workmanship. Tires are warranted for defects "without" prorated charge for tread mileage. Subsequent replacements under this warranty will continue to be covered for the remainder of the New Vehicle Limited Warranty. Any approved tire installed on a GM Vehicle PRIOR to delivery may continue to be warranted on a prorated basis by the tire manufacturer once the New Vehicle Limited Warranty expires. Any approved tire installed AFTER delivery will be covered under the provisions of the tire manufacturer warranty. USA dealers should refer to GM Warranty Administration Bulletin 00-03-10-003I and GM Parts Process / Policy Bulletin IB03-001 for more information. Canadian dealers should refer to GM Warranty Administration Bulletin 01-03-10-003B. GM Warranty Claims Processing Only GM dealerships have the ability to file warranty claims for GM Parts and Accessories. Therefore, any warranty claims filed against such parts must be handled by the servicing GM dealership. This includes those parts purchased from a GM-approved ADI (Accessory Distributor / Installer). Page 7655 1. Align the transfer case input shaft seal evenly on the input shaft. Important: The input shaft seal should be even with the surface of the transfer case after installation. 2. Using the J 42738, install the transfer case input shaft seal. 3. Install the transfer case. 4. Check the fluid level. Add fluid if necessary. Page 8981 Fuse Block - Underhood - Secondary Wire Entry (With RPO Code HP2) Part 4 Page 9932 Alignment: Technical Service Bulletins Steering/Suspension - Revised Caster/Camber Adjustment Info - Revised Front Caster and Camber Adjustment Procedure # 02-03-07-002A - (Mar 24, 2005) Models: 1999-2000 Cadillac Escalade 2002-2005 Cadillac Escalade, Escalade EXT 1999-2005 Chevrolet Express, Silverado, Suburban, Tahoe 2002-2005 Chevrolet Avalanche 1999 GMC Suburban 1999-2005 GMC Savana, Sierra, Yukon, Yukon XL, Yukon XL Denali This bulletin is being revised to add model years and clarify the information. Please discard Corporate Bulletin Number 02-03-07-002 (Section 03 - Suspension). When performing a wheel alignment on any of the above vehicles, please refer to the Front Caster and Camber Adjustment Procedure in SI before contacting the GM Technical Assistance Center (TAC) with issues concerning adjustments, caster out-of-spec, etc. Disclaimer Page 15867 Turn Signal Multifunction Switch - C1 OnStar(R) - Re-establishing OnStar(R) Communications Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Re-establishing OnStar(R) Communications Bulletin No.: 00-08-46-004C Date: January 17, 2008 INFORMATION Subject: Re-establishing Communications with OnStar(R) Center After Battery Disconnect Models: 2000-2008 GM Passenger Cars and Trucks (Including Saturn and Saab) with Digital OnStar(R) (RPO UE1) Supercede: This bulletin is being revised to add models and model years. Please discard Corporate Bulletin Number 00-08-46-004B (Section 08 - Body and Accessories). When servicing any of the above models and a battery cable is disconnected or power to the OnStar(R) Vehicle Communication Interface Module (VCIM) is interrupted for any reason the following procedure must be performed to verify proper Global Positioning System (GPS) function. Never swap OnStar(R) Vehicle Communication Interface Modules (VCIM) from other vehicles. Transfer of OnStar(R) modules from other vehicles should not be done. Each OnStar(R) module has a unique identification number. The VCIM has a specific Station Identification (STID). This identification number is used by the National Cellular Telephone Network and OnStar(R) systems and is stored in General Motors Vehicle History files by VIN. After completing ALL repairs to the vehicle you must perform the following procedure: Move the vehicle into an open area of the service lot. Sit in the vehicle with the engine running and the radio turned on for five minutes. Press the OnStar(R) button in the vehicle. When the OnStar(R) advisor answers ask the advisor to verify the current location of the vehicle. If the vehicle location is different than the location the OnStar(R) advisor gives contact GM Technical Assistance (TAC) and choose the OnStar(R) prompt. GM OnStar(R) TAC will assist in the diagnosis of a failed VCIM and, if appropriate, order a replacement part. Replacement parts are usually shipped out within 24 hours, and a pre-paid return package label will be included for returning the faulty part. By returning the faulty part, you will avoid a non-return core charge. Disclaimer Page 12471 7.2. Remove the console (A). 7.3. Disconnect the connector (B) from the OnStar(R) control module. Important: Secure the cable harness to prevent the risk of scraping and rattling. 7.4. Fold back the cable harness and tape down the connector (C). Fold back the cable harness again and secure with cable ties (D). 7.5. 5D: Assemble the right-hand cover for the luggage compartment floor. 8. Fit the ground cable on the battery's negative cable. Page 3300 Engine Oil: Service and Repair Engine Oil and Oil Filter Replacement Removal Procedure Important: In order to completely drain the oil from the oil pan internal baffling, the bottom of the oil pan must be level during the oil drain procedure. 1. Open the hood. 2. Remove the oil fill cap. 3. Raise and suitably support the vehicle. 4. Place a oil drain pan under the oil pan drain plug. 5. Remove the oil pan drain plug. 6. Drain the engine oil. 7. Wipe the excess oil from the drain plug hole and plug. 8. Remove the oil filter from the engine block. Important: Check the old oil filter to ensure that the filter seal is not left on the engine block. 9. Wipe the excess oil from the oil filter mounting. Installation Procedure 1. Lubricate the oil filter seal with clean engine oil. Recall 04V240000: Incorrect Spare Tire on Vehicle Spare Tire: All Technical Service Bulletins Recall 04V240000: Incorrect Spare Tire on Vehicle Make / Models : Model/Build Years: GMC / 1500 2004 Regency / Chevrolet 1500 2004 MANUFACTURER: General Motors Corp. NHTSA CAMPAIGN ID Number : 04V240000 Recall Date : MAY 14, 2004 COMPONENT: Tires: Temporary/Emergency Spare Tire Potential Number Of Units Affected : 285 SUMMARY: The spare tire and wheel assembly that was provided on certain conversion vehicles will not fit on the front wheel hub due to offset of the wheel. However, it will fit on the rear wheels. CONSEQUENCE: If someone has a flat tire on the front wheel, they will not be able to install the provided spare tire. REMEDY: Dealers will install a spare wheel with the correct offset. Owner notification began on June 11, 2004. Owners should contact Regency at 1-800-989-4727. NOTES: Customers can also contact The National Highway Traffic Safety Administration's Auto Safety Hotline at 1-888-DASH-2-DOT (1-888-327-4236). Page 7224 High Temperature Conditions Tools Required J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency MEASURING FREQUENCY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage MEASURING VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop MEASURING VOLTAGE DROP NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Page 14084 Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA and/or the secondary locks. Micro .64 Connectors MICRO .64 CONNECTORS TOOLS REQUIRED J 38125-D Terminal Repair Kit REMOVAL PROCEDURE Follow the steps below in order to remove terminals from Micro 64 connectors. 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. 2. Disconnect the connector from the component. Page 8773 Electrical Symbols Part 2 Page 4916 Transmission Position Switch/Sensor: Service and Repair Automatic Transmission 4L80-E/4L85-E Park/Neutral Position Switch Replacement Park/Neutral Position Switch Replacement ^ Tools Required J 41364-A Park Neutral Switch Aligner Removal Procedure 1. Apply the park brake. 2. Shift the transmission into neutral. 3. If equipped with 4-wheel drive (4WD), remove the front propeller shaft. 4. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 5. Disconnect the park/neutral position (PNP) switch electrical connector (2). 6. Remove the range selector cable end (2) from the range selector lever ball stud (1). Driveline - Bump/Clunk/Squawking Noises Output Shaft: Customer Interest Driveline - Bump/Clunk/Squawking Noises Bulletin No.: 01-04-17-004B Date: January 05, 2005 TECHNICAL Subject: Clunk, Bump or Squawk when Vehicle Comes to Complete Stop or Accelerating from Complete Stop (Replace Rear Drive Shaft Nickel-Plated Slip Yoke) Models Supercede: This bulletin is being revised to add Cadillac Escalade (Old Style) to the Models section. Please discard Corporate Bulletin Number 01-04-17-004A (Section 04 - Driveline/Axle). Condition Some customers may comment on a clunk, bump or squawk noise when the vehicle comes to a stop or when accelerating from a complete stop. Cause A slip/stick condition between the transfer case output shaft and the driveshaft slip yoke may cause this condition. Diagnostic Tips There are several resources in the electronic Service Information System which can provide the technician with information on diagnosis and repair of clunk conditions, and fix the customer's vehicle right the first time without unnecessary parts replacement. Some of the documents available in SI include: ^ Symptoms - Propeller Shaft Page 15223 9. Use J 38125-12A to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. REPAIR PROCEDURE The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. 1. Cut the wire as close to the terminal as possible. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. Page 1101 Pedal Positioning Switch: Service and Repair Brake Pedal Position Sensor Replacement Removal Procedure 1. Important: Once the Brake Pedal Position Sensor bolt is removed for any reason, a new 4 mm bolt, with fresh LOCTITETM will need to be installed. Remove the brake pedal position sensor bolt (1). 2. Remove the brake pedal position sensor (2) from the mounting bracket. 3. Disconnect the brake pedal position sensor electrical connector (1). 4. Remove the brake pedal position sensor (2) from the vehicle Installation Procedure Page 15219 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Weather Pack Connectors WEATHER PACK CONNECTORS The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. Page 1377 For vehicles repaired under warranty, use the table. Disclaimer Page 15423 Oil Change Reminder Lamp: Description and Operation GM OIL LIFE SYSTEM When the "CHANGE ENGINE OIL" light comes on, it means that service is required for your vehicle. Have your vehicle serviced as soon as possible within the next 1 000 km (600 miles). It is possible that, if you are driving under the best conditions, the engine oil life system may not indicate that vehicle service is necessary for over a year. However, your engine oil and filter must be changed at least once a year and at this time the system must be reset. If the engine oil life system is ever reset accidentally, you must service your vehicle within 5 000 km (3,000 miles) since your last service. Remember to reset the oil life system whenever the oil is changed. Refer to GM Oil Life System - Resetting for information on the engine Oil Life System and resetting the system. When the "CHANGE ENGINE OIL" light appears, certain services, checks and inspections are required. Required services are described in the following for "Maintenance I" and "Maintenance II." Generally, it is recommended that your first service be Maintenance I, your second service be Maintenance II and that you alternate Maintenance I and Maintenance II thereafter. However, in some cases, Maintenance II may be required more often. The engine oil life monitor will indicate when to change the engine oil - usually between 5,000 km (3,000 miles) and 16,000 km (10,000 miles) since the last oil change. Under severe conditions, the "CHANGE OIL SOON" light may be displayed before 5,000 km (3,000 miles). The vehicle must not be driven more than 16,000 km (10,000 miles) or 12 months without an oil change. The engine oil life monitor will not detect dust in the oil. If the vehicle is driven in a dusty area, be sure to change the oil every 5,000 km (3,000 miles) or sooner if the "CHANGE OIL SOON" light is displayed. Page 14899 2. Install the power seat switch bezel to the seat. Page 870 Electrical Symbols Part 6 Page 6574 Tire Monitor System - TPM Sensor Information Tire Pressure Monitor Receiver / Transponder: Technical Service Bulletins Tire Monitor System TPM Sensor Information INFORMATION Bulletin No.: 08-03-16-003 Date: May 12, 2008 Subject: Warranty Reduction - Transfer of Tire Pressure Monitoring (TPM) Sensors to Replacement Wheels and Allowable TPM Sensor Replacements Models: 2000-2009 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2009 HUMMER H2 2006-2009 HUMMER H3 2005-2009 Saab 9-7x with On-Wheel TPM Sensors TPM Sensor / Wheel Warranty Reviews During the last warranty review period it was noted that wheels being returned under the GM New Vehicle Warranty were being shipped back to General Motors with the TPM sensor still attached to the wheel. Return rates ran as high as 60% with the TPM sensors still attached. Operational TPM sensors should not be returned to GM and are to be transferred to replacement wheels if they become necessary. Important: Operational TPM Sensors that are returned under warranty to General Motors will be charged back to the dealer.Sensors have a 10 year /150,000 mile (240,000 km) battery life, and should be transferred if one or more wheels are replaced. TPM Valve Stem / Grommet (0-ring) Replacement When the TPM sensors are transferred to new wheels you should replace the component used to seal the TPM sensor stem to the wheel. On sensors with an aluminum stem and visible nut on the outside of the wheel a replacement grommet (0-ring) should be used to assure a proper seal. The sensor retaining nut (except Aveo) should be tightened to 7 N.m (62 lb in) for all vehicles except Pontiac Vibe (4.0 N.m (35.4 lb in)). Important: ^ DO NOT overtorque the retaining nut. Notice: ^ Factory installed TPM Sensors come with plastic aluminum or nickel-plated brass stem caps. These caps should not be changed. Chrome plated steel caps may cause corrosion of aluminum valve stems due to incompatibility of the metals. On current style sensors the entire rubber stem is replaceable. The service interval on the revised TPM sensor with replaceable stem is the same as for any other traditional valve stem. Replace the stem at the time of tire replacement sensor transfer or whenever air seepage is suspected at the valve stem. When replacing the valve stem tighten the screw to 1.3 N.m (11.5 lb in). For either style of TPM sensor see the service parts guide for the correct GM part numbers to order and use. Disclaimer Page 4339 Body Control Module (BCM) - C4 Part 2 Page 7552 Four Wheel Drive Selector Switch: Diagrams Steering Wheel Position Sensor or Steering Shaft Lower Bearing Replacement Steering Column Position Sensor: Service and Repair Steering Wheel Position Sensor or Steering Shaft Lower Bearing Replacement Steering Wheel Position Sensor or Steering Shaft Lower Bearing Replacement (Centering Required) ^ Tools Required J 42640 Steering Column Anti-Rotation Pin Removal Procedure 1. Set the front wheels in the straight-ahead position. 2. Install J 42640 or set the steering wheel in the LOCKED position. 3. Caution: Refer to SIR Caution in Service Precautions. Disconnect the negative battery cable. 4. Disable the SIR. 5. Important: You MUST make an alignment mark on the upper intermediate shaft to the steering column shaft, where they connect. You will need the alignment marks for installation. Make an alignment mark on the upper intermediate shaft and the steering column shaft, where they connect, before removal. 6. Remove the nut and the bolt from the upper to the lower steering shaft connection. Slide the lower shaft down. 7. Remove the steering wheel position sensor connector by using a suitable tool in order to pull the connector down around the right side of the steering column for accessibility. 8. Important: Do not apply force to the steering wheel position sensor and the adapter and bearing assembly in a sideways direction. If reusing the existing steering wheel position sensor, it MUST be centered before removal. Verify the type of steering wheel position sensor before removal. Refer to Steering Wheel Position Sensor Centering. 9. Remove the steering wheel position sensor and adapter and bearing assembly from the steering column jacket by pulling the assembly straight out. 10. Remove the steering wheel position sensor from the clips in the adapter and bearing assembly. Installation Procedure 1. Important: A new sensor MUST come with a pin installed. If pin is not installed, return and reorder sensor. Verify the following before installing the steering wheel position sensor: ^ The front wheels are in the straight-ahead position. ^ That J 42640 is installed or the steering wheel is in the LOCKED position. 2. If reusing the existing steering wheel position sensor, verify the type of sensor you have before installing. Refer to Steering Wheel Position Sensor Centering. 3. Install the steering wheel position sensor into the adapter and bearing assembly. 4. Install the adapter and bearing assembly into the steering column jacket. 1. Align the notches on the adapter and bearing assembly and the steering column jacket. 2. Important: Propshaft Speed Sensor - Front Page 6815 9. Install a new pinion oil seal using the J 22388, 8.6 inch, 9.5 inch axles, or the J 44414, 11.5 inch axle. 10. Install the pinion into the axle housing. 11. Apply sealant, GM P/N 12346004 (Canadian P/N 10953480) or equivalent, to the splines of the pinion yoke. 12. Install the pinion yoke. Align the marks made during removal. 13. Seat the pinion yoke onto the pinion shaft by tapping it with a soft-faced hammer until a few pinion shaft threads show through the yoke. 14. Install the washer and a new pinion nut. 15. Install the J 8614-01 onto the pinion yoke as shown. 16. Notice: Refer to Fastener Notice in Service Precautions. Important: If the rotating torque is exceeded, the pinion will have to be removed and a new collapsible spacer installed. ^ Tighten the pinion nut while holding the J 8614-01. ^ Tighten the pinion nut until the pinion end play is just taken up. Rotate the pinion while tightening the nut to seat the bearings. Page 2609 Location View Page 5541 Camshaft Position Sensor: Description and Operation CAMSHAFT POSITION (CMP) SENSOR The CMP sensor is also a magneto resistive sensor, with the same type of circuits as the CKP sensor. The CMP sensor signal is a digital ON/OFF pulse, output once per revolution of the camshaft. The CMP sensor information is used by the PCM to determine the position of the valve train relative to the CKP. Page 3144 6. Rotate the crankshaft until the number one piston is at top dead center (TDC) of the compression stroke.In this position, cylinder number one rocker arms will be off lobe lift, and the crankshaft sprocket key will be at the 1:30 position.The engine firing order is 1, 8, 7, 2, 6, 5, 4, 3.Cylinders 1, 3, 5 and 7 are the left bank.Cylinder 2, 4, 6 and 8 are the right bank. Notice: Refer to Fastener Notice in Service Precautions. 7. With the engine in the number one firing position, tighten the following valve rocker arm bolts: ^ Tighten the cylinders 1, 2, 7 and 8 exhaust valve rocker arm bolts to 30 Nm (22 ft. lbs.). ^ Tighten the cylinders 1, 3, 4 and 5 intake valve rocker arm bolts to 30 Nm (22 ft. lbs.). 8. Rotate the crankshaft 360 degrees. 9. Tighten the following valve rocker arm bolts: ^ Tighten the cylinders 3, 4, 5 and 6 exhaust valve rocker arm bolts to 30 Nm (22 ft. lbs.). ^ Tighten the cylinders 2, 6, 7 and 8 intake valve rocker arm bolts to 30 Nm (22 ft. lbs.). 10. Install the valve rocker arm cover. Description and Operation Accessory Delay Module: Description and Operation RETAINED ACCESSORY POWER (RAP) DESCRIPTION AND OPERATION SERIAL DATA CONTROL OF RETAINED ACCESSORY POWER (RAP) The class 2 modules receive the power mode message from the body control module (BCM) over the serial data circuits, indicating when the RAP power mode is current. The BCM monitors the ignition switch position, battery condition and passenger compartment doors status to determine whether RAP should be initiated. The modules then support the operation of the systems under their control as required by their RAP power mode operation. RAP will end when one of the following conditions is met: The BCM receives an input indicating the opening of any compartment door. - The BCM internal timer for the RAP expires after approximately 10 minutes. - The BCM detects a decrease in battery capacity below a prescribed limit. The BCM then sends a serial data power mode message Off-Awake ending the RAP function. The class 2 RAP functions are: The power windows - The radio A/T - Poor Performance/MIL ON/DTC P0757 Valve Body: Customer Interest A/T - Poor Performance/MIL ON/DTC P0757 Bulletin No.: 01-07-30-038D Date: September 12, 2006 TECHNICAL Subject: Diagnostic Trouble Code (DTC) P0757 Set, Malfunction Indicator Lamp (MIL) Illuminated, Poor Performance of Transmission, Transmission Slipping (Clean Transmission Valve Body and Case Oil Passages of Debris) Models: 2007 and Prior GM Passenger Cars and Light Duty Trucks 2003-2007 HUMMER H2 2006-2007 HUMMER H3 2005-2007 Saab 9-7X with 4L60-E/4L65-E/4L70-E Automatic Transmission (RPOs M30/M32/M70) Supercede: This bulletin is being revised to add the 2007 model year and the 4L70-E transmission. Also, information has been added to Condition, Cause and Correction. Please discard Corporate Bulletin Number 01-07-30-038C (Section 07 - Transmission/Transaxle). Condition Some customers may comment on any of the following conditions: An illuminated MIL where DTC P0757 is found as a history code in the PCM or TCM. No 3rd and 4th gear. The transmission does not shift correctly. The transmission feels like it shifts to Neutral or a loss of drive occurs. The vehicle free wheels above 48 km/h (30 mph). High RPM needed to overcome the free wheeling. Cause This condition may be caused by any of the following: Page 13253 Page 9583 Junction Block - I/P - C7 Page 12352 Control Module References Part 1 Page 15209 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors USING CONNECTOR TEST ADAPTERS IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-B Connector Test Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Page 13762 3. Reposition the fuel filler neck. 4. Install the screws to the fuel filler neck. Tighten the screws to 9 N.m (80 lb in). 5. Inspect the alignment of the fuel filler door. Fuel Level Sensor Fuel Gauge Sender: Description and Operation Fuel Level Sensor FUEL LEVEL SENSOR The fuel level sensor consists of a float, a wire float arm, and a ceramic resistor cord. The position of the float arm indicates the fuel level. The fuel level sensor contains a variable resistor, which changes resistance in correspondence to the amount of fuel in the fuel tank. The powertrain control module (PCM) sends the fuel level information via the class 2 circuit to the instrument panel (I/P) cluster. This information is used for the I/P fuel gage and the low fuel warning indicator, if applicable. The PCM also monitors the fuel level input for various diagnostics. Page 14879 For vehicles repaired under warranty, use the table. Disclaimer Page 8393 6. Remove the cable from the mounting bracket by depressing the locking tabs. 7. Remove the cable at the shock absorber bracket by removing the bolt. 8. Perform the following procedure to remove the cable (2) from the backing plate (4): 1. Compress the spring (3) by pushing towards the lever (1). 2. Depress the locking tabs. 3. Pull the cable housing out of the backing plate (4). 4. Remove the cable (2) through the slot in the backing plate. 9. Remove the park brake cable (2) from the lever (1). 10. Remove the cable from the vehicle. Installation Procedure 1. Install the cable to the vehicle. Page 11461 Air Bag Deactivation Switch: Description and Operation Inflatable Restraint I/P Module Disable Switch INFLATABLE RESTRAINT I/P MODULE DISABLE SWITCH The instrument panel (I/P) module disable switch is a manual 2-position key switch. The I/P module disable switch allows the vehicle operator the ability to enable or disable the I/P module (passenger frontal air bag). The I/P module disable switch interfaces with the passenger presence system (PPS) module to request the enabling or disabling of the I/P module. The occupants are notified of the enabling or disabling of the I/P module via the I/P module disable switch ON/OFF indicator and the PASSENGER AIR BAG ON/OFF indicators located on the rear view mirror. Page 6928 1. Place the new small seal clamp (2) onto the small end of the joint seal (1). Compress the joint seal (1) and small seal clamp (2) onto the halfshaft bar. 2. Position the small end of the joint seal (1) into the joint seal groove (3) on the halfshaft bar. 3. Secure the small seal clamp (1) with J 35910 , or equivalent, a breaker bar, and a torque wrench. ^ Tighten the small seal clamp (1) to 136 Nm (100 ft. lbs.). Notice: Refer to Fastener Notice in Service Precautions. 4. Inspect the gap dimension on the clamp ear. Continue tightening until the gap dimension is reached. Page 10914 - Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-D in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-D if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Page 13466 Trailer Connector - Heavy Duty Part 2 Engine Controls - 4L60E/4L65E A/T 2nd Gear Start PROM - Programmable Read Only Memory: All Technical Service Bulletins Engine Controls 4L60E/4L65E A/T 2nd Gear Start Bulletin No.: 05-07-30-013 Date: May 09, 2005 TECHNICAL Subject: 4L60-E/4L65-E Automatic Transmission Second Gear Start, Lack/Loss of Power When Accelerating From a Stop (Reprogram Powertrain Control Module (PCM) Models: 2004-2005 Cadillac Escalade 2004-2005 Chevrolet Avalanche, Express, Silverado, Suburban, Tahoe 2004-2005 GMC Savana, Sierra, Yukon 2004-2005 HUMMER H2 with 4L60-E (RPO M30) or 4L65-E (RPO M32) Automatic Transmission Condition Some customers may comment on a slip on launch, low power on a launch or a second gear start when accelerating from a stop. This condition is usually very intermittent, occurring only once in a few thousand miles of driving. A Tech 2 or VDR snapshot of the event may show 2nd gear being commanded for approximately two seconds, then 1st gear commanded as would be expected. Cause This condition may be caused by an intermittent VSS signal, which causes the PCM to command second gear. Important: There are other conditions that can cause the transmission to start in a gear higher than first. The following are a few of these conditions. ^ Some DTCs can cause the transmission to start in a higher gear. Check for the presence of DTCs and repair as appropriate before proceeding. ^ Debris on top of the spacer plate or in the valve body or a leaking shift solenoid can cause a 4L60-E or 4L65-E transmission to start in a gear higher than first. A start in a higher gear caused by any of these conditions typically occurs with much greater frequency. Refer to Service Bulletin 01-07-30-036D or newer for diagnostic information of these conditions. ^ Placing the shift lever in the D2 position will cause a 4L60-E or 4L65-E transmission to start in second gear. Correction Important: ^ This bulletin ONLY applies to 2004-2005 models year vehicles listed above. ^ Some DTCs can cause the transmission to start in a higher gear. Check for the presence of DTCs and repair as appropriate before proceeding. 1. Using a scan tool, check for the presence of DTCs. If DTCs are present, refer to the appropriate SI Document before proceeding with this calibration. Important: These calibrations also contain the 2-3 shift clunk calibration as detailed in bulletin 05-07-30-012. 2. Technicians are to reprogram the PCM with an updated software calibration. This new service calibration was released with TIS satellite data update version 5 or later available May 1, 2005. Refer to Service Programming System (SPS) in Vehicle Control Systems in the appropriate SI Document. Warranty Information ABS Automated Bleed Procedure Brake Bleeding: Service and Repair ABS Automated Bleed Procedure ABS Automated Bleed Procedure Notice: When adding fluid to the brake master cylinder reservoir, use only Delco Supreme 11®, GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. The use of any type of fluid other than the recommended type of brake fluid, may cause contamination which could result in damage to the internal rubber seals and/or rubber linings of hydraulic brake system components. Notice: Refer to Brake Fluid Effects on Paint and Electrical Components Notice in Service Precautions. Important: This procedure may be performed on all vehicles EXCEPT those equipped with option code JL4, Vehicle Stability Enhancement System (VSES). Important: The base hydraulic brake system must be bled before performing this automated bleeding procedure. If you have not yet performed the base hydraulic brake system bleeding procedure, refer to Hydraulic Brake System Bleeding (Manual) Hydraulic Brake System Bleeding (Pressure) in Hydraulic Brakes before proceeding. 1. Install a scan tool to the vehicle. 2. Start the engine and allow the engine to idle. 3. Depress the brake pedal firmly and maintain steady pressure on the pedal. 4. Using the scan tool, begin the automated bleed procedure. 5. Follow the instructions on the scan tool to complete the automated bleed procedure. Release the brake pedal between each test sequence. 6. Turn the ignition OFF. 7. Remove the scan tool from the vehicle. 8. Fill the brake master cylinder reservoir to the maximum-fill level with Delco Supreme 11® GM P/N 12377967 (Canadian P/N 992667) or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. 9. Bleed the hydraulic brake system. Refer to Hydraulic Brake System Bleeding (Manual) Hydraulic Brake System Bleeding (Pressure) in Hydraulic brakes. 10. With the ignition OFF, apply the brakes 3-5 times, or until the brake pedal becomes firm, in order to deplete the brake booster power reserve. 11. Slowly depress and release the brake pedal. Observe the feel of the brake pedal. 12. If the brake pedal feels spongy, repeat the automated bleeding procedure. If the brake pedal still feels spongy after repeating the automated bleeding procedure inspect the brake system for external leaks. Refer to Brake System External Leak Inspection in Hydraulic Brakes. 13. Turn the ignition key ON, with the engine OFF; check to see if the brake system warning lamp remains illuminated. 14. If the brake system warning lamp remains illuminated, DO NOT allow the vehicle to be driven until it is diagnosed and repaired. Refer to Symptoms - Hydraulic Brakes. 15. Drive the vehicle to exceed 13 kph (8 mph) to allow ABS initialization to occur. Observe brake pedal feel. 16. If the brake pedal feels spongy, repeat the automated bleeding procedure until a firm brake pedal is obtained. Junction Block - I/P Relay Box: Application and ID Junction Block - I/P Location View Location View Brakes - Low Speed ABS Activation/No DTC's Set Wheel Speed Sensor: Customer Interest Brakes - Low Speed ABS Activation/No DTC's Set TECHNICAL Bulletin No.: 03-05-25-007D Date: May 01, 2009 Subject: Antilock Brake (ABS) Activation At Low Speeds (Clean Wheel Speed Sensor Mounting Surface) Models: 2002-2006 Cadillac Escalade, Escalade EXT 2003-2006 Cadillac Escalade ESV 1999-2006 Chevrolet Silverado 2001-2006 Chevrolet Suburban, Tahoe 2002-2006 Chevrolet Avalanche 2003-2006 Chevrolet Express 2007 Chevrolet Silverado Classic 1999-2006 GMC Sierra 2001-2006 GMC Yukon, Yukon Denali, Yukon XL, Yukon Denali XL 2003-2006 GMC Savana 2007 GMC Sierra Classic 2003-2006 HUMMER H2 .............................................................................................................................................................. .................................................................................. Supercede: This bulletin is being revised to add the 2007 Silverado/Sierra Classic models. Please discard Corporate Bulletin Number 03-05-25-007C (Section 05 - Brakes). .............................................................................................................................................................. .................................................................................. Condition Some customers may comment on ABS activation at low speeds, usually below 8 km/h (5 mph). Upon investigation, the technician will find no DTCs set. Cause The cause of this condition may be an increased air gap between the wheel speed sensor and the hub reluctor ring due to rust and debris built up on the sensor mounting surface. Correction Measure AC voltage and clean the wheel speed sensor mounting surfaces. 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in the General Information sub-section of the Service Manual. 2. Disconnect both the front wheel speed sensor connectors at the frame and harness. 3. Place a Digital Volt Meter (DVM) across the terminals of each wheel speed sensor connector. 4. Rotate the wheel clockwise approximately one revolution per second. The minimum reading should be at least 350 ACmV's. If the reading is less than 350 ACmV's, remove the wheel speed sensor. Refer to the applicable Wheel Speed Sensor Replacement procedure in the ABS sub-section of the Service Manual. 5. Plug the wheel speed sensor bore in order to prevent debris from falling into the hub during service. 6. Clean the wheel speed sensor mounting surface using a wire brush, sand paper, emery cloth, scotch brite, or other suitable material. Be sure to thoroughly clean the wheel speed sensor surface. There should be no rust or corrosion. 7. Check the sensor head to determine if it has been warped/distorted due to the corrosion build up or other causes. Check the mounting surface on the sensor head for flatness by placing it on the edge of a metal machinists scale or other suitable straight edge to measure the flatness. Check the sensor for flatness in multiple (minimum 3) positions/directions. If the sensor head is distorted, replace the sensor. 8. Apply (spray) two thin coats of the specified rust penetrating lubricant (corrosion inhibitor) to the complete sensor mounting surface on the bearing hub. Allow to dry for 3-5 minutes between coats. Use ONLY Rust Penetrating Lubricant, P/N 89022217 (in Canada, P/N 89022218). 9. When the corrosion inhibitor is dry to the touch (about 10 minutes), apply a thin layer of bearing grease to the hub surface and sensor O-ring prior to sensor installation. Use ONLY Wheel Bearing Lubricant, P/N 01051344 (in Canada, P/N 993037). 10. Install either the original sensor or a new one in the hub. Ensure that the sensor is seated flush against the hub. Refer to the applicable Wheel Speed Sensor Replacement procedure in the ABS sub-section of the Service Manual. 11. Place the DVM across the sensor terminals and recheck the voltage while rotating the wheel. The voltage should now read at least 350 ACmV's. Page 9056 Relay Block - I/P C1 Part 7 Instruments - Trip Odometer Apparently Inoperative Odometer: All Technical Service Bulletins Instruments - Trip Odometer Apparently Inoperative Bulletin No.: 04-08-49-007 Date: February 26, 2004 INFORMATION Subject: Personal Trip/Business Trip Feature - Must be On for Trip Odometer to Accumulate Models: 2003-2004 Cadillac Escalade, Escalade ESV, Escalade EXT 2003-2004 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2003-2004 GMC Sierra, Sierra Denali, Yukon, Yukon XL, Yukon Denali The purpose of this bulletin is to prevent the inadvertent replacement of the instrument cluster if a customer comes in to your dealership stating that the trip odometer is inoperative or does not accumulate. For vehicles with steering wheel controls, the Personal Trip (or Business Trip) feature must be turned On in order for the trip odometer to accumulate. When the display reads Personal Trip: On (or Business Trip: On), the trip odometer shall accumulate. The Personal Trip and Business Trip features can be turned on or off by pressing the select button. Refer to Driver Information Center (DIC) in the Owner's Manual for additional information. Specifications Ignition Cable: Specifications Spark Plug Wire Resistance ................................................................................................................ .................................................... 1000 ohms per foot Page 14332 Important: Ensure that the alignment is proper. 3. Tighten the tie bar bolts. Tighten the tie bar bolts to 9 N.m (80 lb in). 4. Install the upper headlamp housing support screws. Tighten the upper headlamp housing support screws to 9 N.m (80 lb in). 5. Install the radiator mounting bolts onto the rear side of the tie bar. Tighten the radiator mounting bolts to 25 N.m (18 lb ft). 6. Install the tie bar to the radiator brace bolts (1). Access the bolts from the rear of the tie bar using an extension. Tighten the radiator brace bolts to 9 N.m (80 lb in). 7. Install the upper fan shroud. Page 15870 Turn Signal Multifunction Switch - C4 (With RPO Code K34) Page 6493 through the cooler. ^ Converter bearing noise determined by noise from the bell housing area in Drive or Reverse at idle. The noise is gone in Neutral and Park. ^ If silicon from the viscous clutch is found in the lower pan (4T80-E ONLY). Disclaimer Page 6390 Steps 1-9 Test Description The numbers below refer to the step numbers on the diagnostic table. 2. This step tests for a faulty tow/haul switch. 3. This step tests for voltage input from the BCM to the tow/haul switch. 6. This step tests for ground integrity. Page 880 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors USING CONNECTOR TEST ADAPTERS IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-B Connector Test Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Page 5091 5. Install the CVS clip to the frame crossmember. 6. Connect the EVAP CVS line to the canister. 7. Connect the CVS electrical connector. 8. Install the harness clip to the canister vent solenoid (CVS) line. 9. Lower the vehicle. Page 10594 9.1. Push the mud flap to make contact with the front side of the underbody cross sill and mark location of the hole (5) of the mud flap. 9.2. Center punch the marked location and drill a 5.159 mm (13/64 in) hole. 9.3. Install the screw. Tighten Tighten the screw to 4 N.m (35 lb in). 9.4. Repeat the above steps for hole location 6. 10. Repeat the above steps for the opposite side. Parts Information Parts are expected to be available from GMSPO on June 30, 2004. Warranty Information Please advise the customer that the mud flaps can be purchased as an accessory. Installation and/or cost of the mud flaps will not be covered under the vehicle's warranty. Disclaimer Page 5059 Put unused material on the shelf for future use. Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Page 1727 6. Connect the fuel composition sensor electrical connector. 7. Lower the vehicle. 8. Use the following procedure in order to inspect for leaks: 8.1. Turn the ignition ON, with the engine OFF, for 2 seconds. 8.2. Turn the ignition OFF for 10 seconds. 8.3. Turn the ignition ON, with the engine OFF. 8.4. Inspect for fuel leaks. Mechanical Specifications Page 9218 C223 I/P Harness To Body Harness (Except NYS And HP2) Part 2 Page 15765 Steering Wheel And Column Sub-System Components Recall 04V225000: Child Seat Anchorage Non-Compliance Child Seat: Recalls Recall 04V225000: Child Seat Anchorage Non-Compliance Make / Models : Model/Build Years: Chevrolet / Express 2003 Chevrolet / Silverado 2003-2004 GMC / Savana 2003 GMC / Sierra 2003-2004 MANUFACTURER: General Motors Corp. NHTSA CAMPAIGN ID Number : 04V225000 Recall Date : MAY 10, 2004 COMPONENT: Seat Belts: Front: Anchorage Potential Number Of Units Affected : 736 SUMMARY: certain extended and regular cab pickup trucks and cargo vans converted to compressed natural gas (CNG) fail to conform to the requirements of Federal Motor Vehicle Safety Standard NO. 225, "Child Restraint Anchorage Systems." These vehicles have one seating position, the center rear seat, equipped with child restraint lower anchorages. CONSEQUENCE: The standard requires child seat lower anchorages in two seating positions for vehicles with three rear seating positions. The standard cab and cargo van vehicles, which only have front seating positions, have an air bag off switch to disable the front passenger air bag and do not have child restraint lower anchorages in the passenger seat. The standard requires passenger seat child seat lower anchorages in vehicles with an air bag off switch. however, the standard does not require vehicles with only front seating positions to have lower anchorage provisions if the vehicle is not equipped with an air bag off switch. REMEDY: To bring the standard cab and cargo van vehicles into compliance, dealers will inject epoxy into the air bag off switch to prevent air bag activation, relocate the switch behind the instrument panel and then install a cover over the resulting opening. The sun visor label and owner's manual will also be changed. the correction for the extended cab vehicle will consist of changing the front passenger seat to a seat that has child restraint lower anchorages. The recall began on September 9, 2004. Owners should contact Chevrolet at 1-800-630-2438 OR GMC AT 1-866-996-9463. NOTES: GM Recall NO. 04038. Customers can also contact The National Highway Traffic Safety Administration's Auto Safety Hotline at 1-888-DASH-2-DOT (1-888-327-4236). Page 9202 C201 Steering Column Harness To I/P Harness Part 4 Page 15199 Electrical Symbols Part 6 Page 13359 Important The following information MUST be documented on the repair order. Failure to do so may result in a chargeback. - Customer vehicle condition. - Was a Service Lamp or Service Message illuminated? If yes, specify which Service Lamp or Service Message. - Was a DTC(s) set? If yes, specify which DTC(s) were set. - After following the procedure contained within this bulletin, could the condition be duplicated? ‹› If the condition was not duplicated, then document the affected module/component connector name and number on the repair order. - If the condition was duplicated after the procedure contained within this bulletin was followed, and additional diagnosis led to the replacement of a module or component, the SI Document ID Number MUST be written on the repair order. Parts Information Alternate Distributor For All of North America Note NyoGel(R) 760G Lubricant* is equivalent to GMSPO P/N 12377900, and P/N 10953529 (Canada), specified for use to correct the condition in this bulletin. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to: Warranty Information (Saab Models) Page 6982 14. Remove the retaining ring from the wheel hub. 15. Remove the outer hub bearing and bearing cup using the J 24426 (2) and the J 8092 (1). Installation Procedure 1. Lubricate the following with a light coat of high melting point EP bearing lubricant: ^ The outer wheel bearing ^ The inner wheel bearing ^ The outer wheel bearing cup ^ The inner wheel bearing cup ^ The axle housing 2. Install the outer bearing into the wheel hub. 3. Install the outer bearing cup into the wheel hub. Page 13522 Electrical Symbols Part 13 Page 5593 Knock Sensor: Service and Repair KNOCK SENSOR (KS) REPLACEMENT REMOVAL PROCEDURE 1. Remove the intake manifold. 2. Gently pry up the rubber covers. 3. Disconnect the knock sensor electrical connectors. 4. Remove the knock sensors. INSTALLATION PROCEDURE NOTE: Refer to Fastener Notice in Service Precautions. Page 3171 8. Remove the knock sensor oil seals (1) from the cover (2). 9. If required, clean and inspect the engine valley cover. Installation Procedure Important: All gasket surfaces should be free of oil or other foreign material during assembly. 1. Lubricate the NEW knock sensor seals (1) with clean engine oil. 2. Install the knock sensor oil seals (1) into the engine valley cover (2). 3. Install the engine valley cover and a NEW gasket onto the engine block. Notice: Refer to Fastener Notice in Service Precautions. 4. Install the engine valley cover bolts. ^ Tighten the bolts to 25 Nm (18 ft. lbs.). Page 1710 Intake Air Temperature (IAT)/Mass Air Flow (MAF) Sensor Page 9984 until the sensor is seated into the adapter and bearing assembly. If installing a new sensor, it will come with a pin installed in the sensor. Do not remove the pin until the sensor is seated. If the new sensor did not come with a pin installed, you must reorder a new sensor. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install into the adapter and bearing assembly. 16. Install the connector to the sensor. 17. From the technicians point of view, the FRONT of the sensor will have: ^ A pin hole (2) for the centering pin. Note the location of the pin hole. ^ A flush rotor flange cuff (4) ^ An alignment mark (3) for installation 18. From the technicians point of view, the BACK of the sensor will have an alignment tab (1) for installation. This sensor does not have double D flats. 19. Important: If reusing the existing sensor, you must align the marks on the flush rotor flange cuff before installation. The alignment mark must stay aligned until the sensor is seated into the adapter and bearing assembly. If installing a new sensor, it will come with a pin installed in the sensor. Do not remove the pin until the sensor is seated. If the new sensor did not come with a pin installed, you must reorder a new sensor. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install into the adapter and bearing assembly. 20. Install the connector to the sensor. 21. From the technicians point of view, the FRONT of the sensor will have: ^ A pin hole (3) for the centering pin. Note location of the pin hole. ^ A flush rotor flange cuff (5) ^ An alignment mark (4) for installation ^ A foam ring (6) 22. From the technicians point of view, the BACK of the sensor will have: ^ Double D flats (1) ^ An alignment tab (2) for installing into the adapter and bearing assembly 23. Important: If reusing the existing sensor, you must align the marks on the flush rotor flange cuff before installation. The alignment mark must stay aligned until the sensor is seated into the adapter and bearing assembly. If installing a new sensor, it will come with a pin installed in the sensor. Do not remove the pin until the sensor is seated. If the new sensor did not come with a pin installed, you must reorder a new sensor. Page 14698 Page 10336 11. Remove the lower control arm nuts and the 25/35-series washers. 12. Remove the lower control arm bolts. 13. Remove the lower control arm. Installation Procedure 1. Install the lower control arm. 2. Install the lower control arm 15-series bolts. 3. Install the lower control arm 25/35-series bolts. 4. Install the washers with the shoulder facing the arm. Page 3129 6. Install the camshaft sprocket and position the timing chain. 7. Install the camshaft sprocket bolts. ^ Tighten the camshaft sprocket bolts to 35 Nm (26 ft. lbs.). 8. Inspect the camshaft sensor O-ring seal. If the O-ring seal is not cut or damaged, it may be reused. 9. Lubricate the O-ring seal with clean engine oil. 10. Install the camshaft sensor and bolt. ^ Tighten the bolt to 25 Nm (18 ft. lbs.). 11. Install the valve lifters. 12. Install the front cover. 13. Install the radiator support. 14. Remove the hood hinge bolts from the service position (2). 15. Lower the hood to the normal position. 16. Install the hood hinge bolts. ^ Tighten the bolts to 25 Nm (18 ft. lbs.). Page 7478 3. If the vehicle is a 1500 series, position the transfer case shield, if equipped. Notice: Refer to Fastener Notice in Service Precautions. 4. Install the transfer case shield bolts, if equipped. ^ Tighten the bolts/screws to 20 Nm (15 ft. lbs.). 5. Lower the vehicle. Page 9550 Fuse Block - Underhood C1 Part 4 Locations SEO Harness Routing Page 12226 Important: The optic cable must not be bent with a radius less than 25 mm (1 in). 12.5. Cars with brackets for e.g. an amplifier: Fit the cable tie (11 900 515) to the wiring harness approx. 100 mm (4 in) from H2-9, fit the cable tie (H) to the bracket. Gather the optic cable in a gentle loop (I) and then place the loop behind the bracket. Important: The optic cable must not be bent with a radius less than 25 mm (1 in). 12.6. Cars without brackets for e.g. an amplifier: Gather the optic cable in a gentle loop (J) and secure with cable tie. 13. CV: Fit the left-hand, rear side hatch trim in accordance with WIS - 8. Body - Interior equipment - Adjustment/Replacement. 14. Fit the ground cable to the battery's negative terminal. 15. Carry out procedures after disconnecting the battery, see WIS - 3. Electrical System - Charging system - Adjustment/Replacement. Important: Follow Tech 2(R) on-screen instructions. 16. Add ECU ICM, choose without OnStar(R). See WIS-General-Tech 2(R) - Description and Operation - Add/Remove. 2000-2004 Saab 9-5 2000-2004 Saab 9-5 Page 12552 Diagnostic Tips Review # 2 - Delphi Legacy Navigation Radio Page 10095 1. Install the power steering pump (3) bracket to the engine. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the power steering pump bracket retaining bolts. ^ Tighten the power steering pump bracket retaining bolts to 25 Nm (18 ft. lbs.). 3. Install the power steering pump to the bracket. 4. Install the positive battery junction block bracket retaining bolts (2) to the power steering pump bracket. ^ Tighten the battery junction block retaining bolts to 9 Nm (80 inch lbs.). Page 3915 Step 25 - 27 Page 13251 Page 13645 11. Install hinge using nuts supplied, torque to 25 N.m (20 FT. LB.) (Fig.1.16). 12. Clean and prepare all surfaces as necessary for refinish. 13. Apply sealers and refinish as necessary. Do not combine paint systems. Refer to paint manufacturer's recommendations. 14. Install and align all related panels and components. Door Side REMOVE OR DISCONNECT 1. Remove door from body. (Refer to appropriate service manual.) 2. Visually inspect and restore as much of the damage as possible to factory specifications. 3. Lightly hand-sand existing body hinge with 100 grit or finer sandpaper to locate the four welds attaching hinge to door (Fig. 1.17). 4. Center punch each of the four weld marks on the original hinge base. It is critical to punch the center of the weld so that as much of the weld is removed during drilling as possible. Page 4736 Service and Repair Air Bag(s) Arming and Disarming: Service and Repair SIR Disabling and Enabling The SIR Identification Views shown below illustrate the approximate location of all SIR components available for the vehicle. This will assist in determining the appropriate SIR Disabling and Enabling for a given service procedure. Refer to See: Locations/SIR Zone Identification Views There are several reasons for disabling the SIR system, such as repairs to the SIR system or servicing a component near or attached to an SIR component. There are several ways to disable the SIR system depending on what type of service is being performed. The following information covers the proper procedures for disabling/enabling the SIR system. SIR Service Precautions Caution: When performing service on or near the SIR components or the SIR wiring, the SIR system must be disabled. Failure to observe the correct procedure could cause deployment of the SIR components. Serious injury can occur. Failure to observe the correct procedure could also result in unnecessary SIR system repairs. The inflatable restraint sensing and diagnostic module (SDM) maintains a reserved energy supply. The reserved energy supply provides deployment power for the air bags if the SDM loses battery power during a collision. Deployment power is available for as much as 1 minute after disconnecting the vehicle power. Waiting 1 minute before working on the system after disabling the SIR system prevents deployment of the air bags from the reserved energy supply. General Service Instructions The following are general service instructions which must be followed in order to properly repair the vehicle and return it to its original integrity: - Do not expose inflator modules to temperatures above 65°C (150°F). - Verify the correct replacement part number. Do not substitute a component from a different vehicle. - Use only original GM replacement parts available from your authorized GM dealer. Do not use salvaged parts for repairs to the SIR system. Discard any of the following components if it has been dropped from a height of 91 cm (3 feet) or greater: - Inflatable restraint sensing and diagnostic module (SDM) - Any Inflatable restraint air bag module - Inflatable restraint steering wheel module coil - Any Inflatable restraint sensor - Inflatable restraint seat belt pretensioners - Inflatable restraint Passenger Presence System (PPS) module or sensor Disabling Procedure - Air Bag Fuse 1. Turn the steering wheel so that the vehicles wheels are pointing straight ahead. 2. Place the ignition in the OFF position. Important: The SDM may have more than one fused power input. To ensure there is no unwanted SIR deployment, personal injury, or unnecessary SIR system repairs, remove all fuses supplying power to the SDM. With all SDM fuses removed and the ignition switch in the ON position, the AIR BAG warning indicator illuminates. This is normal operation, and does not indicate a SIR system malfunction. 3. Locate and remove the fuse(s) supplying power to the SDM. 4. Wait 1 minute before working on the system. Page 10352 6. Install the outer tie rod retaining nut to the steering knuckle. ^ Tighten the nut to 55 Nm (40 ft. lbs.). 7. Install the outer tie rod retaining bracket (2). ^ Tighten the bracket to 65 Nm (48 ft. lbs.). 8. Install the tire and wheel. 9. Lower the vehicle. 10. Perform a four wheel alignment. Automatic Transmission - 4L60-E/4L65-E Page 12956 Speaker - LR Door - Crew Cab Page 9036 Fuse Block- I/P C3 Part 3 Page 2467 Fluid - A/T: Fluid Type Specifications Transmission Fluid Type Type ..................................................................................................................................................... ...................................... DEXRON III or Equivalent Page 12229 7.2. Remove the console (A). 7.3. Disconnect the connector (B) from the OnStar(R) control module. Important: Secure the cable harness to prevent the risk of scraping and rattling. 7.4. Fold back the cable harness and tape down the connector (C). Fold back the cable harness again and secure with cable ties (D). 7.5. 5D: Assemble the right-hand cover for the luggage compartment floor. 8. Fit the ground cable on the battery's negative cable. Page 5278 Fuel Injector: Testing and Inspection Fuel Injector Balance Test With special Tool FUEL INJECTOR BALANCE TEST WITH SPECIAL TOOL DESCRIPTION Fuel Injector Balance Test With Special Tool The scan tool is first used to energize the fuel pump. The fuel injector tester is then used to pulse each injector for a precise amount of time, allowing a measured amount of fuel into the manifold. This causes a drop in system fuel pressure that can be recorded and used to compare each injector. TEST DESCRIPTION Steps 1 - 3 Page 9736 C214 I/P Harness To Headliner Harness (With RPO Code U42) Part 2 Page 6222 Disclaimer Page 467 Electrical Symbols Part 4 Page 929 Body Control Module: Description and Operation BODY CONTROL MODULE (BCM) The body control module (BCM) monitors several inputs in order to arm and disarm the CTD system. The BCM controls the alarm function outputs. When the BCM detects an unauthorized entry (any door opened), the BCM applies ground to the horn, the park lamp and the headlamp relays. The BCM will send messages to the security telltale in the instrument cluster through the Class 2 serial data link. The BCM has the following 8 basic modes for operating the CTD system. The more detailed descriptions are below. - Off state - Idle state - Disarmed state - Ready-to-arm state - Arm initiated state - Arm delay state - Armed state - Alarm state The BCM has the following 6 discrete inputs in order to monitor the CTD system: - Ignition 1 - Driver door latch (door jamb) switch - Passenger door latch (door jamb) switch - Door lock relay - Door key switch - Passenger door unlock relay The BCM applies ground once per second for approximately 2 minutes, or until a valid input to disarm the system is received by the BCM. The Body Control Module (BCM) contains the theft deterrent system logic. The BCM reads the Passlock(TM) data from the Passlock(TM) sensor. If the Passlock(TM) data is correct, the BCM will pass theft. The BCM will then transmit the fuel continue password to the VCM/PCM. During the tamper mode the vehicle may start. The vehicle will then stall. If the BCM receives the wrong Passlock(TM) data, the VTD will immediately go into the tamper mode. The tamper mode will lock-out the vehicle fuel injectors for 10 minutes. The SECURITY indicator will flash while the VTD is in the tamper mode. If the Passlock(TM) sensor sends a correct password to the BCM when the ignition is in the ON position, the BCM will send a fuel enable signal to the VCM/PCM. The VCM/PCM will not disable the fuel due to any BCM message for the remainder of the ignition cycle. Fuel Pressure Gage Installation and Removal Fuel Pressure Release: Service and Repair Fuel Pressure Gage Installation and Removal FUEL PRESSURE GAGE INSTALLATION AND REMOVAL INSTALLATION PROCEDURE TOOLS REQUIRED J 34730-1A Fuel Pressure Gage CAUTION: - Refer to Gasoline/Gasoline Vapors Caution in Service Precautions. - Refer to Fuel Gage Leak Caution in Service Precautions. 1. Remove the engine sight shield. 2. Remove the fuel rail pressure fitting cap. 3. Connect the J 34730-1A to the fuel pressure valve. Wrap a shop towel around the fitting while connecting the gage in order to avoid spillage. 4. Install the bleed hose on J 34730-1A into an approved container. REMOVAL PROCEDURE 1. Remove the bleed hose on the J 34730-1A from the approved container. 2. Remove the shop towel from around the fitting and discard into an approved container. 3. Disconnect the J 34730-1A from the fuel pressure valve. 4. Install the fuel rail pressure fitting cap. 5. Install the engine sight shield. Page 9429 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Micro-Pack 100W Connectors MICRO-PACK 100W CONNECTORS TOOLS REQUIRED J 38125-D Terminal Repair Kit REMOVAL PROCEDURE There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2)has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. IMPORTANT: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Page 5352 9. Connect the brake lines to the BPMV. Tighten Tighten the fittings to 25 N.m (18 lb ft). 10. Connect the chassis electrical harness connectors to the EBCM. 11. Install the EVAP canister. 12. Install the transfer case harness to the clip bracket. 13. Install the clip to the bracket on the frame. 14. If equipped with 4WD, install the fuel hose/pipe clip to the bracket on the transfer case. 15. Install the fuel hose/pipe clip to the bracket on the automatic transmission. 16. Install the HO2S sensor connector to the bracket. 17. Install the fuel pipe bracket to the bellhousing stud. 18. Install the fuel pipe bracket nut (2). Page 4819 1. Locate the air flow direction arrow (2) on the MAF/IAT sensor. 2. Install the MAF/IAT sensor to the air cleaner assembly. NOTE: Refer to Fastener Notice in Service Precautions. 3. Tighten the MAF/IAT clamp. Tighten Tighten the clamp to 7 N.m (62 lb in). 4. Connect the MAF/IAT sensor electrical connector (4). 5. Push in the gray CPA retainer. 6. Install the air cleaner outlet duct. Page 8731 Jump Starting: Service and Repair JUMP STARTING IN CASE OF EMERGENCY (NON HP2) CAUTION: Batteries produce explosive gases. Batteries contain corrosive acid. Batteries supply levels of electrical current high enough to cause burns. Therefore, in order to reduce the risk of personal injury while working near a battery, observe the following guidelines: - Always shield your eyes. - Avoid leaning over the battery whenever possible. - Do not expose the battery to open flames or sparks. - Do not allow battery acid to contact the eyes or the skin. - Flush any contacted areas with water immediately and thoroughly. - Get medical help. NOTE: This vehicle has a 12 volt, negative ground electrical system. Make sure the vehicle or equipment being used to jump start the engine is also 12 volt, negative ground. Use of any other type of system will damage the vehicle's electrical components. This vehicle has a 12-volt positive, negative ground electrical system. Do not try to jump start a vehicle, if you are unsure of the other vehicle's positive voltage or ground position. The booster battery and the discharged battery should be treated carefully when using jumper cables. 1. Position the vehicle with the booster battery so that the jumper cables will comfortably reach the battery of the other vehicle. - Do not let the 2 vehicles touch. - Make sure that the jumper cables do not have loose clamps or missing insulation. 2. Perform the following steps on both vehicles: 2.1. Place the automatic transmission in PARK. 2.2. Block the wheels. 2.3. Set the parking brake. 2.4. Turn off all electrical loads that are not needed-Leave the hazard flashers ON. 2.5. Turn OFF the ignition switch. IMPORTANT: Some vehicles have a battery remote positive stud-ALWAYS use the battery remote positive stud in order to give or to receive a jump start-Consult the vehicle's owner's manual for proper connections. 3. Attach the end of one jumper cable to the positive terminal of the discharged battery. 4. Attach the other end of the first cable to the positive terminal of the booster battery. 5. Attach one end of the remaining jumper cable to the negative terminal of the booster battery. NOTE: Do not connect the negative charger lead to the housings of other vehicle electrical accessories or equipment. The action of the battery charger may damage such equipment. 6. Make the final connection of the negative jumper cable to the block or suitable bracket connected directly to the block, away from the battery. 7. Start the engine of the vehicle that is providing the jump start and turn off all electrical accessories. Raise the engine RPM to approximately 1,500 RPM. 8. Crank the engine of the vehicle with the weak battery. If the engine does not crank or cranks too slowly, perform the following steps: 8.1. Turn the ignition OFF. 8.2. Allow the booster vehicle engine to run at approximately 1,500 RPM for 5 minutes. Page 4480 Electrical Symbols Part 2 Page 9234 C306 Infotainment Jumper Harness To Console Harness (With RPO Code Y91) Part 3 Page 15060 For vehicles repaired under warranty use the table. Disclaimer Correction 1. Repair the damaged pickup box using the following procedure. When repairing any damage to the front of the pickup box, it may be necessary to remove the pickup box from the frame. A. Drill a 6 mm (0.23 in) hole in the extreme end of the crack. B. Prepare inner crack for welding. Important: Do not use oxyacetylene welding equipment. MIG WELD ONLY. C. Weld the crack using the appropriate welding technique. D. Clean and prepare all of the welding surfaces. E. Return surface contour to its original contour. Important: Prior to refinishing, refer to the GM4901M-D-2005 (English) or GM4901M-D-F 2005 (French) GM Approved Refinish Materials booklet for recommended products. The information for the 2005 GM Approved Refinish Materials booklet will now be online at the GMGOODWRENCH WEB SITE ONLY. Printed books have been discontinued. Steps to the site are as follows: a. Go to www.gmgoodwrench.com. b. Click on GM Collision Parts. c. Click on GM Technical Repair Information. d. Click on Paint Shop. Do not combine the paint systems. Refer to the paint manufacturer's recommendations. F. Refinish as necessary. Page 12041 Page 2191 2. Remove the transmission from the vehicle. Refer to the appropriate SI document. Important: ^ Inspect all the transmission components for damage or wear. Replace all damaged or worn components. The parts shown above should be sufficient to correct this concern. ^ This condition does not normally require replacement of the transmission completely. Components such as clutches, valve body, pump and torque converters will NOT require replacement to correct this condition. Disassemble the transmission and replace the appropriate parts listed below. Refer to the Unit Repair Manual - Repair Instructions. 3. Reinstall the transmission in the vehicle. Refer to appropriate service information. When servicing the transmission as a result of this condition, the transmission oil cooler and lines MUST be flushed. Refer to Corporate Bulletin Number 02-07-30-052. Page 13676 Front Door Weatherstrip: Service and Repair Weatherstrip Replacement - Side Door Opening Weatherstrip Replacement - Side Door Opening Removal Procedure 1. Open both doors. 2. Remove the sill plate. 3. Remove the hinge pillar trim pillar. 4. Remove the windshield pillar molding. 5. Remove the weather-strip from the rear side door pinch-weld flange. Installation Procedure 1. Install the weather-strip from the rear side door opening fully seating the weather-strip into the pinch-weld flange. 2. Install the windshield pillar molding. 3. Install the hinge pillar trim pillar. 4. Install the sill plate. 5. Inspect the door closing effort and seal to door fit. Page 9024 Fuse Block - Underhood C6 Page 10602 *This product is currently available from 3M. To obtain information for your local retail location please call 3M at 1-888-364-3577. **This product is currently available from Meguiars (Canada). To obtain information for your local retail location please call Meguiars at 1-800-347-5700 or at www.meguiarscanada.com. ^ This product is currently available from Tri-Peek International. To obtain information for your local retail location please call Tri-Peek at 1-877-615-4272 or at www.tripeek.com. Disclaimer Page 14384 Control Module References Part 3 Page 3423 Disclaimer Page 15016 Service Procedure Classic Silverado and Sierra (GMT400) The following procedure provides instructions for inspecting, and if necessary, replacing the rear endgate (tailgate) support cables and inspecting the right side tailgate hinge for damage, and replacing if recessary. Notice: It is recommended that a support be placed under the open tailgate in the next step to prevent the tailgate from being damaged in the event that it drops when disconnecting, inspecting, and replacing the support cables. Hinge Inspection - Classic CK and Sierra 1. Release (unhook) the RIGHT side tailgate support cable from the pickup box. 2. With the tailgate (1) completely open as shown in the upper part of the illustration, pull the RIGHT SIDE of the tailgate rearward as shown in the lower illustration. Do not pull on the left side of the tailgate. - If the tailgate hinge (2) will NOT disengage from the pickup box on the right side, no repair is needed to the hinge. Proceed to the section titled, "Support Cable Replacement" and replace both support cables. - If the tailgate hinge (3) WILL disengage from the pickup box on the right side, proceed to the next step. 3. With the right side of the tailgate disengaged from the pickup box, inspect the hinge on the right side of the tailgate for damage. The illustration above shows an undamaged hinge (1) and a damaged or bent hinge (2). - If the hinge is NOT damaged, no repair is needed to the hinge. Proceed to the section titled, "Support Cable Replacement" and replace both support cables. - If the hinge IS damaged or bent, the hinge needs to be replaced. Proceed to the section titled, "Hinge Replacement" before proceeding with the replacement of the support cables. Hinge Replacement - Classic CK and Sierra Page 15663 Headlamp Alignment Switch: Service and Repair HEADLAMP LEVELING SWITCH REPLACEMENT REMOVAL PROCEDURE 1. Remove the instrument panel bezel. 2. Pull out the accessary switch housing. 3. Disconnect the electrical connectors. 4. Remove the head lamp leveling switch from the accessary switch housing. INSTALLATION PROCEDURE 1. Install the head lamp leveling switch into accessary switch housing. 2. Connect the electrical connectors. 3. Install the accessary switch housing. 4. Install the instrument panel bezel. Drivetrain - Wheel Drive Shaft Nut Torque Revision Axle Nut: Technical Service Bulletins Drivetrain - Wheel Drive Shaft Nut Torque Revision Bulletin No.: 04-04-95-001 Date: March 02, 2004 SERVICE MANUAL UPDATE Subject: Revised Wheel Drive Shaft Nut Torque Specification Models: 2002-2004 Cadillac Escalade, Escalade EXT 2003-2004 Cadillac Escalade ESV 1999-2004 Chevrolet Silverado 2000-2004 Chevrolet Suburban 2002-2004 Chevrolet Avalanche 2003-2004 Chevrolet Astro, Express 1999-2004 GMC Sierra 2000-2004 GMC Yukon, Yukon XL 2003-2004 GMC Safari, Savana 2003-2004 HUMMER H2 This bulletin is being issued to revise the torque specification for the wheel drive shaft nut in the Wheel Drive Shafts sub-section of the Service Manual. Please replace the current information in the Service Manual with the following information. The following information has been updated within SI. If you are using a paper version of this Service Manual, please make a reference to this bulletin on the affected page. Page 8379 1. Install the new brake cable (2) into the rear brake cable mounting bracket (3) by pushing the cable into place until the locking tabs (1) snap into place. 2. Install the park brake cable to the lever. 3. Notice: Refer to Fastener Notice in Service Precautions. Install the rear park brake cable bracket bolt. ^ Tighten the rear park brake cable bracket bolt to 61 Nm (45 ft. lbs.). 4. Install the park brake cable and the bolt to the lower shock absorber mount. ^ Tighten the park brake cable bolt to 25 Nm (18 ft. lbs.). Page 3397 9. If equipped with vacuum assisted brakes, install the vacuum brake booster hose to the rear of the intake manifold. 10. Route the electrical harness into position over the engine. 11. Connect the knock sensor harness electrical connector to the intake manifold. 12. Connect the following electrical connectors. ^ MAP sensor (1) ^ Knock sensor (2) 13. Install the fuel injectors. 14. Install the throttle body. Fuel Level Sensor Replacement - 1 Fuel Gauge Sender: Service and Repair Fuel Level Sensor Replacement - 1 FUEL LEVEL SENSOR REPLACEMENT REMOVAL PROCEDURE 1. Remove the sending unit. 2. Disconnect the fuel pump electrical connector. 3. Remove the fuel lever sensor electrical connector retaining clip. 4. Disconnect the fuel level sensor electrical connector. 5. Remove the fuel level sensor retaining clip. 6. Remove the fuel level sensor (1). INSTALLATION PROCEDURE 1. Install the fuel level sensor (1). 2. Install the fuel level sensor retaining clip. 3. Connect the fuel level sensor electrical connector. 4. Install the fuel lever sensor electrical connector retaining clip. 5. Connect the fuel pump electrical connector. 6. Install the sending unit. Page 10464 6. Install the wheel hub and bearing (5) and splash shield (6) to the vehicle, 15 series. 7. Install the wheel hub and bearing mounting bolts, the 15 series. 8. Install the wheel hub and bearing mounting bolts, 25/35 series. ^ Tighten the wheel hub to knuckle bolts to 180 Nm (133 ft. lbs.). 9. Install the nut (2) and washer (3) retaining the wheel drive shaft assembly to the wheel hub and bearing. ^ Tighten the nut to 240 Nm (177 ft. lbs.). 10. Install the wheel speed sensor and brake hose mounting bracket bolt to the steering knuckle. ^ Tighten the brake hose clip bolt to 12 Nm (106 inch lbs.). 11. Install the rotor. Refer to Brake Rotor Replacement - Front in Disc Brakes. 12. Install the tire and wheel. 13. Lower the vehicle. Page 8858 Lower Center Of The I/P Components Page 15681 Steering Wheel And Column Sub-System Components Page 14531 3. Remove the head restraint retainers from the seat back frame by squeezing the retaining tabs together at the base of the guide(s) and lifting up. Installation Procedure 1. Install the head restraint retainers by pressing into the seat back frame until the retaining tabs snap into place at the bottom of the frame opening. 2. Position the cardboard panel to the seat back frame and install the panel fasteners. 3. Install the seat back trim cover. Page 12040 ^ For U.S. Saturn retailer claim submission, use Net Item code "M" and Case Type VW. Page 8635 7. Release the C-clamp. 8. Remove the nut from the stud. 9. Remove the J 26889. 10. Install the master cylinder to the hydraulic booster. 11. Release the park brake and unblock the wheels. Page 748 Radio (With RPO Code UB7,Y91 Shown, Others Similar) Page 11979 The control module ID number list above provides a method for determining which module is not communicating. A module with a class 2 serial data circuit malfunction or which loses power during the current ignition cycle will have a Loss of Communication DTC set by other modules that depend on information from that failed module. The modules that can communicate will set a DTC indicating the module that cannot communicate. Diagnostic Order When more than one Loss of Communication DTC is set in either one module or in several modules, diagnose the DTCs in the following order: 1. Current DTCs before history DTCs unless told otherwise in the diagnostic table. 2. The DTC which is reported the most times. 3. From the lowest number DTC to the highest number DTC. Conditions for Running the DTC The following DTCs do not have a current status: ^ B1327 ^ B1328 ^ U1300 ^ U1301 ^ U1305 AND ^ The vehicle power mode requires serial data communication to occur. Conditions for Setting the DTC A node alive message has not been received from a module with a learned identification number within the last 5 seconds. Action Taken When the DTC Sets Page 7310 Control Module: Diagrams Page 10908 9. Use J 38125-12A to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. REPAIR PROCEDURE The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. 1. Cut the wire as close to the terminal as possible. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. Page 3882 Instruments - Odometer/Hour Meter Programming Procedure Odometer: All Technical Service Bulletins Instruments - Odometer/Hour Meter Programming Procedure INFORMATION Bulletin No.: 07-08-49-015D Date: May 04, 2010 Subject: Information on Instrument Panel Cluster (IPC) Odometer and Engine Hour Meter Set Up at Dealership After IPC Replacement Models: 2004-2007 Buick Rainier 2003-2006 Cadillac Escalade Models 2002-2009 Chevrolet TrailBlazer 2003-2006 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007 Chevrolet Silverado Classic (12th Digit of VIN 1 or 2) 2002-2009 GMC Envoy 2003-2006 GMC Sierra, Yukon Models 2007 GMC Sierra Classic (12th Digit of VIN 1 or 2) 2002-2004 Oldsmobile Bravada 2003-2007 HUMMER H2 2005-2009 Saab 9-7X Attention: The purpose of this bulletin is to inform dealership personnel that the Instrument Panel Cluster (IPC) odometer and engine hour meter (when applicable) setting will no longer be performed at an Electronic Service Center (ESC). Dealerships will now receive IPCs with the odometer and engine hour meter not programmed. The technician will be required to note the odometer reading and engine hour (when applicable) values of the original IPC, then use the SPS application to program these values into the new IPC. Supercede: This bulletin is being revised to update the text in Steps 1, 2, 3, 4, 5, 6 and 7. Please discard Corporate Bulletin Number 07-08-49-015C (Section 08 - Body and Accessories). Background Information Previous IPC replacement procedures specify that the odometer and engine hour values be communicated to and programmed by the Electronic Service Centers (ESC) into the replacement IPC at the time the replacement is ordered. This required the vehicle to be parked after the replacement IPC is ordered so that no additional mileage can be accumulated on the vehicle while the new IPC is in transit to the dealership. Improvements to the TIS2WEB SPS application will now allow IPC odometer and engine hour programming to be performed as an additional function of the IPC programming event. This new process will allow the vehicle to be returned to the customer, if necessary, and driven while waiting for the replacement IPC to arrive at the dealership. Odometer and engine hour values will no longer be communicated to the ESC for programming purposes but ESCs still need the odometer value for warranty reporting. Dealerships will now receive a replacement IPC with the odometer and engine hour values NOT programmed. The technician will be required to note the odometer and engine hour values of the original IPC, then use the TIS2WEB SPS application to program these values into the replacement IPC. The odometer and engine hour programming will now be included as a normal part of the IPC replacement procedure in SI. Odometer and Engine Hour Programming Procedure Information - If the original IPC odometer value cannot be obtained from the customer's vehicle, follow local and federal regulations regarding unknown odometer mileage situations. - Because the odometer and engine hour values can now be read from the original IPC and programmed into the replacement IPC during the same visit, the customer's vehicle will no longer need to be parked until the replacement IPC is received from an ESC. - Avalanche, Escalade, Sierra, Silverado, H2, Suburban, Tahoe and Yukon vehicles will also require the engine hour data to be recorded for transfer to the replacement IPC. The replacement IPC may already have engine hours showing. This does not affect the IPC Setup procedure. Bravada, Envoy, Rainier and TrailBlazer vehicles do not support the calculation or display of engine hour data. - Ensure that the correct odometer value is entered when prompted. Once programming is complete, the odometer and engine hour values, when applicable cannot be changed. - By default, the application odometer entry will be set to: miles. For metric units, click the button on the left next to: Kilometers. Service Procedure Important The replacement IPC requires IPC Setup procedures and SPS programming to be performed. Legacy Pass-Thru will no longer be Page 980 Engine Control Module: Description and Operation Electronic Ignition (EI) System POWERTRAIN CONTROL MODULE (PCM) The PCM controls all ignition system functions, and constantly corrects the basic spark timing. The PCM monitors information from various sensor inputs that include the following: - The throttle position (TP) sensor - The engine coolant temperature (ECT) sensor - The mass air flow (MAF) sensor - The intake air temperature (IAT) sensor - The vehicle speed sensor (VSS) - The transmission gear position or range information sensors - The engine knock sensors (KS) Recall - 2nd Row Center Seat Belt Loop Modification Technical Service Bulletin # 05037 Date: 050714 Recall - 2nd Row Center Seat Belt Loop Modification Second Row Center Safety Belt # 05037 - (Jul 14, 2005) Models: 2003-2005 CADILLAC ESCALADE, ESCALADE ESV, ESCALADE EXT 2003-2005 CHEVROLET AVALANCIE, SILVERADO CREW CAB, SUBURBAN, TAHOE 2003-2005 GMC SIERRA CREW CAB, YUKON, YUKON XL 2004-2005 HUMMER H2 Condition General Motors has decided that a defect, which relates to motor vehicle safety, exists in certain 2003-2005 Cadillac Escalade, Escalade ESV, Escalade EXT; Chevrolet Avalanche, Silverado Crew Cab, Suburban, Tahoe; GMC Sierra Crew Cab, Yukon, Yukon XL; and 2004-2005 HUMMER H2 vehicles. On these vehicles, the seat loop in the second row center seating position may make it difficult to position the lap portion of the safety belt low around the hips of the occupant. In the event of a vehicle accident, if the lap portion of the safety belt routing is not low and snug on the hips, it may not properly restrain the occupant and could increase the risk of abdominal injury. Correction Dealers are to eliminate the seat loop by removing the safety belt from the loop and stitching the loop closed. Vehicles Involved Page 9942 1. For vehicles equipped with a torsion bar suspension turn the bolt (1) that contacts the torsion arm clockwise to raise the and counterclockwise to lower the height adjustment. One revolution of the bolt (1) into the nut increases the Z height by approximately 6.0 mm (0.2 inch). 2. For vehicles without torsion bars, replace damaged or worn components as necessary. D Height Measurement Important: There are no specified trim heights specifications on leaf spring vehicles because it is not an adjustable feature. The height of the suspension will depend on the option content of the vehicle as well as the aftermarket equipment that is placed on the vehicle. The measurements are used for comparison only and should be within 15 mm with the vehicle at curb and no accessories. 1. With the vehicle on a flat surface, lift upward on the rear bumper 38 mm (1.5 inch). 2. Allow the vehicle to settle into position. 3. Important: Measure the metal to metal contact points of the rear axle to the frame on the inboard side of the leaf springs. Measure the D height by measuring the distance between the bumper bracket and the top of the rear axle tube. 4. Repeat the jouncing operation 2 more times for a total of 3 times. 5. Use the highest and lowest measurements to calculate the average height. 6. The true D height dimension number is the average of the highest and the lowest measurements. 7. If these measurements are out of specifications, inspect for the following conditions: ^ Sagging front suspension Refer to Front Coil Springs Replacement or Torsion Bar Replacement in Front Suspension. ^ Sagging rear leaf/coil springs Refer to Leaf Spring Replacement in Rear Suspension. ^ Worn rear suspension components, such as leaf spring bushings Refer to Spring Bushing Replacement in Rear Suspension. ^ Improper tire inflation Refer to Tire Inflation Pressure Specifications. ^ Improper weight distribution ^ Collision damage Page 9676 Important The M6 conductive rivet stud as shown, can accommodate a panel thickness range of 0.7-4.2 mm (0.03-0.17 in). If there are layers of sheet metal, they should be touching without any air gaps to ensure a good ground. 5. Select a M6 conductive rivet stud. Refer to the Parts Information section of this bulletin. Note Use the GE-50317 rivet stud tool kit. 6. Place the M6 conductive rivet stud (1) in the 10 mm (0.40 in) hole. Assemble the rivet stud tool (2) with the groove and flare side facing the rivet stud, then the washer and the M6 nut (3). 7. Using a wrench on the rivet stud tool, and a socket on the M6 nut, secure the M6 conductive rivet stud. 8. Ensure the rivet stud is securely fastened, WITHOUT ANY detectable movement. 9. Completely wrap the threads of the rivet stud with painters tape or equivalent. Note The rivet stud and surrounding panel area MUST BE properly refinished PRIOR to the installation of the ground wire terminal and conductive nut to maintain a secure, stable and corrosion-free electrical ground. 10. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 11. Allow the refinished repair area to cure sufficiently before removing the protective material applied to the rivet stud threads. 12. Remove the painters tape or equivalent from the rivet stud threads. 13. Using GM approved residue-free solvent or equivalent, thoroughly clean the rivet stud threads to remove any adhesive and allow to dry. 14. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive rivet stud. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. Page 3568 Important: All gaskets surfaces are to be free of oil or other foreign material during assembly. 1. Install the water pump and NEW gaskets. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the water pump bolts. 1. Tighten the bolts a first pass to 15 Nm (11 ft. lbs.). 2. Tighten the bolts a final pass to 30 Nm (22 ft. lbs.). 3. Install the heater inlet hose to the water pump. 4. Position the heater inlet hose clamp at the water pump. 5. Install the surge tank outlet hose to the water pump. 6. Position the surge tank outlet hose clamp at the water pump. Page 9050 Relay Block - I/P C1 Part 1 Page 1758 Inflatable Restraint I/P Module Disable Switch (With RPO Code C99) Page 2520 3. Install the fill plug. ^ Tighten the plug to 20 Nm (15 ft. lbs.). 4. Lower the vehicle. Page 7649 1. Position the seal on the input shaft. Important: When installing the input shaft seal, make sure that the part numbers on the seal are facing outward (toward the technician). The input shaft seal should be even with the surface of the transfer case after installation. 2. Using the J 42738, install the input shaft seal. 3. Install the transfer case. Page 3785 Electrical Symbols Part 13 Page 2096 Disclaimer Page 10846 1. Install the mode actuator as an assembly with the actuator cam. - Line up the heater/defroster valve lever with the mode actuator cam slot. - Line up the A/C valve lever with the mode actuator cam NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the mode actuator mounting screws to the HVAC module. Tighten Tighten the screws to 1.6 N.m (14 lb in). 3. Connect the electrical connection at the mode actuator (10). 4. Install the center console duct. 5. Install the screws to the center console duct. Page 3615 Coolant Temperature Sensor/Switch (For Computer): Service and Repair ENGINE COOLANT TEMPERATURE (ECT) SENSOR REPLACEMENT REMOVAL PROCEDURE NOTE: Use care when handling the coolant sensor. Damage to the coolant sensor will affect the operation of the fuel control system. 1. Drain the cooling system to a level below the engine cooling temperature (ECT) sensor. Refer to Draining and Filling Cooling System in Cooling System. 2. Disconnect the ECT sensor electrical connector (5). 3. Remove the ECT sensor. INSTALLATION PROCEDURE NOTE: Replacement components must be the correct part number for the application. Components requiring the use of the thread locking compound, lubricants, corrosion inhibitors, or sealants are identified in the service procedure. Some replacement components may come with these coatings already applied. Do not use these coatings on components unless specified. These coatings can affect the final torque, which may affect the operation of the component. Use the correct torque specification when installing components in order to avoid damage. - Use care when handling the coolant sensor. Damage to the coolant sensor will affect the operation of the fuel control system. Page 388 2. Connect the Techline Information System (TIS) terminal to the Tech2(R). 3. Scroll to the bottom of the Controller List, and select the "ONSA TIS2WEB Pass-Thru OnStar(R) Activation (Replaced/Upgraded Units Only)" option using the Service Programming System (SPS). Important: Do not use the clear DTC function. This will only temporarily turn the LED to green. 4. Upon completion of the OnStar(R) TIS2WEB step, disconnect the TIS terminal from the Tech2(R) and perform the VCIM/OnStar(R) Set-up Procedure using the Tech2(R). The set up procedure is located under the special function menu option. Important: Failure to perform the above steps will result in a red LED, DTC being set and limited or incomplete OnStar(R) services, and will require a customer return visit to the dealership. 5. The default language for the new VCIM will be English. To change to French or Spanish, access the special functions menu on the Tech 2(R), and follow the instructions accordingly. 7. Skip to the next step if the vehicle to be upgraded is not listed below: ^ 2002-2004 Cadillac DeVille ^ 2002-2004 Cadillac Seville ^ 2005 Cadillac STS Set up the Dash Integration Module (DIM) using the following procedure: 1. On the Tech2(R) select the correct Year, Make and Model. 2. Enter Dash Integration Module (DIM) > Special Functions > Set Options > Misc. Options 1 > and turn off phone (if the vehicle does not have the UV8 option). 3. Enter Nav Radio Present and set to "No Nav" (if the vehicle does not have a navigation radio). 4. Turn the ignition off and open the door to turn off the RAP. 5. Turn the ignition on and enter the Vehicle Comm. Interface Module > Special Functions > Set Up OnStar /VCIM. 6. When prompted select "No Phone" (if the vehicle does not have the UV8 phone) and "No Nav" (if the vehicle does not have a navigation radio). 7. Turn the ignition off and open the door to turn off the RAP. Important: OnStar(R) Emergency Services are immediately available after these steps, however, full configuration, including activation of Hands-Free Calling, may take up to 24 hours to complete. Processing the Module Exchange Processing the Module Exchange For this program, submitting a credit request for the removed OnStar(R) VCIM (the core) will be performed through a website. When this process is followed, the removed Analog / Digital-Ready VCIM, in most cases, will not be mailed back to the distributor, but can be scrapped by the dealership. U.S. Dealers 1. Return the removed Analog / Digital-Ready OnStar(R) VCIM to the Parts Manager. 2. The Parts Manager will log onto www.autocraft.com. 3. Select Account Maintenance. 4. Select Outstanding Cores. Page 1737 Camshaft Position Sensor: Service and Repair CAMSHAFT POSITION (CMP) SENSOR REPLACEMENT REMOVAL PROCEDURE IMPORTANT: Clean the area around the CMP sensor before removal in order to prevent debris from entering the engine. 1. Remove the camshaft position (CMP) sensor bolt. 2. Remove the CMP sensor. INSTALLATION PROCEDURE 1. Install the CMP sensor. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the CMP sensor bolt. Tighten Tighten the bolt to 29 N.m (21 lb ft). Page 15812 1. Connect the electrical connectors. 2. Install the headlamp switch by snapping the headlamps switch into place. 3. Install the bezel to the instrument panel. Page 4488 Electrical Symbols Part 11 Page 13526 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors USING CONNECTOR TEST ADAPTERS IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-B Connector Test Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Locations Coolant Temperature Sensor/Switch (For Computer): Locations Full Engine View Left Side Page 349 SRS - Air Bag Lamp ON/DTC B0092 Set Seat Occupant Sensor: All Technical Service Bulletins SRS - Air Bag Lamp ON/DTC B0092 Set Bulletin No.: 02-09-41-002A Date: March 24, 2004 TECHNICAL Subject: Air Bag Lamp On, Passenger Air Bag Indicator Always Reads OFF, DTC B0092 Set (Repair Passenger Presence System (PPS) Sensor Harness) Models: 2003-2004 Cadillac Escalade, Escalade EXT 2003-2004 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2003-2004 GMC Sierra, Yukon, Yukon XL with Sensor Indicator Inflatable Restraint Front Passenger/Child Presence Detector (RPO ALO) Supercede: This bulletin is being revised to add the 2004 model year. Please discard Corporate Bulletin Number 02-09-41-002 (Section 09 - Restraints). Condition Some customers may comment that the Air Bag Lamp is on and the Passenger Air Bag indicator always reads OFF. Upon investigation, the technician may find DTC B0092 set. Cause The cause of this condition may be a shorted Passenger Presence System (PPS) sensor wire. The PPS sensor harness is located under the front passenger seat. This harness may be pinched between the seat frame and the track/riser. Correction Locate the PPS sensor (1) and inspect the harness for proper routing. If the harness is pinched between the seat frame and the track/riser, use the procedure listed below to repair wire(s). 1. Move the front passenger seat to the full rearward and full tilt up position. 2. Loosen the seat frame to track/riser nut and remove the harness. 3. Tighten the seat frame to track/riser nut. 4. Repair any damaged wires. Refer to Wiring Repairs in the Wiring Systems sub-section of the Service Manual. Warranty Information Page 1802 For vehicles repaired under warranty, use the table. Disclaimer Page 7167 5. Using a hammer and a punch, remove the transmission housing front oil seal from the input shaft bearing retainer. 6. Remove the old gasket material from the input shaft bearing retainer. Installation Procedure Important: Inspect the input shaft bearing retainer for any nicks or cracks that may result in a leak. Replace as necessary. 1. Position a NEW oil seal in the input shaft bearing retainer. 2. Using a suitable tool, install the oil seal. 3. Apply RTV sealer GM P/N 12345739 (Canadian P/N 10953472), or equivalent to the inside edge of the bearing retainer mating surface. Page 16094 - Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-D in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-D if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Page 8453 Claim Information Refer to the General Motors WINS Claims Processing Manual for details on Product Recall Claim Submission. Customer Notification -- For US and Canada General Motors will notify customers of this recall on their vehicle (see copy of customer letter shown in this bulletin). Customer Notification -- For Letters will be sent to known owners of record located within areas covered by the US National Traffic and Motor Vehicle Safety Act. For owners outside these areas, dealers should notify customers using the sample letter. Dealer Recall Responsibility -- For US and Export (US States, Territories and Possessions) The US National Traffic and Motor Vehicle Safety Act provides that each vehicle which is subject to a recall of this type must be adequately repaired within a reasonable time after the customer has tendered it for repair. A failure to repair within sixty days after tender of a vehicle is prima facie evidence Page 3666 Radiator Hose: Service and Repair Outlet Radiator Hose Replacement - Outlet (4.8, 5.3, and 6.0L Engines) Removal Procedure 1. Drain the cooling system. 2. Loosen the air cleaner outlet duct clamps at the following locations: ^ Throttle body ^ Mass Airflow/Intake Air Temperature (MAF/IAT) sensor 3. Remove the radiator inlet hose clip from the outlet duct. 4. Remove the air cleaner outlet duct. 5. Reposition the outlet hose clamp at the water pump. 6. Remove the outlet hose from the water pump. 7. Reposition the outlet hose clamp at the radiator. 8. Remove the outlet hose from the radiator. Installation Procedure Page 6920 12. Pack the CV joint boot (1) and the CV joint assembly with the grease supplied in the kit. The amount of grease supplied in this kit has been pre-measured for this application. 13. Place the new small boot clamp (2) onto the CV joint seal (1). 14. Slide the CV joint boot (1) onto the halfshaft bar. 15. Position the small end of the CV joint boot (1) into the joint boot groove (3) on the halfshaft bar. 16. Secure the small boot clamp (1) using J 35910 (or equivalent), a breaker bar, and a torque wrench. ^ Tighten the small clamp (1) to 136 Nm (100 ft. lbs.). 17. Check the gap dimension on the clamp ear. Continue tightening until the gap dimension is reached. Page 11995 Page 14047 Utility Storage Compartment: Service and Repair Tool Storage Compartment Replacement (PRO) Tool Storage Compartment Replacement (PRO) Removal Procedure 1. Raise the rear seat. 2. Remove the nuts that retain the tool storage compartment to the mounting brackets. 3. Remove the tool storage compartment from the vehicle. Installation Procedure 1. Install the tool storage compartment to the vehicle. 2. Install the nuts that retain the tool storage compartment to the vehicle. Notice: Refer to Fastener Notice in Service Precautions. 3. Install the nuts that retain the tool storage compartment to the mounting brackets. Tighten the nuts to 10 N.m (88 lb in). 4. Lower the rear seat. Page 3052 6. Important: Do not reuse the nut. A new nut must be used when installing the wheel drive shaft. Remove the wheel driveshaft assembly retaining nut (2) and washer (3) from the wheel driveshaft. 7. Disengage the wheel drive shaft from the wheel hub and bearing using J 45859 or equivalent. Page 12088 Description and Operation Fuel Pressure Regulator: Description and Operation FUEL PRESSURE REGULATOR ASSEMBLY The fuel pressure regulator is a vacuum operated diaphragm relief valve. The diaphragm has fuel pressure on one side and regulator spring pressure and intake manifold vacuum on the other side. The fuel pressure regulator compensates for changes in intake manifold vacuum by changing the fuel pressure. In this way, the fuel pressure regulator maintains a constant pressure differential across the fuel injectors under all operating conditions. Page 493 9. Use J 38125-12A to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. REPAIR PROCEDURE The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. 1. Cut the wire as close to the terminal as possible. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. Automatic Transmission - 4L60-E/4L65-E Pressure Regulating Solenoid: Service and Repair Automatic Transmission - 4L60-E/4L65-E Pressure Regulator Replacement Removal Procedure 1. Remove the transmission filter. 2. Compress the reverse boost valve sleeve into the bore of the oil pump to release tension on the reverse boost valve retaining ring. 3. Remove the reverse boost valve retaining ring, then slowly release tension on the reverse boost valve sleeve. 4. Remove the reverse boost valve sleeve (5) and the reverse boost valve (4). 5. Remove the pressure regulator isolator spring (3) and the pressure regulator valve spring (2). 6. Remove the pressure regulator valve (1). Installation Procedure 1. Install the pressure regulator valve (1). 2. Install the pressure regulator isolator spring (3) and the pressure regulator valve spring (2). 3. Install the reverse boost valve (4) in the reverse boost valve sleeve (5). 4. Install the reverse boost valve (4) and sleeve (5) in the oil pump cover. Page 6037 Page 9165 You MUST use a silver-bearing solder to make the solder joint. DO NOT attempt this repair with conventional tin/lead alloy solders. Most suppliers have this type of solder available and it is available nationally at Radio Shack(R)*. It is sold in several diameters and either are acceptable for this repair. 5. For this step, it is permitted that two technicians be used if required. Heat the new connector on the surface of the buss bar that is to be soldered. Long nose pliers are suggested to hold the electrical connector and the defroster tab in place. Keep the solder ready and begin flowing out the solder as soon as the melting temperature has been reached. Tip If a single technician is attempting this repair, it is beneficial to wrap one turn of the solder around the new contacts base. In this manner, as the melting point of the solder is reached, a layer is deposited on the bottom side of the contact. Important Try to align the new contact so that it is positioned with the same orientation as the original contact. 6. The above illustrates an ideal finished solder joint. Additional stray solder will not harm the performance of the bond; however, while it is unlikely that customers may refer to the appearance of the rear window defroster and its components as a positive styling feature of the vehicle interior, it is easy to elicit the opposite reaction due to a poor cosmetic application. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Parts Information Acrysol(TM) can be ordered directly from Kent Automotive at 1-800-654-6333 (in Canada, 1-800-563-1717). Radio Shack(R) products can be found nationally at retail locations, www.radioshack.com, or at 1-800-843-7422. All other parts can be ordered through GMSPO or SSPO. Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use: Warranty Information (Saab U.S. Models) Page 2661 Fuse Block- I/P C1 Part 2 Locations Air Temperature Sensor - Outside Page 14716 Disclaimer Page 6245 10. Grasp firmly while pulling down with a twisting motion in order to remove the filter. 11. Remove and discard the filter seal. The filter seal may be stuck in the pump; if necessary, carefully use pliers or another suitable tool to remove the seal. 12. Inspect the fluid color. 13. Inspect the filter. Pry the metal crimping away from the top of the filter and pull apart. The filter may contain the following evidence for root cause diagnosis: ^ Clutch material ^ Bronze slivers indicating bushing wear ^ Steel particles 14. Clean the transmission case and the oil pan gasket surfaces with solvent, and air dry. You must remove all traces of the old gasket material. Installation Procedure 1. Coat the NEW filter seal with automatic transmission fluid. 2. Install the NEW filter seal into the transmission case. Tap the seal into place using a suitable size socket. 3. Install the NEW filter. Page 11267 Low Pressure Sensor / Switch: Service and Repair AIR CONDITIONING (A/C) LOW PRESSURE SWITCH REPLACEMENT REMOVAL PROCEDURE 1. Disconnect the electrical connector from the A/C low pressure switch. 2. Remove the A/C low pressure switch from the accumulator. 3. Remove the O-ring and discard. INSTALLATION PROCEDURE 1. Lightly coat the NEW O-ring seal with mineral base 525 viscosity refrigerant oil. 2. Install the NEW O-ring seal to the switch. NOTE: Refer to Fastener Notice in Service Precautions. 3. Install the A/C low pressure switch to the accumulator. Tighten Tighten the switch to 6 N.m (53 lb in). 4. Connect the electrical connector to the A/C low pressure switch. 5. Leak test the fittings of the components using the J 39400-A. Page 13521 Electrical Symbols Part 12 Page 1532 Accelerator Pedal Position (APP) Sensor Part 2 Page 9408 Electrical Symbols Part 6 Page 13052 10.4. Remove the end cap from the new optic cable, connect to the connector and refit the secondary catch (D). Fit the terminal housing (C) to the connector and refit the locking strip (B). 10.5. Secure the old optic cable together with the new one (E). Important: The optic cable must not be bent with a radius less than 25 mm (1 in). Important: Secure the wiring harness so that there is no risk of chafing and rattling. 11. CV: Remove the rear seat in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. The O-bus connector H2-9 is located behind the left speaker. 12. M04-05: Disconnect the optic cables on the OnStar(R) control modules and join the cables: 12.1. Cut off the cable tie holding the connector (H2-9) against REC. Page 9152 3. Prepare the surface of the used defroster tab (not required for new tabs on new-style full-size utility models) and the defroster buss bar with fine grain (500 grit) sandpaper or Emery cloth. It is not necessary to remove all of the original solder, but it should be scuffed sufficiently so that no oxidation is present. The photo above shows a close up of a properly prepared surface. Tip You may want to mask the glass around the contact area with tape. This is easy to do and will allow you to safely prepare the contact surface without the risk of scratching the glass or the black painted shading. Important Most rear glass has a black painted masking around the edge of the glass. When cleaning up the connection surface, be very careful not to damage the surface of the black shading or the surface of the glass. 4. Wipe the newly prepared contact area with Kent Automotive* Acrysol(TM) (or equivalent) to remove any residual oil or dirt. Important Page 13223 2007 Model Year Vehicles and Newer all have Digital OnStar(R) Modules. Part 1 OnStar(R) Description and Operation This OnStar(R) digital system consists of the following components: ^ Vehicle Communication Interface Module (VCIM) ^ OnStar(R) button assembly ^ Microphone ^ Cellular antenna ^ Navigation antenna Note This system also interfaces with the factory installed vehicle audio system. Vehicle Communication Interface Module (VCIM) The vehicle communication interface module (VCIM) is a cellular device that allows the user to communicate data and voice signals over the national cellular network. Power is provided by a dedicated, fused B+ circuit. Ground is provided through the vehicle wiring harness attached to the module. The ignition state is determined by the VCIM through serial data messaging. Dedicated circuits are used to connect the VCIM to a microphone, the button assembly, and to command the status LED. The VCIM communicates with the rest of the vehicle modules using the serial data bus. The module houses 2 technology systems, one to process GPS data, and another for cellular information. The cellular system connects the OnStar(R) system to the cellular carrier's communication system by interacting with the national cellular infrastructure. The module sends and receives all cellular communications over the cellular antenna and cellular antenna coax. GPS satellites orbiting earth are constantly transmitting signals of their current location. The OnStar(R) system uses the GPS signals to provide location on demand. The module also has the capability of activating the horn, initiating door lock/unlock, or activating the exterior lamps using the serial data circuits. These functions can be commanded by the OnStar(R) Call Center per: a customer request. OnStar(R) Button Assembly The OnStar(R) button assembly may be part of the rearview mirror, or a separate, stand alone unit. The button assembly is comprised of 3 buttons and a status LED. The buttons are defined as follows: ^ The answer/end call button, which is black with a white phone icon, allows the user to answer and end calls or initiate speech recognition. ^ The blue OnStar(R) call center button, which displays the OnStar(R) logo, allows the user to connect to the OnStar(R) call center. ^ The emergency button, which displays a white cross with a red background, sends a high priority emergency call to the OnStar(R) call center when pressed. The VCIM supplies 10 volts to the OnStar(R) button assembly on the keypad supply voltage circuit. When pressed, each button completes a circuit across a resistor allowing a specific voltage to be returned to the VCIM on the keypad signal circuit. Depending upon the voltage range returned the VCIM is able to identify which button has been pressed. The OnStar(R) status LED is located with the button assembly. The LED is green when the system is ON and operating normally. When the status LED is green and flashing, it is an indication that a call is in progress. When the LED is red, this indicates a system malfunction is present. In the event there is a system malfunction and the OnStar(R) system is still able to make a call, the LED will flash red during the call. If the LED does not illuminate, this may indicate that the customers OnStar(R) subscription is not active or has expired. Push the blue OnStar button to connect to an advisor who can then verify the account status. Each LED is controlled by the VCIM over dedicated LED signal circuits. Ground for the LED is provided by the wiring harness attached to the button assembly. Page 3652 6. Remove the outlet heater hose. INSTALLATION PROCEDURE 1. Install the outlet heater hose. 2. Install the outlet heater hose to the engine. 3. Connect the outlet heater hose to the heater core. Firmly push the quick connect onto the heater core pipe until you hear an audible click. 4. Install the heater and surge tank hose to the mounting clip. 5. Install the air intake tube. 6. Fill the cooling system. Refer to Draining and Filling Cooling System (with HP2)Draining and Filling Cooling System (without HP2) in Cooling System. Page 632 4. Install the ground, then the washer and then the bolt to the frame. Important: It is important to use the bolts, washers and nuts specified in this bulletin. These parts have been identified due to their conductive finish. 5. Install a washer and nut to the back side of the frame. Tighten Tighten the nut to 9 Nm (79 lb in). 6. Cover the front and back side of the repair area using Rubberized Undercoating. An additional check can be made to ensure a good connection for the battery cable to frame ground. It is possible for this ground to cause similar symptoms with the ABS as described above. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Parts Information Warranty Information Disclaimer Page 4509 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. REPLACEMENT PROCEDURE After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Insure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the Terminal Removal Procedure. Repairing Connector Terminals REPAIRING CONNECTOR TERMINALS TOOLS REQUIRED J 38125-D Terminal Repair Kit Use the following repair procedures in order to repair the following: - Push to Seat terminals - Pull to Seat terminals - Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-D contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100 World terminals. Soldering Micro-Pack 100 World terminals may damage the terminal. Circuit Protection - Circuit Breakers CIRCUIT PROTECTION - CIRCUIT BREAKERS A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Page 9741 C221 I/P Harness To Body Harness (With Single Stage Air Bag) Page 2995 Parts Information Warranty Information Wheels All GM Accessories sold and permanently installed on a GM vehicle PRIOR to new vehicle delivery will be covered under the provisions of the New Vehicle Limited Warranty. For the U.S., in the event GM Accessories are installed AFTER the New Vehicle Delivery, or are replaced under the New Vehicle Warranty, they will be covered (parts and labor) for the balance of the vehicle warranty, but in no event less than 12 months/12,000 miles. This coverage is only effective for GM Accessories permanently installed by a GM dealer or a GM approved ADI (Accessory Distributor/Installer). For Canada, in the event GM Accessories are installed AFTER the New Vehicle Delivery, they will be covered (parts and labor) for the balance of the vehicle warranty, or up to 12 months/Unlimited kilometers depending on month installed. For replacement after the new vehicle warranty expires, but within the 12 months/unlimited kilometers coverage, refer to claim type "B" guidelines. GM Accessories sold over-the-counter, or those not requiring installation, will continue to receive the standard GM Dealer Parts Warranty of 12 months from the date of purchase (parts only). Tires Any approved tire installed on a GM Vehicle PRIOR to delivery will be covered under the provisions of the New Vehicle Limited Warranty. Tires are covered against defects in material and workmanship. Tires are warranted for defects "without" prorated charge for tread mileage. Subsequent replacements under this warranty will continue to be covered for the remainder of the New Vehicle Limited Warranty. Any approved tire installed on a GM Vehicle PRIOR to delivery may continue to be warranted on a prorated basis by the tire manufacturer once the New Vehicle Limited Warranty expires. Any approved tire installed AFTER delivery will be covered under the provisions of the tire manufacturer warranty. USA dealers should refer to GM Warranty Administration Bulletin 00-03-10-003I and GM Parts Process / Policy Bulletin IB03-001 for more information. Canadian dealers should refer to GM Warranty Administration Bulletin 01-03-10-003B. GM Warranty Claims Processing Only GM dealerships have the ability to file warranty claims for GM Parts and Accessories. Therefore, any warranty claims filed against such parts must be handled by the servicing GM dealership. This includes those parts purchased from a GM-approved ADI (Accessory Distributor / Installer). Page 4881 Transmission Position Switch/Sensor: Service and Repair Automatic Transmission 4L80-E/4L85-E Park/Neutral Position Switch Replacement Park/Neutral Position Switch Replacement ^ Tools Required J 41364-A Park Neutral Switch Aligner Removal Procedure 1. Apply the park brake. 2. Shift the transmission into neutral. 3. If equipped with 4-wheel drive (4WD), remove the front propeller shaft. 4. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 5. Disconnect the park/neutral position (PNP) switch electrical connector (2). 6. Remove the range selector cable end (2) from the range selector lever ball stud (1). Page 7432 Speed Sensor: Service and Repair Transfer Case - NVG 263-NP1 Transfer Case Speed Sensor Replacement Removal Procedure 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. Disconnect the speed sensor electrical connector. 3. Remove the speed sensor. Installation Procedure 1. Notice: Refer to Fastener Notice in Service Precautions. Install the speed sensor. ^ Tighten the sensor to 15 Nm (11 ft. lbs.). Page 6557 Transmission Position Switch/Sensor: Adjustments Automatic Transmission - 4L80-E/4L85-E Park/Neutral Position Switch Adjustment Important: ^ The following procedure is for vehicles that have not had the park/neutral position (PNP) switch removed or replaced. If the switch has been removed or replaced, refer to Park/Neutral Position Switch Replacement for the proper adjustment procedure. ^ Apply the park brake. ^ The engine must start in the park (P) or neutral (N) positions only. ^ Check the PNP switch for proper operation. If adjustment is required, proceed as follows: 1. Place the shift lever in the neutral (N) position. 2. With an assistant in the drivers seat, raise and suitably support the vehicle. Refer to Vehicle Lifting. 3. Loosen the PNP switch bolts. 4. With the vehicle in neutral (N), rotate the PNP switch while the assistant attempts to start the engine. 5. Following a successful start, turn the engine off. 6. Notice: Refer to Fastener Notice in Service Precautions. Tighten the PNP switch bolts. ^ Tighten the bolts to 25 Nm (18 ft. lbs.). 7. Lower the vehicle. 8. Check the PNP switch for proper operation. The engine must start in the park (P) or neutral (N) positions only. 9. Replace the PNP switch if proper operation can not be achieved. Page 7384 Four Wheel Drive Selector Switch: Diagrams Page 516 Driver Door Module (DDM) - C3 (With RPO Code YE9) Part 2 Interior - Intermittent Seat Heater Operation Seat Heater Control Module: Customer Interest Interior - Intermittent Seat Heater Operation Bulletin No.: 05-08-50-008 Date: August 19, 2005 TECHNICAL Subject: Intermittent Heated Seats Inoperative, DTC B3941 Set (Reprogram Driver Seat Module) Models: 2003-2005 Cadillac Escalade, Escalade ESV, Escalade EXT 2003-2005 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2003-2005 GMC Sierra, Yukon, Yukon XL, Yukon Denali All with Seat FRT, Individual (Non BKT) (RPO AN3) 2003-2005 HUMMER H2 with Seat, Front Bucket Deluxe (RPO AR9) Condition Some customers may comment that occasionally the seat heater will not operate when activated. If the ignition key is cycled OFF and back ON again, the heated seat will operate correctly. Also, on some LB7 diesel engine vehicles, the seat heater may turn itself off during the first 10 minutes of operation. This occurs only with the first activation for the day and works correctly with subsequent activations immediately after the event. These conditions are intermiffent and DTC B3941 may be set. Correction Technicians are to reprogram the driver seat module with an updated software calibration. This new service calibration was released with TIS satellite data update version 6.5 available June 13, 2005. As always, make sure your Tech 2(R) is updated with the latest software version. Warranty Information Page 13403 High Temperature Conditions Tools Required J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency MEASURING FREQUENCY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage MEASURING VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop MEASURING VOLTAGE DROP NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Fuel Level Sensor Replacement - 1 Fuel Level Sensor: Service and Repair Fuel Level Sensor Replacement - 1 FUEL LEVEL SENSOR REPLACEMENT REMOVAL PROCEDURE 1. Remove the sending unit. 2. Disconnect the fuel pump electrical connector. 3. Remove the fuel lever sensor electrical connector retaining clip. 4. Disconnect the fuel level sensor electrical connector. 5. Remove the fuel level sensor retaining clip. 6. Remove the fuel level sensor (1). INSTALLATION PROCEDURE 1. Install the fuel level sensor (1). 2. Install the fuel level sensor retaining clip. 3. Connect the fuel level sensor electrical connector. 4. Install the fuel lever sensor electrical connector retaining clip. 5. Connect the fuel pump electrical connector. 6. Install the sending unit. Page 14989 Submit a Product Recall claim with the information shown. Customer Notification -- For US and Canada General Motors will notify customers of this recall on their vehicle (see copy of customer letter shown in this bulletin)) Customer Notification -- For IPC Letters will be sent to known owners of record located within areas covered by the US National Traffic and Motor Vehicle Safety Act. For owners outside these areas, dealers should notify customers using the sample letter. Dealer Recall Responsibility - For US and IPC (US States, Territories, and Possessions) The US National Traffic and Motor Vehicle Safety Act provides that each vehicle which is subject to a recall of this type must be adequately repaired within a reasonable time after the customer has tendered it for repair. A failure to repair within sixty days after tender of a vehicle is prima facie evidence of failure to repair within a reasonable time. If the condition is not adequately repaired within a reasonable time, the customer may be entitled to an identical or reasonably equivalent vehicle at no charge or to a refund of the purchase price less a reasonable allowance for depreciation. To avoid having Page 7481 Case: Service and Repair Transfer Case - NVG 263-NP1 Transfer Case Shield Replacement Removal Procedure 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. Remove the transfer case shield bolts, if equipped. 3. Remove the transfer case shield, if equipped. Installation Procedure 1. Position the transfer case shield to the crossmember, if equipped. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the transfer case shield bolts, if equipped. ^ Tighten the bolts to 20 Nm (15 ft. lbs.). 3. Lower the vehicle. Page 12202 Page 10630 Important Other forms of slow air leaks are possible. If the body of the tire, valve stem and wheel flange show no signs of air seepage, refer to Corporate Bulletin Number 05-03-10-003D for additional information on possible wheel porosity issues. 3. Bead seat corrosion is identified by what appears like blistering of the wheel finish, causing a rough or uneven surface that is difficult for the tire to maintain a proper seal on. Below is a close-up photo of bead seat corrosion on an aluminum wheel that was sufficient to cause slow air loss. Close-Up of Bead Seat Corrosion 4. If corrosion is found on the wheel bead seat, measure the affected area as shown below. - For vehicles with 32,186 km (20,000 mi) or less, the total allowable combined linear area of repairable corrosion is 100 mm (4 in) or less. If the total area(s) of corrosion exceed these dimensions, the wheel should be replaced. - For vehicles that have exceeded 32,186 km (20,000 mi), the total allowable combined linear area of repairable corrosion is 200 mm (8 in) or less. If the total area(s) of corrosion exceed these dimensions, the wheel should be replaced. 5. In order to correct the wheel leak, use a clean-up (fine cut) sanding disc or biscuit to remove the corrosion and any flaking paint. You should remove the corrosion back far enough until you reach material that is stable and firmly bonded to the wheel. Try to taper the edge of any flaking paint as best you can in order to avoid sharp edges that may increase the chance of a leak reoccurring. The photo below shows an acceptable repaired surface. Notice Corrosion that extends up the lip of the wheel, where after the clean-up process it would be visible with the tire mounted, is only acceptable on the inboard flange. The inboard flange is not visible with the wheel assembly in the mounted position. If any loose coatings or corrosion extend to the visible surfaces on the FACE of the wheel, that wheel must be replaced. Important Remove ONLY the material required to eliminate the corrosion from the bead seating surface. DO NOT remove excessive amounts of material. ALWAYS keep the sealing surface as smooth and level as possible. Page 14850 6. Remove the door module from the switch panel bezel. INSTALLATION PROCEDURE 1. Install the door module into the switch panel bezel until it snaps into place. 2. Install the switch panel bezel and module to the door panel. NOTE: Refer to Fastener Notice in Service Precautions. 3. Install the screw that retains the switch panel bezel (1) to the front door panel. Tighten Tighten the screw to 2 N.m (18 lb in). Engine - Rough Idle/Misfire/MIL ON/DTC P0300 Intake Manifold Gasket: All Technical Service Bulletins Engine - Rough Idle/Misfire/MIL ON/DTC P0300 Bulletin No.: 05-06-04-029A Date: June 24, 2005 TECHNICAL Subject: Flexible Fuel (RPO L59) Rough Idle, Misfire, MIL DTC P0300 (Install Intake Manifold Gaskets With Teal Green Gasket Material) Models: 2002-2004 Chevrolet Silverado, Suburban, Tahoe 2002-2004 GMC Sierra, Yukon, Yukon XL with 5.3L Engine and Flexible Fuel (VIN Z - RPO L59) This bulletin may apply to the following engines using regular fuel: 4.8L, 5.3L, 6.0L (VINs V, T, P, U, N - RPOs LR4, LM7, LM4, LQ4, LQ9). Supercede: This bulletin is being revised to add additional diagnostic information. Please discard Corporate Bulletin Number 05-06-04-029 (Section 06 - Engine/Propulsion System). Important: Always begin your diagnosis with the Diagnostic System Check - Engine Controls (SI Document ID # 1289827) for any MIL or driveability concern. The Diagnostic System Check directs you to the next logical step in your diagnosis. Follow the instructions in this bulletin should the rough idle, misfire, or DTC P0300 diagnostic procedure point to an air leak in the intake manifold gasket. Following the published diagnostic procedures will improve diagnostic accuracy and support our fix it right the first time approach. Condition Some customers may comment that the vehicle may have a rough idle, misfires and/or a MIL illuminated with a stored DTC P0300. Cause The L59 engine is calibrated for ethanol fuel (E85). Due to the low volatility of ethanol, the PCM provides higher fuel flow through the injector, which may pool on the upper manifold to head gasket material. Overtime (usually 12 months and longer), the gasket material may degrade resulting in an unmetered air leak. Correction Replace the upper intake manifold gaskets with the teal green gasket material, P/N 89017589. Important: Do not replace the upper intake manifold gaskets with the original orange gasket material, P/N 17113557. Inspect Intake Manifold to Cylinder head Deck for Warpage Underhood Electrical Center or Junction Block Replacement Relay Box: Service and Repair Underhood Electrical Center or Junction Block Replacement UNDERHOOD ELECTRICAL CENTER OR JUNCTION BLOCK REPLACEMENT REMOVAL PROCEDURE 1. Disconnect the negative battery cable. 2. Remove the left fender upper brace. 3. Remove the electrical center brace cover assemble by lifting the cover (3) outwards to clear the tabs. 4. Remove all fuses and relays. Page 12835 Page 10402 For vehicles repaired under warranty, use the table. Disclaimer Page 2746 Location View Page 9455 Auxiliary Power Outlet 120-Volt AC - Exterior (With RPO Code HP2) Page 5697 4. Important: When installing the pressure control solenoid, the electrical connector (2) must be in the position shown. Install the pressure control solenoid (377). 5. Install the pressure control solenoid retainer (378) and retainer bolt (364A). ^ Tighten the bolt to 11 Nm (97 inch lbs.). 6. Install the TCC PWM solenoid to the control valve body. 7. Install the TCC PWM solenoid retainer. 8. Connect the internal wiring harness electrical connectors to the following components: ^ Transmission fluid pressure switch (1) ^ 1-2 shift control solenoid (2) ^ 2-3 shift control solenoid (3) ^ Pressure control solenoid (4) Wheels/Tires - Slow Tire Leak/Vibration Wheels: All Technical Service Bulletins Wheels/Tires - Slow Tire Leak/Vibration Bulletin No.: 03-03-10-001D Date: January 17, 2008 TECHNICAL Subject: Tire Slowly Goes Flat and/or Excessive wheel Vibration Caused By Bead Splits (Replace wheels with New Heavy Duty Rim Version) Models: 1999-2006 Chevrolet Silverado 1500 Series Pickup Models (Classic) 1999-2006 Chevrolet Express 1500 Series Vans 2000-2006 Chevrolet Suburban Tahoe 1999-2006 GMC Sierra 1500 Series Pickup Models (Classic) 1999-2006 GMC Savana 1500 Series Vans 2002-2006 GMC Yukon Yukon XL 2007 GMC Sierra Denali Crew Cab with 6-Bolt, 16 X 6.5 Full Face Steel wheel (Base and RPO PY2) Supercede: This bulletin is being revised to add the Express and Savana models and add information to the Correction section. Please discard Corporate Bulletin Number 03-03-10-001C (Section 03 Suspension). Implementation of this service bulletin by "GM of Canada" dealers requires prior District Service Manager approval. Condition Some customers may comment on a tire that slowly goes flat and/or excessive wheel vibration. This condition is more apparent on vehicles in which customer usage typically involves frequent severe conditions such as: High load (at or above gross vehicle weight) Rough road/off road usage Fleet/Commercial usage Cause The wheel may experience a crack or split in the outboard bead seat weld area. A weld attaches the rim and disc together on full-face wheels in this area. To identify this wheel it is offered in a silver painted version P/N 9593915 code "TZA" and a chrome-clad version, P/N 9593150 code "RSC" (these codes are stamped into the wheel's disc near the bolt holes). Correction Wheel replacement should only be done for air loss and/or vibration caused by bead splits. A new heavy-duty rim version of these wheels has been released for service. The new heavy-duty painted wheel is P/N 9595245 code "FFU" used as a road wheel and spare. The new heavy-duty chrome clad version is P/N 9595306 code "FFW" used as a road wheel only (these codes are stamped into the inboard rim flange balance weight area and are also on a sticker near the bolt holes). If a condition of a crack or split as described above occurs all (5) five of the original wheels on the vehicle should be replaced with the new heavy-duty wheels as follows: Replace road wheel P/N 9593915 with P/N 9595245. Replace road wheel PIN 9593150 with P/N 9595306. Replace the spare wheel with P/N 9595245 on all vehicles. Page 13038 Claim Information - GM, Saturn Canada and Saab Canada Only Claim Information - Saturn US Only Customer Reimbursement Claims - Special Attention Required Customer reimbursement claims must have entered into the "technician comments" field the CSO # (if repair was completed at a Saturn Retail Facility) date, mileage, customer name, and any deductibles and taxes paid by the customer. Claim Information - Saab US Only Page 16027 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly, Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Pull to Seat Connectors PULL TO SEAT CONNECTORS TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Page 11372 Discharge Air Temperature Sensor / Switch: Service and Repair Air Temperature Sensor Replacement - Lower Left AIR TEMPERATURE SENSOR REPLACEMENT - LOWER LEFT REMOVAL PROCEDURE 1. Disconnect the electrical connector from the lower left air temperature sensor (1). 2. Remove the lower left air temperature sensor (1) from the HVAC module (2). INSTALLATION PROCEDURE 1. Install the lower left air temperature sensor (1) to the HVAC module (2). 2. Connect the electrical connector to the lower left air temperature sensor (1). Page 3225 6. Compress the valve spring using the J 38606. 7. Install the valve keys. ^ Use grease in order to hold the valve keys in place. ^ Make sure the keys seat properly in the groove of the valve stem. ^ Carefully release the valve spring pressure, making sure the valve keys stay in place. ^ Remove the J 38606. ^ Tap the end of the valve stem with a plastic faced hammer to seat the keys (if necessary). 8. Remove J 22794 from the spark plug port. 9. Notice: Refer to Fastener Notice in Service Precautions. Hand start the spark plug. ^ Tighten the spark plug to 15 Nm (11 ft. lbs.). 10. Install the spark plug wires at the ignition coil. 11. Install the spark plug wire to the spark plug. 12. Inspect the wires for proper installation: ^ Push sideways on each boot in order to check for proper installation. ^ Reinstall any loose boot. 13. Install the valve rocker arm. Page 2760 Location View Drivetrain - Updated Transfer Case Speed Sensor Conn. Speed Sensor: All Technical Service Bulletins Drivetrain - Updated Transfer Case Speed Sensor Conn. Bulletin No.: 06-04-21-001 Date: May 17, 2006 INFORMATION Subject: Updated Transfer Case Connector Service Kit Now Available For Transfer Case Speed Sensor Wire Harness Connector that Comes Loose Or Connector Retainer Clip Breaks Models: 2007 and Prior GM Light Duty Trucks 2007 and Prior HUMMER H2, H3 2005-2007 Saab 9-7X with Four-Wheel Drive or All-Wheel Drive Technicians may find that when the transfer case speed sensor wire harness connector is removed, the connector lock flexes/bends and does not return to the original position. The transfer case speed sensor wire harness connector then has no locking device. On older vehicles, the plastic connector retainer becomes brittle and the clip may break as soon as it is flexed. In the past, the only service fix was to install a wire harness connector service pack, P/N 88987183. This repair procedure involved splicing a new service connector with an integral connector lock. This connector service kit is of the same design and was still prone to failure over time. A new connector service repair kit is now available, P/N 15306187, that is an updated design. This new kit should be used whenever the speed sensor wire harness connector requires replacement. Parts Information Disclaimer Page 4548 Step 5 Page 3553 - Inspect the insulator (2) for cracks. All or part of the electrical charge may arc through the crack instead of the electrodes (3, 4). - Inspect for evidence of improper arcing. Measure the gap between the center electrode (4) and the side electrode (3). Refer to Ignition System Specifications. An excessively wide electrode gap can prevent correct spark plug operation. - Inspect for the correct spark plug torque. Refer to Ignition System Specifications. Insufficient torque can prevent correct spark plug operation. An over torqued spark plug, causes the insulator (2) to crack. - Inspect for signs of tracking that occurred near the insulator tip instead of the center electrode (4). - Inspect for a broken or worn side electrode (3). - Inspect for a broken, worn, or loose center electrode (4) by shaking the spark plug. A rattling sound indicates internal damage. - A loose center electrode (4) reduces the spark intensity. - Inspect for bridged electrodes (3, 4). Deposits on the electrodes (3, 4) reduce or eliminates the gap. - Inspect for worn or missing platinum pads on the electrodes (3, 4), if equipped. - Inspect for excessive fouling. - Inspect the spark plug recess area of the cylinder head for debris. Dirty or damaged threads can cause the spark plug not to seat correctly during installation. VISUAL INSPECTION - Normal operation - Brown to grayish-tan with small amounts of white powdery deposits are normal combustion by-products from fuels with additives. - Carbon fouled - Dry, fluffy black carbon, or soot caused by the following conditions: Rich fuel mixtures Leaking fuel injectors - Excessive fuel pressure - Restricted air filter element - Incorrect combustion - Reduced ignition system voltage output Weak ignition coils Connector Views Fuse Block: Connector Views Fuse Block - I/P C4 (Crew Cab) Page 13143 7.3. If equipped, connect the rear seat heater's connector and install the switch. 8. Install the floor console: 8.1. Install the floor console's retaining bolts (C) and retaining nuts (F). 8.2. Align the rear cover; make sure that the air duct connects firmly to the air nozzle. Screw in the cover (E). 8.3. Install the ashtray/cover (D). 8.4. Install the ignition switch cover (B). 8.5. Plug in the immobilizer unit (A) connector. Install the unit, bayonet fitting. 9. Remove the OnStar(R) control modules and secure the wiring: 9.1. Remove the right-hand rear luggage compartment trim in accordance with WIS - 8. Body - Interior equipment - Adjustment/Replacement. 9.2. Unplug the connectors (A) from the OnStar(R) control modules. 9.3. Remove the console (B) together with the OnStar(R) control modules. Page 9503 For vehicles repaired under warranty, use the table. Disclaimer Page 11355 Cabin Temperature Sensor / Switch: Description and Operation AIR TEMPERATURE SENSORS The air temperature sensors are a 2-wire negative temperature co-efficient thermistor. The vehicle uses the following air temperature sensors: Ambient Air Temperature Sensor - Inside Air Temperature Sensor Assembly - Upper Left Air Temperature Sensor - Upper Right Air Temperature Sensor - Lower Left Air Temperature Sensor - Lower Right Air Temperature Sensor A signal and a low-reference circuit enables the sensor to operate. As the air temperature surrounding the sensor increases, the sensor resistance decreases. The sensor signal voltage decreases as the resistance decreases. The sensor operates within a temperature range between -40°C (-40°F) to 101°C (215°F). The sensor signal varies between 0.5 volts. The input of the duct air temperature sensors are different from the ambient and inside sensors. The HVAC control module converts the signal to a range between 0-255 counts. As the air temperature increases the count value will decrease. If the HVAC control module detects a malfunctioning sensor, then the control module software will use a defaulted air temperature value. The default value for the ambient and inside air temperature sensors will be displayed on the scan tool. The default value for the duct air temperature sensors will not be displayed on the scan tool. The scan tool parameter for the duct air temperature sensors are the actual state of the signal circuit. The default action ensures that the HVAC system can adjust the inside air temperature near the desired temperature until the condition is corrected. The ambient air temperature sensor mounts underhood and can be affected by city traffic, by idling, and by restarting a hot engine. Therefore, the HVAC control module filters the value of the ambient air temperature sensor for temperature display. The ambient air temperature value is updated under the above conditions. The scan tool has the ability to update the displayed ambient air temperature. To update the ambient air temperature display on the HVAC control module, perform the following procedure: Simultaneously press the MODE, FRONT DEFROST and REAR DEFROST switches. 1. Turn ON the ignition. 2. Simultaneously press the MODE, FRONT DEFROST and REAR DEFROST switches. Page 13723 Rear Door Striker: Service and Repair Striker Replacement - Upper Striker Replacement - Upper Removal Procedure 1. Open the side access door. 2. Remove the upper door striker bolts. 3. Remove the upper door striker from the vehicle. Installation Procedure 1. Install the upper door striker to the vehicle. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the upper door striker bolts. Tighten the upper door striker bolts to 24 N.m (18 lb ft). 3. Close the door and inspect for proper operation. Page 10046 Power Steering Line/Hose: Service and Repair Power Steering Gear Outlet Pipe/Hose (Recirculating Ball) Power Steering Gear Outlet Pipe/Hose Replacement (Recirculating Ball) Removal Procedure 1. Notice: Refer to Power Steering Hose Disconnected Notice in Service Precautions. Install a drain pan under the vehicle. 2. Remove the power steering gear outlet hose (3) from the steering gear (2). 3. Remove the clamp retaining the power steering gear outlet hose (3) to the power steering pump (1).Remove the power steering gear outlet hose from the power steering pump. 4. Remove the power steering gear outlet hose from the vehicle. Installation Procedure 1. Notice: Refer to Installing Hoses Without Twists or Bends Notice in Service Precautions. Route the hose in the same position the hose occupied prior to removal. 2. Install the power steering gear outlet hose (3) to the power steering pump (1).Position the clamp at the end of the hose. 3. Notice: Refer to Fastener Notice in Service Precautions. Install the power steering gear outlet hose to the power steering gear. ^ Tighten the outlet hose fitting to 28 Nm (20 ft. lbs.). 4. Remove the drain pan from under the vehicle. 5. Bleed the power steering system. Refer to Bleeding the Power Steering System. (Rack and Pinion) Power Steering Gear Outlet Pipe/Hose Replacement (Rack and Pinion) Page 9282 Relay Box: Application and ID Relay Block - I/P Location View Automatic Transmission - 4L60-E/4L65-E Transmission Cooler: Service and Repair Automatic Transmission - 4L60-E/4L65-E Transmission Oil Cooler Line Quick Connect Fitting Transmission Oil Cooler Line Quick Connect Fitting Removal Procedure 1. Important: Perform the following procedure when removing the retaining rings and cooler lines from the quick connect fittings located on the radiator and/or the transmission. Pull the plastic cap back from the quick connect fitting and down along the cooler line about 5 cm (2 inch). 2. Using a bent-tip screwdriver, pull on one of the open ends of the retaining ring in order to rotate the retaining ring around the quick connect fitting until the retaining ring is out of position and can be completely removed. 3. Remove the retaining ring from the quick connect fitting. 4. Discard the retaining ring. 5. Pull the cooler line straight out from the quick connect fitting. Installation Procedure 1. Important: ^ Do not reuse any of the existing oil lines or oil line fittings if there is excessive corrosion. ^ Do not reuse any of the existing retaining rings that were removed from the existing quick connect fittings. Install new retaining rings. ^ Ensure the following procedures are performed when installing the new retaining rings onto the fittings. Install a new retaining ring into the quick connect fitting using the following procedure: OnStar(R) - Generation 6 Service Procedures Technical Service Bulletin # 09-08-46-001 Date: 090409 OnStar(R) - Generation 6 Service Procedures INFORMATION Bulletin No.: 09-08-46-001 Date: April 09, 2009 Subject: Servicing Vehicles Upgraded to OnStar(R) Generation 6 Digital‐Capable System (Follow Information Below) Models Attention: This bulletin is being issued to provide dealer personnel with information and the procedures to diagnose an upgraded OnStar(R) Generation 6 Digital-Capable system. Program Overview Since it was launched in 1996, OnStar® has relied on an analog wireless network to provide communication to and from OnStar-equipped vehicles. As part of an industry wide change in the North American wireless telecommunications industry, wireless carriers are transitioning to digital technology and will no longer support the analog wireless network beginning early 2008. Effective January 1, 2008, OnStar(R) service in the United States and Canada will be available only through vehicles that are capable of operating on the digital network. Refer to Corporate Bulletin Number 05-08-46-006H for information about upgrading certain vehicles to digital service. Details were covered in both the November 2006 and December 2007 issues of TechLink, which are available in the Archives of the TechLink website. Vehicles eligible for an OnStar(R) hardware upgrade are listed in this bulletin. Vehicle upgradeability can also be determined by typing the VIN into the field entitled "Determine VIN Hardware Functionality" on the OnStar(R) Online Enrollment website, located in the sales or service workbench tab of GM GlobalConnect. Canadian Dealers can use a similar tool that is available within the OnStar(R) Canada Online Enrollment site that can be accessed from the OnStar(R) Brand Resources in GlobalConnect. Access to the sales and/or service workbench in the GM GlobalConnect website can be granted by the dealership's Partner Security Coordinator (PSC). Cupholder Replacement (Luxury) Drink Holders: Service and Repair Cupholder Replacement (Luxury) Cupholder Replacement (Luxury) Removal Procedure 1. Remove the upper trim bezel from the center console. 2. Remove the remote CD player if equipped. 3. Insert a flat bladed tool between the console and cupholder assembly. 4. Remove the cupholder assembly by prying the cupholder to release the clips (2). 5. Remove the wire connector for the cupholder. 6. Remove the cupholder from the console. Installation Procedure 1. Place the cupholder assembly over the console. 2. Connect the wire connector to the cupholder assembly. 3. Push on the corners of the cupholder assembly till all the retaining clips (2) are seated. 4. Install the remote CD player if equipped. 5. Install the upper trim bezel. Page 15732 The 1999 though early 2003 wiring harness jumper that plugs into the relay block will have a reddish/brown 6-way connector and a tag with the last four digits of the wiring harness part number. Second design 2003-05 may have a white plastic connector with part number 5418 as well. ^ The 1999 jumper is/was P/N 12171982 with a pink/purple tag identifier of 1982. This number has been superseded to 15366255, with a pink/purple tag identifier of 6255. ^ The 2000 jumper harness is P/N 15366255. The pink/purple tag identifier is 6255. ^ The 2001-2002 jumper is P/N 15086884. The orange tag identifier is 6884. ^ The 2003-05 jumper is P/N 15085418. The orange tag identifier is 5418. When transferring the brake controller with the wiring jumper attached from a 2001-2002 vehicle to a 2003-05 vehicle, a change to the jumper harness connector must be performed. Page 1175 2. Install the power seat switch bezel to the seat. Page 5026 Page 1840 2. Rotate the coil hub slowly, counterclockwise until the centering window appears yellow and both arrows (2) line up. This is the CENTER position. 3. While holding the coil hub in the CENTER position, align the SIR coil with the horn tower and slide onto the steering shaft assembly. 4. If the front side (3) of the SIR coil has NO centering window, but the back side (2) includes a spring service lock (1), perform the following steps: 0. Hold the SIR coil with the back side up. 1. While depressing the spring service lock, rotate the coil hub in the direction of the arrow (4) until the coil ribbon stops. 2. Still pressing the spring service lock, rotate the coil hub in the opposite direction 21⁄2 revolutions. 3. Release the spring service lock between locking tabs. The SIR coil is now centered. 4. Align the centered SIR coil with the horn tower and slide onto the steering shaft assembly. 5. If the front side (2) of the SIR coil has NO centering window, and the back side (1) includes NO spring service lock, perform the following steps: 0. Hold the SIR coil with the face up. 1. Rotate the coil hub in the direction of the arrow until the coil ribbon stops. 2. Rotate the coil hub, slowly, counterclockwise, for 21⁄2 revolutions. This is the CENTER position. 3. While maintaining the coil hub in the CENTER position, align the centered SIR coil with the horn tower and slide onto the steering shaft assembly. 6. If double wire harness strap is installed onto the wire harness assembly and column, you must route the wires up against the steering column. One wire harness strap will surround one lead from the coil to the steering column. The other wire harness strap will surround all leads to the steering column. Page 2678 Junction Block - Rear Lamps - C1 Part 1 Page 8330 ^ Tighten the three EHCU bracket bolts (4) to 25 Nm (18 ft. lbs.). 7. Connect the chassis electrical harness connectors to the EBCM (1). 8. Important: The brake pipes are held in the proper place by a frame mounted plastic bracket. Make sure that the brake pipes stay in the correct place for proper reassembly. Install the 5 brake pipes to the BPMV (6). ^ Tighten the brake pipe fittings to 25 Nm (18 ft. lbs.). 9. Connect negative battery cable. 10. Bleed the brake system. Refer to ABS Automated Bleed Procedure. Page 9519 Fuse Block - Underhood - Secondary Wire Entry (With RPO Code HP2) Part 2 Page 12218 Important: Secure the wiring harness so that there is no risk of chafing or rattling. 6.1. Remove the passenger seat in accordance with WIS 8. Body - Seats Adjustment/Replacement. 6.2. Remove the right-hand B-pillar trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.3. Remove the right-hand C pillar trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.4. Fold the rear seat backrest forward. 6.5. Remove the right-hand side bolster in accordance with WIS - 8. Body - Seats Adjustment/Replacement. 6.6. Remove the A-pillar's lower side piece. 6.7. Open the cover on the right-hand wiring harness channels. 6.8. Loosen the locking strip (A) on the 2-pin connector (H2-11) for the optic cable, located by the right-hand A-pillar. 6.9. Loosen the catch (B) and remove the optic cable that runs backward in the car. 6.10. Dismantle the end cap from the new optic cable (12 783 577) and connect it to the connector H2-11. Push in the optic cable and make sure the catch (B) locks and refit the locking strip (A). 6.11. Secure the connector and the old optic cable using the cable tie for the existing wiring harness (C). Description and Operation Keyless Entry Receiver: Description and Operation REMOTE CONTROL DOOR LOCK RECEIVER MODULE SYSTEM The remote control door lock receiver module system may also arm and disarm the CTD system. When the remote control door lock receiver receives a door lock or an unlock signal from the key fob, the remote control door lock receiver sends a message to the BCM. The message orders the BCM to perform the appropriate door lock/unlock command. The BCM detects the message and performs one of the following functions: - Locks the doors and enters the armed initiated mode - Unlocks the doors and enters the ready-to-arm mode Page 4302 IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections TESTING FOR INTERMITTENT AND POOR CONNECTIONS TOOLS REQUIRED - J 35616-C GM-Approved Terminal Test Kit - J 38125-D Terminal Repair Kit - J 42675 Flat-Wire Probe Adapter Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector. - Poor terminal to wire connection - Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. - Wire insulation which is rubbed through - This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. - Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. Testing For Proper Terminal Contact It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-D or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-D, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. Page 6054 1. Install a new 3-4 accumulator piston seal (1) to the 3-4 accumulator piston. 2. Install the 3-4 accumulator pin (1) into the transmission case and retain the pin with J 36850. 3. Install the 3-4 accumulator piston (2) onto the pin (1) in the transmission case.Ensure that the 3-4 accumulator piston legs face away from the transmission case. 4. Install the J 25025-B (2, 3) to the transmission case. 5. Install the spacer plate to transmission case gasket and the spacer plate to valve body gasket to the spacer plate; use J 36850 in order to retain the gaskets to the spacer plate. ^ The case gasket is identified by a C. Be sure to place the case gasket on the transmission case side of the spacer plate. ^ The valve body gasket is identified by a V.Be sure to place the valve body gasket on the valve body side of the spacer plate. Page 2770 4. Push on the top part until it clicks in place. 5. Connect the harness to the front of the junction block. 6. Install the cover to the junction block until it clicks in place. 7. Hand tighten the retaining nut until seated. Page 1506 Headlamp Switch: Service and Repair HEADLAMP SWITCH REPLACEMENT REMOVAL PROCEDURE 1. Remove the instrument cluster bezel. 2. Unsnap the switch from the housing. 3. Disconnect the electrical connectors. 4. Remove the switch. INSTALLATION PROCEDURE Page 1864 Page 4227 3.2. Reinstall any loose boot. Instruments - Service Tire Monitor Message is Displayed Low Tire Pressure Indicator: All Technical Service Bulletins Instruments - Service Tire Monitor Message is Displayed Bulletin No.: 05-08-49-018A Date: May 11, 2006 ADVANCE SERVICE INFORMATION RESOLUTION Subject: EI 05065 - Service Tire Monitor Message Displayed (Pull/Reinstall IPC Fuse or Verify Correct Passenger Door Module (PDM) and Tires) Models: 2004 Chevrolet Silverado 2004 GMC Sierra Supercede: This bulletin is being revised to provide correction action. Please discard Corporate Bulletin Number 05-08-49-018 (Section 08 - Body and Accessories). Condition Some customers may comment that the "SERVICE TIRE MONITOR" message is being displayed on the DIC. Correction DO NOT REPLACE THE INSTRUMENT PANEL CLUSTER. If the DIC is displaying the SERVICE TIRE MONITOR message: 1. Verify if the vehicle has an electronic aftermarket module spliced into the ALDL Class 2 data line (purple wire). 2. If the vehicle HAS an aftermarket module spliced into the Class 2 line, pull the IPC fuse (located underhood) for 25 seconds. Important: Due to the electronic aftermarket module, the SERVICE TIRE MONITOR message may reoccur. 3. Reinstall the IPC fuse. This will clear the SERVICE TIRE MONITOR message from the display. 4. If the vehicle DOES NOT have an aftermarket module spliced into the Class 2 line, verify the vehicle is equipped with the correct PDM (Passenger Door Module) and tires. Warrant Information This repair is not covered under the vehicle warranty due to the installation of an aftermarket module. Disclaimer Page 1982 Electrical Symbols Part 9 Page 6939 16. Pivot the CV joint cage (4) and the inner race 90 degrees to the center line of the outer race (1). At the same time, align the cage windows (3) with the lands of the outer race (2). 17. Lift out the cage (4) and the inner race. Page 8688 2. Install the EBCM to the BPMV. 3. Notice: Refer to Fastener Notice in Service Precautions. Install the new screws (1) in the EBCM (2). ^ Tighten the screws to 5 Nm (39 inch lbs.) in an X-pattern. Page 4522 Control Module References Part 3 Page 8721 10. Install the brake rotor (2) shown on the 1500 series. Refer to Brake Rotor Replacement - Front in Disc Brakes. 11. Install the tire and wheel. 12. Perform the Diagnostic System Check - ABS. Page 7638 Control Module: Service and Repair NVG 263-NP1 Transfer Case Shift Control Module Replacement Transfer Case Shift Control Module Replacement Removal Procedure 1. Disconnect the shift control module electrical connectors. 2. Unsnap and remove the shift control module from the bracket. Installation Procedure Page 10149 11. From the technicians point of view, the FRONT of the sensor will have: ^ A raised rotor flange cuff (3) ^ An alignment mark (2) on the rotor flange cuff (3) for installation ^ A pin hole (1) for the centering pin. Note the location of the pin hole. 12. Remove the connector from the sensor. 13. Remove the sensor from the adapter and bearing assembly. 14. To install the sensor, proceed to step 9 in the installation procedure. 15. From the technicians point of view, the FRONT of the sensor will have: ^ A raised rotor flange cuff (3) ^ An alignment mark (2) on the rotor flange cuff (3) for installation ^ A pin hole (1) for the centering pin. Note location of the pin hole. ^ A sensor clip in FRONT of the sensor 16. Remove the connector from the sensor. 17. Remove the sensor clip from the sensor. 18. Remove the sensor from the adapter and bearing assembly. 19. To install the sensor, proceed to step 13 in the installation procedure. 20. From the technicians point of view, the FRONT of the sensor will have: ^ A flush rotor flange cuff (3) ^ A pin hole (1) for the centering pin. Note the location of the pin hole. ^ An alignment mark (2) on the flush rotor flange cuff (3) for installation 21. Remove the connector from the sensor. 22. Remove the sensor from the adapter and bearing assembly. 23. To install the sensor, proceed to step 17 in the installation procedure. Page 3395 5. Install the EVAP purge solenoid (3), isolator (1), and bolt (2) to the intake manifold. ^ Tighten the bolt to 10 Nm (89 inch lbs.). 6. Install the EVAP purge solenoid vent tube to the solenoid (1) and vapor pipe (2). Page 6667 Valve Body: Service and Repair Automatic Transmission - 4L80-E/4L85-E Valve Body and Pressure Switch Replacement ^ Tools Required J 25025-5 Valve Body Align Pin - J 36850 Transjel® Removal Procedure 1. Ensure that removal of the valve body is necessary before proceeding. ^ Important: The following components can be serviced without removing the valve body: The 2-3 solenoid (1) ^ The internal wiring harness (2) ^ The 1-2 shift solenoid (3) ^ The transmission fluid temperature sensor (4) ^ The transmission fluid pressure manual valve position switch (5) ^ The pressure control solenoid (6) ^ The torque converter clutch pulse width modulation (TCC PWM) solenoid (7) 2. Remove the fluid level indicator. 3. Remove the transmission filter. 4. Disconnect the internal wire harness from the transmission fluid pressure (TFP) manual valve position switch. Important: Use care not to loose the 5 O-rings that are located between the TFP manual valve position switch and the valve body. 5. Remove the valve body bolts (1) that retain the (TFP) manual valve position switch (2). 6. Remove the TFP manual valve position switch. 7. Disconnect the internal wiring harness electrical connectors from the remaining valve body electrical components. Page 6074 Disclaimer Navigation Radio - Adaptation After Radio/Battery R&R; Navigation System: All Technical Service Bulletins Navigation Radio - Adaptation After Radio/Battery R&R; INFORMATION Bulletin No.: 08-08-44-023 Date: June 18, 2008 Subject: Information On Navigation Radio Not Displaying Accurate Vehicle Location After Radio Replacement, Power Loss Or Battery Replacement Models: 2009 and Prior GM Passenger Cars and Trucks (Including Saturn) 2009 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X with Navigation Radio The purpose of this bulletin is to inform technicians and customers that the Navigation Radio may not display the vehicle location icon on the map accurately after a radio or battery has been replaced or after battery power has been removed from the radio. The vehicle location icon accuracy may be degraded if the GPS signal is not available and the GPS displayed icon has a red line through it. The Navigation Radio does not keep learned GPS information or gyroscope and vehicle speed signals stored when the battery power is removed from the radio. The Navigation radio continually uses GPS, gyroscope and vehicle speed data to maintain the vehicle location icon positioned accurately on the displayed map. There may be periods of time during a drive cycle when the GPS signal may not be available and the vehicle location icon still appears to be accurate. This is due to the radio having internal gyroscopes and receiving a vehicle speed signal to maintain accuracy if the radio had received a good GPS signal earlier in the drive cycle. Normal driving will improve the accuracy of the vehicle location icon on the displayed map. It may be necessary for the vehicle to be driven up to 40 km (25 mi) with 15 left and 15 right turns while the vehicle location icon is matched to roads on the displayed map. Do not replace the radio for this condition. Disclaimer Page 7580 Page 1871 Steps 1-9 Test Description The numbers below refer to the step numbers on the diagnostic table. 2. This step tests for a faulty tow/haul switch. 3. This step tests for voltage input from the BCM to the tow/haul switch. 6. This step tests for ground integrity. A/C - Underhood Rattle Noise on Hard Acceleration Refrigerant Filter: Customer Interest A/C - Underhood Rattle Noise on Hard Acceleration File In Section: 01 - HVAC Bulletin No.: 03-01-38~019A Date: September, 2004 TECHNICAL Subject: Underhood Rattle Noise Heard On Acceleration (Check A/C System Performance and Compressor Operation) Models: 2003-2004 Cadillac CTS 2002-2004 Cadillac Escalade, Escalade EXT 2003-2004 Cadillac Escalade ESV 2002-2004 Chevrolet Avalanche, Express, Silverado, Suburban, Tahoe 2002-2004 GMC Denali, Denali XL, Savana, Sierra, Yukon, Yukon XL 2002-2004 Commercial Upfitter Chassis Vehicles with Air Conditioning (A/C) This bulletin is being revised to update the service procedure and parts information. Please discard Corporate Bulletin Number 03-01-38-019 (Section 01 - HVAC). Condition Some customers may comment about an underhood rattle noise heard on acceleration or a sudden loss of A/C system performance. Cause This condition may be caused by liquid slugging of the A/C compressor. This condition may cause an internal failure in the A/C compressor. The serpentine belt tensioner and serpentine belt may also be damaged. Correction Technicians are to check the A/C system performance and compressor operation using the following repair procedure: 1. Open the hood and inspect the A/C compressor for damage and to see if the compressor is seized. Verify that the serpentine belt is not damaged or missing. If the A/C compressor is seized, proceed to Step 5. 2. Perform the A/C System Performance test. Refer to the Heating, Ventilation and Air Conditioning (HVAC) section of SI. Correct any performance concerns or refrigerant leaks that are found. 3. Inspect the vehicle for other possible sources of A/C compressor noise or performance concerns. Refer to Corporate Bulletin Number 01-01-38-013 for more information. 4. After all other possible sources of A/C compressor noise or performance concerns have been eliminated, only then should the A/C compressor be replaced. 5. Remove the A/C compressor. Refer to the A/C Compressor Replacement procedure in the HVAC section of SI. 6. Inspect the transmission cooler lines for damage due to contact from the serpentine belt. Replace the transmission cooler lines if necessary. 7. Install an inline A/C system filter. Refer to Corporate Bulletin Number 01-01-38-006C for more information about A/C system flushing and filter installation procedures. An A/C system flush is not to be done unless prior authorization is given by the GM Area Service Manager (in Canada, the District Service Manager). 8. Install an A/C Suction Screen. Refer to Corporate Bulletin Number 01-01-39-003A for more information about A/C suction screen repair recommendations and procedures. 9. Install a new A/C compressor. Refer to the Compressor Replacement procedure in the HVAC section of SI. 10. Install a new orifice tube for the front A/C system. Refer to the Expansion (Orifice) Tube Replacement procedure in SI. Page 756 HVAC Control Module - C2 Part 2 Diagrams Headlamp Switch: Diagrams Headlamp Switch Part 1 Page 872 Electrical Symbols Part 9 Recall 04V225000: Child Seat Anchorage Non-Compliance Child Seat: All Technical Service Bulletins Recall 04V225000: Child Seat Anchorage Non-Compliance Make / Models : Model/Build Years: Chevrolet / Express 2003 Chevrolet / Silverado 2003-2004 GMC / Savana 2003 GMC / Sierra 2003-2004 MANUFACTURER: General Motors Corp. NHTSA CAMPAIGN ID Number : 04V225000 Recall Date : MAY 10, 2004 COMPONENT: Seat Belts: Front: Anchorage Potential Number Of Units Affected : 736 SUMMARY: certain extended and regular cab pickup trucks and cargo vans converted to compressed natural gas (CNG) fail to conform to the requirements of Federal Motor Vehicle Safety Standard NO. 225, "Child Restraint Anchorage Systems." These vehicles have one seating position, the center rear seat, equipped with child restraint lower anchorages. CONSEQUENCE: The standard requires child seat lower anchorages in two seating positions for vehicles with three rear seating positions. The standard cab and cargo van vehicles, which only have front seating positions, have an air bag off switch to disable the front passenger air bag and do not have child restraint lower anchorages in the passenger seat. The standard requires passenger seat child seat lower anchorages in vehicles with an air bag off switch. however, the standard does not require vehicles with only front seating positions to have lower anchorage provisions if the vehicle is not equipped with an air bag off switch. REMEDY: To bring the standard cab and cargo van vehicles into compliance, dealers will inject epoxy into the air bag off switch to prevent air bag activation, relocate the switch behind the instrument panel and then install a cover over the resulting opening. The sun visor label and owner's manual will also be changed. the correction for the extended cab vehicle will consist of changing the front passenger seat to a seat that has child restraint lower anchorages. The recall began on September 9, 2004. Owners should contact Chevrolet at 1-800-630-2438 OR GMC AT 1-866-996-9463. NOTES: GM Recall NO. 04038. Customers can also contact The National Highway Traffic Safety Administration's Auto Safety Hotline at 1-888-DASH-2-DOT (1-888-327-4236). Page 15555 2. Connect the backup lamp switch electrical connector (3). 3. Lower the vehicle. Page 922 Body Control Module (BCM) - C6 Part 1 Page 14331 9. Remove the radiator mounting bolts from the rear side of the tie bar. 10. Remove the tie bar bolts. 11. Remove the upper headlamp housing support screws. 12. Remove the tie bar. Installation Procedure 1. Position the tie bar onto the lower radiator support. 2. Install the tie bar bolts hand tight. Notice: Refer to Fastener Notice in Service Precautions. Page 4559 Knock Sensor: Service and Repair KNOCK SENSOR (KS) REPLACEMENT REMOVAL PROCEDURE 1. Remove the intake manifold. 2. Gently pry up the rubber covers. 3. Disconnect the knock sensor electrical connectors. 4. Remove the knock sensors. INSTALLATION PROCEDURE NOTE: Refer to Fastener Notice in Service Precautions. Page 5956 Vehicle Speed Sensor(VSS) Page 6359 Remove all rust from the ground terminal, the cylinder head and the retaining nut or bolt. Position the main engine wiring harness ground terminal and install the nut or bolt. Tighten: Tighten the retaining nut or bolt to 16 N.m (12 lb ft). Apply some type of electrical moisture sealant to protect the harness terminal from further corrosion. Disclaimer Diagrams Engine Oil Level Switch Page 4110 Transmission Position Switch/Sensor: Service and Repair Automatic Transmission 4L80-E/4L85-E Park/Neutral Position Switch Replacement Park/Neutral Position Switch Replacement ^ Tools Required J 41364-A Park Neutral Switch Aligner Removal Procedure 1. Apply the park brake. 2. Shift the transmission into neutral. 3. If equipped with 4-wheel drive (4WD), remove the front propeller shaft. 4. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 5. Disconnect the park/neutral position (PNP) switch electrical connector (2). 6. Remove the range selector cable end (2) from the range selector lever ball stud (1). Page 8039 Electronic Brake Control Module: Diagrams ABS Connector End Views Electronic Brake Control Module (ECBCM) - C1 Page 14139 Disclaimer Page 6122 When Servicing transmissions with the new seal design, use the following precautions: ^ The outer diameter of the pump assembly and case bore must be clean and free of burrs or raised surfaces. Be aware of sharp edges that could damage the seal during installation. ^ The seal should be clean and dry before installation. It does not require lubrication for installation. ^ The seal should be inspected prior to installation for obvious damage. ^ It is preferable to hand-start the seal positioning the seal evenly around the case bore before installing the torque converter housing. ^ The seal can be easily removed by prying it out, typical of a pressed-on seal. ^ The seal may be reused, however a thorough inspection must be performed. Inspect the seal for the following conditions: ^ Distortion of the metal carrier or separation from the rubber seal. ^ A cut, deformed, or damaged seal. ^ Refer to the appropriate unit repair information in SI for seal removal and installation procedures. Parts Interchangeability Information In order to properly service the different designs, it is necessary to correctly identify and select corresponding parts for each level. This table provides a summary of the part usage for the different design levels. Page 15120 Cruise Control Module (CCM) Part 2 Page 3829 Body Control Module (BCM) - C4 Part 2 Page 6255 10. Grasp firmly while pulling down with a twisting motion in order to remove the filter. 11. Remove and discard the filter seal. The filter seal may be stuck in the pump; if necessary, carefully use pliers or another suitable tool to remove the seal. 12. Inspect the fluid color. 13. Inspect the filter. Pry the metal crimping away from the top of the filter and pull apart. The filter may contain the following evidence for root cause diagnosis: ^ Clutch material ^ Bronze slivers indicating bushing wear ^ Steel particles 14. Clean the transmission case and the oil pan gasket surfaces with solvent, and air dry. You must remove all traces of the old gasket material. Installation Procedure 1. Coat the NEW filter seal with automatic transmission fluid. 2. Install the NEW filter seal into the transmission case. Tap the seal into place using a suitable size socket. 3. Install the NEW filter. Wheels - Changing Procedures/Precautions Wheels: All Technical Service Bulletins Wheels - Changing Procedures/Precautions INFORMATION Bulletin No.: 06-03-10-010A Date: June 09, 2010 Subject: Information on Proper Wheel Changing Procedures and Cautions Models: 2011 and Prior GM Passenger Cars and Trucks 2010 and Prior HUMMER Models 2005-2009 Saab 9-7X 2005-2009 Saturn Vehicles Attention: Complete wheel changing instructions for each vehicle line can be found under Tire and Wheel Removal and Installation in Service Information (SI). This bulletin is intended to quickly review and reinforce simple but vital procedures to reduce the possibility of achieving low torque during wheel installation. Always refer to SI for wheel lug nut torque specifications and complete jacking instructions for safe wheel changing. Supercede: This bulletin is being revised to include the 2011 model year and update the available special tool list. Please discard Corporate Bulletin Number 06-03-10-010 (Section 03 Suspension). Frequency of Wheel Changes - Marketplace Driven Just a few years ago, the increasing longevity of tires along with greater resistance to punctures had greatly reduced the number of times wheels were removed to basically required tire rotation intervals. Today with the booming business in accessory wheels/special application tires (such as winter tires), consumers are having tire/wheel assemblies removed - replaced - or installed more than ever. With this increased activity, it opens up more of a chance for error on the part of the technician. This bulletin will review a few of the common concerns and mistakes to make yourself aware of. Proper Servicing Starts With the Right Tools The following tools have been made available to assist in proper wheel and tire removal and installation. - J 41013 Rotor Resurfacing Kit (or equivalent) - J 42450-A Wheel Hub Resurfacing Kit (or equivalent) Corroded Surfaces One area of concern is corrosion on the mating surfaces of the wheel to the hub on the vehicle. Excessive corrosion, dirt, rust or debris built up on these surfaces can mimic a properly tightened wheel in the service stall. Once the vehicle is driven, the debris may loosen, grind up or be washed away from water splash. This action may result in clearance at the mating surface of the wheel and an under-torqued condition. Caution Before installing a wheel, remove any buildup on the wheel mounting surface and brake drum or brake disc mounting surface. Installing wheels with poor metal-to-metal contact at the mounting surfaces can cause wheel nuts to loosen. This may cause a wheel to come off when the vehicle is moving, possibly resulting in a loss of control or personal injury. Whenever you remove the tire/wheel assemblies, you must inspect the mating surfaces. If corrosion is found, you should remove the debris with a die grinder equipped with a fine sanding pad, wire brush or cleaning disc. Just remove enough material to assure a clean, smooth mating surface. The J 41013 (or equivalent) can be used to clean the following surfaces: - The hub mounting surface - The brake rotor mounting surface - The wheel mounting surface Use the J 42450-A (or equivalent) to clean around the base of the studs and the hub. Lubricants, Grease and Fluids Page 8720 5. Notice: Refer to Fastener Notice in Service Precautions. Install the WSS mounting bolt. ^ Tighten the WSS mounting bolt to 18 Nm (13 ft. lbs.). 6. Install the WSS cable mounting clip to the knuckle. 7. Install the WSS cable mounting clip to the upper control arm. 8. Install the WSS cable mounting clip to the frame attachment point. 9. Connect the WSS cable electrical connector. Page 14595 Memory Seat Module - C4 Part 1 Page 6023 Page 9560 Fuse Block - Underhood C3 Part 3 Page 10994 1. Install the blower motor resistor. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the blower motor resistor retaining screws. Tighten Tighten the screws to 1.6 N.m (14 lb in). 3. Connect the electrical connection to the blower motor resistor. 4. Connect the electrical connection to the blower motor. 5. If equipped, install the IP sound insulator. Keyless Entry - Inoperative Keyless Entry Module: Customer Interest Keyless Entry - Inoperative Bulletin No.: 04-08-52-005 Date: June 15, 2004 TECHNICAL Subject: Remote Keyless Entry (RKE) System Inoperative (Reprogram Passenger Door Module (PDM)) Models: 2004 Cadillac Escalade, Escalade ESV, Escalade EXT 2004 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2004 GMC Sierra, Yukon, Yukon XL Condition Some customers may comment on any of the following conditions: ^ The RKE key fob does not function. ^ The "Service Tire Pressure Monitoring System" message is displayed, if equipped. ^ The passenger door will not unlock from the passenger's or driver's door switches. ^ The passenger door window is inoperative. Correction Reprogram the PDM with the Tech 2(R). Currently the Tech 2(R) software is not available for the 2004 model year. Engineering is aware of this and are working to release a new service calibration. In the meantime, build the Tech 2(R) as a 2003 model year and perform the reprogram using the procedure listed below. 1. Turn the ignition switch to the ON position. 2. Connect the Tech 2(R) to the vehicle's diagnostic link connector (DLC), power it up and press enter. ^ Select: Diagnostics. ^ Select model year: 2003. ^ Select: Light truck. ^ Select: Body. ^ Select the proper Product line. ^ Select the proper HVAC Type. ^ Select the proper Radio System type. ^ Select: Passenger Door Module. ^ Select: Special Functions. ^ Select: Refresh. Important: You must remove the described fuse in the next step for the "Refresh" program to be performed. If you do not remove the fuse for five seconds, the Tech 2 will continue to display "Test in Progress" and the program will not complete. ^ Remove the PDM fuse for 5 seconds from the fuse center located behind the panel on the left end of the instrument panel. Page 3232 Disclaimer Weatherstrip Replacement - Auxiliary Rear Door Weatherstrip: Service and Repair Weatherstrip Replacement - Auxiliary Weatherstrip Replacement - Auxiliary Removal Procedure 1. Open the door. 2. Pull the weather-strip from the pinchweld flange. Installation Procedure 1. Push the weather-strip over the pinch-weld flange. 2. Close the door. Page 4641 Electrical Symbols Part 12 Page 12185 Action Taken When the DTCs Sets The module suspends all message transmission. The module uses default values for all parameters received on the serial data circuits. The module inhibits the setting of all other communication DTCs. Conditions for Clearing the DTC A current DTC clears when the malfunction is no longer present. A history DTC clears when the module ignition cycle counter reaches the reset threshold of 50, without a repeat of the malfunction. Circuit/System Verification Refer to Data Link References to determine which serial data system is used for a specific module. This DTC cannot be retrieved with a current status. Diagnosis is accomplished using the following symptom procedures: Scan Tool Does Not Communicate with High Speed GMLAN Device in SI. OR Scan Tool Does Not Communicate with Low Speed GMLAN Device in SI. DTC U0140 - U0184 Circuit Description Modules connected to the GMLAN serial data circuit monitor for serial data communications during normal vehicle operation. Operating information and commands are exchanged among the modules. In addition to this, Node Alive messages are transmitted by each module on the GMLAN serial data circuit. When the module detects one of the following conditions on the GMLAN serial data circuit, a DTC will set. Operating information and commands are exchanged among the modules. In addition to this, Node Alive messages are transmitted by each module on the GMLAN serial data circuit. Conditions for Setting the DTCs Diagnostic algorithms are designed so that a single point failure within a particular node shall result in a single DTC/FTB combination being set. Any recognized faults shall generate one DTC. Recognized faults may include but are not limited to the following: ^ Open or shorted condition on an I/O Circuit outside of normal operation of that circuit. ^ Erratic signal of a circuit, outside of normal operation, which can be readily and repeatedly recognized as erratic. ^ A condition, outside of normal operation, which causes a customer perception of a performance problem. ^ A condition whether hardware or data link error, which causes a device to operate in a default or fail soft mode. ^ A condition which changes or limits system performance. ^ Network supervision/signal supervision errors. ^ ECU Internal errors. ^ Criteria determined by legislation. An initialization or shutdown self-test shall be performed and may include but is not limited to the following: ^ RAM check ^ ROM/EEPROM/Flash check Page 6080 3. Clean the area around and below the cover. 4. Inspect the transmission fluid level. Refer to Transmission Fluid Checking Procedure in the appropriate Service Manual. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 11548 1. Snap the top of the knee bolster into the I/P assembly. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the knee bolster screws. Tighten Tighten the screws to 2 N.m (18 lb in). 3. Install the I/P cluster trim plate bezel. Page 16030 7. Insert the J 38125-13A (GM P/N 12031876-1) tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the Terminal Repair Kit to ensure that the correct release tool is used. 8. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. REPAIR PROCEDURE Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. Page 8084 The 1999 though early 2003 wiring harness jumper that plugs into the relay block will have a reddish/brown 6-way connector and a tag with the last four digits of the wiring harness part number. Second design 2003-05 may have a white plastic connector with part number 5418 as well. ^ The 1999 jumper is/was P/N 12171982 with a pink/purple tag identifier of 1982. This number has been superseded to 15366255, with a pink/purple tag identifier of 6255. ^ The 2000 jumper harness is P/N 15366255. The pink/purple tag identifier is 6255. ^ The 2001-2002 jumper is P/N 15086884. The orange tag identifier is 6884. ^ The 2003-05 jumper is P/N 15085418. The orange tag identifier is 5418. When transferring the brake controller with the wiring jumper attached from a 2001-2002 vehicle to a 2003-05 vehicle, a change to the jumper harness connector must be performed. Page 10871 Ambient Air Temperature Sensor Page 4739 Page 7263 PTO Preset Mode Function Chart PTO Preset Mode Function Chart PTO - Variable Mode The PTO speed control mode is used for both stationary and mobile applications. This mode allows PTO to be controlled in a fashion similar to cruise control. The operator is able to hold an engine RPM between 800 and 2200 with the SET switch on the cruise stock or the PTO switch. The operator can "tap up" to increase engine speed in 100 RPM increments with the RESUME switch. The operator may also "tap down" to decrease engine speed with either SET switch on the cruise control multifunction switch or the PTO switch. Vehicles not equipped with cruise control will not have the "tap up" capability. A/C - Window Defroster Contact/Tab Repair Information Back Window Glass: All Technical Service Bulletins A/C - Window Defroster Contact/Tab Repair Information INFORMATION Bulletin No.: 03-08-48-006H Date: April 11, 2011 Subject: Repair Information for Reconnection of Rear Window Defroster Contact or Tab Models: 2000-2012 GM Passenger Cars and Trucks 2003-2009 HUMMER H2 2006-2010 HUMMER H3 2005-2009 Saab 9-7X 2007-2010 Opel GT 2007-2008 Daewoo G2X Equipped With Electric Rear Window Defroster - RPO C49 Supercede: This bulletin is being revised to add the 2012 model year. Please discard Corporate Bulletin Number 03-08-48-006G (Section 08 - Body and Accessories). Repair Suggestions Soldering Defroster Contact Tabs In many cases the terminal tab will still be in the connector when you examine the vehicle. For Chevrolet Tahoe, Suburban, GMC Yukon, and Cadillac Escalade vehicles (with moveable glass), always replace the defroster tab (GM P/N 25916031) and the defroster electrical power connector (P/N 12034110). For all other vehicles, reconnect the original defroster tab. In most applications it is preferable to create a new solder connection to reattach a separated rear defroster tab. If you take note of the steps below, it is possible to create a new solder joint that is equal to, or stronger than, the original. The generic procedure below is not very time intensive, but does include minor preparation work to create a good bonding surface. Be sure to follow each of the steps, as combined they will produce the strongest bond possible. Please consider the following before attempting the repair: - Soldering introduces significant heat to the glass window of the vehicle. When performing the re-connection of the tab, use only the heat required to do the job. Pre-heat the soldering iron and have the solder in your other hand, ready to go, the moment you have enough heat to melt the solder. - If it is winter, bring the vehicle into the service garage and remove any snow from the back window area. Allow time for the glass to warm to the temperature inside the building. Soldering creates a "hot spot" in the glass. DO NOT solder on cold glass. Caution Heating the glass excessively, or repeatedly without time to cool, may result in glass breakage. ALWAYS wear safety glasses when performing this repair! - You MUST use a silver-bearing solder to make the connection. DO NOT attempt this repair with conventional tin/lead alloy solders. Silver bearing solder will adhere to the electrical buss bar, making a strong and lasting repair. - Protect surfaces under the area to be soldered. It is very easy to drip solder when performing this repair. Placing a shop towel under the soldering area is sufficient protection. Soldering Procedure 1. It is imperative to remove and replace the rear defroster electrical power connector by crimping a new connector to the feed wire. The proper connector P/N 12034110 can be found in the Packard Electrical Assortment, Tray 18, Position 5. - Insert Delphi pick 12094430 to depress the locking tab on the terminal. - Insert Delphi pick 12094429 to release the secondary lock tab. Important DO NOT re-use the existing defroster tab on new-style full-size utility vehicles with moveable glass. 2. Connect the electrical connector to the defroster tab. Fully engage the connector. An improperly seated connector may cause excessive resistance and impede the proper operation of the defroster. Add a small bead of solder to mate the electrical connector tab to the defroster tab. Page 9791 Junction Block - I/P Wire Entry Part 2 Page 3042 1. Install the tire and wheel. Align the locating mark of the tire and wheel to the hub. 2. Install the wheel nuts. ^ Tighten the wheel nuts as shown to 190 Nm (140 ft. lbs.). Notice: Refer to Fastener Notice in Service Precautions. Important: ^ Tighten the nuts evenly and alternately in order to avoid excessive runout. 3. Install the wheel center cap. 4. Remove the safety stands. 5. Lower the vehicle. Page 10186 7. From inside the vehicle remove the upper bolt from the upper intermediate steering shaft (1) to the steering column connection. 8. Remove the upper intermediate steering shaft assembly. 1. From inside the vehicle slide the shaft down and off the steering column. 2. From inside the vehicle slide the upper intermediate shaft through the dash boot seal and remove the shaft from the vehicle. 9. Replace the upper intermediate shaft. 10. Install the upper intermediate steering shaft through the dash boot seal and slide the lower end into the steering gear coupling shaft. 11. Raise the upper end of the intermediate steering shaft and install into the steering column shaft. 12. Install the upper bolt and nut. Tighten Tighten the bolt to 47 N.m (35 lb ft). 13. Install the lower bolt and nut. Tighten Tighten the bolt to 50 N.m (37 lb ft). 14. For vehicles equipped with adjustable foot pedals perform the following steps: 1. Reposition the accelerator pedals into position on the bulkhead. 2. Install the two retaining nuts. Tighten Tighten the nuts to 20 N.m (15 lb ft). 3. Reposition the carpet into place. Parts Information Warranty Information For vehicles repaired under warranty use, the table. Page 15194 Electrical Symbols ELECTRICAL SYMBOLS Electrical Symbols Part 1 Page 8153 19. Important: Care must be used when removing the piston boot and seal from the caliper. Use a small plastic or wood tool for removal. Do not use a metal tool because it may damage the caliper bore or seal groove. Remove the piston boots from the brake caliper. 20. Remove the piston seals from the brake caliper. 21. Remove the brake caliper bleeder valve and cap from the brake caliper. 22. Important: Do not use abrasives to clean the brake caliper piston. Clean the brake caliper piston bore and seal counterbore, and the caliper piston with denatured alcohol, or equivalent. 23. Dry the caliper piston bores and counterbores, and the piston with non-lubricated, filtered air. 24. Inspect all of the brake caliper parts as follows. ^ Piston - Inspect for scoring, nicks, cracks, wear, or corrosion. Replace the pistons if any damage is found. ^ Caliper Bore - Inspect for scoring, nicks, cracks, wear, or corrosion. Use crocus cloth to polish out light corrosion. Otherwise, replace the caliper. Do not hone the caliper bore. ^ Seal groove in the caliper bore for nicks or burrs. If found, replace the caliper. 25. Install the brake caliper bleeder valve and bleeder valve cap into the brake caliper. 26. Lubricate the new piston seal with Delco Supreme 11®, GM P/N 12377967 (Canadian P/N 10953488) or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. 27. Install the lubricated, new piston seals into the caliper bores. 28. Install the caliper piston into the caliper bore. 29. Install the new piston dust boot seal over the piston. 30. Using the J 45515 , fully seat the piston dust boot seal in the caliper. 31. Install the brake caliper to the vehicle. Refer to Brake Caliper Replacement - Front. Brake Caliper Replacement - Rear Brake Caliper Replacement - Rear (1500 Series) Caution: Refer to Brake Dust Caution in Service Precautions. Caution: Refer to Brake Fluid Irritant Caution in Service Precautions. Removal Procedure 1. Inspect the fluid level in the brake master cylinder reservoir. 2. If the brake fluid level is midway between the maximum-full point and the minimum allowable level, no brake fluid needs to be removed from the reservoir before proceeding. 3. If the brake fluid level is higher than midway between the maximum-full point and the minimum allowable level, remove brake fluid to the midway point before proceeding. Page 14115 Driver Door Module (DDM) - C4 (With RPO Code YE9) Part 1 Page 9467 Auxiliary Power Outlet: Scan Tool Testing and Procedures Scan Tool Data Definitions SCAN TOOL DATA DEFINITIONS Ignition 1 Signal: The scan tool displays the current voltage at the battery. GEN L-Terminal Signal Command: The scan tool displays OK/No Output. The scan tool displays OK until malfunction is detected on the generator L terminal circuit, then it reads No Output. GEN F-Terminal Signal: The scan tool displays 0-100%. The scan tool displays 0-5% until the engine is running, then the percentage value varies depending on electrical loads. Powertrain Control Module (PCM) Page 16153 Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. 1. Disconnect the connector from the component. 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. Locations Ambient Air Temperature Sensor Page 5311 Fuel Pressure: Testing and Inspection Fuel System Diagnosis FUEL SYSTEM DIAGNOSIS SYSTEM DESCRIPTION The control module enables the fuel pump relay when the ignition switch is turned ON. The control module will disable the fuel pump relay within two seconds unless the control module detects ignition reference pulses. The control module continues to enable the fuel pump relay as long as ignition reference pulses are detected. The control module disables the fuel pump relay within two seconds if ignition reference pulses cease to be detected and the ignition remains ON. The Fuel System is a returnless on-demand design. The fuel pressure regulator is a part of the fuel sender assembly, eliminating the need for a return pipe from the engine. A returnless fuel system reduces the internal temperature of the fuel tank by not returning hot fuel from the engine to the fuel tank. Reducing the internal temperature of the fuel tank results in lower evaporative emissions. The fuel tank stores the fuel supply. An electric turbine style fuel pump attaches to the fuel sender assembly inside the fuel tank. The fuel pump supplies high pressure fuel through the fuel filter and the fuel feed pipe to the fuel injection system. The fuel pump provides fuel at a higher rate of flow than is needed by the fuel injection system. The fuel pump also supplies fuel to a venturi pump located on the bottom of the fuel sender assembly. The function of the venturi pump is to fill the fuel sender assembly reservoir. The fuel pressure regulator, a part of the fuel sender assembly, maintains the correct fuel pressure to the fuel injection system. The fuel pump and sender assembly contains a reverse flow check valve. The check valve and the fuel pressure regulator maintain fuel pressure in the fuel feed pipe and the fuel rail in order to prevent long cranking times. TEST Steps 1 - 2 Page 965 PCM Location Page 14370 9. Use J 38125-12A to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. REPAIR PROCEDURE The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. 1. Cut the wire as close to the terminal as possible. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. OnStar(R) - Aftermarket Device Interference Information Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Aftermarket Device Interference Information INFORMATION Bulletin No.: 08-08-46-004 Date: August 14, 2008 Subject: Information on Aftermarket Device Interference with OnStar(R) Diagnostic Services Models: 2009 and Prior GM Passenger Car and Truck (including Saturn) 2009 and Prior HUMMER H2, H3 Models 2009 and Prior Saab 9-7X with OnStar(R) (RPO UE1) This bulletin is being issued to provide dealer service personnel with information regarding aftermarket devices connected to the Diagnostic Link Connector (DLC) and the impact to OnStar(R) diagnostic probes and Vehicle Diagnostic e-mails. Certain aftermarket devices, when connected to the Diagnostic Link Connector, such as, but not limited to, Scan Tools, Trip Computers, Fuel Economy Analyzers and Insurance Tracking Devices, interfere with OnStar's ability to perform a diagnostic probe when requested (via a blue button call) by a subscriber. These devices also prohibit the ability to gather diagnostic and tire pressure data for a subscriber's scheduled OnStar(R) Vehicle Diagnostic (OVD) e-mail. These aftermarket devices utilize the Vehicles serial data bus to perform data requests and/or information gathering. When these devices are requesting data, OnStar(R) is designed not to interfere with any data request being made by these devices as required by OBD II regulations. The OnStar(R) advisor is unable to definitively detect the presence of these devices and will only be able to inform the caller or requester of the unsuccessful or incomplete probe and may in some cases refer the subscriber/requester to take the vehicle to a dealer for diagnosis of the concern. When performing a diagnostic check for an unsuccessful or incomplete OnStar(R) diagnostic probe, or for concerns regarding completeness of the OnStar(R) Vehicle Diagnostic (OVD) e-mail, verify that an aftermarket device was not present at the time of the requested probe. Regarding the OVD e-mail, if an aftermarket device is interfering (including a Scan Tool of any type), the e-mail will consistently display a "yellow" indication in diagnostics section for all vehicle systems except the OnStar(R) System and Tire Pressure data (not available on all vehicles) will not be displayed (i.e. section is collapsed). Successful diagnostic probes and complete OVD e-mails will resume following the removal or disconnecting of the off-board device. Disclaimer Page 7448 8. Install the transmission mount nuts. ^ Tighten the nuts to 40 Nm (30 ft. lbs.). 9. Remove the transmission jack. 10. Install a NEW transfer case gasket, if necessary. 11. Install the transfer case. 12. Check the fluid level. Add fluid if necessary. Page 8742 INSTALLATION PROCEDURE 1. Install the negative battery cable. 2. Raise the vehicle. 3. Position the negative cable and forward lamp wiring harness ring terminals to the frame. Insert the anti-rotation tab on the forward lamp wiring harness into the hole in the frame. NOTE: Refer to Fastener Notice in Service Precautions. 4. Install the forward lamp wiring harness ground/negative cable bolt. Tighten Tighten the bolt to 9 N.m (80 lb in). IMPORTANT: The engine wiring harness ground is to be installed under the negative cable ground. 5. If equipped with a 8.1L engine, position the wiring harness ground and negative cables. Position the anti-rotation tab on the negative cable in the correct location. 6. Install the engine wiring harness ground/negative cable bolt. Tighten Tighten the bolt to 25 N.m (18 lb ft). 7. Lower the vehicle. 8. Install the negative cable clip to the positive cable clip. Page 9415 Electrical Symbols Part 14 Locations Crankshaft Position (CKP) Sensor Location Page 4436 Page 11120 Discharge Air Temperature Sensor / Switch: Service and Repair Air Temperature Sensor Replacement - Lower Right AIR TEMPERATURE SENSOR REPLACEMENT - LOWER RIGHT REMOVAL PROCEDURE 1. Remove the I/P lower closeout panel. 2. Remove the right floor duct. 3. Remove the center console. 4. Disconnect the electrical connector from the lower right air temperature sensor (1). 5. Remove the lower right air temperature sensor (1). INSTALLATION PROCEDURE 1. Install the lower right air temperature sensor (1). 2. Connect the electrical connector to the lower right air temperature sensor (1). 3. Install the center console. 4. Install the right floor duct. 5. Install the I/P lower closeout panel Page 4386 Data Link Connector: Service and Repair DATA LINK CONNECTOR REPLACEMENT REMOVAL PROCEDURE 1. Remove the bolt from the data link connector. 2. Remove the data link connector from the instrument panel. INSTALLATION PROCEDURE 1. Install the data link connector to the instrument panel. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the data link connector bolt. Tighten Tighten the bolt to 6 N.m (53 lb in). Page 9745 C223 I/P Harness To Body Harness (Except NYS And HP2) Part 2 Page 4090 Tighten Tighten the sensor to 42 N.m (31 lb ft). 3. If equipped with a 6.0L engine, connect the HO2S electrical connector (2). 4. If equipped with a 4.8L or 5.3L engine, connect the HO2S electrical connector (2). 5. If equipped with a fuel composition sensor, install the HO2S electrical connector to the fuel line clip. 6. Disconnect the CPA retainer. 7. If equipped, connect the fuel composition sensor electrical connector. 8. Lower the vehicle. Page 13536 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Weather Pack Connectors WEATHER PACK CONNECTORS The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. Page 1434 Ambient Light Sensor (With RPO Code CJ3) Page 9366 For vehicles repaired under warranty, use the table. Disclaimer Interior - Seat Memory Feature Appears Inoperative Memory Positioning Module: Customer Interest Interior - Seat Memory Feature Appears Inoperative Bulletin No.: 04-08-50-003 Date: February 26, 2004 INFORMATION Subject: Enabling Memory Seat Feature via DIC If Feature Appears Inoperative Models: 2003-2004 Cadillac Escalade, Escalade ESV, Escalade EXT 2003-2004 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2003-2004 GMC Sierra, Yukon, Yukon Denali, Yukon Denali XL 2003-2004 HUMMER H2 with Steering Wheel Controls (RPO UK3) (standard on H2) If the memory seat feature appears inoperative, check the Driver Information Center (DIC). Many of the memory seat modules that were returned through the Warranty Parts Center for a condition of inoperative have shown No Trouble Found. The Driver Information Center (DIC), programmed for Seat Entry and Exit, is set to the default "Off" mode at the assembly plant. DO NOT REPLACE THE MEMORY SEAT MODULE. Perform the following procedure. Important: The following procedure will need to be completed for each Remote/Key selection. Using the DIC menu, do the following steps: 1. Set the "Seat Recall" to either "At Key In" or "On Remote" based on the customer's preference. 2. Set the "Exit Seat" to "On". 3. Adjust the following items: Memory Seat: 3.1. Driver's Seat (including the seat back, recliner, lumbar, and side wings) 3.2. Throttle and Brake Pedals (not available on H2 or Silverado and Sierra Trucks) 3.3. Outside Mirrors 3.4. Radio Station Presets 3.5. Last Chosen Climate Control System Settings (not available on Silverado or Sierra Trucks) 3.6. Press and hold the "1" or "2" (for driver 1 or 2) button of the memory control for three seconds. A double chime will sound to let you know that the position has been stored. Easy Exit Seat: 3.1. Press and release the 1 or 2 button or press the unlock button on the desired remote keyless entry transmitter. The seat will move to the stored memory position. 3.2. Adjust the seat to the desired exit position. 3.3. Press and hold the exit button of the memory control (located on the door) for three seconds. A double chime will sound to let you know that the position has been stored for the identified driver (1 or 2). Instruments - Reduced PRNDL Display Visibility Transmission Shift Position Indicator Lamp: Technical Service Bulletins Instruments - Reduced PRNDL Display Visibility Bulletin No.: 02-08-42-004A Date: March 30, 2007 INFORMATION Subject: PRNDL Display Reduced Visibility For Approximately One Minute Models: 2007 and Prior Passenger Cars and Trucks (Including Saturn) 2007 and Prior HUMMER H2, H3 2005-2007 Saab 9-7X with Automatic Headlamp Control and Vacuum Fluorescent PRNDL Indicator Instrument Panel Cluster Supercede: This bulletin is being revised to include additional models and model years. Please discard Corporate Bulletin Number 02-08-42-0004 (Section 08 - Body and Accessories). After backing the vehicle out of a garage or dark environment into a daylight environment, the PRNDL display has reduced visibility for approximately one minute. While the vehicle is parked in a dark environment, the sensor for the automatic headlamp/driving lamps senses that it is dark. When the key is turned to the run/start position, the automatic headlamp module will turn all driving lamps, the instrument panel cluster and PRNDL display ON in the night-time mode. The night-time mode intensity of the instrument panel lamps and PRNDL display is controlled by the automatic headlamp module and can be dimmed further by the customer using the dimming control of the headlamp switch. When the customer then moves the vehicle from the dark environment into the bright sunlight, it will take approximately one minute before the headlamp control module recognizes this as true daylight and not just a bright overhead street lamp shining on the sensor. The headlamp control module will then turn the headlamps off and restore the instrument panel and PRNDL display to full brilliance. Without the time delay, the automatic headlamp control module would switch to the night mode (turn on all driving lamps, instrument panel lamps and PRNDL display would dim) each time the vehicle was driven under an overpass or other darkened environment. This is a normal condition and no repair should be attempted. Ensure the instrument panel backlighting control is in the full bright position. This will help alleviate the condition. You may demonstrate to the customer what happens by placing a repair order over the automatic headlamp control light sensor, which will cause the automatic headlamp control module to switch to the night mode in approximately one minute. All driving lamps will come ON, the instrument panel backlight will be dim, and the PRNDL display will also dim to the night setting in conjunction with the position of the headlamp switch dimming control. Demonstrate to the customer the variance in the instrument panel backlighting and PRNDL display while adjusting the headlamp switch dimming control to both ends of its allowable range. Advise the customer to keep the headlight switch dimming control in the highest position to allow viewing of the PRNDL display in a bright environment. Disclaimer Page 6418 Page 7041 Drive/Propeller Shaft: Description and Operation Propeller Shaft Description and Operation The propeller shaft is a tube with universal joints at both ends which do not require periodic maintenance, that transmit power from the transfer case or transmission output shaft to the differential. Front Propeller Shaft Description The front propeller shaft transmits rotating force from the transfer case to the front differential when the transfer case is engaged. The front propeller shaft connects to the transfer case using a splined slip joint. One Piece Propeller Shaft Description A 1 piece propeller shaft uses a splined slip joint to connect the driveline to the transmission or transfer case. Two Piece Propeller Shaft Description There are 3 universal joints used on the two piece propeller shaft, A center bearing assembly is used to support the propeller shaft connection point, and help isolate the vehicle from vibration. Propeller Shaft Phasing Description The propeller shaft is designed and built with the yoke lugs (ears) in line with each other. This produces the smoothest running shaft possible. A propeller shaft designed with built in yoke lugs in line is known as in - phase. An out of phase propeller shaft often causes vibration. The propeller shaft generates vibration from speeding up and slowing down each time the universal joint goes around. The vibration is the same as a person snapping a rope and watching the wave reaction flow to the end. An in phase propeller shaft is similar to 2 persons snapping a rope at the same time and watching the waves meet and cancel each other out. A total cancellation of vibration produces a smooth flow of power in the drive line. All splined shaft slip yokes are keyed in order to ensure proper phasing. Universal Joint Description The universal joint is connected to the propeller shaft. The universal consist of 4 caps with needle bearings and grease seals mounted on the trunnions of a cross or spider. These bearings and caps are greased at the factory and no periodic maintenance is required. There are 2 universal joints used in a one piece propeller shaft and 3 used in two piece propeller shaft. The bearings and caps are pressed into the yokes and held in place with snap rings, except for 2 bearings on some models witch are strapped onto the pinion flange of the differential. Universal joints are designed to handle the effects of various loads and rear axle windup conditions during acceleration and braking. The universal joint operates efficiently and safely within the designed angle variations. when the design angles are exceeded, the operational life of the joint decreases. Center Bearing Description Center bearings support the driveline when using 2 or more propeller shafts. The center bearing is a ball bearing mounted in a rubber cushion that attaches to a frame crossmember. The manufacturer prelubricates and seals the bearing. The cushion allows vertical motion at the driveline and helps isolate the vehicle from vibration. Page 4738 Fuel Injector Cleaning Procedure Fuel Injector: Service and Repair Fuel Injector Cleaning Procedure FUEL INJECTOR CLEANING PROCEDURE TOOLS REQUIRED - J 37287 Fuel Line Shut-Off Adapters - J 38500-A Fuel Injector Cleaner - J 42873-1 3/8 Fuel Line Shut-Off Adapter - J 42873-2 5/16 Fuel Line Shut-Off Adapter - J 42964-1 3/8 Fuel Line Shut-Off Adapter - J 42964-2 5/16 Fuel Line Shut-Off Adapter IMPORTANT: GM Top-Engine Cleaner is the only injector cleaning agent recommended. Do not use other cleaning agents, as they may contain methanol which can damage fuel system components. - Under NO circumstances should the top engine cleaner be added to the vehicles fuel tank, as it may damage the fuel pump and other system components. - Do not exceed a 10 percent cleaning solution concentration. Higher concentrations may damage fuel system components. Testing has demonstrated that exceeding the 10 percent cleaning solution concentration does not improve the effectiveness of this procedure. - During this procedure you will need a total of 960 ml (32.4 oz) of cleaning solution. That is 2 tanks of solution for the J 38500-A. Other brands of tools may have a different capacity and would therefore require more or less tanks to complete the procedure. You must use all 960 ml (32.4 oz) of solution to insure complete injector cleaning. 1. Obtain J 38500-A (2). IMPORTANT: Make sure the valve at the bottom of the canister (3) is closed. 2. For US dealers, empty 2 pre-measured GM Top-Engine Cleaner containers, 24 ml (0.812 oz) each, GM P/N 12346535, into the J 38500-A. 3. For Canadian dealers, measure and dispense 48 ml (1.62 oz) of Top-Engine Cleaner, Canadian P/N 992872, into the J 38500-A. 4. If you are using any other brand of tank you will need a total of 96 ml (3.24 oz) of Top-Engine Cleaner mixed with 864 ml (29.16 oz) of regular unleaded gasoline. 5. Fill the injector cleaning tank with regular unleaded gasoline. Be sure to follow all additional instructions provided with the tool. 6. Electrically disable the vehicle fuel pump by removing the fuel pump relay and disconnecting the oil pressure switch connector, if equipped. 7. Disconnect the fuel feed and return lines at the fuel rail. Plug the fuel feed and return lines coming off the fuel rail with J 37287 , or J 42964-1 , and J 42964-2 , or J 42873-1 and J 42873-2 as appropriate for the fuel system. 8. Connect the J 38500-A to the vehicle's fuel rail. 9. Pressurize the J 38500-A to 510 kPa (75 psi). 10. Start and idle the engine until it stalls, due to lack of fuel. This should take approximately 15-20 minutes. 11. Disconnect J 38500-A from the fuel rail. 12. Reconnect the vehicle's fuel pump relay and oil pressure switch connector, if equipped. 13. Remove J 37287, or J 42964-1, and J 42964-2, or J 42873-1 and J 42873-2 and reconnect the vehicles fuel feed and return lines. 14. Start and idle the vehicle for an additional 2 minutes to ensure residual injector cleaner is flushed from the fuel rail and fuel lines. 15. Repeat steps 1-5 of the Injector Balance Test, and record the fuel pressure drop from each injector. 16. Subtract the lowest fuel pressure drop from the highest fuel pressure drop. If the value is 15 kPa (2 psi) or less, no additional action is required. If the value is greater than 15 kPa (2 psi), replace the injector with the lowest fuel pressure drop. 17. Add one ounce of Port Fuel Injector Cleaner, GM P/N 12345104 (Canadian P/N 10953467), to the vehicles fuel tank for each gallon of gasoline estimated to be in the fuel tank. Instruct the customer to add the reminder of the bottle of Port Fuel Injector Cleaner to the vehicle fuel tank at the Drivetrain - Updated Transfer Case Speed Sensor Conn. Speed Sensor: All Technical Service Bulletins Drivetrain - Updated Transfer Case Speed Sensor Conn. Bulletin No.: 06-04-21-001 Date: May 17, 2006 INFORMATION Subject: Updated Transfer Case Connector Service Kit Now Available For Transfer Case Speed Sensor Wire Harness Connector that Comes Loose Or Connector Retainer Clip Breaks Models: 2007 and Prior GM Light Duty Trucks 2007 and Prior HUMMER H2, H3 2005-2007 Saab 9-7X with Four-Wheel Drive or All-Wheel Drive Technicians may find that when the transfer case speed sensor wire harness connector is removed, the connector lock flexes/bends and does not return to the original position. The transfer case speed sensor wire harness connector then has no locking device. On older vehicles, the plastic connector retainer becomes brittle and the clip may break as soon as it is flexed. In the past, the only service fix was to install a wire harness connector service pack, P/N 88987183. This repair procedure involved splicing a new service connector with an integral connector lock. This connector service kit is of the same design and was still prone to failure over time. A new connector service repair kit is now available, P/N 15306187, that is an updated design. This new kit should be used whenever the speed sensor wire harness connector requires replacement. Parts Information Disclaimer Page 10259 Control Module References Part 2 Page 4505 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Micro-Pack 100W Connectors MICRO-PACK 100W CONNECTORS TOOLS REQUIRED J 38125-D Terminal Repair Kit REMOVAL PROCEDURE There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2)has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. IMPORTANT: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Page 2698 Relay Block - I/P C10 Part 1 Page 14709 - Customer induced cuts (knife cuts, cut by customer tools, etc.) - Paint stains (customer should have cleaned paint stains while paint was still wet) - Coffee stains and other removable dirt These should be cleaned as described in the Owner's Manual under Appearance Care. Also, refer to Corporate Bulletin Number 06-00-89-029A or later. - Evidence of chemicals used for cleaning, other than those specified in the Owner's Manual - Other chemical spills - Minor and normal leather wrinkles as a result of use - Other defects to the seat cover not detected during the pre-delivery inspection (PDI). Inform the customer that the above issues were not present when the vehicle was purchased and cannot be replaced under warranty. The covers, however, may be repaired or replaced at the customer's expense. The following conditions are not caused by the customer and should be covered by warranty: - Split seams Page 5565 Ignition Coil 5 Page 8828 Alternator: Service and Repair Generator Replacement GENERATOR REPLACEMENT REMOVAL PROCEDURE CAUTION: Refer to Battery Disconnect Caution in Service Precautions. 1. Disconnect the negative battery cable. 2. Remove the accessory drive belt. 3. If necessary, remove the engine sight shield. 4. Disconnect the generator electrical connector (3). 5. Remove the generator cable from the generator, perform the following: 5.1. Slide the boot down revealing the terminal stud. 5.2. Remove the generator cable nut from the terminal stud. 5.3. Remove the generator cable. Procedures Carpet: Procedures Eliminating Unwanted Odors in Vehicles Eliminating Unwanted Odors in Vehicles GM Vehicle Care Odor Eliminator, GM P/N 12378554, US ACDelco 88900909, Canadian P/N 88901678, may control or eliminate odors in the interior and luggage compartment areas of GM vehicles. This non-toxic, biodegradable, odorless product has been shown to greatly reduce or remove the following types of odor: * Objectionable smells of mold and mildew resulting from vehicle water leaks * Customer created odors, such as smoke You may safely use GM Vehicle Care Odor Eliminator on fabrics, vinyl, leather, carpet, and sound deadening materials. You may also induce this product into HVAC modules and instrument panel ducts for the control of non-bacterial related odors. Important: This product leaves no residual scent and should not be used as an air freshener. This product may result in the permanent elimination of an odor and may be preferable to customers whose allergies make them sensitive to perfumes. This product may effectively remove odors when directly contacting the odor source. In cases such as water leaks, use this product with diagnostic procedures to first eliminate the primary cause of the odor. Then use further applications on the residual odor to permanently correct the vehicle condition. How to Use this Product * Spray GM Vehicle Care Odor Eliminator directly or as an additive with carpet shampoo in steam cleaners. * Do not use on any interior surface that plain water would deteriorate, because this product will have the same effect. Also avoid letting this product come into contact with vinegar or any acidic substance. Acid-based products will hamper the effectiveness of GM Vehicle Care Odor Eliminator. * Instructions and cautions are printed on the bottle, but additional help is available. If you encounter a persistent or recurring odor, you may call to obtain additional information and usage suggestions. Floor Carpet Drying Floor Carpet Drying If the carpet or the pad or insulator is wet, use the following criteria for drying or for replacing the components: * For a 1-piece carpet assembly bonded to a cotton or a fiber padding, replace the entire assembly. * For a 2-piece carpet assembly with a cotton or a fiber padding, replace the padding only. While the carpet is out of the vehicle, dry the carpet using the method described below. * For a 1-piece carpet assembly bonded to a foam padding or attached to a synthetic padding, dry the carpet using the method described below. * For a 2-piece carpet assembly with a synthetic padding, dry the assembly using the method described below. Drying Method 1. If you observe puddles of liquid on the carpet face, use a wet vacuum to remove the excess moisture. 2. Blot the face of the carpet with a towel in order to absorb as much moisture as possible. 3. Point a fan at the affected area and air dry the carpet. Page 13279 1. Remove the ground cable from the battery's negative cable. 2. Remove the center console, see WIS - Body - Interior. 3. Loosen the gear shift housing (A). AUT: Disconnect the 6-pin connector (B) to improve access to the gear shift housing screws. 4. Disconnect the signal cable from the SRS control module to the OnStar(R) control module and secure the cable. 4.1. Disconnect the connector (A) from the SRS control module and cut the cable tie (B). Service and Repair Hood Weatherstrip: Service and Repair Seal Replacement - Hood Rear Removal Procedure Pull up on the rear hood seal and remove from the cowl pinch-weld flange. Installation Procedure Align the slot in the rear hood seal with the cowl pinch-weld flange and press into place. Service and Repair Condenser HVAC: Service and Repair CONDENSER REPLACEMENT TOOLS REQUIRED J 39400-A Halogen Leak Detector REMOVAL PROCEDURE 1. Recover the refrigerant. Refer to Refrigerant Recovery and Recharging. 2. Remove the grille. 3. Remove the tie bar to radiator brace bolts (1). Access the bolts from the rear of the upper radiator support. 4. Remove the lower bolts from the hood latch support bracket. 5. Remove the compressor discharge hose assembly bolt from the condenser. 6. Disconnect the compressor discharge hose assembly from the condenser. 7. Remove the evaporator tube nut from the condenser. 8. Disconnect the evaporator tube from the condenser. 9. Remove the insulator retainer bolts and the upper insulator retainers. Page 11002 Cabin Air Filter: Service and Repair This Article has been updated by bulletin #PIT3330, dated December 22, 2004. Condition/Concern: A customer may inquire about the availability of the passenger compartment air filter. Recommendation/Instructions: Starting in 2003 model year, the passenger compartment air filter is no longer available as a factory option. With the redesigned HVAC case, there is no longer a cavity for the filter. The GM parts catalog indicates there is a replacement filter available; however, there is no provision for it. Page 9818 4. Push on the top part until it clicks in place. 5. Connect the harness to the front of the junction block. 6. Install the cover to the junction block until it clicks in place. 7. Hand tighten the retaining nut until seated. Electrical - Information For Electrical Ground Repair Wiring Harness: All Technical Service Bulletins Electrical - Information For Electrical Ground Repair INFORMATION Bulletin No.: 10-08-45-001B Date: October 25, 2010 Subject: Information for Electrical Ground Repair - Use New Replacement Fasteners with Conductive Finish Models: 2011 and Prior GM Passenger Cars and Trucks (including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X Supercede: This bulletin is being revised to add the 2011 model year and update the Warranty Information. Please discard Corporate Bulletin Number 10-08-45-001A (Section 08 - Body and Accessories). Electrical Ground Repair Overview Proper electrical system function relies on secure, stable and corrosion-free electrical ground connections. Loose, stripped, or corroded connections increase the possibility of improper system function and loss of module communication. These conditions may also lead to unnecessary repairs and component replacement. In general, electrical ground connections are accomplished using one, or a combination of the following attachment methods: - Welded M6 stud and nut - Welded M6 nut and bolt - Welded M8 nut and bolt Determine which attachment method is used and perform the appropriate or alternative repair as described in this bulletin. M6 Weld Stud Replacement Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. Select a location adjacent the damaged or missing M6 ground stud having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the M6 conductive rivet stud flange. 2. Using GM approved residue-free solvent or equivalent, remove any grease from the repair site and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 3. Drill a 10 mm (0.40 in) diameter hole through the panel. 4. Remove paint and primer from the area surrounding the 10 mm (0.40 in) hole until bare metal is visible. Page 10886 Electrical Symbols Part 9 Service and Repair Hood Stop: Service and Repair Hood Bumper Replacement Removal Procedure 1. Remove the front hood bumper by turning the front hood bumper (1) out counterclockwise. 2. Remove the side hood bumper by sliding the side hood bumper (2) rearward and pulling up. Installation Procedure 1. Install the side hood bumper by pushing down and sliding the side hood bumper (2) forward. 2. Install the front hood bumper (1) by turning the front hood bumper in clockwise until the hood closes flush with the fender. Page 13799 Hood Hinge: Service and Repair Hood Hinge Replacement Removal Procedure Caution: When a hood hold open device is being removed or installed, provide alternate support to avoid the possibility of damage to the vehicle or personal injury. 1. Raise and support the hood. 2. Remove the hinge to the hood bolts. 3. Remove the hinge from the hood. Installation Procedure Notice: Refer to Fastener Notice in Service Precautions. 1. Install the hinge to the hood bolts. Tighten the hinge to the hood bolts to 25 N.m (18 lb ft). 2. Remove the hood support and lower hood. Page 13167 ^ On 2002 Sevilles and DeVilles, the GPS jumper cable MUST be unclipped from the back seat cross brace, or unplugged from the VCIM first. DO NOT pull back on the mounting bracket until the GPS antenna jumper cable is unclipped from the back seat cross brace or unplugged from the VCIM. The short length of jumper cable does not allow the VCIM mounting bracket to be pulled back very far, and could lead to a break at the VCIM connector. ^ On 2000-2002 Bonnevilles and LeSabres and 2001-2002 Auroras you will need to follow these steps: 1. Remove the 4 nuts that secure the VCU/VIU bracket assembly to the rear seat back brace. Note: Save these nuts for later use. 2. Remove and discard the plastic VCU/VIU bracket assembly from the vehicle. 3. Remove the upper right stud (1) from the rear seat back brace and re-install in the middle lower slot (2) on the brace. Tighten the fastener to 4 Nm (36 lb in). 4. Position the new VCIM in the vehicle over the studs on the rear seat back brace. 5. Install two of the nuts saved from step (1). Tighten the nuts to 4 Nm (36 lb in). 6. Connect the new OnStar jumper harness supplied in the kit to the VCIM (two white connectors) and the body wiring harness (C345 connector). 7. Connect the small coaxial jumper cable supplied in the kit, to the VCIM, with the end that has a blue plastic housing connector. Plug the other end of this coaxial jumper cable to the OnStar Global Positioning Satellite (GPS) antenna coaxial cable at the right angle connector. Note: The GPS cable in the new OnStar jumper harness is not utilized. 8. Connect the cellular coaxial cable to the OnStar VCIM. On 2001 Impala and Monte Carlos you will need to follow these steps: 9. Remove the Vehicle Communications Unit (VCU) and Vehicle Interface Unit (VIU) following the procedures listed in SI. Save the bracket nuts for later use. NVG 246-NP8 Control Module: Locations NVG 246-NP8 Transfer Case Shift Control Module Transfer Case Shift Control Module 1 - I/P Harness 2 - Transfer Case Shift Control Module Connectors 3 - Transfer Case Shift Control Module 4 - Instrument Panel Locations Accelerator Pedal Position (APP) Sensor Connector Page 7743 Parts Information Warranty Information (excluding Saab U.S. Models) Warranty Information (Saab U.S. Models) Page 10797 The new calibrations have been updated to compensate for the actuator overtravel condition, the actuator hunting and the ticking/clicking noises. The new calibrations effectively eliminate the codes listed above, the default position of the doors associated with the DTCs and opens up the feedback position value. The new calibrations should not be used unless the vehicle has one or more of the customer concerns listed above or a DTC listed above has been set. The new calibrations will not correct any other DTC or NC system performance concern. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 10834 1. Remove the floor air outlet duct extension (1) from the floor duct (2). 2. Remove the center console. 3. Remove the screws from the center console duct. 4. Remove the center console duct. 5. Disconnect the electrical connection from the mode actuator (10). 6. Remove the mode actuator mounting screws from the HVAC module. 7. Remove the mode actuator as an assembly with the actuator cam. INSTALLATION PROCEDURE Page 1958 Page 12241 2. Connect the Techline Information System (TIS) terminal to the Tech2(R). 3. Scroll to the bottom of the Controller List, and select the "ONSA TIS2WEB Pass-Thru OnStar(R) Activation (Replaced/Upgraded Units Only)" option using the Service Programming System (SPS). Important: Do not use the clear DTC function. This will only temporarily turn the LED to green. 4. Upon completion of the OnStar(R) TIS2WEB step, disconnect the TIS terminal from the Tech2(R) and perform the VCIM/OnStar(R) Set-up Procedure using the Tech2(R). The set up procedure is located under the special function menu option. Important: Failure to perform the above steps will result in a red LED, DTC being set and limited or incomplete OnStar(R) services, and will require a customer return visit to the dealership. 5. The default language for the new VCIM will be English. To change to French or Spanish, access the special functions menu on the Tech 2(R), and follow the instructions accordingly. 7. Skip to the next step if the vehicle to be upgraded is not listed below: ^ 2002-2004 Cadillac DeVille ^ 2002-2004 Cadillac Seville ^ 2005 Cadillac STS Set up the Dash Integration Module (DIM) using the following procedure: 1. On the Tech2(R) select the correct Year, Make and Model. 2. Enter Dash Integration Module (DIM) > Special Functions > Set Options > Misc. Options 1 > and turn off phone (if the vehicle does not have the UV8 option). 3. Enter Nav Radio Present and set to "No Nav" (if the vehicle does not have a navigation radio). 4. Turn the ignition off and open the door to turn off the RAP. 5. Turn the ignition on and enter the Vehicle Comm. Interface Module > Special Functions > Set Up OnStar /VCIM. 6. When prompted select "No Phone" (if the vehicle does not have the UV8 phone) and "No Nav" (if the vehicle does not have a navigation radio). 7. Turn the ignition off and open the door to turn off the RAP. Important: OnStar(R) Emergency Services are immediately available after these steps, however, full configuration, including activation of Hands-Free Calling, may take up to 24 hours to complete. Processing the Module Exchange Processing the Module Exchange For this program, submitting a credit request for the removed OnStar(R) VCIM (the core) will be performed through a website. When this process is followed, the removed Analog / Digital-Ready VCIM, in most cases, will not be mailed back to the distributor, but can be scrapped by the dealership. U.S. Dealers 1. Return the removed Analog / Digital-Ready OnStar(R) VCIM to the Parts Manager. 2. The Parts Manager will log onto www.autocraft.com. 3. Select Account Maintenance. 4. Select Outstanding Cores. Page 8992 Location View Page 12315 Electrical Symbols Part 5 Locations Upper Steering Column Page 5448 3. Locate the auxiliary fuel tank vent hose. The vent hose is the smaller diameter of the two hoses that comes from the auxiliary fuel tank and feeds into the main tank vent hose. 4. Disconnect the auxiliary tank vent hose from the main tank vent hose connection. 5. Install the cap supplied with kit, P/N 15213990, to the main tank vent hose connector where the auxiliary tank vent hose was just removed. 6. Locate the section of vent hose on the main tank between the fuel filler neck and the metal pipe. The smaller of the two hoses on the filler neck. 7. Cut the main tank vent hose between the filler neck and the metal pipe using an appropriate cutting tool. 8. Install the "T" and the two hose clamps supplied with kit, P/N 15213990, into the main tank vent hose. Tighten Tighten the hose clamps to 2.5 N.m (22 lb in). 9. Install the new auxiliary tank vent hose and clamp supplied with kit, P/N 15213990, to the "T" that was just installed. Tighten Tighten the hose clamp to 2.5 N.m (22 lb in). 10. Connect the new vent hose to the original auxiliary tank hose. 11. Secure the newly installed vent hose and the original auxiliary tank vent hose with plastic ties supplied in kit, P/N 15213990. 12. If necessary, reinstall the left rear tires/wheels assemblies. Page 507 Control Module References Part 3 Page 7144 11. If the vehicle is a 2003 model year Chevrolet Express or GMC Savana van, the vehicle may require a new accumulator. Refer to Corporate Bulletin Number 03-01-38-016 for more information. This bulletin refers to an updated design accumulator that may improve the performance of the A/C system. 12. Install a new serpentine belt tensioner and serpentine belt if they have been damaged due to A/C system slugging or an A/C compressor seizure. The serpentine belt tensioner may have broken stop tabs and/or a missing front cap. 13. Verify proper operation of the A/C system. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 6452 7. Important: DO NOT hold the transmission end (1) during this operation, this will result in a mis-adjusted cable. Release the transmission end (3) and allow the spring (2) to tension/adjust the cable system. 8. Pull the white cover (5) on the shifter end (1) back. 9. Push the natural colored lock button (4) down to engage the locking teeth on the transmission end (3). 10. Release the white cover (1). 11. Verify the white cover (1) conceals the natural colored lock (2). 12. If the white cover (1) does not conceal the natural colored lock (2), the shift cable must be re-adjusted. 13. Lower the vehicle. 14. Test the transmission for proper shift operation. 15. If all of the gear positions cannot be achieved, the shift cable must be re-adjusted. Cable Re-Adjustment Page 1924 2. Connect the selector switch electrical connectors (2, 3). 3. Slide the selector switch into the housing until the switch snaps into place. Important: Make sure that the selector switch is seated properly in the housing before installing the I/P cluster bezel. 4. Install the I/P cluster bezel. Page 7991 Page 3780 Electrical Symbols Part 8 Page 16096 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Page 14294 WA812K/88 - WA815K/91 Page 9020 Fuse Block - Underhood C3 Part 3 Fuel System - Cranks But No Start/Inaccurate Fuel Gauge Fuel Gauge Sender: Customer Interest Fuel System - Cranks But No Start/Inaccurate Fuel Gauge Bulletin No.: 04-08-49-018E Date: January 05, 2005 TECHNICAL Subject: Cranks But No Start, Stall, Inaccurate/Incorrect Fuel Gauge Reading, No Fuel, Vehicle is Out of Fuel and Fuel Gauge Reads Above Empty (Replace Fuel Level Sensor) Models: 2001-2004 Cadillac Trucks 1999-2004 Chevrolet and GMC Trucks with Gasoline Engine (VINs Z, X, V, T, U, N, G, 6, 8 - RPOs LU3, LR4, LM7, LQ4, LQ9, L59, L18,LK5 L52) Attention: Parts are currently available for vehicles with Variable Fuel (VIN Z - RPO L59) vehicles. Please refer to Corporate Bulletin Number 04-06-04-01 2B or newer for Variable Fuel (VIN Z - RPO L59) vehicles. Supercede: This bulletin is being revised to include information on the Chevrolet Colorado and the GMC Canyon. Please discard Corporate Bulletin Number 04-08-49-018D (Section 08 - Body and Accessories). Condition Some customers may comment on the vehicle stalling and will not restart, vehicle ran out of fuel, vehicle appears to be out of fuel but the fuel gauge reads above empty. The fuel gauge may read 1/4 tank. Cause Contamination on the fuel sending card may cause inaccurate/incorrect fuel gauge readings. Correction Follow the service procedure below for diagnosis and repair of this concern. 1. Confirm that the vehicle is actually out of fuel. ^ If the vehicle is not out of fuel but Engine Cranks but Does Not Run, refer to the appropriate Service Information. ^ If the vehicle is out of fuel and the gauge does not read empty, test the fuel gauge. Refer to the following information: - Fuel Gage Inaccurate or Inoperative Single Tank - Fuel Gage Inaccurate or Inoperative Dual Tanks - Fuel Gage Inaccurate or Inoperative Colorado and Canyon 2. If testing reveals that the fuel gauge is operating correctly, replace the fuel sensor assembly and auxiliary tank fuel level sensor if equipped. 3. Replace the fuel level sensor. Refer to the following appropriate service information: ^ Fuel Level Sensor Replacement 4.8L and 5.3L Engines ^ Fuel Level Sensor Replacement 6.0L Engine - Front Tank ^ Fuel Level Sensor Replacement 6.0L Engine - Rear Tank ^ Fuel Level Sensor Replacement 8.1L vehicles with Front Tank ^ Fuel Level Sensor Replacement 8.1 L vehicles with Rear Tank Page 9042 Junction Block - I/P - C6 Page 12556 Diagnostic Tips Review # 3 - Denso Navigation Radios Page 9316 Junction Block - I/P Wire Entry Part 3 Page 11052 The new calibrations have been updated to compensate for the actuator overtravel condition, the actuator hunting and the ticking/clicking noises. The new calibrations effectively eliminate the codes listed above, the default position of the doors associated with the DTCs and opens up the feedback position value. The new calibrations should not be used unless the vehicle has one or more of the customer concerns listed above or a DTC listed above has been set. The new calibrations will not correct any other DTC or NC system performance concern. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 10588 Parts Information Warranty Information For vehicles repaired under warranty use, the table. Disclaimer Page 16102 Control Module References Part 3 Page 10848 3. Remove the mode actuator mounting screws from the HVAC module. 4. Remove the mode actuator as an assembly with the actuator cam. INSTALLATION PROCEDURE 1. Install the mode actuator as an assembly with the actuator cam. - Line up the heater/defroster valve lever with the mode actuator cam slot. - Line up the A/C valve lever with the mode actuator cam. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the mode actuator mounting screw to the HVAC module. Tighten Tighten the screw to 1.6 N.m (14 lb in). Evaporator Core Replacement (Delphi) Evaporator Core: Service and Repair Evaporator Core Replacement (Delphi) Air Conditioning Evaporator Core Replacement (Delphi) Removal Procedure 1. Remove the HVAC module. 2. If equipped remove the heat stakes (1) from the HVAC module (2) with a screw driver and a hammer. Page 390 ^ For U.S. Saturn retailer claim submission, use Net Item code "M" and Case Type VW. Page 12677 Page 4956 Important The new canister vent valve will be installed in a new location, outside of the frame. 7. Position and secure the new valve assembly to the frame bracket on the outside of the frame using the existing hole and mounting bolt. Tighten Tighten the bracket mounting bolt to 12 Nm (106 lb in). 8. Connect the vent valve pipe to the EVAP canister. 9. Install the two vent valve pipe clips into the existing underbody holes. 10. Connect the EVAP canister vent valve electrical connector, if equipped. 11. Attach bulk 5/8" heater hose to the vent valve port and secure using a clamp. Run a length as needed along the frame rail routing to the area above the transmission. 12. Cut the hose to determined length and install the supplied filter box. Secure using a clamp. 13. Remove the transmission support and lower the transmission assembly as necessary to allow for access to the new filter box location. 14. Secure the filter box to the transmission vent hose just forward of the hose tee-section using a tie strap. DO NOT pinch or restrict the transmission vent hose. The filter box opening should be pointing downward. 15. Raise the transmission and reinstall the transmission support. 16. Tie strap the hose as needed along the frame rail in order to keep the hose away from pinch-points and heat sources. 17. Lower the vehicle. 2004-2007 Model Year (Use Service Kit P/N 19152349) 1. Raise the vehicle. Suitably support the vehicle. 2. Disconnect the EVAP canister vent valve electrical connector. 3. Disconnect the canister pipe from the vent valve. 4. Push in the retainer and remove the existing canister vent valve from the fuel tank clip or mounting bracket. Discard the old valve. 5. Cut back the existing canister pipe approximately 51 mm (2 in) to remove the quick connect end. Crew Cab Short Box Shown Below, Other Configurations Similar Page 2332 Power Steering Line/Hose: Service and Repair (Rack and Pinion) Power Steering Gear Inlet Pipe/Hose Replacement (Rack and Pinion) Removal Procedure Notice: Refer to Power Steering Hose Disconnected Notice in Service Precautions. 1. Remove the power steering inlet hose (2) from the power steering pump (1). 2. Remove the power steering inlet hose (2) from the power steering gear (3). Installation Procedure 1. Connect the power steering inlet hose (2) to the power steering gear (3). 2. Notice: Refer to Fastener Notice in Service Precautions. Connect the power steering inlet hose (2) to the power steering pump (1). ^ Tighten the hose connections to 28 Nm (20 ft. lbs.). 3. Bleed the power steering system. Refer to Bleeding the Power Steering System. 4. Inspect all the hose connections for leaks. (With Hydroboost) Power Steering Gear Inlet Pipe/Hose Replacement (With Hydroboost) Removal Procedure Page 16007 Electrical Symbols Part 2 Page 9518 Fuse Block - Underhood - Secondary Wire Entry (With RPO Code HP2) Part 1 Page 3189 Notice: Refer to Fastener Notice in Service Precautions. 7. Tighten the J 41476 mounting bolts until snug. Do not overtighten. 1. Tighten the oil pan-to-rear cover bolts to 12 Nm (106 inch lbs.). 2. Tighten the engine rear cover bolts to 25 Nm (18 ft. lbs.). 8. Remove the J 41476. 9. Install a NEW crankshaft rear oil seal. 10. Install the engine flywheel. Restraints - SRS Lamp ON/Multiple DTC's are Set Air Bag Harness: Customer Interest Restraints - SRS Lamp ON/Multiple DTC's are Set TECHNICAL Bulletin No.: 05-09-41-001B Date: June 02, 2008 Subject: Supplemental Inflatable Restraint (SIR) Light ON, Diagnostic Trouble Codes (DTC) B0013, B0014, B0017, B0018, B0024, B0026, B0043, B0044 (Inspect and/or Replace IP Harness to Inflatable Restraint Module (Air Bag) Yellow 4-Way Connector C221 and/or C222) Models: 2003 - 2006 Cadillac Escalade Models 2003 - 2006 Chevrolet Avalanche, Suburban, Tahoe 2003 - 2007 Chevrolet Silverado (Classic Only) 2003 - 2006 GMC Yukon, Yukon XL, Yukon Denali, Yukon Denali XL 2003 - 2007 GMC Sierra (Classic Only) Supercede: This bulletin is being revised to add the 2007 model year for pickups and change a part number. Please discard Corporate Bulletin Number 05-09-41-001A (Section 09 - Restraints). Condition Some customers may comment that the Service Supplemental Inflatable Restraint Light is on. Diagnosis with a scan tool may indicate a DTC B0013, B0014, B0017, B0018, B0024, B0026, B0043, B0044. Cause The most likely cause of any one of the following DTCs: B0013, B0014, B0017, B0018, B0024, B0026, B0043, B0044 is improper connection/high resistance in the IP harness to inflatable restraint module connector C221 and/or C222. Diagnostic Information DTC B0013, B0014, B0017, B0018, B0024, B0026, B0043, B0044 will set when one of the following conditions occur: ^ The SDM detects the air bag module deployment loop resistance is greater than 4.8 ohms for 500 milliseconds. ^ The SDM detects that the voltage at the air bag module high control is less than 2.4 volts and deployment loop resistance is 6 ohms or greater for 500 milliseconds. ^ For additional diagnostic information, refer to DTC B0013, B0014, B0017, B0018, B0024, B0026, B0043, B0044 in the appropriate SI Document. Correction Caution: When performing service on or near the SIR components or the SIR wiring, the SIR system must be disabled. Refer to SIR Disabling and Enabling Zones. Failure to observe the correct procedure could cause deployment of the SIR components, personal injury, or unnecessary SIR system repairs. Important: The IP harness to inflatable restraint module connectors C221 or C222 is NOT located at the base of the steering column. ^ C221 (4 Cavities) - I/P Harness to Body Harness, behind the left kick panel ^ C222 (4 Cavities) (w/o HP2) - I/P harness to body harness, behind the right kick panel Page 12198 Front Wheel Bearing Wheel Bearing: Service and Repair Front Wheel Bearing Front Wheel Hub, Bearing, and Seal Replacement (4WD) ^ Tools Required J 45859 Axle Remover Removal Procedure 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Remove the tire and wheel. 3. Remove the rotor. Refer to Brake Rotor Replacement - Front in Disc Brakes. 4. Remove the wheel speed sensor and brake hose mounting bracket bolt from the steering knuckle. 5. Remove the wheel drive shaft nut retaining cover. Page 9190 C150 4-Wheel Drive Harness To 4-Wheel Drive Jumper Harness (With RPO Code NP8) Page 14179 6. Remove the rubber plug in order to disengage the outside handle rod retainer. 7. Disconnect the cylinder lock rod. 8. Remove the bolts which retain the door lock actuator to the door. 9. Remove the door lock actuator and control rods as an assembly. 10. Disconnect the electrical connector from the door lock actuator, if equipped. 11. Remove the control rods as necessary. INSTALLATION PROCEDURE 1. Install the control rods to the assembly. 2. Connect the electrical connectors to the door lock actuator, if equipped 3. Install the door lock actuator to the door. 4. Connect the outside door handle control rod. 5. Connect the cylinder lock rod. NOTE: Refer to Fastener Notice in Service Precautions. 6. Install the bolts which retain the door lock actuator to the door. Tighten Tighten the screws to 9 N.m (80 lb in). Page 7005 8. Separate the wheel drive shaft from the wheel hub and bearing using J 45859 (2) or equivalent. 9. Remove the wheel hub and bearing (1) from the vehicle. Installation Procedure Page 5149 Fuel Pressure Release: Service and Repair Fuel Pressure Relief Procedure FUEL PRESSURE RELIEF PROCEDURE TOOLS REQUIRED J 34730-1A Fuel Pressure Gage CAUTION: Relieve the fuel system pressure before servicing fuel system components in order to reduce the risk of fire and personal injury. After relieving the system pressure, a small amount of fuel may be released when servicing the fuel lines or connections. In order to reduce the chance of personal injury, cover the regulator and the fuel line fittings with a shop towel before disconnecting. This will catch any fuel that may leak out. Place the towel in an approved container when the disconnection is complete. 1. Disconnect the negative battery cable. 2. Install the J 34730-1A. 3. Loosen the fuel fill cap in order to relieve fuel tank vapor pressure. 4. Open the valve on J 34730-1A in order to bleed the system pressure. The fuel connections are now safe for servicing. 5. Drain any fuel remaining in the gage into an approved container. 6. Once the system pressure is completely relieved, remove the J 34730-1A. Page 3776 Electrical Symbols Part 3 Page 7997 1. Notice: Refer to Fastener Notice in Service Precautions. Install the left rear speed sensor. ^ Tighten the speed sensor to 15 Nm (11 ft. lbs.). 2. Connect the left rear speed sensor electrical connector (4) 3. Lower the vehicle. Transfer Case Speed Sensor Replacement - Right Rear Transfer Case Speed Sensor Replacement - Right Rear Removal Procedure 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. Disconnect the right rear speed sensor electrical connector (3). Page 11484 Impact Sensor: Service and Repair Side INFLATABLE RESTRAINT SIDE IMPACT SENSOR REPLACEMENT REMOVAL PROCEDURE CAUTION: - Refer to SIR Inflator Module Handling and Storage Caution in Service Precautions. - When carrying an undeployed inflatable restraint seat belt pretensioner: - Do not carry the seat belt pretensioner by the wires or connector. - Carry the seat belt pretensioner by the piston tube, keeping hands and fingers away from the cable. - Make sure the open end of the seat belt pretensioner piston tube points away from you and other people. - Do not cover the seat belt pretensioner piston tube opening with your hand. Failure to observe these guidelines may result in personal injury. 1. Disable the SIR system. Refer to SIR Disabling and Enabling Zone 6. 2. Remove the front door trim panel. 3. Loosen the 2 inflatable restraint side impact sensor fasteners (2). 4. Remove the inflatable restraint side impact sensor (1) from the door (4). 5. Remove the connector position assurance (CPA) (3), and disconnect the inflatable restraint side impact sensor yellow 2-way harness connector (5). INSTALLATION PROCEDURE 1. Connect the inflatable restraint side impact sensor yellow 2-way harness connector (5) to the inflatable restraint side impact sensor (1). 2. Install the CPA (3) to the inflatable restraint side impact sensor yellow 2-way connector (5). 3. Install the inflatable restraint side impact sensor (1) to the door (4). Page 6998 Wheel Bearing: Service and Repair With Full Floating 10.5" or 11.5" Ring Gear Rear Axle Hub, Bearing, Cup, and/or Seal Replacement ^ Tools Required J 8092 Universal Driver Handle - 3/4 inch - 10 - J 2222-C Wheel Bearing Nut Wrench - J 24426 Wheel Bearing Race Installer - Outer - J 24427 Wheel Bearing Race Installer - Inner - J 44419 Hub Outer Bearing Race Installer - J 44420 Differential Bearing and Hub Seal Installer Removal Procedure 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Remove the tire and wheel assembly. 3. Remove the brake caliper. 4. Remove the axle shaft. 5. Remove the axle nut retaining ring. 6. Remove the key. 7. Remove the adjusting nut using the J 2222-C. Page 4170 Crankshaft Position (CKP) Sensor Brakes - Low Speed ABS Activation/No DTC's Set Wheel Speed Sensor: Customer Interest Brakes - Low Speed ABS Activation/No DTC's Set TECHNICAL Bulletin No.: 03-05-25-007D Date: May 01, 2009 Subject: Antilock Brake (ABS) Activation At Low Speeds (Clean Wheel Speed Sensor Mounting Surface) Models: 2002-2006 Cadillac Escalade, Escalade EXT 2003-2006 Cadillac Escalade ESV 1999-2006 Chevrolet Silverado 2001-2006 Chevrolet Suburban, Tahoe 2002-2006 Chevrolet Avalanche 2003-2006 Chevrolet Express 2007 Chevrolet Silverado Classic 1999-2006 GMC Sierra 2001-2006 GMC Yukon, Yukon Denali, Yukon XL, Yukon Denali XL 2003-2006 GMC Savana 2007 GMC Sierra Classic 2003-2006 HUMMER H2 .............................................................................................................................................................. .................................................................................. Supercede: This bulletin is being revised to add the 2007 Silverado/Sierra Classic models. Please discard Corporate Bulletin Number 03-05-25-007C (Section 05 - Brakes). .............................................................................................................................................................. .................................................................................. Condition Some customers may comment on ABS activation at low speeds, usually below 8 km/h (5 mph). Upon investigation, the technician will find no DTCs set. Cause The cause of this condition may be an increased air gap between the wheel speed sensor and the hub reluctor ring due to rust and debris built up on the sensor mounting surface. Correction Measure AC voltage and clean the wheel speed sensor mounting surfaces. 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in the General Information sub-section of the Service Manual. 2. Disconnect both the front wheel speed sensor connectors at the frame and harness. 3. Place a Digital Volt Meter (DVM) across the terminals of each wheel speed sensor connector. 4. Rotate the wheel clockwise approximately one revolution per second. The minimum reading should be at least 350 ACmV's. If the reading is less than 350 ACmV's, remove the wheel speed sensor. Refer to the applicable Wheel Speed Sensor Replacement procedure in the ABS sub-section of the Service Manual. 5. Plug the wheel speed sensor bore in order to prevent debris from falling into the hub during service. 6. Clean the wheel speed sensor mounting surface using a wire brush, sand paper, emery cloth, scotch brite, or other suitable material. Be sure to thoroughly clean the wheel speed sensor surface. There should be no rust or corrosion. 7. Check the sensor head to determine if it has been warped/distorted due to the corrosion build up or other causes. Check the mounting surface on the sensor head for flatness by placing it on the edge of a metal machinists scale or other suitable straight edge to measure the flatness. Check the sensor for flatness in multiple (minimum 3) positions/directions. If the sensor head is distorted, replace the sensor. 8. Apply (spray) two thin coats of the specified rust penetrating lubricant (corrosion inhibitor) to the complete sensor mounting surface on the bearing hub. Allow to dry for 3-5 minutes between coats. Use ONLY Rust Penetrating Lubricant, P/N 89022217 (in Canada, P/N 89022218). 9. When the corrosion inhibitor is dry to the touch (about 10 minutes), apply a thin layer of bearing grease to the hub surface and sensor O-ring prior to sensor installation. Use ONLY Wheel Bearing Lubricant, P/N 01051344 (in Canada, P/N 993037). 10. Install either the original sensor or a new one in the hub. Ensure that the sensor is seated flush against the hub. Refer to the applicable Wheel Speed Sensor Replacement procedure in the ABS sub-section of the Service Manual. 11. Place the DVM across the sensor terminals and recheck the voltage while rotating the wheel. The voltage should now read at least 350 ACmV's. Page 15000 Instruments - Service Tire Monitor Message is Displayed Fuse: All Technical Service Bulletins Instruments - Service Tire Monitor Message is Displayed Bulletin No.: 05-08-49-018A Date: May 11, 2006 ADVANCE SERVICE INFORMATION RESOLUTION Subject: EI 05065 - Service Tire Monitor Message Displayed (Pull/Reinstall IPC Fuse or Verify Correct Passenger Door Module (PDM) and Tires) Models: 2004 Chevrolet Silverado 2004 GMC Sierra Supercede: This bulletin is being revised to provide correction action. Please discard Corporate Bulletin Number 05-08-49-018 (Section 08 - Body and Accessories). Condition Some customers may comment that the "SERVICE TIRE MONITOR" message is being displayed on the DIC. Correction DO NOT REPLACE THE INSTRUMENT PANEL CLUSTER. If the DIC is displaying the SERVICE TIRE MONITOR message: 1. Verify if the vehicle has an electronic aftermarket module spliced into the ALDL Class 2 data line (purple wire). 2. If the vehicle HAS an aftermarket module spliced into the Class 2 line, pull the IPC fuse (located underhood) for 25 seconds. Important: Due to the electronic aftermarket module, the SERVICE TIRE MONITOR message may reoccur. 3. Reinstall the IPC fuse. This will clear the SERVICE TIRE MONITOR message from the display. 4. If the vehicle DOES NOT have an aftermarket module spliced into the Class 2 line, verify the vehicle is equipped with the correct PDM (Passenger Door Module) and tires. Warrant Information This repair is not covered under the vehicle warranty due to the installation of an aftermarket module. Disclaimer Page 524 Front Passenger Door Module (FPDM) - C3 (With RPO Code YE9) Part 1 Diagrams Headlamp Switch: Diagrams Headlamp Switch Part 1 Page 11077 - Proof of ownership at time of repair. - Original paid receipt confirming the amount of unreimbursed repair expense(s) (including Service Contract deductibles), a description of the repair, and the person or entity performing the repair. If the work was done by someone other than a GM dealership, the amount of reimbursement will be limited to the amount that the repair would have cost GM to have it completed by a GM dealership. Courtesy Transportation The General Motors Courtesy Transportation program is intended to minimize customer inconvenience when a vehicle requires a repair that is covered by the New Vehicle Limited Warranties. The availability of courtesy transportation to customers whose vehicles are within the warranty coverage period and involved in a product program is very important in maintaining customer satisfaction. Dealers are to ensure that these customers understand that shuttle service or some other form of courtesy transportation is available and will be provided at no charge. Dealers should refer to the General Motors Service Policies and Procedures Manual for Courtesy Transportation guidelines. Warranty Transaction Information Submit a transaction using the table below. * The amount identified in "Net Item" should represent the dollar amount reimbursed to the customer. Disclaimer Page 15200 Electrical Symbols Part 8 Diagram Information and Instructions Body Control Module: Diagram Information and Instructions Truck Zoning TRUCK ZONING Truck Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that corresponds to where they are located in the vehicle. The table explains the numbering system. Page 4193 Steps 10 - 13 Page 12101 Test Description DTC U1001 and U1254 Circuit/System Description Modules connected to the Class 2 serial data circuit monitor for serial data communications during normal vehicle operation. Operating information and commands are exchanged among the modules. When a module receives a message for a critical operating parameter, the module records the identification number of the module which sent the message for State of Health monitoring. A critical operating parameter is one which, when not received, requires that the module use a default value for that parameter. Once an identification number is learned by a module, it will monitor for that module's Node Alive message. Each module on the class 2 serial data circuit which is powered and performing functions that require detection of a communications malfunction is required to send a Node Alive message every 2 seconds. When no message is detected from a learned identification number for 5 seconds, a DTC U1XXX where XXX is equal to the 3-digit identification number is set. Service and Repair Keyless Entry Transmitter Battery: Service and Repair TRANSMITTER BATTERY REPLACEMENT REMOVAL PROCEDURE Under normal use, the battery in the transmitter will last about 2 years. For battery replacement, use a Panasonic(R) 3 volt, type CR2032, or equivalent. 1. Open the transmitter case and perform the following steps: 1.1. Insert a dime between the 2 halves of the transmitter near the key ring hole. 1.2. Twist the dime. 2. Remove the battery. INSTALLATION PROCEDURE 1. Install the battery with the (+) positive side down. 2. Close the transmitter case and perform the following steps: 2.1. Align the top and bottom covers. Page 5070 3. Disconnect the vent valve pipe quick connect from the canister. 4. Either cut the existing valve vent pipe and leave the remaining section of pipe in the vehicle or remove along with the valve. 5. Push in the retainer and remove the existing canister vent valve from the fuel tank clip or mounting bracket. 6. Cut back the existing canister pipe approximately 51 mm (2 in) and retain the pipe for use with new valve. 7. Connect the canister pipe quick connect to the canister. 2500 Crew Cab Short Box Shown Below, Other Configurations Similar 1500 Extended Cab Short Box Shown Below, Other Configurations Similar 8. Install the new canister vent valve solenoid to the fuel tank clip or mounting bracket as shown above. The valve port closest to the electrical connector must point towards the canister. 9. Cut bulk 5/8" heater hose to a length of approximately 76 mm (3 in). Install the hose between the solenoid and the canister pipe and secure using clamps. 10. Attach bulk 5/8" heater hose to the vent port and secure using a clamp. Run a length as needed along the frame rail routing to the passenger side area above the transmission. 11. Cut the hose to determined length and install the supplied filter box. Secure using a clamp. 12. Remove the transmission heat shield, if necessary. 13. Remove the transmission support and lower the transmission assembly as necessary to allow for access to the new filter box location. 14. Secure the filter box to the transmission vent hose just forward of the hose tee-section using a tie strap. DO NOT pinch or restrict the transmission vent hose. The filter box opening should be pointing downward. 15. Raise the transmission and reinstall the transmission support. 16. Reinstall the transmission heat shield. 17. Connect the EVAP canister vent valve electrical connector. 18. Tie strap the hose as needed along the frame rail in order to keep the hose away from pinch-points and heat sources. 19. Lower the vehicle. Parts Information Page 8865 Electrical Symbols Part 3 Page 12343 circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links CIRCUIT PROTECTION - FUSIBLE LINKS Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Flat Wire Repairs FLAT WIRE REPAIRS NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Heated Oxygen Sensor (HO2S) Wiring Repairs HEATED OXYGEN SENSOR (HO2S) WIRING REPAIRS TOOLS REQUIRED J 38125-D Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: - Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-D. Repairing Damaged Wire Insulation REPAIRING DAMAGED WIRE INSULATION Page 15608 Dome Lamp: Service and Repair DOME LAMP REPLACEMENT REMOVAL PROCEDURE 1. Remove the lamp lens assembly using a small screw driver. 2. Remove the dome lamp assembly from the headliner. 3. Disconnect the electrical connector. 4. Remove the bulb. Page 13416 Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. 1. Disconnect the connector from the component. 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. Page 8983 Application Tabel Part 1 Page 1769 Inflatable Restraint Front End Sensor (With RPO Code HVY) Page 12881 Labor Time Information Page 11780 Antenna, Navigation: Description and Operation CELLULAR AND NAVIGATION ANTENNAS This vehicle will be equipped with either separate cellular and navigation antennas, or a combination cellular and navigation antenna, which brings the functions of both into a single part. The cellular antenna is the component that allows the Onstar(R) system to send and receive data over airwaves by means of cellular technology. This antenna is connected at the base to a coax cable that plugs directly into the vehicle communication interface module (VCIM). The navigation antenna is used to collect the constant signals of the orbiting satellites. Within the antenna, is housed a low noise amplifier that allows for a more broad and precise reception of this data. The current global positioning system (GPS) location is collected by the module every time a keypress is made. The Onstar(R) Call Center also has the capability of pinging the vehicle during an Onstar(R) call, which commands the module to retrieve the latest GPS location and transmit it to the Onstar(R) Call Center. A history location of the last recorded position of the vehicle is stored in the module and marked as aged. In the event the VCP loses, or is removed from power, this history location is used by the Onstar(R) Call Center as a default. Actual GPS location may take up to 10 minutes to register in the event of a loss of power. This antenna requires a clear and unobstructed path to the satellites in the sky. Window tinting on vehicles may interfere with the GPS sensor functions, depending upon the amount of darkening and/or metallic particles that are embedded in the film of the tinting material. Seat Belt Buckle and Latch - Rear (Extended Cab) Seat Belt Latch: Service and Repair Seat Belt Buckle and Latch - Rear (Extended Cab) SEAT BELT BUCKLE AND LATCH REPLACEMENT - REAR (EXTENDED CAB) CAUTION: To avoid personal injury to the occupants of the vehicle, observe the following precautions: - More than one supplier's seat belts are used, therefore, install ONLY the seat belt components specified in the GM parts catalog. - To verify that the correct seat belt components were installed, insert the seat belt latch in the seat belt buckle. The latch must be fully seated and be retained in the buckle until purposely released. REMOVAL PROCEDURE 1. Pull the seat belt buckles through the rear seat cushion. Fold the rear seat up. 2. Remove the rear seat belt buckle nuts. 3. Remove the buckle assembly. INSTALLATION PROCEDURE 1. Position the buckle assembly to the floor panel stud. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the rear seat belt buckle nuts. Tighten Tighten the nuts to 53 N.m (39 lb ft). Page 1643 HO2S Page 2721 Fuse Block: Application and ID Junction Block - I/P Location View Location View Page 10261 Control Module References Part 4 Page 7662 Seals and Gaskets: Service and Repair Transfer Case - NVG 263-NP1 Transfer Case Output Shaft Seal Replacement - Front Transfer Case Output Shaft Seal Replacement - Front ^ Tools Required J 8092 Driver Handle - J 43484 Output Shaft Seal Installer Removal Procedure 1. Remove the transfer case shield, if equipped. 2. Remove the front propeller shaft. 3. Insert a flat-tipped screwdriver into the inner race. 4. Pry the inner race back. 5. Insert a small pry bar into the inner race. 6. Remove the inner part of the seal. Page 7765 Speed Sensor: Service and Repair Transfer Case - NVG 263-NP1 Transfer Case Speed Sensor Replacement Removal Procedure 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. Disconnect the speed sensor electrical connector. 3. Remove the speed sensor. Installation Procedure 1. Notice: Refer to Fastener Notice in Service Precautions. Install the speed sensor. ^ Tighten the sensor to 15 Nm (11 ft. lbs.). Page 7661 1. Important: When installing the input shaft seal, make sure that the part numbers on the seal are facing outward (away from the body of the transfer case). Align the transfer case input shaft seal evenly on the input shaft. 2. Important: The input shaft seal should be even with the surface of the transfer case after installation. Using the J 42738, install the transfer case input shaft seal. 3. Install the transfer case. 4. Check the fluid level. Add fluid of necessary. C100 - C198 Multiple Junction Connector: Diagrams C100 - C198 C100 I/P Harness To Engine Harness Part 1 Page 14957 3. Install the endgate hinge to the vehicle. 4. Install the endgate hinge bolts. Tighten the bolts to 25 N.m (18 lb ft). 5. Install the endgate. Page 2858 Put unused material on the shelf for future use. Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Page 4113 10. Connect the PNP switch electrical connector (2). 11. If equipped with 4WD, install the front propeller shaft. 12. Lower the vehicle. 13. Check the PNP switch for proper operation. The engine must start in the park (P) or neutral (N) positions only. If proper operation of the switch can not be obtained, replace the switch. Park Lock Pawl and Actuator Replacement Park Lock Pawl and Actuator Replacement Removal Procedure 1. Remove the transmission filter. 2. Remove the park/neutral position (PNP) switch. 3. Remove the manual shaft nut and pin. 4. Remove the detent lever and actuator. 5. Remove the parking pawl bracket bolts. 6. Remove the parking pawl return spring. Page 7426 Speed Sensor: Service and Repair Transfer Case - NVG 246-NP8 Transfer Case Speed Sensor Replacement - Front Transfer Case Speed Sensor Replacement - Front Removal Procedure 1. Remove the transfer case shield, if equipped. 2. Disconnect the front speed sensor electrical connector (5). 3. Remove the front speed sensor. Installation Procedure 1. Notice: Refer to Fastener Notice in Service Precautions. Install the front speed sensor. ^ Tighten the speed sensor to 15 Nm (11 ft. lbs.). Page 12872 2. Skip to the next step if the vehicle to be upgraded is not shown above. 3. Skip to the next step if the vehicle to be upgraded is not a 2005 Cadillac STS. The 2005 Cadillac STS kit may include a new inside rearview (ISRV) mirror assembly and a new ISRV mirror wiring cover. If the kit you receive includes these parts, please remove the existing ISRV mirror and wire cover from the vehicle and install the ones provided in the kit per the instructions in SI. 4. Skip this step if the vehicle to be upgraded is not listed below. ^ 2003-2004 Saturn L-Series ^ 2003 Saturn ION ^ 2002-2003 Saturn VUE 1. Locate and remove the Right Audio output signal terminal 7 from Connector C2 at the Vehicle Communication Interface Module (VCIM). 2. Remove the terminal end and strip the wire. 3. Locate the Left Audio output signal wire from terminal 1 in Connector C2. 4. Splice the Right Audio output signal wire from terminal 7 with the Left Audio output signal wire from terminal 1. 5. See Wiring Repairs in SI for approved splicing methods. Specifications A/T - 4T65E Fluid Leaking From A/T Vent Channel Plate: Customer Interest A/T - 4T65E Fluid Leaking From A/T Vent TECHNICAL Bulletin No.: 01-07-30-032E Date: September 29, 2008 Subject: Transmission Oil Leaking From Transmission Vent (Replace Transmission Case Cover (Channel Plate) Gasket) Models: 1997-2009 GM Passenger Cars and Light Duty Trucks (including Saturn) with Hydra-Matic 4T65-E Automatic Transmission (RPOs MN3, MN7, M15, M76) Supercede: This bulletin is being revised to add the 2008 and 2009 model years. Please discard Corporate Bulletin Number 01-07-30-032D (Section 07 - Transmission/Transaxle). Condition Some customers may comment on a transmission oil leak. Cause This condition may be caused by an improperly torqued channel plate gasket. Correction To correct this condition, replace the case cover (channel plate) gaskets (429 and 430). Refer to Unit Repair publication in SI of the appropriate vehicle being serviced. Visual inspection of the upper gasket (1) will reveal damage at the referenced area. Parts Information Warranty Information Page 11237 11. If the vehicle is a 2003 model year Chevrolet Express or GMC Savana van, the vehicle may require a new accumulator. Refer to Corporate Bulletin Number 03-01-38-016 for more information. This bulletin refers to an updated design accumulator that may improve the performance of the A/C system. 12. Install a new serpentine belt tensioner and serpentine belt if they have been damaged due to A/C system slugging or an A/C compressor seizure. The serpentine belt tensioner may have broken stop tabs and/or a missing front cap. 13. Verify proper operation of the A/C system. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 9661 1. Install the ground strap to the stud. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the ground strap nut to the stud at the front of dash. Tighten Tighten the nut to 9 N.m (80 lb in). 3. Position the ground strap and engine wiring harness ground. 4. Install the engine wiring harness ground bolt. Tighten Tighten the bolt to 16 N.m (12 lb ft). 5. If necessary, install the engine sight shield. Page 419 ^ Reinstall the fuse and fuse panel cover. ^ Press the "Enter" button to perform the "Refresh" function. ^ "Test in Progress" will be displayed and the right front passenger door lock will cycle once. ^ The screen will display "Procedure Completed". ^ Press the "Exit" button as necessary to return to the main menu screen. 3. Using the switches in the right front passenger door, verify that the power window and power door lock located in that door function properly. Important: The calibrations required for performing SPS reprogram in the next step are based on the type of exterior rearview mirror the vehicle has. To determine the correct calibration, check the Service Parts Identification Label on the vehicle for the RPO code for exterior mirrors. 4. Follow normal Service Programming System (SPS) to reprogram the passenger door module with the current calibration available in TIS 2000. 5. After reprogramming is complete, using the switches in the right front passenger door, verify that the power window and power door lock located in that door function properly. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Brakes - ABS Lamp ON/DTC's C0265/C0201/U1041 Set Electronic Brake Control Module: All Technical Service Bulletins Brakes - ABS Lamp ON/DTC's C0265/C0201/U1041 Set TECHNICAL Bulletin No.: 04-05-25-002E Date: March 11, 2009 Subject: ABS Light On, DTCs C0265, C0201, U1041 Set and/or Loss of Communication with Brake Module (Reground EBCM Ground) Models Supercede: This bulletin is being revised to add step 2 to the procedure and update the Parts and Warranty Information. Please discard Corporate Bulletin Number 04-05-25-002D (Section 05 - Brakes). Condition Some customers may comment that the ABS light is on. Upon further inspection, DTCs C0265 and C0201 may be set in the brake module. It is also possible for DTC U1041 to set in other modules. There may also be a loss of communication with the brake module. Cause A poor connection at the EBCM ground is causing unnecessary replacement of brake modules. Important: The EBCM ground is different for each application. Refer to the list below for the proper ground reference: ^ Midsize Utilities = Ground 304 ^ SSR = Ground 400 ^ Fullsize Trucks and Utilities = Ground 110 Correction Important: Do not replace the brake module to correct this condition. Perform the following repair before further diagnosis of the EBCM. Perform the following steps to improve the connection of the EBCM Ground: 1. Remove the EBCM Ground. The EBCM Ground is located on the frame beneath the driver's side door. If multiple grounds are found in this location, the EBCM ground can be identified as the heavy (12-gauge) wire. 2. If the original fastener has a welded on nut, remove the nut from the frame, and if required, enlarge the bolt hole to accommodate the new bolt and nut. 3. Clean the area, front and back, using a tool such as a *3M(TM) Scotch-Brite Roloc disc or equivalent. Page 12190 Conditions for Running the DTC Ignition is in RUN or ACC position System voltage is between 9.5 - 15.5 volts. The above conditions are met for more than 1 second. Conditions for Setting the DTC The VCIM does not detect the presence of a cellular antenna for more than 1 second. Action Taken When the DTC Sets The vehicle is unable to connect to the OnStar(R) Call Center. The OnStar(R) status LED turns red. Conditions for Clearing the DTC The VCIM detects the presence of a cellular antenna. A history DTC clears after 50 malfunction-free ignition cycles. Circuit/System Testing Perform a visual inspection as shown above in order to verify that the cellular antenna and the cellular antenna coupling assembly are not damaged. If any components are damaged replace the assembly. DTC B2476 or B2482 DTC Descriptors Page 3873 results from the alteration or modification of a vehicle using non-GM approved parts or accessories. Dealers should be especially cautious of accessory companies that claim the installation of their product will not void the factory warranty. Many times these companies have even given direction on how to quickly disassemble the accessory in an attempt to preclude the manufacturer from finding out that is has been installed. Any suspect repairs should be reviewed by the Fixed Operations Manager (FOM), and in Canada by the Warranty Manager (WM) for appropriate repair direction. If it is decided that a goodwill repair is to be made on the vehicle, even with the installation of such non-GM approved components, the customer is to be made aware of General Motors position on this issue and is to sign the appropriate goodwill documentation required by General Motors. It is imperative for dealers to understand that by installing such devices, they are jeopardizing not only the warranty coverage, but also the performance and reliability of the customer's vehicle. Disclaimer Page 2116 Spark Plug: Specifications Spark Plug Torque ............................................................................................................................... ........................................................ 15 Nm (11 lb ft) Spark Plug Gap ................................................ ........................................................................................................................................ 1.01 mm (0.040 in) Page 8977 Location View Page 8322 Refer to Fastener Notice in Service Precautions. Install the junction block retaining bolt to the axle. ^ Tighten the bolt to 22 Nm (16 ft. lbs.). 3. Uncap or unplug the rear brake pipes and connect the pipes to the junction block on the axle. ^ Tighten the fitting to 25 Nm (18 ft. lbs.). 4. Important: The hose must not be twisted. Make sure the hose is not in contact with any suspension component. Install the brake hose into the bracket. 5. Install the jounce hose retaining clip. 6. Remove the rubber cap or plug from the exposed brake pipe fitting end. 7. Connect the brake pipe fitting nut to the brake hose: ^ Use a backup wrench on the hose fitting. ^ Do not bend the bracket or the pipe. ^ Tighten the fitting to 25 Nm (18 ft. lbs.). 8. Ensure that the hose does not make contact with any part of the suspension. If the hose makes contact remove the hose and correct the condition. 9. Bleed the hydraulic brake system. 10. Lower the vehicle. Service and Repair Oil Level Sensor: Service and Repair Engine Oil Level Sensor and/or Switch Replacement Removal Procedure 1. Drain the engine oil. 2. Disconnect the oil level sensor electrical connector (3). 3. Remove the oil level sensor from the oil pan. Installation Procedure 1. Notice: Refer to Fastener Notice in Service Precautions. Interior - Erratic Memory Seat Operation Power Seat Control Module: Customer Interest Interior - Erratic Memory Seat Operation Bulletin No.: 04-08-50-016C Date: August 12, 2005 TECHNICAL Subject: Memory Seat May Not Return to Requested Position (Reprogram Driver Seat Module) Models: 2003-2005 Cadillac Escalade, Escalade ESV, Escalade EXT 2003-2005 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2003-2005 GMC Sierra, Yukon, Yukon XL, Yukon Denali All with Seat FRT, Individual (Non BKT) (RPO AN3) 2003-2005 HUMMER H2 with Seat, Front Bucket Deluxe (RPO AR9) Supercede: This bulletin is being revised to update the correction information. Please discard Corporate Bulletin Number 04-08-50-016B (Section 08 - Body and Accessories). Condition Some customers may comment that with repeated cycling of the memory seat between the "exit" and one of the "presets", the position of the seat may "creep" forward or rearward out of expected adjustment. Cause There is a coding deficiency in the software for the memory seat module. Correction Technicians are to reprogram the driver seat module with an updated software calibration. The previous bulletin stated to use a service calibration that was released with TIS satellite data update version 4.5. Feedback has proved that calibration to be ineffective in eliminating the memory seat creep condition. An updated service calibration was released with TIS satellite data update version 6.5 available June 13, 2005. This new calibration has additional memory seat creep protection. As always, make sure your Tech 2(R) is updated with the latest software version. Important: After programming is complete, move the seat all the way rearward and down, then bump the seat slightly forward and up. This position will be just off the end of travel hard stops. Reset both memory seat exit positions at this position. Having the seat set at just off the hard stops will aid in reducing the creep condition. Warranty Information Page 5762 Page 11698 Inflatable Restraint Front End Sensor - Right Page 8188 4. Slide the rotor all the way to the hub and hold it in place until you have placed one of the conical washers (with the tapered hole side facing out) and run the first lug nut up tight by hand so the rotor doesn't move when you release it. 5. Place the conical washers on the rest of the studs (with the tapered hole side facing out), start and snug the lug nuts by hand. 6. Using the one half inch drive impact wrench and a torque stick (J 39544) or equivalent, start with the lug nut opposite of the one you first tightened by hand and tighten the lug nuts using a star pattern until they touch the hub but do not completely torque. Then again, starting with the first lug nut you tightened by hand, tighten all the lug nuts in a star pattern to the specific vehicle torque specification. 7. DO NOT reinstall the caliper or the wheel at this time. On-Car Type Lathe 1. Leave the On-Car adapter on the wheel. 2. Proceed to Step 9. 9. Fasten the dial indicator to the steering knuckle so that the indicator needle contacts the rotor outboard friction surface approximately 6.35 mm (0.25 in) from the rotor's outer edge. The stylus should be perpendicular to the friction surface of the rotor. Important Make sure the dial indicator needle tip is screwed tight, a loose tip could cause false readings. 10. Measure for LRO. Follow the procedure below to determine if the LRO is within specification (0.050 mm (0.002 in) or LESS). 1. Rotate the rotor and locate the point on the rotor where the lowest dial indicator reading is indicated and set the dial indicator to zero. 2. Rotate the rotor from the low point and locate the point with the highest dial indicator reading (rotor "high spot"). Note the amount and mark the location of the "high spot" on the rotor and mark the closest wheel stud relative to this location. If the high point falls between two studs, mark both studs. In instances where the vehicle has "capped lug nuts" you should mark the hub. 11. If the Lateral Run Out (LRO) measurement is 0.050 mm (0.002 in) or LESS, no correction is necessary. Go to Step 15 if this is the first rotor completed. Go to Step 16 if this is the second rotor completed. If the LRO is GREATER than 0.050 mm (0.002 in), go to Step 12. 12. If the LRO measurement is greater than 0.050 mm (0.002 in), use the following procedure to correct for LRO: Important If the LRO measurement is over 0.279 mm (0.011 in), determine the source or cause of the LRO and correct it (i.e. verify drive axle nut torque specification, refinished rotor is source of LRO due to a lathe qualification issue - see "Brake Lathe Calibration Procedure"). Hubless Rotor 1. Remove the rotor and using the Brake Align(R) application chart (found in TSB 01-05-23-001B), choose the correct plate to bring the rotor LRO to 0.050 mm (0.002 in) or less. The plates come in 0.0762 mm (0.003 in), 0.1524 mm (0.006 in) and 0.2286 (0.009 in) compensation. For more information on proper plate selection, see the instruction video/DVD included in the "Brake Align(R)" kit or TSB 01-05-23-001B. 2. Align the V-notch of the selected Brake Align(R) correction plate to the marked wheel stud ("high spot") or between the two points marked (if the "high spot" is between two wheel studs). Important IF Brake Align(R) Correction Plates are not available for the vehicle being serviced, refer to SI Document - Brake Rotor Assembled Lateral Runout Correction for correcting LRO. Important Per Brake Align(R) manufacturer, NEVER attempt to stack two or more Correction Plates together on one hub. NEVER attempt to reuse a previously installed Correction Plate. 3. Reinstall the rotor using the same method and precautions as the first time - found in Step 8. Make sure to index the rotor correctly to the marks made in step 10, otherwise LRO will be comprised. Hubbed / Captured / Trapped Rotor 1. Measure the rotor thickness. 2. Refinish or replace the rotor (see Service Information for further details). Page 9430 Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. 1. Disconnect the connector from the component. 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. Engine - Oil Leaks In Extreme Cold Temperatures Engine Oil Filler / Breather Cap: All Technical Service Bulletins Engine - Oil Leaks In Extreme Cold Temperatures Bulletin No.: 05-06-01-014 Date: May 09, 2005 TECHNICAL Subject: Oil Leak Under Extreme Cold Temperatures (-34°C (-30°F) or Colder) (Install Vented Oil Fill Cap) Models: 2004-2005 Buick Rainier 2003-2005 Cadillac Escalade Models 2004-2005 Cadillac CTS-V 2003-2005 Chevrolet Avalanche, Express, Kodiak, Silverado, SSR, Suburban, Tahoe, TrailBlazer, TrailBlazer EXT 2003-2005 GMC Denali Models, Envoy Models, Savana Van Models, Sierra Models, Topkick, Yukon Models 2004-2005 Pontiac GTO 2005 Pontiac Grand Prix 2003-2005 HUMMER H2 2003 Isuzu NPR/NQR Commercial Models 2003 Work Horse Custom Chassis with 4.8L, 5.3L, 5,7L or 6.0L Gas Engine (VINs V, M, T, P, B, Z, G, S, U, N - RPOs LR4, LH6, LM7, LM4, L33, L59, LS1, LS6, LS2, LQ4, LQ9) Condition Some customers may comment on an engine oil leak under extreme cold temperatures (-34°C (-30°F) or colder). The customer may also comment that there may be some oil seepage out of the engine oil level indicator (dipstick) and/or out of the front or rear crankshaft seals during engine operation only. Cause Under extreme cold temperatures (-34°C (-30°F) or colder) and extended driving conditions, the PCV system may experience a freezing condition and shut off all crankcase gases to pass through the PCV system. This may cause crankcase pressure to rise steadily and, in some cases, this high pressure unseats (pushes out) the oil level indicator from the indicator tube and causes an oil leak during engine operation. Important: If a visual inspection indicates that oil is still leaking from the front or rear crankshaft seals after this bulletin has been performed, then further diagnosis must be performed using the Oil Leak Diagnosis and/or Crankcase Ventilation System Inspection/Diagnosis in SI. Refer to the following SI document number(s) in this bulletin and print a copy for further assistance in diagnosing this condition. ^ Oil Leak Diagnosis (Truck) (SI Document ID #204344) ^ Oil Leak Diagnosis (Car) (SI Document ID #1406822) ^ Crankcase Ventilation System Inspection/Diagnosis (Truck) (SI Document ID #1246823) ^ Crankcase Ventilation System Inspection/Diagnosis (Car) (SI Document ID #954724) Correction Follow the service procedure below for diagnosis and correction of this condition. 1. Inspect for the oil fill dipstick being pushed out of the dipstick tube and that there is engine oil seeping out when the engine is under operation. This condition could be caused by the PCV valve freezing shut. 2. If an icing or freezing condition is found with a PCV valve inspection, then replace the oil fill cap with a vented oil fill cap. 3. Use a new vented oil fill cap, P/N 12589430. A vented oil fill cap will regulate the crankcase pressure between 15 kPa and 18 kPa. This will prevent the over pressurization of the crankcase under the freezing conditions of the PCV system. Once the PCV system thaws out, the crankcase gases will pass through the PCV system and normal crankcase pressure will be restored. 4. Inspect the engine oil level. Start and operate the engine under normal conditions and visually inspect that the engine oil leak has been repaired. If another engine oil leak has been detected, then refer to the above mentioned SI Document Numbers for further assistance in repairing the condition. Page 14361 TOOLS REQUIRED J 34142-B 12 V Unpowered Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. When testing for voltage: 1. Attach 1 lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach 1 lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Using Connector Test Adapters USING CONNECTOR TEST ADAPTERS NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-B Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires USING FUSED JUMPER WIRES TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Connector Position Assurance Locks CONNECTOR POSITION ASSURANCE LOCKS The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Terminal Position Assurance Locks TERMINAL POSITION ASSURANCE LOCKS The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Push to Seat Connectors PUSH TO SEAT CONNECTORS TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Page 4164 Camshaft Position (CMP) Sensor Page 1750 Knock Sensor (KS) Page 639 Electronic Brake Control Module: Locations ABS Component Views Electronic Brake Control Module (EBCM) Locations Accelerator Pedal Position (APP) Sensor Connector Park/Turn Signal Lamp Replacement (Old Style) Turn Signal Lamp: Service and Repair Park/Turn Signal Lamp Replacement (Old Style) PARK/TURN SIGNAL LAMP REPLACEMENT (OLD STYLE) REMOVAL PROCEDURE 1. Ensure the headlamp switch is in the OFF position. 2. Remove the headlamp. 3. Remove the park/turn signal lamp assembly by pushing on the inboard retainer clip. 4. Disconnect the electrical connector from the assembly. INSTALLATION PROCEDURE 1. Install the electrical connector to the park/turn signal lamp assembly. 2. Install the lamp assembly. 3. Install the headlamp. Emissions - MIL ON/DTC P0446 Stored In ECM Evaporative Canister Filter: All Technical Service Bulletins Emissions - MIL ON/DTC P0446 Stored In ECM TECHNICAL Bulletin No.: 02-06-04-037I Date: September 16, 2010 Subject: Check Engine Light On, Fuel Tank Hard to Fill, DTCs P0442, P0446, P0455 or P0449 Set (Replace Evaporative Emission (EVAP) Vent Valve Solenoid Assembly and Add/Relocate Filter Box Using Service Kit) Models: 1999-2007 Chevrolet Silverado (Classic) Models 1999-2007 GMC Sierra (Classic) Models 2007-2010 Chevrolet Silverado Models (Including Hybrid) 2007-2010 GMC Sierra Models (Including Hybrid) Supercede: This bulletin is being revised to add the 2010 model year and to include the Hybrid models. Please discard Corporate Bulletin Number 02-06-04-037H (Section 06 - Engine/Propulsion System). Condition Some customers may comment about the check engine light being illuminated. They may also comment that their vehicle is difficult to fill with fuel or when filling, the pump continuously shuts off before the tank is full. When checking the vehicle for DTCs, the ECM may report one or more of the following DTCs set as current or in history: P0442, P0446, P0449 or P0455. Cause The EVAP canister vent solenoid (CVS) valve draws fresh air into the system through a vent. Under certain operating conditions, dirt and dust intrusion into the EVAP CVS fresh air intake/venting system, may result in restricted air flow. Under certain operating conditions, water, if ingested into the EVAP CVS fresh air intake/venting system, may reach the CVS valve causing corrosion in the CVS valve, and may cause restrictions in the fresh air intake path, when the valve is in the closed position. Correction (1999-2007 Classic/Old Style Models) After following the published SI diagnostics and determining that the EVAP canister vent valve is the cause of the MIL light, replace the existing EVAP canister vent valve assembly with a new assembly. This new assembly is a sealed unit that is designed to be vented through a remote filter box. To ensure correct installation, follow the procedures below. Important DO NOT replace the EVAP canister assembly for this concern unless it fails the leak test. 1999-2003 Model Year (Use Service Kit P/N 19207762) 1. Raise the vehicle. Suitably support the vehicle. 2. Disconnect the EVAP canister vent valve electrical connector, if equipped. 3. Disengage the two vent valve pipe clips securing the pipe to the underbody. Remove the clips from the underbody and discard. 4. Disconnect the vent valve pipe at the EVAP canister. 5. Remove and retain the EVAP canister vent valve bracket mounting bolt. 6. Remove the complete EVAP canister vent valve assembly with bracket attached and discard. Page 16035 9. Use J 38125-12A to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. REPAIR PROCEDURE The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. 1. Cut the wire as close to the terminal as possible. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. Page 1193 Front Passenger Door Page 1473 Door Latch Assembly (Door Jamb Switch) - Front Passenger - C2 Page 13315 2. Install the module on the bracket. NOTE: Refer to Fastener Notice in Service Precautions. 3. Install the retaining nuts (2). Tighten Tighten the nuts to 1.6 N.m (14 lb in). 4. Connect the coaxial cable (3) to the module. 5. Connect the wire connectors (2) to the module. 6. Install the I/P trim panel. IMPORTANT: After replacing the vehicle communication interface module, you must reconfigure the Onstar(R) system. Failure to reconfigure the system will result in an additional customer visit for repair. In addition, pressing and holding the white dot button on the keypad will NOT reset this version of the Onstar(R) system. This action will cause a DTC to set. 7. Reconfigure the Onstar(R) system. Refer to OnStar Reconfiguration. See: Testing and Inspection/Programming and Relearning Locations SEO Harness Routing Page 3891 Engine Control Module: Service and Repair POWERTRAIN CONTROL MODULE (PCM) REPLACEMENT Service of the powertrain control module (PCM) should consist of either replacement of the PCM or programming of the electrically erasable programmable read only memory (EEPROM). If the diagnostic procedures call for the PCM to be replaced, the replacement PCM should be checked to ensure that the correct part is being used. If the correct part is being used, remove the faulty PCM and install the new service PCM. REMOVAL PROCEDURE IMPORTANT: To prevent internal PCM damage, the ignition switch must be OFF when disconnecting or connecting power to the PCM. - Remove any debris from around the PCM connector surfaces before servicing the PCM. Inspect the PCM module connector gaskets when diagnosing or replacing the PCM. Ensure that the gaskets are installed correctly. The gaskets prevent contaminant intrusion into the PCM. - The replacement PCM must be programmed. 1. Disconnect the negative battery cable. 2. If equipped with regular production option (RPO) NYS, remove the harness ground clip from the PCM cover. 3. Release the PCM cover mounting tabs. 4. Release the PCM cover from the mounting bracket. Page 14307 WA8743/28 - WA885K/70 Page 16048 Control Module References Part 2 Page 8899 Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips SPLICING COPPER WIRE USING SPLICE CLIPS IMPORTANT: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. TOOLS REQUIRED J 38125-D Terminal Repair Kit 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-D in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. Page 13415 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Micro-Pack 100W Connectors MICRO-PACK 100W CONNECTORS TOOLS REQUIRED J 38125-D Terminal Repair Kit REMOVAL PROCEDURE There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2)has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. IMPORTANT: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Page 9809 Relay Box: Application and ID Relay Block - I/P Location View Page 2049 Frame Angle Measurement (Express / Savana Only) ........ Fuel System - SES Lamp ON/Gauge Reads Empty/DTC's Set Fuel Gauge: Customer Interest Fuel System - SES Lamp ON/Gauge Reads Empty/DTC's Set Bulletin No.: 05-06-04-008A Date: April 14, 2005 TECHNICAL Subject: Diagnostic Trouble Code (DTC) P1172 or P2636, Fuel Gauge Reads Empty, Service Engine Soon (SES) Light On (Relocate Auxiliary Fuel Tank Vent Hose) Models: 2001-2005 Chevrolet Silverado (Cab Chassis Models Only) 2001-2005 GMC Sierra (Cab Chassis Models Only) with Auxiliary Fuel Tank Supercede: This bulletin is being revised to clarify the difference between the auxiliary fuel tank balance hose and vent hose. Please discard Corporate Bulletin Number 05-06-04-008 (Section 06 Engine/Propulsion System). Condition Some customers may comment that the SES light comes on and the fuel gauge reads empty. when This may occur when the vehicle is parked on an incline with the engine running. Diagnosis with a scan tool may reveal a DTC P1172 and/or P2636. Cause Important: A similar condition may occur if the vehicle is fueled with the engine running AND the rear tank is fueled first. The engine must be shut off (as required by law) during vehicle refueling. The auxiliary fuel tank vent hose is located in the same "T" connection on the main tank vent hose as the auxiliary tank balance hose. During fuel transfer, the fuel is pumped out of the auxiliary tank to the main tank via the balance hose. The fuel is then sucked back into the auxiliary tank via the vent hose rather then dumping the fuel into the main tank. When the Powertrain Control Module (PCM) does not detect a fluid level transfer between the main tank and the auxiliary tank, the PCM shuts off the auxiliary tank pump and the fuel gauge goes to empty. Correction Follow the service procedure below to correct this condition. 1. Depending on the body upfitter, it may be necessary to raise the vehicle in order to gain access to the auxiliary tank balance hose. 2. Depending on the body upfitter, it may be necessary to remove the left rear tire/wheel assemblies in order to gain access to the auxiliary tank balance hose. Page 10050 Power Steering Line/Hose: Service and Repair (Rack and Pinion) Power Steering Gear Inlet Pipe/Hose Replacement (Rack and Pinion) Removal Procedure Notice: Refer to Power Steering Hose Disconnected Notice in Service Precautions. 1. Remove the power steering inlet hose (2) from the power steering pump (1). 2. Remove the power steering inlet hose (2) from the power steering gear (3). Installation Procedure 1. Connect the power steering inlet hose (2) to the power steering gear (3). 2. Notice: Refer to Fastener Notice in Service Precautions. Connect the power steering inlet hose (2) to the power steering pump (1). ^ Tighten the hose connections to 28 Nm (20 ft. lbs.). 3. Bleed the power steering system. Refer to Bleeding the Power Steering System. 4. Inspect all the hose connections for leaks. (With Hydroboost) Power Steering Gear Inlet Pipe/Hose Replacement (With Hydroboost) Removal Procedure Page 14923 Memory/Heated Seat Switch - Driver (DDM C5) Part 2 Page 1174 1. Remove the power seat switch bezel from the seat. 2. Remove the power seat switch to bezel screws. 3. Remove the power seat switch. INSTALLATION PROCEDURE NOTE: Refer to Fastener Notice in Service Precautions. 1. Install the power seat switch to bezel screws. Tighten Tighten the screws to 2 N.m (18 lb in). Page 10253 Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips SPLICING COPPER WIRE USING SPLICE CLIPS IMPORTANT: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. TOOLS REQUIRED J 38125-D Terminal Repair Kit 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-D in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. Electrical - Trailer Brakes Apply With Headlamps ON Trailer Adapter Kit: All Technical Service Bulletins Electrical - Trailer Brakes Apply With Headlamps ON Bulletin No.: 02-05-22-004C Date: April 05, 2005 TECHNICAL Subject: Trailer Brakes Applied When Headlights/Park Lamps Are On, Brake Controller Illumination (Modify Brake Controller Wiring Harness) Models: 2002-2005 Cadillac Escalade, Escalade EXT 1999-2005 Chevrolet Silverado 2000-2005 Chevrolet Suburban, Tahoe 2002-2005 Chevrolet Avalanche 1999-2005 GMC Sierra 2000-2005 GMC Yukon, Yukon XL 2003-2005 HUMMER H2 Supercede: This bulletin is being revised to add additional model years. Please discard Corporate Bulletin Number 02-05-22-004B (Section 05 - Brakes). Condition Some customers may comment that when the headlamps or park lamps are on, the brakes on the trailer are always applied, or that the back lighting for the trailer brake controller only illuminates when the brakes are applied. Cause The cause of this condition may be due to wiring changes within the vehicle electrical system for the 2003 model year. Correction Inspect the brake controller wiring harness jumper that is plugged into the vehicle relay block-body. The relay block-body is located under the left side of the instrument panel near the left kick panel, behind a plastic cover. Page 16082 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the cover up until the dress cover releases. Repeat this procedure for the other locking tab. 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. 5. If the connector has a nose piece, use a small flat-blade tool to remove the nose piece by inserting the blade into the slot on the front of the connector and prying up on the nose piece. IMPORTANT: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 6. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. IMPORTANT: Be careful not to angle or rock the J 38125-13A tool when inserting it into the connector or the tool may break. Page 4564 Malfunction Indicator Lamp: Service and Repair SERVICE VEHICLE SOON INDICATOR The "SERVICE VEHICLE SOON" light will come on if there are certain non-emission related vehicle problems. These problems may not be obvious and may affect vehicle performance or durability. The light will come on briefly when the ignition is turned on to show that it is working properly. This light does NOT come on at certain mileage intervals. There is probably a PCM or a BCM Code set that will aid you in diagnosis. RESET PROCEDURE The only way to get the light to go off is to clear the PCM or BCM code(s). This light can NOT be reset or shut off any other way. PCM/BCM codes should be read & repaired before clearing them. Page 6510 Torque Converter Clutch Solenoid: Connector Locations Connector Views Fuse Block: Connector Views Fuse Block - I/P C4 (Crew Cab) Page 9711 C117 Battery Negative Harness To Accessory Jumper Harness (With RPO Code 9L4) Page 10437 1. Make an indentation 10 mm (0.4 inch) from the bottom (4) of the tube (3) using a centerpunch. 2. Clamp the shock absorber in a vise horizontally with the shock absorber rod (1) completely extended. 3. Drill a hole in the shock absorber at the centerpunch (4) using a 5 mm (3/16 inch) drill bit. Gas or a gas/oil mixture will exhaust when the drill bit penetrates the shock absorber. Use shop towels in order to contain the escaping oil. 4. Make an indentation in the middle (2) of the tube (3) with a centerpunch. 5. Drill a second hole in the shock absorber at the centerpunch (2) using a 5 mm (3/16 inch) drill bit. Oil will exhaust when the drill bit penetrates the shock absorber. Use shop towels in order to contain the escaping oil. 6. Remove the shock absorber from the vise. Hold the shock absorber over a drain pan horizontally with the holes down. Move the rod (1) in and out of the tube (3) to completely drain the oil from the shock absorber. Page 10059 3. Install the booster outlet hose to the power steering pump nipple (5) and retaining clamp. 4. Install the booster inlet hose (1) to the booster. 5. Install the gear inlet hose to the booster. ^ Tighten both power steering inlet hose fittings to 32 Nm (24 ft. lbs.). Notice: Refer to Fastener Notice in Service Precautions. 6. Install the booster outlet hose (3) to the booster and install the retaining clamp (2). 7. Remove the drain pan from under the vehicle. 8. Bleed the power steering system. Refer to Bleeding the Power Steering System. 9. Connect the energy storage box after servicing the vehicle. (Rack and Pinion) Power Steering Hose Assembly Replacement (Rack and Pinion) Body - Bumps or Rust Colored Spots in Paint Paint: Customer Interest Body - Bumps or Rust Colored Spots in Paint TECHNICAL Bulletin No.: 05-08-51-008C Date: June 22, 2009 Subject: Bumps or Rust Colored Spots in Paint Due to Rail or Iron Dust (Remove Rail Dust) Models: 1994-2010 GM Passenger Cars and Trucks (Including Saturn) 2003-2010 HUMMER H2 2006-2010 HUMMER H3 2005-2009 Saab 9-7X Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 05-08-51-008B (Section 08 - Body and Accessories). Condition Visible rust colored spots or bumps on a vehicle's paint surface from rail or iron dust. Cause Rail dust comes from tiny iron particles produced from the friction between train wheels and the tracks and gets deposited on the vehicle surfaces. Iron dust can get deposited on the surface if the vehicle is stored near any operation producing iron dust such as an iron ore yard. Either material can lay on top of, or become embedded in, the paint surface. Correction Because the severity of the condition varies, proper diagnosis of the damage is critical to the success of repairs. Diagnosis should be performed on horizontal surfaces (hood, roof, deck lid, pick up box, etc.) after the vehicle has been properly cleaned. There are two types of repair materials recommended to repair rail dust or iron dust: 1. GEL TYPE OXALIC ACID: - Has the characteristics of the liquid type oxalic acid but stays where you put it because of its gel consistency. 2. CLAY TYPE NON-ACID BASED: - Requires surface lubricant during use. - Has different grades available. Caution Rail dust remover (Oxalic Acid) is an acidic substance containing chemicals that will break down the iron particles embedded in the finish. When working with rail dust remover, use the necessary safety equipment, including gloves and goggles. Follow the chemical manufacturer's directions closely because it may require special handling and disposal. If, upon inspection, some particles are still present, the various chemical manufacturer's processes can be repeated. After the removal process, small pits may remain in the clearcoat and can be corrected, in most cases, with a finesse/polish operation. Procedure 1. Move the vehicle to a cool shaded area and make sure that the vehicle surfaces are cool during the removal process. DO NOT PERFORM THE REMOVAL PROCESS IN DIRECT SUNLIGHT OR ON A VEHICLE WITH HOT OR WARM BODY PANELS. 2. Wash the vehicle with soap and water. Dry it immediately and clean the affected areas with a wax and grease remover. 3. Perform the removal process according to the chemical manufacturer's directions. Once the damage has been repaired, the final step involves a polishing process. Rail Dust Remover Manufacturers Use the chemical manufacturers listed below, or equivalent: Service and Repair Brake Pedal Assy: Service and Repair Brake Pedal Assembly Replacement Removal Procedure 1. Remove the pushrod retaining clip (4). 2. Remove the stop lamp switch (2) and the pushrod (3) from the brake pedal stud (1). 3. Remove the nut from the brake pedal bolt. 4. Remove the brake pedal bolt. 5. Remove the brake pedal. Installation Procedure 1. Install the brake pedal. 2. Install the brake pedal bolt. 3. Notice: Refer to Fastener Notice in Service Precautions. Install the nut to the brake pedal bolt. Hold the nut with a wrench and tighten the brake pedal bolt to 47 Nm (35 ft. lbs.). Page 6369 5. Notice: Refer to Fastener Notice in Service Precautions. Install the indicator tube bolt, if equipped with RPO HP2. ^ Tighten the bolt to 18 Nm (13 ft. lbs.). 6. Install the indicator tube nut. ^ Tighten the nut to 18 Nm (13 ft. lbs.). 7. Remove the plugs from the transmission oil cooler line fittings. 8. Connect the transmission oil cooler lines. SRS - Air Bag Lamp ON/DTC B0092 Set Seat Occupant Sensor: Customer Interest SRS - Air Bag Lamp ON/DTC B0092 Set Bulletin No.: 02-09-41-002A Date: March 24, 2004 TECHNICAL Subject: Air Bag Lamp On, Passenger Air Bag Indicator Always Reads OFF, DTC B0092 Set (Repair Passenger Presence System (PPS) Sensor Harness) Models: 2003-2004 Cadillac Escalade, Escalade EXT 2003-2004 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2003-2004 GMC Sierra, Yukon, Yukon XL with Sensor Indicator Inflatable Restraint Front Passenger/Child Presence Detector (RPO ALO) Supercede: This bulletin is being revised to add the 2004 model year. Please discard Corporate Bulletin Number 02-09-41-002 (Section 09 - Restraints). Condition Some customers may comment that the Air Bag Lamp is on and the Passenger Air Bag indicator always reads OFF. Upon investigation, the technician may find DTC B0092 set. Cause The cause of this condition may be a shorted Passenger Presence System (PPS) sensor wire. The PPS sensor harness is located under the front passenger seat. This harness may be pinched between the seat frame and the track/riser. Correction Locate the PPS sensor (1) and inspect the harness for proper routing. If the harness is pinched between the seat frame and the track/riser, use the procedure listed below to repair wire(s). 1. Move the front passenger seat to the full rearward and full tilt up position. 2. Loosen the seat frame to track/riser nut and remove the harness. 3. Tighten the seat frame to track/riser nut. 4. Repair any damaged wires. Refer to Wiring Repairs in the Wiring Systems sub-section of the Service Manual. Warranty Information Page 4250 Accelerator Pedal Position (APP) Sensor Part 2 Page 4347 Door Control Module Diagram 3 Part 2 Page 14966 4. Connect the cables on each side of the endgate to the side panel cable retainer bolts. 5. Engage the linkage rods (1). 6. Raise the endgate. 7. Install the endgate handle bezel. Pressing into place until fully seated. 8. Tighten the handle bolts. Tighten the bolts to 25 N.m (18 lb ft). Page 8864 Electrical Symbols Part 2 Page 3812 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves SPLICING COPPER WIRE USING SPLICE SLEEVES TOOLS REQUIRED J 38125-D Terminal Repair Kit IMPORTANT: Use only GM splice sleeves, other splice sleeves may not protect the splice from moisture or a provide good electrical connection. Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. Page 6000 Pressure Regulating Solenoid: Service and Repair Automatic Transmission - 4L80-E/4L85-E Pressure Regulator Replacement ^ Tools Required J 36850 Transjel Removal Procedure 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. Remove the transmission filter. 3. Caution: Valve springs can be tightly compressed. Use care when removing retainers and plugs. Personal injury could result. Remove the reverse boost valve bushing retainer ring (2). 4. Remove the following from the reverse boost valve cylinder: ^ The reverse boost valve bushing ^ The reverse boost valve ^ The pressure regulator spring retainer ^ The pressure regulator spring ^ The pressure regulator valve ^ The reverse boost valve bushing Installation Procedure 1. Install the pressure regulator valve using J 36850. 2. Pre-assemble the following parts: Page 9712 C119 Accessory Jumper Harness To Brake/Clutch Harness (With RPO Code 9L4) Automatic Transmission - 4L60-E/4L65-E Page 10243 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Micro-Pack 100W Connectors MICRO-PACK 100W CONNECTORS TOOLS REQUIRED J 38125-D Terminal Repair Kit REMOVAL PROCEDURE There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2)has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. IMPORTANT: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Page 8207 Removal Procedure 1. Release the park brake. 2. Raise and support the vehicle. Refer Vehicle Lifting 3. Remove the tire and wheel assembly. 4. Remove the hub and rotor assembly. 5. Mark the relationship of the hub to the rotor. 6. Place the hub and rotor assembly on a hydraulic press. 7. Press the wheel studs out of the hub and rotor assembly. Installation Procedure 1. Align the hub and the rotor (if applicable). 2. Install each of the new wheel studs into the hub and rotor assembly by performing the following steps: 1. Install the stud. 2. Install 4 washers to the stud. 3. Install a lug nut to the stud with the flat side of the nut towards the washers. 4. Tighten the lug nut to draw the stud into the hub and rotor assembly. 5. Inspect the hub and rotor assembly to ensure that the hub is tight against the rotor and the stud is seated completely. 6. Remove the lug nut and the washers. 3. Install the hub and rotor assembly to the vehicle. 4. Install the tire and wheel assembly. 5. Lower the vehicle. 6. With the engine OFF, gradually apply the brake pedal to approximately 2/3 of it's travel distance. 7. Slowly release the brake pedal. 8. Wait 15 seconds, then repeat steps 6-7 until a firm pedal is obtained. This will properly seat the brake caliper pistons and brake pads. 9. Fill the master cylinder reservoir to the proper level with clean brake fluid. Refer to Master Cylinder Reservoir Filling in Hydraulic Brakes. Page 16127 Electrical Symbols Part 2 Page 12783 Vehicles Built with Upgradeable OnStar(R) System Analog Modules Note: Page 13486 The 1999 though early 2003 wiring harness jumper that plugs into the relay block will have a reddish/brown 6-way connector and a tag with the last four digits of the wiring harness part number. Second design 2003-05 may have a white plastic connector with part number 5418 as well. ^ The 1999 jumper is/was P/N 12171982 with a pink/purple tag identifier of 1982. This number has been superseded to 15366255, with a pink/purple tag identifier of 6255. ^ The 2000 jumper harness is P/N 15366255. The pink/purple tag identifier is 6255. ^ The 2001-2002 jumper is P/N 15086884. The orange tag identifier is 6884. ^ The 2003-05 jumper is P/N 15085418. The orange tag identifier is 5418. When transferring the brake controller with the wiring jumper attached from a 2001-2002 vehicle to a 2003-05 vehicle, a change to the jumper harness connector must be performed. Page 2194 1. Install a NEW air filter element. 2. Install the air cleaner housing cover. 3. Tighten the air cleaner housing top screws until snug. 4. Connect the MAF/IAT sensor electrical connector (4). 5. Install the air cleaner outlet duct. Interior - Erratic Memory Seat Operation Memory Positioning Module: All Technical Service Bulletins Interior - Erratic Memory Seat Operation Bulletin No.: 04-08-50-016C Date: August 12, 2005 TECHNICAL Subject: Memory Seat May Not Return to Requested Position (Reprogram Driver Seat Module) Models: 2003-2005 Cadillac Escalade, Escalade ESV, Escalade EXT 2003-2005 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2003-2005 GMC Sierra, Yukon, Yukon XL, Yukon Denali All with Seat FRT, Individual (Non BKT) (RPO AN3) 2003-2005 HUMMER H2 with Seat, Front Bucket Deluxe (RPO AR9) Supercede: This bulletin is being revised to update the correction information. Please discard Corporate Bulletin Number 04-08-50-016B (Section 08 - Body and Accessories). Condition Some customers may comment that with repeated cycling of the memory seat between the "exit" and one of the "presets", the position of the seat may "creep" forward or rearward out of expected adjustment. Cause There is a coding deficiency in the software for the memory seat module. Correction Technicians are to reprogram the driver seat module with an updated software calibration. The previous bulletin stated to use a service calibration that was released with TIS satellite data update version 4.5. Feedback has proved that calibration to be ineffective in eliminating the memory seat creep condition. An updated service calibration was released with TIS satellite data update version 6.5 available June 13, 2005. This new calibration has additional memory seat creep protection. As always, make sure your Tech 2(R) is updated with the latest software version. Important: After programming is complete, move the seat all the way rearward and down, then bump the seat slightly forward and up. This position will be just off the end of travel hard stops. Reset both memory seat exit positions at this position. Having the seat set at just off the hard stops will aid in reducing the creep condition. Warranty Information Page 5094 Canister Vent Valve: Service and Repair EVAP Canister Vent Solenoid Valve Replacement (1500 Crew Cab) EVAPORATIVE EMISSION (EVAP) CANISTER VENT SOLENOID VALVE REPLACEMENT (1500 CREW CAB) REMOVAL PROCEDURE 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. Disconnect the canister vent solenoid (CVS) electrical connector. 3. Remove the CVS bracket bolt. 4. Disconnect the CVS line from the evaporative emission (EVAP) canister. 5. Remove the CVS from the vehicle. 6. If necessary, remove the CVS from the CVS bracket. INSTALLATION PROCEDURE Page 6660 6. Remove the fluid indicator stop bracket bolt (2). 7. Remove the fluid indicator bracket (1). 8. Remove the TCC PWM solenoid retainer (2) with a small screwdriver. Rotate the solenoid (1) in the bore, if necessary, until the flat part of the retainer (2) is visible. 9. Remove the TCC PWM solenoid (1) in order to access the TCC solenoid bolts. 10. Remove the TCC solenoid bolts. 11. Remove the TCC solenoid (with O-ring seal) and wiring harness from the valve body. 12. Reposition the harness to the side of the transmission case. Page 6687 Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use the table. Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table. Disclaimer Page 12967 Speaker - RF - Tweeter - With RPO Code UQ3 Page 5048 Extended Cab Short Box Shown Below, Other Configurations Similar 6. Install the new canister vent valve solenoid to the fuel tank clip or mounting bracket as shown above. The valve port closest to the electrical connector must point towards the canister. 7. Cut bulk 5/8" heater hose to a length of approximately 76 mm (3 in). Install the hose between the solenoid and the canister pipe and secure using clamps. 8. Attach bulk 5/8" heater hose to the vent port and secure using a clamp. Run a length as needed along the frame rail routing to the area above the transmission. 9. Cut the hose to determined length and install the supplied filter box. Secure using a clamp. 10. Remove the transmission support and lower the transmission assembly as necessary to allow for access to the new filter box location. 11. Secure the filter box to the transmission vent hose just forward of the hose tee-section using a tie strap. DO NOT pinch or restrict the transmission vent hose. The filter box opening should be pointing downward. 12. Raise the transmission and reinstall the transmission support. 13. Connect the EVAP canister vent valve electrical connector. 14. Tie strap the hose as needed along the frame rail in order to keep the hose away from pinch-points and heat sources. 15. Lower the vehicle. Correction (2007-2010 New Style Models) After following the published SI diagnostics and determining that the EVAP canister vent valve is the cause of the MIL light, replace the EVAP canister vent valve assembly and relocate the remote filter box. To ensure correct installation, follow the procedures below. Important DO NOT replace the EVAP canister assembly for this concern unless it fails the leak test. Use Service Kit P/N 19207763 1. Raise the vehicle. Suitably support the vehicle. 2. Disconnect the EVAP canister vent valve electrical connector. Page 4547 Steps 1 - 4 Page 9082 Location View Page 12678 HVAC System - Manual A/C Compressor Clutch Page 8224 Caution: Refer to Brake Dust Caution in Service Precautions. Removal Procedure 1. Raise and support the vehicle. Refer Vehicle Lifting 2. Remove the tire and wheel assembly. 3. Remove the hub and bearing assembly. 4. Remove the splash shield (15 series). 5. Remove the splash shield (25/35 series). Installation Procedure 1. Install the splash shield (25/35 series). Page 9756 C306 Infotainment Jumper Harness To Console Harness (Without RPO Code Y91) Part 1 Page 11732 For vehicles repaired under warranty, use the table. Disclaimer Page 9354 - HVAC Actuator - Inflatable Restraint Sensing and Diagnostic Module (SDM) - Any AIR BAG module - Seatbelt Lap Anchor Pretensioner - Seatbelt Retractor Pretensioner - An SIR system connection or connector condition resulting in the following DTCs being set: B0015, B0016, B0019, B0020, B0022, or B0023 - Powertrain Control Module (PCM) - Remote Control Door Lock Receiver (RCDLR) - Transmission Control Module (TCM) Correction Important DO NOT replace the control module, wiring or component for the following conditions: - The condition is intermittent and cannot be duplicated. - The condition is present and by disconnecting and reconnecting the connector the condition can no longer be duplicated. Use the following procedure to correct the conditions listed above. 1. Install a scan tool and perform the Diagnostic System Check - Vehicle. Retrieve and record any existing history or current DTCs from all of the control modules (refer to SI). ‹› If any DTC(s) are set, refer to Diagnostic Trouble Code (DTC) List - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). ‹› If DTCs are not set, refer to Symptoms - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). 2. When identified, use the appropriate DTC Diagnostics, Symptoms, Schematics, Component Connector End Views and Component Locator documents to locate and disconnect the affected harness connector(s) which are causing the condition. Note Fretting corrosion looks like little dark smudges on electrical terminals and appear where the actual electrical contact is being made. In less severe cases it may be unable to be seen or identified without the use of a magnifying glass. Important DO NOT apply an excessive amount of dielectric lubricant to the connectors as shown, as hydrolock may result when attempting to mate the connectors. Use ONLY a clean nylon brush that is dedicated to the repair of the conditions in this bulletin. 3. With a one-inch nylon bristle brush, apply dielectric lubricant to both the module/component side and the harness side of the affected connector(s). 4. Reconnect the affected connector(s) and wipe away any excess lubricant that may be present. 5. Attempt to duplicate the condition by using the following information: - DTC Diagnostic Procedure - Circuit/System Description - Conditions for Running the DTC - Conditions for Setting the DTC - Diagnostic Aids - Circuit/System Verification ‹› If the condition cannot be duplicated, the repair is complete. ‹› If the condition can be duplicated, then follow the appropriate DTC, Symptom or Circuit/System Testing procedure (refer to SI). Repair Order Documentation Page 8633 9. Remove the accumulator retainer ring (1) using a small hook shaped tool. 10. Release the C-clamp. 11. Remove the nut from the stud. 12. Remove the J 26889. 13. Remove the accumulator (2) and the O-ring seal (3). Installation Procedure Page 3650 1. Install the inlet heater hose (3) to the auxiliary water pump (1). 2. Position the inlet heater hose clamp (2) to the auxiliary water pump (1). 3. Connect the inlet heater hose to the heater core. 4. Firmly push the quick connect onto the heater core pipe until you hear an audible click. 5. Fill the cooling system. Refer to Draining and Filling Cooling System (with HP2)Draining and Filling Cooling System (without HP2) in Cooling System. Page 7897 Page 15486 5. Connect the fuel pump electrical connector. 6. Install the sending unit. Locations Chassis And License Lamp Harnesses Page 10228 Electrical Symbols Part 13 Page 12733 networks, and will not require an upgrade in connection with the cellular industry's transition to the digital network. In order to verify the type of OnStar(R) Hardware in a vehicle, type the VIN into the VIN look-up tool, which is available at the OnStar(R) Online Enrollment website within GM GlobalConnect (for U.S. dealers) or InfoNet (for Canadian dealers). Disclaimer Page 7161 3. Fill the transmission to just below the bottom of the fill plug hole. 4. Install the oil fill plug. ^ Tighten the plug to 37 Nm (27 ft. lbs.). 5. Lower the vehicle. Page 8497 of failure to repair within a reasonable time. If the condition is not adequately repaired within a reasonable time, the customer may be entitled to an identical or reasonably equivalent vehicle at no charge or to a refund of the purchase price less a reasonable allowance for depreciation. To avoid having to provide these burdensome remedies, every effort must be made to promptly schedule an appointment with each customer and to repair their vehicle as soon as possible. In the recall notification letters, customers are told how to contact the US National Highway Traffic Safety Administration if the recall is not completed within a reasonable time. Dealer Recall Responsibility -- All All unsold new vehicles in dealers' possession and subject to this recall MUST be held and inspected/repaired per the service procedure of this recall bulletin BEFORE customers take possession of these vehicles. Dealers are to service all vehicles subject to this recall at no charge to customers, regardless of mileage, age of vehicle, or ownership, from this time forward. Customers who have recently purchased vehicles sold from your vehicle inventory, and for which there is no customer information indicated on the dealer listing, are to be contacted by the dealer. Arrangements are to be made to make the required correction according to the instructions contained in this bulletin. A copy of the customer letter is shown in this bulletin for your use in contacting customers. Recall follow-up cards should not be used for this purpose, since the customer may not as yet have received the notification letter. In summary, whenever a vehicle subject to this recall enters your vehicle inventory, or is in your dealership for service in the future, please take the steps necessary to be sure the recall correction has been made before selling or releasing the vehicle. Disclaimer Service Procedure Inspection Tools Required CH 47950 Hydro-Boost Checking Tool 1. With the vehicle transmission in PARK or NEUTRAL, set the park brake. 2. With the engine OFF, make a minimum of five (5) high effort brake applies until the pedal feels hard. 3. Start the engine. Important: DO NOT depress the brake pedal until instructed. 4. Turn the steering wheel to the "steering lock" (fully turned) position. Hold at the steering lock position for 1 to 2 seconds and then release the steering wheel. Repeat a total of 3 times. 5. Turn the vehicle off being careful not to step on the brake pedal. 6. For Express/Savana only: A. Remove the remote power steering reservoir mounting nuts. B. Disconnect the reservoir outlet hose from the booster unit. Keeping the hose end higher than the reservoir, reposition the reservoir forward and down out of the way. 7. Using a clean, lint-free shop cloth, wipe any dirt away from the steering pump supply hose/tube connection area on the hydro-boost (this is the center hose/tube of the three). 8. Disconnect the power steering supply hose/tube from the hydro-boost unit and wrap a clean lint-free shop cloth around the end of the hose and secure it in the engine compartment. 9. Using a clean lint-free shop cloth, clean any dirt off of the inlet port adapter valve assembly. Before installing the inlet port adapter, place a shop Page 8409 5. Notice: Refer to Fastener Notice in Service Precautions. For 15 series vehicles, install the equalizer and the nut to the threaded end of the intermediate cable. ^ Tighten the nut to 3.5 Nm (31 inch lbs.). 6. For 25/35 series vehicles, enable the park brake cable automatic adjuster. Refer to Enabling the Park Brake Cable Automatic Adjuster. 7. Remove the safety stands and lower the vehicle. 8. Adjust the park brake system. Park Brake Cable Mounting Bracket Replacement Park Brake Cable Mounting Bracket Replacement Removal Procedure 1. Release the parking brake. 2. Raise and support the vehicle. Refer Vehicle Lifting 3. Release the tension on the cables by loosening the nut at the equalizer. 4. Disconnect the rear cables from the equalizer. 5. Remove the rear cables from the mounting bracket by depressing the retaining tabs and pulling rearward. 6. Remove the cable support bracket nuts. 7. Remove the cable support bracket. Installation Procedure Specifications Connecting Rod Bearing: Specifications Connecting Rod Bearing Clearance - Production ...................................................................................................... 0.023-0.065 mm (0.0009-0.0025 inch) Connecting Rod Bearing Clearance - Service ............................................................................................................. 0.023-0.076 mm (0.0009-0.003 inch) Page 3664 10. Reposition the inlet hose clamp at the water pump. 11. Remove the inlet hose from the water pump. Installation Procedure 1. Install the inlet hose to the water pump. 2. Position the inlet hose clamp at the water pump. 3. Install the inlet hose to the radiator. 4. Position the inlet hose clamp at the radiator. 5. Install the inlet hose clip to the fan shroud. 6. Install the radiator vent inlet hose to the radiator inlet hose clips. 7. If necessary, install the engine sight shield. Component Locations Transmission Temperature Sensor/Switch: Component Locations Automatic Transmission - 4L60-E/4L65-E Automatic Transmission Electronic Component Views (M30/M32) Electronic Components Page 4213 Air Filter Element: Service and Repair AIR CLEANER ELEMENT REPLACEMENT REMOVAL PROCEDURE 1. Remove the air cleaner outlet duct. 2. Disconnect the mass air flow/intake air temperature (MAF/IAT) sensor electrical connector (4). 3. Loosen the air cleaner housing top screws. 4. Remove the air cleaner housing cover. 5. Remove the air filter element. INSTALLATION PROCEDURE Page 3220 20. Install the spark plug wires to the ignition coils. 21. Position the engine harness, if necessary. 22. Install the harness clips (1). 23. Connect the main electrical connector (4) feeding the ignition coils. 24. Install the CPA lock (5). 25. Install the engine sight shield, if required. 26. If equipped with RPO HP2, connect the ESB. Page 9979 Do not apply force to the steering wheel position sensor and the adapter and bearing assembly in a sideways direction. Seat the adapter and bearing assembly into the steering column jacket. 5. Connect the steering wheel position sensor connector. 6. Notice: Refer to Fastener Notice in Service Precautions. Align the marks on the upper intermediate shaft and the steering column shafts, where they connect, that you made during the removal procedure. 7. Install the intermediate shaft to the steering column pinch bolt. ^ Tighten the nut to 62 Nm (46 ft. lbs.). 8. Connect the negative battery cable. 9. Enable the SIR system. Service and Repair Parking Brake Warning Switch: Service and Repair Park Brake Warning Lamp Switch Replacement Removal Procedure 1. Caution: Refer to Battery Disconnect Caution in Service Precautions. Disconnect the negative battery cable. 2. Remove the MID-bussed electrical center from the bracket. 3. Disconnect the park brake warning lamp switch electrical connector. 4. Remove the park brake warning lamp switch mounting bolt. 5. Remove the park brake warning lamp switch. Installation Procedure Page 12329 IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections TESTING FOR INTERMITTENT AND POOR CONNECTIONS TOOLS REQUIRED - J 35616-C GM-Approved Terminal Test Kit - J 38125-D Terminal Repair Kit - J 42675 Flat-Wire Probe Adapter Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector. - Poor terminal to wire connection - Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. - Wire insulation which is rubbed through - This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. - Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. Testing For Proper Terminal Contact It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-D or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-D, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. Page 3984 Intake Air Temperature (IAT) Sensor: Service and Repair MASS AIR FLOW (MAF)/INTAKE AIR TEMPERATURE (IAT) SENSOR REPLACEMENT REMOVAL PROCEDURE IMPORTANT: Use care when handling the mass air flow/intake air temperature (MAF/IAT) sensor. Do not dent, puncture, or otherwise damage the honeycell located at the air inlet end of the MAF/IAT. Do not touch the sensing elements or allow anything including cleaning solvents and lubricants to come in contact with them. Use a small amount of a non-silicone based lubricant, on the air duct only, to aid in installation. 1. Remove the air cleaner outlet duct. 2. Pull out the gray connector position assurance (CPA) retainer. 3. Push down on the black clip in order to disconnect the MAF/IAT sensor electrical connector (4). 4. Loosen the MAF/IAT clamp. 5. Remove the MAF/IAT sensor from the air cleaner assembly. INSTALLATION PROCEDURE IMPORTANT: The embossed arrow on the MAF/IAT sensor indicates the proper air flow direction. The arrow must point toward the engine. Page 14034 Trim Panel: Service and Repair Trim Panel Replacement - Hinge Pillar Trim Panel Replacement - Hinge Pillar Removal Procedure 1. Remove the door-sill plate. 2. Remove the hinge pillar panel. Installation Procedure 1. Install the hinge pillar panel. 2. Install the door-sill plate. Page 1129 Seat Rear Vertical Position Sensor - Driver (With RPO Code AN3) Page 3775 Electrical Symbols Part 2 Page 13439 Steering Mounted Controls Transmitter: Electrical Diagrams Steering Wheel Controls Diagram Page 913 Body Control Module: Connector Views Body Control Module (BCM) - C1 Page 7904 Steps 1-9 Test Description The numbers below refer to the step numbers on the diagnostic table. 2. This step tests for a faulty tow/haul switch. 3. This step tests for voltage input from the BCM to the tow/haul switch. 6. This step tests for ground integrity. Service and Repair Steering Angle Sensor: Service and Repair Rear Position Sensor Replacement Removal Procedure 1. Notice: Refer vehicle Lifting. Raise the vehicle. Refer to Vehicle Lifting. 2. Remove the steering gear protection shield (1) retaining bolts (3). 3. Disconnect the electrical connector (1). 4. Notice: When removing the rear position cover from the steering gear be careful not to damage to the rear position sensor. Remove the rear wheel position sensor cover (4) from the steering gear by prying on the cover using the slot. 5. Remove the rear wheel position sensor retaining bolts (3). 6. Important: Check the inner tie rod boot for wear or damage. If the boots are damaged replace the steering gear actuator. 7. Important: Page 5605 Steps 19 - 23 Page 4640 Electrical Symbols Part 11 Page 16301 7. Remove the drive link from the wiper motor crank arm with the J 39232. 8. Remove the 2 bolts retaining the wiper motor. 9. Remove the wiper motor from the wiper transmission assembly. INSTALLATION PROCEDURE NOTE: Refer to Fastener Notice in Service Precautions. 1. Install the wiper motor onto the wiper transmission assembly with the 2 bolts. Tighten Tighten the 2 bolts to 8 N.m (71 lb in). Page 13037 Page 4901 Vehicle Speed Sensor: Service and Repair Automatic Transmission - 4L60-E/4L65-E Vehicle Speed Sensor (VSS) Replacement Removal Procedure 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. Disconnect the vehicle speed sensor (VSS) electrical connector (2). 3. Remove the VSS bolt (2). 4. Remove the VSS (1). 5. Remove the O-ring seal (3). Installation Procedure 1. Install the O-ring seal (3) onto the VSS (1). 2. Coat the O-ring seal (3) with a thin film of transmission fluid. 3. Install the VSS (1). 4. Notice: Refer to Fastener Notice in Service Precautions. Install the VSS bolt (2). ^ Tighten the bolt to 11 Nm (97 inch lbs.). Page 13664 1. Connect the electrical connectors. 2. Carefully align the panel, and slide the panel into the retainer slots in order to install the trim panel to the door. Notice: Refer to Fastener Notice in Service Precautions. 3. Install the trim panel screws (2,3). Tighten the trim panel screws (2,3) to 2 N.m (18 lb in). 4. Install the manual lock lever to the trim panel. 1. Align the manual lock lever to the opening in the door trim panel. 2. Push inward until the manual lock lever is fully seated into the trim panel. 5. Install the door trim panel upper extension. 6. Install the door handle bezel. Trim Panel Replacement - Side Front Door (With YE9 Late Production) Trim Panel Replacement - Side Front Door (With YE9 Late Production) Removal Procedure Page 14643 Power Seat Switch: Locations Driver Seat (1 Of 2) OnStar(R) - Analog/Digital Ready System Digital Upgrade Technical Service Bulletin # 05-08-46-006Q Date: 081028 OnStar(R) - Analog/Digital Ready System Digital Upgrade INFORMATION Bulletin No.: 05-08-46-006Q Date: October 28, 2008 Subject: Information on Upgrading Certain OnStar(R) Analog/Digital-Ready Systems to OnStar(R) Generation 6 Digital-Capable System Models Supercede: This bulletin is being revised to update the upgrade kit installation information for the 2001 Chevrolet Impala and Monte Carlo. Please discard Corporate Bulletin Number 05-08-46-006P (Section 08 - Body and Accessories). This bulletin is being issued to provide dealer personnel with information and procedures to follow should an owner wish to upgrade their OnStar(R) Analog/Digital-Ready system to an OnStar(R) Generation 6 Digital-Capable system. Disclaimer Program Overview Program Overview To upgrade their vehicle to an OnStar(R) Generation 6 Digital-Capable system, all that a customer must do is: ^ Take their vehicle to their dealer for the system upgrade. Page 4130 Vehicle Speed Sensor: Service and Repair Automatic Transmission - 4L60-E/4L65-E Vehicle Speed Sensor (VSS) Replacement Removal Procedure 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. Disconnect the vehicle speed sensor (VSS) electrical connector (2). 3. Remove the VSS bolt (2). 4. Remove the VSS (1). 5. Remove the O-ring seal (3). Installation Procedure 1. Install the O-ring seal (3) onto the VSS (1). 2. Coat the O-ring seal (3) with a thin film of transmission fluid. 3. Install the VSS (1). 4. Notice: Refer to Fastener Notice in Service Precautions. Install the VSS bolt (2). ^ Tighten the bolt to 11 Nm (97 inch lbs.). Page 2715 Location View Page 4295 Electrical Symbols Part 13 Page 13942 The information shown is for the 1999-2002 wiring harnesses and for the 2003-05 wiring harness. To modify a 12171982, 15366255 or 15086884 harness for use in a 2003-05 vehicle, switch the wires in cavities "A" and "D". To modify a 15085418 harness for use in a 1999-2002 vehicle (see model list at the front of this bulletin for applicable models), switch the wires in cavities "A" and "D". Warranty Information When the correct wiring harness P/N is matched to the specific model year of the vehicle, everything works properly. Therefore, conversion of an incorrect wiring jumper to match the vehicle would not be considered a warrantable repair. Disclaimer Page 486 Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA and/or the secondary locks. Micro .64 Connectors MICRO .64 CONNECTORS TOOLS REQUIRED J 38125-D Terminal Repair Kit REMOVAL PROCEDURE Follow the steps below in order to remove terminals from Micro 64 connectors. 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. 2. Disconnect the connector from the component. Page 998 Steps 1 - 3 Page 11112 Air Temperature Sensor - Upper Right Page 6186 interchangeable. Important: The wear plate (640) and input thrust washer (660) are not required with the new sprag. Use of the thrust washer and wear plate with the new sprag assembly will cause a misbuild (correct end play cannot be obtained). Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 9232 C306 Infotainment Jumper Harness To Console Harness (With RPO Code Y91) Part 1 Recall - Brake Hydroboost Relief Valve Seal Defect Technical Service Bulletin # 04004 Date: 040601 Recall - Brake Hydroboost Relief Valve Seal Defect File In Section: Product Recalls Bulletin No.: 04004 Date: June 2004 F/CMVSS NONCOMPLIANCE RECALL SUBJECT: BRAKE HYDRO-BOOST RELIEF VALVE SEAL FRACTURE MODELS: 2003-2004 CADILLAC ESCALADE, ESCALADE EXT, ESCALADE ESV 2003-2004 CHEVROLET SILVERADO, AVALANCHE, SUBURBAN, EXPRESS 2004 CHEVROLET TAHOE 2003-2004 GMC SIERRA, YUKON, YUKON XL, SAVANA CONDITION General Motors has decided that certain 2003 and 2004 model year Cadillac Escalade, Escalade EXT and Escalade ESV; Chevrolet Silverado, Avalanche, Suburban, and Express; GMC Sierra, Yukon, Yukon XL, and Savana; and 2004 model year Chevrolet Tahoe vehicles fail to conform to either Federal/Canada Motor Vehicle Safety Standard 105, "Hydraulic and Electric Brake System", or Standard 135, "Light Vehicle Brake Systems". These vehicles may have a relief valve bore within the brake hydro-boost module that is not to specification. An out-of-specification bore could result in fracture of the relief valve 0-ring seal within the module. If this happens, during braking applications the driver may be able to hear an engine compartment noise similar to the sound that occurs when the steering wheel is turned to a full stop position. The driver could also experience a slight increase in steering efforts while braking and parking. Under certain driving conditions, a fractured seal may require a slight increase in the applied brake pedal effort to achieve the same vehicle deceleration rate as prior to the seal fracture. If this were to occur, it could result in a vehicle crash without prior warning. CORRECTION Dealers are to inspect the hydro-boost module, and replace the relief valve, if necessary. VEHICLES INVOLVED Page 1674 8. Connect the PNP switch electrical connector (2). 9. If equipped with 4WD, install the front propeller shaft. 10. Lower the vehicle. 11. Check the switch for proper operation. The engine must start in the park (P) or neutral (N) positions only. If proper operation of the switch can not be obtained, replace the switch. Page 9384 Tighten Tighten to 8 Nm (71 lb in). Note The repair area MUST BE properly refinished to maintain a secure, stable and corrosion-free electrical ground. 12. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 13. Verify proper system operation. M8 Weld Nut Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M8 weld nut electrical ground location is accessible from both sides of the panel, a M8 conductive bolt and a M8 conductive nut may be used to secure the electrical ground wire terminal. Refer to the Parts Information section of this bulletin. 2. Select a location adjacent the M8 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the new electrical ground site. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the ground location and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 10 mm (0.40 in) diameter hole through the panel. 5. Remove paint and primer from the area surrounding the 10 mm (0.40 in) hole until bare metal is visible. 6. Select a M8 conductive bolt. Refer to the Parts Information section of this bulletin. 7. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M8 conductive bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 8. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 9. Install the electrical ground wire terminal and the M8 conductive bolt to the ground location. 10. Select a M8 conductive nut. Refer to the Parts Information section of this bulletin. 11. Install the M8 conductive nut to the bolt and: Tighten Tighten to 22 Nm (16 lb ft). Note The repair area MUST BE properly refinished to maintain a secure, stable and corrosion-free electrical ground. 12. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 13. Verify proper system operation. M8 Weld Nut Alternative Repair Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M8 weld nut electrical ground location is not accessible from both sides of the panel, a M6 conductive rivet stud and a M6 conductive nut may be used to secure the electrical ground wire terminal. 2. Select a location adjacent the damaged M8 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the M6 conductive rivet stud flange. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the repair site and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 10 mm (0.40 in) diameter hole through the panel. Page 12907 Pedal Positioning Switch: Service and Repair Brake Pedal Position Sensor Replacement Removal Procedure 1. Important: Once the Brake Pedal Position Sensor bolt is removed for any reason, a new 4 mm bolt, with fresh LOCTITETM will need to be installed. Remove the brake pedal position sensor bolt (1). 2. Remove the brake pedal position sensor (2) from the mounting bracket. 3. Disconnect the brake pedal position sensor electrical connector (1). 4. Remove the brake pedal position sensor (2) from the vehicle Installation Procedure Page 947 Remove all rust from the ground terminal, the cylinder head and the retaining nut or bolt. Position the main engine wiring harness ground terminal and install the nut or bolt. Tighten: Tighten the retaining nut or bolt to 16 N.m (12 lb ft). Apply some type of electrical moisture sealant to protect the harness terminal from further corrosion. Disclaimer Page 1014 Inflatable Restraint Sensing and Diagnostic Module (SDM) - Part 3 Page 2480 Fluid - M/T: Fluid Type Specifications Transmission Fluid 5-SPEED WITH LOW GEAR (RPO MW3) Grade ............................................................................... .............................................................................................................................. GL-4 Synthetic Viscosity .............................................................................................................................................. ..................................................................... 75W-90 5-SPEED WITHOUT LOW GEAR (RPO MG5) Fluid Type ................................................................................................................................................. Synchromesh Transmission Fluid P/N 12345349 6-SPEED Fluid Type ....................................................................................................................... Synthetic Transmission Fluid approved for Allison Transmission Page 14393 Driver Door Module (DDM) - C3 (With RPO Code YE9) Part 2 Page 4241 Compression Check: Testing and Inspection Engine Compression Test 1. Charge the battery if the battery is not fully charged. 2. Disable the ignition system. 3. Disable the fuel injection system. 4. Remove all the spark plugs. 5. Turn the ignition to the ON position. 6. Depress the accelerator pedal to position the throttle plate wide open. 7. Start with the compression gage at zero and crank the engine through four compression strokes, four puffs. 8. Check the compression for each cylinder. Record the readings. 9. If a cylinder has low compression, inject approximately 15 ml (1 tablespoon) of engine oil into the combustion chamber through the spark plug hole. Check the compression again and record the reading. 10. The minimum compression in any one cylinder should not be less than 70 percent of the highest cylinder. No cylinder should read less than 690 kPa (100 psi). For example, if the highest pressure in any one cylinder is 1 035 kPa (150 psi), the lowest allowable pressure for any other cylinder would be 725 kPa (105 psi). (1 035 x 70% = 725) (150 x 70% = 105). ^ Normal - Compression builds up quickly and evenly to the specified compression for each cylinder. ^ Piston Rings Leaking - Compression is low on the first stroke. Compression builds up with the following strokes, but does not reach normal. Compression improves considerably when you add oil. ^ Valves Leaking - Compression is low on the first stroke. Compression usually does not build up on the following strokes. Compression does not improve much when you add oil. ^ If two adjacent cylinders have lower than normal compression, and injecting oil into the cylinders does not increase the compression, the cause may be a head gasket leaking between the cylinders. A/T - Revised Converter Check Valve/Cooler Line Fitting Fluid Line/Hose: Technical Service Bulletins A/T - Revised Converter Check Valve/Cooler Line Fitting INFORMATION Bulletin No.: 04-07-30-017B Date: November 25, 2008 Subject: Information on 4T65-E MN7, M15, M76, MN3 Automatic Transmission Case, Cooler Fitting and Torque Converter Drain Back Check Ball Change Models: 2008 and Prior GM Passenger Cars and Light Duty Trucks with one of the HYDRA-MATIC(R) Automatic Transmissions shown above. Supercede: This bulletin is being revised to update the Parts Information. Please discard Corporate Bulletin Number 04-07-30-017A (Section 07 - Transmission/Transaxle). Effective with Julian date 4019 (January 19, 2004), the 4T65E transaxle cases and cooler fittings have changed and are not interchangeable with past models. The technician may find that when replacing the inlet or outlet transmission cooler lines, the new lines cannot be connected to the transmission. A change to the transmission cooler line fittings was implemented in production on February 1, 2004. The cooler line fittings were changed to a design with a longer lead in pilot (1). The cooler line fittings with the longer lead in pilot will not fit on models built before February 1, 2004. The longer lead in pilot fittings (1) (9/16-18 UNF) have replaced the shorter lead in pilot fittings (2) (3/8-18 NPSF w/check ball & 1/4-18 NPSF). If the transmission cooler lines will not connect, then replace them with the following cooler line fittings as appropriate with the older, shorter lead in pilot design: ^ For vehicles built prior to February 1, 2004, use Transmission Fluid Cooler Inlet Hose, P/N 20793004. ^ For vehicles built after February 1, 2004, use Transmission Fluid Cooler Inlet Hose, second design P/N 15264588. ^ For vehicles built prior to February 1, 2004, use Transmission Fluid Cooler Outlet Hose, P/N 20793005. ^ For vehicles built after February 1, 2004, use Transmission Fluid Cooler Outlet Hose, second design P/N 15264589. Page 11325 - Proof of ownership at time of repair. - Original paid receipt confirming the amount of unreimbursed repair expense(s) (including Service Contract deductibles), a description of the repair, and the person or entity performing the repair. If the work was done by someone other than a GM dealership, the amount of reimbursement will be limited to the amount that the repair would have cost GM to have it completed by a GM dealership. Courtesy Transportation The General Motors Courtesy Transportation program is intended to minimize customer inconvenience when a vehicle requires a repair that is covered by the New Vehicle Limited Warranties. The availability of courtesy transportation to customers whose vehicles are within the warranty coverage period and involved in a product program is very important in maintaining customer satisfaction. Dealers are to ensure that these customers understand that shuttle service or some other form of courtesy transportation is available and will be provided at no charge. Dealers should refer to the General Motors Service Policies and Procedures Manual for Courtesy Transportation guidelines. Warranty Transaction Information Submit a transaction using the table below. * The amount identified in "Net Item" should represent the dollar amount reimbursed to the customer. Disclaimer Page 15217 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the cover up until the dress cover releases. Repeat this procedure for the other locking tab. 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. 5. If the connector has a nose piece, use a small flat-blade tool to remove the nose piece by inserting the blade into the slot on the front of the connector and prying up on the nose piece. IMPORTANT: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 6. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. IMPORTANT: Be careful not to angle or rock the J 38125-13A tool when inserting it into the connector or the tool may break. Page 14893 Seat Bolster/Lumbar Switch - Driver (With RPO Code AN3) Page 14304 WA8555/41 - WA8624/50 Page 5876 are secure and the TIS terminal operating software is up to date. 1. Verify the battery charge of 12 to 16 volts. The battery must be able to maintain the charge during programming. Use an additional jump battery if necessary. 2. Use the normal "request method" through "Service Programming System" to request information from the vehicle. 3. At the Techline Terminal, enter TIS SPS programming system. 4. Select Tech 2(R) from the "Select Diagnostic Tool" window. 5. Select Reprogram ECU from the Select Programming Process window. 6. Select Vehicle from the "Select ECU Location" window. 7. Select Next to go to the "Preparing for Communication" instruction screen. 8. Select Next to view the Validate Vehicle ID Number screen. If the vehicle ID number does not appear on the screen, manually insert the VIN into the VIN window of the Validate Vehicle ID Number screen. 9. Select Next to view the "Supported Controllers" screen. 10. Select PCM/VCM Powertrain/Vehicle Control Module from "Supported Controllers" window. 11. Select Next to view the "Select Programming Type" window. 12. Select Normal from the Select Programming Type window. 13. Select Next to view the "Service Programming System Calibration Selection" screen. 14. Select Next to view Summary screen. 15. Verify that current and selected calibration information is displayed on the Summary screen. 16. Select Next to download the calibration to the Tech 2(R). 17. Back at the vehicle, enter "Service Programming Systems". 18. Select Program ECU and follow the on-screen instructions. 19. When programming is complete, do the following: 19.1. Turn the Tech 2(R) OFF. 19.2. Turn the ignition switch OFF. 20. Wait 30 seconds. 21. Turn the ignition switch to ON with the engine OFF. 22. Go into Diagnostics and check for DTC codes. 23. Clear all codes. Claim Information Page 14046 Utility Storage Compartment: Service and Repair Tool Storage Compartment Lock Replacement (PRO) Tool Storage Compartment Lock Replacement (PRO) Removal Procedure Caution: Eye protection must be worn when drilling rivets to reduce the chance of personal injury. 1. Raise the rear seat. 2. Remove the rivets retaining the lock assembly to the tool storage compartment. 3. Remove the lock assembly from the vehicle. Installation Procedure 1. Install the lock assembly to the vehicle. 2. Install the rivets retaining the lock assembly to the tool storage compartment. 3. Lower the rear seat. Page 3062 8. Separate the wheel drive shaft from the wheel hub and bearing using J 45859 (2) or equivalent. 9. Remove the wheel hub and bearing (1) from the vehicle. Installation Procedure Page 8787 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors USING CONNECTOR TEST ADAPTERS IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-B Connector Test Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Page 2077 Steps 10 - 13 Engine - Oil Leaks In Extreme Cold Temperatures Engine Oil Filler / Breather Cap: Customer Interest Engine - Oil Leaks In Extreme Cold Temperatures Bulletin No.: 05-06-01-014 Date: May 09, 2005 TECHNICAL Subject: Oil Leak Under Extreme Cold Temperatures (-34°C (-30°F) or Colder) (Install Vented Oil Fill Cap) Models: 2004-2005 Buick Rainier 2003-2005 Cadillac Escalade Models 2004-2005 Cadillac CTS-V 2003-2005 Chevrolet Avalanche, Express, Kodiak, Silverado, SSR, Suburban, Tahoe, TrailBlazer, TrailBlazer EXT 2003-2005 GMC Denali Models, Envoy Models, Savana Van Models, Sierra Models, Topkick, Yukon Models 2004-2005 Pontiac GTO 2005 Pontiac Grand Prix 2003-2005 HUMMER H2 2003 Isuzu NPR/NQR Commercial Models 2003 Work Horse Custom Chassis with 4.8L, 5.3L, 5,7L or 6.0L Gas Engine (VINs V, M, T, P, B, Z, G, S, U, N - RPOs LR4, LH6, LM7, LM4, L33, L59, LS1, LS6, LS2, LQ4, LQ9) Condition Some customers may comment on an engine oil leak under extreme cold temperatures (-34°C (-30°F) or colder). The customer may also comment that there may be some oil seepage out of the engine oil level indicator (dipstick) and/or out of the front or rear crankshaft seals during engine operation only. Cause Under extreme cold temperatures (-34°C (-30°F) or colder) and extended driving conditions, the PCV system may experience a freezing condition and shut off all crankcase gases to pass through the PCV system. This may cause crankcase pressure to rise steadily and, in some cases, this high pressure unseats (pushes out) the oil level indicator from the indicator tube and causes an oil leak during engine operation. Important: If a visual inspection indicates that oil is still leaking from the front or rear crankshaft seals after this bulletin has been performed, then further diagnosis must be performed using the Oil Leak Diagnosis and/or Crankcase Ventilation System Inspection/Diagnosis in SI. Refer to the following SI document number(s) in this bulletin and print a copy for further assistance in diagnosing this condition. ^ Oil Leak Diagnosis (Truck) (SI Document ID #204344) ^ Oil Leak Diagnosis (Car) (SI Document ID #1406822) ^ Crankcase Ventilation System Inspection/Diagnosis (Truck) (SI Document ID #1246823) ^ Crankcase Ventilation System Inspection/Diagnosis (Car) (SI Document ID #954724) Correction Follow the service procedure below for diagnosis and correction of this condition. 1. Inspect for the oil fill dipstick being pushed out of the dipstick tube and that there is engine oil seeping out when the engine is under operation. This condition could be caused by the PCV valve freezing shut. 2. If an icing or freezing condition is found with a PCV valve inspection, then replace the oil fill cap with a vented oil fill cap. 3. Use a new vented oil fill cap, P/N 12589430. A vented oil fill cap will regulate the crankcase pressure between 15 kPa and 18 kPa. This will prevent the over pressurization of the crankcase under the freezing conditions of the PCV system. Once the PCV system thaws out, the crankcase gases will pass through the PCV system and normal crankcase pressure will be restored. 4. Inspect the engine oil level. Start and operate the engine under normal conditions and visually inspect that the engine oil leak has been repaired. If another engine oil leak has been detected, then refer to the above mentioned SI Document Numbers for further assistance in repairing the condition. Page 15952 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the cover up until the dress cover releases. Repeat this procedure for the other locking tab. 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. 5. If the connector has a nose piece, use a small flat-blade tool to remove the nose piece by inserting the blade into the slot on the front of the connector and prying up on the nose piece. IMPORTANT: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 6. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. IMPORTANT: Be careful not to angle or rock the J 38125-13A tool when inserting it into the connector or the tool may break. Page 1052 For vehicles repaired under warranty, use the table. Disclaimer Locations Full Engine View Left Side Page 2747 Relay Box: Locations Relay Block - I/P Location View Page 7410 Parts Information Warranty Information (excluding Saab U.S. Models) Warranty Information (Saab U.S. Models) Page 8051 ^ Tighten the three EHCU bracket bolts (4) to 25 Nm (18 ft. lbs.). 7. Connect the chassis electrical harness connectors to the EBCM (1). 8. Important: The brake pipes are held in the proper place by a frame mounted plastic bracket. Make sure that the brake pipes stay in the correct place for proper reassembly. Install the 5 brake pipes to the BPMV (6). ^ Tighten the brake pipe fittings to 25 Nm (18 ft. lbs.). 9. Connect negative battery cable. 10. Bleed the brake system. Refer to ABS Automated Bleed Procedure. Page 1895 Vehicle Speed Sensor (VSS) Tow/Haul Switch Location Page 7086 Page 3978 Fuel Tank Pressure Sensor: Description and Operation FUEL TANK PRESSURE SENSOR The FTP sensor measures the difference between the pressure or vacuum in the fuel tank and outside air pressure. The control module provides a 5-volt reference and a ground to the FTP sensor. The FTP sensor provides a signal voltage back to the control module that can vary between 0.1-4.9 volts. A high FTP sensor voltage indicates a low fuel tank pressure or vacuum. A low FTP sensor voltage indicates a high fuel tank pressure. Page 14627 Seat Recliner Motor Position Sensor - Driver (With RPO Code AN3) Page 13095 If you are unsure who the PSC is, check with the Sales Manager. General Information 1. The first step is to verify if the OnStar(R) account is active or not. This can be done by pressing the blue OnStar(R) button and connecting to the OnStar(R) call center. Analog only accounts are no longer active. Only digital upgraded accounts will be active. On Gen 6 digital systems, a clear, or "dark" LED may indicate that the OnStar(R) system has been deactivated or may possibly have a no power/no communication condition. 2. If the account isn't active, the next step is to verify what version of OnStar(R) module is in the vehicle. This can be done via the Tech 2 (Body>VCIM>Module ID Information>Module Information 2) or by using www.onstarenrollment.com. 3. A Generation 5 or older analog module can be diagnosed by following the original electronic Service Information developed for the model year of the vehicle. Note: If the customer has an old analog module, the vehicle can be repaired by replacing the module, but the customer cannot have an active account without upgrading to a digital module. 4. Modules, antennas, brackets, and other equipment are in the same location, whether original analog production or digital upgrade. 5. An upgraded vehicle may also have a new vehicle communication interface module (VCIM) bracket. If it does, order the new bracket when replacing the bracket. Don't order the original bracket. The kit may also include a small wiring jumper cable. If it does, this jumper will be required for a new module replacement. Do not discard. 6. After replacing the VCIM, it is essential to configure the new OnStar(R) system. Failure to configure the system will result in an additional customer visit for repair. DO NOT press and hold the white dot or phone button on the keypad as it will not reset this version of the OnStar(R) system and may result in a DTC being set. Use of the TIS2WEB and SPS applications, along with the Tech2(R), are required in order to perform the VCIM configuration and setup procedure for this vehicle. The configuration and set-up procedure is now a two-step process which enables an automated activation by the OnStar(R) Center, without a button press by the technician to the OnStar(R) Call Center. Page 9889 15. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 16. Install the electrical ground wire terminal to the rivet stud. 17. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 18. Install the M6 conductive nut to the rivet stud and: Tighten Tighten to 8 Nm (71 lb in). 19. Verify proper system operation. M6 Weld Nut Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M6 weld nut at the electrical ground location is damaged or stripped, a M7 conductive self-threading bolt may be used to secure the ground wire terminal. 2. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the weld nut and allow to dry. 3. Remove any loose metal particles from the damaged or stripped weld nut with a stiff brush. 4. Select a M7 conductive self-threading bolt. Refer to the Parts Information section of this bulletin 5. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M7 conductive self-threading bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 6. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 7. Install the electrical ground wire terminal to the M7 conductive self-threading bolt. 8. Install the M7 conductive self-threading bolt and: Tighten Tighten to 9 Nm (80 lb in). 9. Verify proper system operation. M6 Weld Nut Alternative Repair Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the electrical ground location is accessible from both sides of the panel, a M6 conductive bolt and a M6 conductive nut may be used to secure the electrical ground wire terminal. Refer to the Parts Information section of this bulletin. 2. Select a location adjacent the damaged M6 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the new electrical ground site. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the ground location and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 8.5 mm (0.33 in) diameter hole through the panel. 5. Remove paint and primer from the area surrounding the 8.5 mm (0.33 in) hole until bare metal is visible. 6. Select a M6 conductive bolt. Refer to the Parts Information section of this bulletin. 7. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 8. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 9. Install the electrical ground wire terminal and the M6 conductive bolt to the ground location. 10. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 11. Install the M6 conductive nut to the bolt and: Page 4521 Control Module References Part 2 Page 8266 9.1. Push the mud flap to make contact with the front side of the underbody cross sill and mark location of the hole (5) of the mud flap. 9.2. Center punch the marked location and drill a 5.159 mm (13/64 in) hole. 9.3. Install the screw. Tighten Tighten the screw to 4 N.m (35 lb in). 9.4. Repeat the above steps for hole location 6. 10. Repeat the above steps for the opposite side. Parts Information Parts are expected to be available from GMSPO on June 30, 2004. Warranty Information Please advise the customer that the mud flaps can be purchased as an accessory. Installation and/or cost of the mud flaps will not be covered under the vehicle's warranty. Disclaimer OnStar(R) - Incorrect GPS Position Reported During Call Navigation System: Customer Interest OnStar(R) - Incorrect GPS Position Reported During Call Bulletin No.: 02-08-46-006C Date: January 08, 2008 INFORMATION Subject: Incorrect OnStar(R) Global Positioning System (GPS) Location Reported During OnStar(R) Call Models: 2000-2008 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2008 HUMMER H2 2006-2008 HUMMER H3 2005-2008 Saab 9-7X with OnStar(R) Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 02-08-46-006B (Section 08 - Body and Accessories). A small number of the above-mentioned vehicles may exhibit a condition in which the vehicle reports an inaccurate location to the OnStar(R) Call Center. This condition can only be identified via a button press to the OnStar(R) Call Center by the customer. Call Center personnel will be able to identify this inaccurate location condition. Customers will then be notified through the mail by OnStar(R) if their vehicle exhibits this condition. Once this condition has been identified OnStar(R) will instruct the customer to return to the dealership to have this condition corrected. It is not necessary to reconfigure the vehicle after the following procedure. In order to correct this condition you must cycle power to the OnStar(R) system. This can be done by either removing the fuses powering the OnStar(R) system or disconnecting the OnStar(R) module (VCIM) from the vehicle. As a last resort you can disconnect the vehicle's battery. The power needs to be removed from the system for approximately 15 minutes. After completing this procedure the vehicle should be taken to an area with an unobstructed view of the sky. The vehicle should be kept running for approximately 10 minutes to allow the vehicle to reacquire the global positioning system (GPS). Then contact the OnStar(R) Call Center via the blue OnStar(R) button and ask the advisor to verify the GPS position. If the OnStar(R) advisor still has an inaccurate GPS location refer to the Navigation Systems and Cellular Communications sub-sections in the Service Manual in order to diagnose and repair the concern. If the normal diagnostics lead to module replacement you will need to contact Technical Assistance (TAC) and choose the OnStar(R) prompt. GM OnStar(R) TAC will assist in the diagnosis and if appropriate order a replacement part. Replacement parts are usually shipped out within 24 hours and a pre-paid return package label will be included for returning the faulty part. By returning the faulty part you will avoid a significant non-return core charge. Warranty Information (excluding Saab US Models) For vehicles repaired under warranty, use the table. Warranty Information (Saab US Models) Locations Brake Light Switch: Locations ABS Component Views Stoplamp Switch Page 1443 3. Connect the backup lamp switch electrical connector (1). 4. Lower the vehicle. Page 8907 Control Module References Part 4 Page 10056 1. Notice: The inlet and outlet hoses must not be twisted during installation. Do not bend or distort the inlet or outlet hoses to make installation easier. Failure to follow these procedures could result in component damage. Route the hose in the same position the hose occupied prior to removal. 2. Install the brake booster outlet hose (1) to the brake booster (2).Position the clamp at the end of the hose. 3. Install the brake booster outlet hose to the power steering pump (4).Position the clamp at the end of the hose. 4. Remove the drain pan from under the vehicle. 5. Bleed the power steering system. Refer to Bleeding the Power Steering System. (Non Rack and Pinion) Power Steering Hose Assembly Replacement (Non Rack and Pinion) Removal Procedure 1. Disconnect the energy storage box before serving the vehicle. 2. Install a drain pan under the vehicle. Notice: Refer to Power Steering Hose Disconnected Notice in Service Precautions. 3. Remove the power steering gear inlet hose (4) from the brake booster. 4. Remove the power brake booster outlet hose (3) retaining clamp (2) to remove the power brake booster hose outlet hose from the brake booster. 5. Remove the power brake booster inlet hose (1) from the brake booster. Page 4748 Engine Control Module: Service and Repair POWERTRAIN CONTROL MODULE (PCM) REPLACEMENT Service of the powertrain control module (PCM) should consist of either replacement of the PCM or programming of the electrically erasable programmable read only memory (EEPROM). If the diagnostic procedures call for the PCM to be replaced, the replacement PCM should be checked to ensure that the correct part is being used. If the correct part is being used, remove the faulty PCM and install the new service PCM. REMOVAL PROCEDURE IMPORTANT: To prevent internal PCM damage, the ignition switch must be OFF when disconnecting or connecting power to the PCM. - Remove any debris from around the PCM connector surfaces before servicing the PCM. Inspect the PCM module connector gaskets when diagnosing or replacing the PCM. Ensure that the gaskets are installed correctly. The gaskets prevent contaminant intrusion into the PCM. - The replacement PCM must be programmed. 1. Disconnect the negative battery cable. 2. If equipped with regular production option (RPO) NYS, remove the harness ground clip from the PCM cover. 3. Release the PCM cover mounting tabs. 4. Release the PCM cover from the mounting bracket. Page 12792 Locations Engine Oil Pressure (EOP) Sensor And CMP Sensor Page 14349 Electrical Symbols Part 10 Page 15310 For vehicles repaired under warranty, use the table. Disclaimer Page 7520 Remote Programming Feature 1. Connect the scan tool to the vehicle. 2. Power-up the scan tool and select the Service Programming feature. 3. Select the appropriate vehicle. 4. Press the Request Info button on the scan tool. 5. Connect the scan tool to the computer station. 6. Follow the menu select items for reprogramming and provide information about the type of device you are programming and whether you are reprogramming or replacing the electronic control unit (ECU). 7. Select "vehicle" from the selection menu. 8. Select the module you wish to program. 9. Select "Normal" for Programming Type. 10. Select the applicable software calibrations. 11. Transfer data file to the scan tool. 12. Connect the scan tool to the vehicle. 13. Turn ON the ignition, with the engine OFF. 14. Select the Service Programming feature on the scan tool. 15. Press the Program button on the scan tool. Programming Using Scan Tool Pass-Through Connection 1. Connect the scan tool to vehicle and power it up. 2. Connect the computer station to the scan tool. 3. Select "PC Using Scan Tool Connection" from the programming menu on the computer station. 4. Follow the menu select items for reprogramming and provide information about the type of device you are programming and whether you are reprogramming or replacing the electronic control unit (ECU). 5. Select "vehicle" from the selection menu. 6. Select the module you wish to program. 7. Select "Normal" for Programming Type. 8. Select the applicable software calibrations. 9. Transfer data file to the scan tool. Page 10346 1. Install the transmission support to the frame. (15 series) 2. Install the transmission support to the frame. (25/35 series) Notice: Refer to Fastener Notice in Service Precautions. 3. Install the bolts and the nuts in order to retain the transmission support to the frame. Tighten the nuts to 95 N.m (70 lb ft). 4. Lower the rear of the transmission. 5. Install the transmission mount to the transmission support. 6. Install the nuts in order to retain the transmission mount to the transmission support. Tighten the nuts to 40 N.m (30 lb ft). 7. Remove the transmission jack. 8. Lower the vehicle. Page 9914 For vehicles repaired under warranty, use the table. Disclaimer Page 7519 1. If a NEW control module is being installed, program the new module. 2. Install the shift control module to the bracket. 3. Connect the shift control module electrical connectors. 4. Start the engine and test the automatic transfer case system for proper shift operation. Transfer Case Control Module Reprogramming Transfer Case Control Module Reprogramming Set-up for Module Programming/Reprogramming Important: Ensure that the vehicle battery is fully charged and that a battery charger is no longer connected. If performing this procedure for module replacement, install a new module before proceeding. Before reprogramming, close the doors and wait two minutes to allow other modules to stop communicating via the class 2 data line. Failure to do so could result in a failed reprogramming procedure. ^ Turn OFF all accessories. ^ Turn ON the ignition, with the engine OFF. Page 494 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. REPLACEMENT PROCEDURE After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Insure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the Terminal Removal Procedure. Repairing Connector Terminals REPAIRING CONNECTOR TERMINALS TOOLS REQUIRED J 38125-D Terminal Repair Kit Use the following repair procedures in order to repair the following: - Push to Seat terminals - Pull to Seat terminals - Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-D contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100 World terminals. Soldering Micro-Pack 100 World terminals may damage the terminal. Circuit Protection - Circuit Breakers CIRCUIT PROTECTION - CIRCUIT BREAKERS A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Locations Fuel Pump And Sender Assembly Components Page 7962 9. Disassemble the harness connector (1) from the encoder. 10. Remove the encoder from the output shaft using a flat tip screwdriver. Installation Procedure 1. Assemble the harness to the NEW encoder with the connector legend "TOP" (1) and the encoder part number facing up. 2. Assemble the output shaft into the encoder, being sure to align the encoder tab with the groove on the shaft. 3. Ensure the encoder is seating properly on the output gear. 4. Place the output shaft encoder on the casting. 5. Place the grommet harness on the casting slot, the flat area on the grommet will be facing up. Page 9746 C230 I/P Harness (With RPO Codes UE1 And Y91) Or Infotainment Jumper Harness (With RPO Code UE1 & Without RPO Code Y91) To Roofmarker Harness Page 3008 Do not use cleaning solutions that contain hydrofluoric, oxalic and most other acids on chrome wheels (or any wheels). If the customer is unsure of the chemical make-up of a particular wheel cleaner, it should be avoided. For wheels showing signs of milky staining from acidic cleaners, refer to Customer Assistance and Instructions below. Warranty of Stained Chrome Wheels Stained wheels are not warrantable. Most acid based cleaners will permanently stain chrome wheels. Follow-up with dealers has confirmed that such cleaners were used on wheels that were returned to the Warranty Parts Center (WPC). Any stained wheels received by the WPC will be charged back to the dealership. To assist the customer, refer to Customer Assistance and Instructions below. Pitting or Spotted Appearance of Chrome Wheels Figure 2 A second type or staining or finish disturbance may result from road chemicals, such as calcium chloride used for dust control of unpaved roads. The staining will look like small pitting (refer to Figure 2). This staining will usually be on the leading edges of each wheel spoke, but may be uniformly distributed. If a vehicle must be operated under such conditions, the chrome wheels should be washed with mild soap and water and thoroughly rinsed as soon as conveniently possible. Important Road chemicals, such as calcium chloride used for dust control of unpaved roads, can also stain chrome wheels. The staining will look like small pitting. This staining will usually be on the leading edges of each wheel spoke. This is explained by the vehicle traveling in the forward direction while being splashed by the road chemical. If a vehicle must be operated under such conditions, the chrome wheels should be washed with mild soap and water and thoroughly rinsed as soon as conveniently possible. Warranty of Pitted or Spotted Chrome Wheels Wheels returned with pitting or spotting as a result of road chemicals may be replaced one time. Damage resulting from contact with these applied road chemicals is corrosive to the wheels finish and may cause damage if the wheels are not kept clean. Important Notify the customer that this is a one time replacement. Please stress to the customer the vital importance of keeping the wheels clean if they are operating the vehicle in an area that applies calcium chloride or other dust controlling chemicals! "GM of Canada" dealers require prior approval by the District Manager - Customer Care and Service Process (DM-CCSP). "Stardust" Corrosion of Chrome Wheels Figure 3 A third type of finish disturbance results from prolonged exposure to brake dust and resultant penetration of brake dust through the chrome. As brakes are applied hot particles of brake material are thrown off and tend to be forced through the leading edge of the wheel spoke windows by airflow. These Page 4065 5. Remove paint and primer from the area surrounding the 10 mm (0.40 in) until bare metal is visible. Important The M6 conductive rivet stud as shown, can accommodate a panel thickness range of 0.7-4.2 mm (0.03-0.17 in). If there are layers of sheet metal, they should be touching without any air gaps to ensure a good ground. 6. Select a M6 conductive rivet stud. Refer to the Parts Information section of this bulletin. Note Use the GE-50317 rivet stud tool kit. 7. Place the M6 conductive rivet stud (1) in the 10 mm (0.40 in) hole. Assemble the rivet stud tool (2) with the groove and flare side facing the rivet stud, then the washer and the M6 nut (3). 8. Using a wrench on the rivet stud tool, and a socket on the M6 nut, secure the M6 conductive rivet stud. 9. Ensure the new rivet stud is securely fastened, WITHOUT ANY detectable movement. 10. Completely wrap the threads of the rivet stud with painters tape or equivalent. Page 11596 Policies and Procedures Manual for courtesy transportation guidelines. Claim Information Submit a Product Recall Claim with the information shown. Customer Notification -- For US and Canada General Motors will notify customers of this recall on their vehicle (see copy of customer letter shown this bulletin). Customer Notification -- For Export Letters will be sent to known owners of record located within areas covered by the US National Traffic and Motor Vehicle Safety Act. For owners outside these areas, dealers should notify customers using the sample letter. Dealer Recall Responsibility -- For US and Export (US States, Territories, and Possessions) The US National Traffic and Motor Vehicle Safety Act provides that each vehicle which is subject to a recall of this type must be adequately repaired within a reasonable time after the customer has tendered it for repair. A failure to repair within sixty days after tender of a vehicle is prima facie evidence of failure to repair within a reasonable time. If the condition is not adequately repaired within a reasonable time, the customer may be entitled to an identical or reasonably equivalent vehicle at no charge or to a refund of the purchase price less a reasonable allowance for depreciation. To avoid having to provide these burdensome remedies, every effort must be made to promptly schedule an appointment with each customer and to repair their vehicle as soon as possible. In the recall notification letters, customers are told how to contact the US National Highway Traffic Safety Administration if the recall is not completed within a reasonable time. Dealer Recall Responsibility -- All All unsold new vehicles in dealers' possession and subject to this recall MUST be held and inspected/repaired per the service procedure of this recall bulletin BEFORE customers take possession of these vehicles. Dealers are to service all vehicles subject to this recall at no charge to customers, regardless of mileage, age of vehicle, or ownership, from this time forward. Customers who have recently purchased vehicles sold from your vehicle inventory, and for which there is no customer information indicated on the dealer listing, are to be contacted by the dealer. Arrangements are to be made to make the required correction according to the instructions contained in this bulletin. A copy of the customer letter is shown in this bulletin for your use in contacting customers. Recall follow-up cards should not be used for this purpose, since the customer may not as yet have received the notification letter. Page 15568 Brake Lamp: Description and Operation STOP LAMPS The STOP LP 25-amp fuse in the underhood fuse block supplies battery positive voltage to the normally open stop lamp switch. When the driver presses the brake pedal, the switch contacts close and battery positive voltage is supplied to both the STOP 15-amp fuse and the center high mounted stop lamp (CHMSL) 10-amp fuse in the instrument panel (I/P) fuse block, and to the turn signal/hazard module. The turn signal/hazard module then supplies voltage to both of the trailer rear turn/stop lamp supply voltage circuits. The voltage from the CHMSL 10-amp fuse is to the CHMSL and the trailer jumper harness. The voltage from the STOP 15-amp fuse is to the stop lamps, throttle actuator control (TAC) module, and the cruise control. Page 9093 Location View Page 1962 Speed Sensor: Service and Repair Transfer Case - NVG 246-NP8 Transfer Case Speed Sensor Replacement - Front Transfer Case Speed Sensor Replacement - Front Removal Procedure 1. Remove the transfer case shield, if equipped. 2. Disconnect the front speed sensor electrical connector (5). 3. Remove the front speed sensor. Installation Procedure 1. Notice: Refer to Fastener Notice in Service Precautions. Install the front speed sensor. ^ Tighten the speed sensor to 15 Nm (11 ft. lbs.). Service and Repair Muffler: Service and Repair Muffler Replacement (4.3L, 4.8L, and 5.3L Engines) Removal Procedure 1. Raise and suitably support the vehicle. 2. Remove the exhaust muffler nuts. 3. Apply lubricant to the exhaust insulators in order to aid in removal. 4. Remove the muffler brackets from the insulators. 5. Remove the exhaust muffler. Installation Procedure 1. Apply lubricant to the exhaust insulators in order to aid in installation. 2. Install the muffler to the insulators. Page 14857 1. Install the door module into the switch panel bezel until it snaps into place. 2. Install the switch panel bezel and module to the door panel. Notice: Refer to Fastener Notice in Service Precautions. 3. Install the screw that retains the switch panel bezel (1) to the front door panel. Tighten the screw to 2 N.m (18 lb in). 4. Connect the electrical connectors. 5. Install the front door trim panel. 6. If equipped with camper mirrors program the door module. Refer to Service Programming System (SPS). See: Testing and Inspection/Programming and Relearning Page 13555 Control Module References Part 4 Page 7817 6. Remove the 1-2 shift solenoid retainer (395) and the 1-2 shift solenoid (267A). 7. Remove the 2-3 shift solenoid retainer (395) and the 2-3 shift solenoid (367A). 8. Remove the 3-2 control solenoid retainer (395) and the 3-2 control solenoid (394). Installation Procedure 1. Install the 3-2 control solenoid (394) and the 3-2 control solenoid retainer (395). Locations Crankshaft Position (CKP) Sensor Location Page 8204 Brake Rotor/Disc: Service and Repair Brake Rotor Replacement - Rear (Except Dual Wheels or NYS) Brake Rotor Replacement - Rear (Except Dual Wheels or NYS) ^ Tools Required J 2619-01 Slide Hammer With Adapter - J 41013 Rotor Resurfacing Kit - J 42450-A Wheel Hub Resurfacing Kit - J-46277 Rotor Removal Tool Caution: Refer to Brake Dust Caution in Service Precautions. Removal Procedure 1. Release the park brake. 2. Raise and suitably support the vehicle. Refer Vehicle Lifting 3. Remove the tire and wheel assembly. 4. Mark the relationship of the rotor to the hub. 5. Install a C-clamp over the body of the brake caliper, with the C-clamp ends against the rear of the caliper body and the outboard disc brake pad. 6. Slowly tighten the C-clamp until the pistons are pushed into the caliper bores enough to remove the caliper from the pads. 7. Remove the C-clamp from the caliper. 8. Remove the brake caliper bracket mounting bolts. 9. Notice: Support the brake caliper with heavy mechanic's wire, or equivalent, whenever it is separated from its mount and the hydraulic flexible brake hose is still connected. Failure to support the caliper in this manner will cause the flexible brake hose to bear the weight of the caliper, which may cause damage to the brake hose and in turn may cause a brake fluid leak. Remove the brake caliper and brake caliper bracket as an assembly and support with heavy mechanic's wire or equivalent. DO NOT disconnect the hydraulic brake flexible hose from the caliper. 10. Remove the rotor retaining push nuts from the wheel studs, if applicable. 11. It may be necessary to strike the end of the hub or the rotor with a dead blow hammer to separate the rotor from the hub. Page 15970 Control Module References Part 1 AWD/4WD - AWD/4WD Lamps/System Inop./DTC C0550 Control Module: All Technical Service Bulletins AWD/4WD - AWD/4WD Lamps/System Inop./DTC C0550 Bulletin No.: 02-04-21-006E Date: July 20, 2006 TECHNICAL Subject: Inoperative 4WD/AWD Lamps, Inoperative 4WD/AWD System, DTC C0550 Set, No Communication with TCCM (Reprogram Transfer Case Control Module) Models: 2004 Buick Rainier 2002-2004 Chevrolet TrailBlazer, TrailBlazer EXT 2003-2004 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2002-2004 GMC Envoy, Envoy XL 2003-2004 GMC Sierra, Yukon, Yukon XL 2004 GMC Envoy XUV 2002-2004 Oldsmobile Bravada with Electronic Shift or Active Transfer Case (RPOs NP1, NP4 or NP8) Supercede: This bulletin is being revised to add Subject information and change the labor operation. This bulletin cancels and supersedes Bulletin Number 03-04-21-006. Please discard Corporate Bulletin Numbers 02-04-21-006D and 03-04-21-006 (Section 04 - Driveline/Axle). Condition Some customers may comment that the 4WD/AWD indicator lights on the selector switch do not work, or the 4WD/AWD system may be inoperative and/or the service 4WD light is illuminated. The condition is typically intermittent and always occurs at key-up. Upon investigation, the technician may find DTC C0550 set. Cause The Transfer Case Control Module (TCCM) has not received the wake-up call during key-up and has remained in the "sleep mode". When the TCCM is in the "sleep mode", it will not communicate with the class II bus or the Tech 2(R). Correction 1. Try to communicate with the TCCM. If no communication, go to step 2. If communication is possible, go to step 5. 2. Remove the underhood (ATCM or TREC) TCCM fuse. 3. Wait 30 seconds. 4. Reinstall the fuse. The module should wake up and communicate with the Tech 2(R). 5. Check for codes in the TCCM. If a C0550 is found current or in history with or without other codes, replace the module and go to step 6. 6. Reprogram the TCCM with the latest TIS software using normal SPS procedures. 7. Verify operation and that no codes are present. Important: For the 2002 model year, the TCCM must be replaced and reprogrammed. Warranty Information 06-08-111-004B - BULLETIN CANCELLATION NOTIFICATION Body Emblem: Technical Service Bulletins 06-08-111-004B - BULLETIN CANCELLATION NOTIFICATION TECHNICAL Bulletin No.: 06-08-111-004B Date: September 25, 2009 Subject: Information on Discoloration, Blistering, Peeling or Erosion of Various Exterior Emblems Including Chevy Bowtie (Bulletin Cancelled) Models: 2009 and Prior GM Passenger Cars and Trucks (including Saturn) 2003-2009 HUMMER H2 2006-2009 HUMMER H3 2005-2009 Saab 9-7X Supercede: This bulletin is being cancelled. Please discard Corporate Bulletin Number 06-08-111-004A (Section 08 - Body & Accessories). This bulletin is being cancelled. The information is no longer applicable. Disclaimer Automatic Transmission - 4L60-E/4L65-E Shift Cable: Service and Repair Automatic Transmission - 4L60-E/4L65-E Range Selector Cable Replacement Automatic Transmission Range Selector Cable Replacement Removal Procedure 1. Position the steering column shift lever to the park position. 2. Remove the instrument panel knee bolster. 3. Remove the driver's seat. 4. Pull back the carpet and insulation around the driver's area. 5. Remove the retainer securing the cable to the steering column. 6. Remove the cable end from the steering column ball stud. 7. Depress the tangs and remove the cable from the steering column bracket. 8. Remove the bolt securing the cable support to the brace. Page 3172 5. Install the knock sensors. ^ Tighten the sensors to 20 Nm (15 ft. lbs.). 6. Connect the knock sensor electrical connectors. 7. Push down on the rubber covers. 8. Install the intake manifold. Page 13349 For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to refer to the table above. Disclaimer Page 10462 6. Important: Do not reuse the nut. A new nut must be used when installing the wheel drive shaft. Remove the wheel driveshaft assembly retaining nut (2) and washer (3) from the wheel driveshaft. 7. Disengage the wheel drive shaft from the wheel hub and bearing using J 45859 or equivalent. Service and Repair Front Bumper Bracket: Service and Repair Bracket Replacement - Front Bumper (1500) 1. Remove all related panels and components. 2. Remove damaged bumper bracket. Important: Do not remove any material from end of frame rail. 3. Position the service template on the end of the frame rail. Use 3M's Repositionable Adhesive or equivalent. 4. Drill three 13 mm (1/2 in) holes at locations indicated on template. Important: Prior to refinishing, refer to the Publication GM 4901M-D-2000 "GM Approved Refinish Materials" for recommended products. Do not combine paint systems. Refer to paint manufacturer's recommendations. 5. Apply approved anti-corrosion primer to bare metal surfaces. 6. Position replacement bumper bracket. Notice: Refer to Fastener Notice in Service Precautions. 7. Install the bolts. Tighten the bolts to 50 N.m (37 lb ft). Page 6469 7. Lower the vehicle. 8. Install the cable grommet to the floor panel. 9. Important: Avoid unnecessary twisting/bending of the range selector cable when installing the cable to the support. Install the range selector cable to the support. 10. Notice: Refer to Fastener Notice in Service Precautions. Install the bolt securing the cable support to the brace. ^ Tighten the bolt to 10 Nm (89 inch lbs.). 11. Install the cable to the steering column bracket. Page 8099 perform the following steps: 1. Inspect the brake system for external leaks. 2. Pressure bleed the hydraulic brake system in order to purge any air that may still be trapped in the system. 22. Turn the ignition key ON, with the engine OFF. Check to see if the brake system warning lamp remains illuminated. 23. Important: If the brake system warning lamp remains illuminated, DO NOT allow the vehicle to be driven until it is diagnosed and repaired. If the brake system warning lamp remains illuminated, refer to Symptoms - Hydraulic Brakes. Page 2348 4. Remove the bolts (2) retaining the power steering cooler from the radiator support. 5. Remove the power steering cooler from the vehicle. Installation Procedure 1. Notice: Refer to Fastener Notice in Service Precautions. Install the power steering cooler (1) to the vehicle. ^ Tighten the power steering cooler retaining bolts to 5 Nm (44 inch lbs.). 2. Connect the power steering outlet hose (3) to the power steering gear (4). 3. Install the retaining clamp. 4. Connect the power steering inlet hose to the power steering pump. 5. Install the retaining clamp. 6. Bleed the power steering system. Refer to Bleeding the Power Steering System. 7. Inspect all the hose connections for leaks. 8. Install the front grille. Refer to Grille Replacement (GMC) Grille Replacement (Chevrolet) in Exterior Trim. (Parallel Hybrid Truck) Power Steering Cooler Pipe/Hose Replacement (Parallel Hybrid Truck) Removal Procedure 1. Disconnect the energy storage box before servicing the vehicle. 2. Remove the front grille. Refer to Grille Replacement (GMC) Grille Replacement (Chevrolet) in Exterior Trim. Page 9639 Fuse Block: Service and Repair I/P Electrical Center or Junction Block Replacement - Left INSTRUMENT PANEL ELECTRICAL CENTER OR JUNCTION BLOCK REPLACEMENT - LEFT REMOVAL PROCEDURE 1. Remove the left side end panel. 2. Remove the knee bolster. 3. Disconnect all the wiring connectors from the fuse block. 4. Remove all the fuses. 5. Remove the turn signal relay from the back of the fuse block. 6. From behind the fuse block, remove the retaining bolt. 7. Insert a screw driver between the fuse block and the wire harness block to separate. 8. Push on the retainers in order to remove the fuse block. 9. Remove the fuse block from the vehicle. INSTALLATION PROCEDURE 1. Install the fuse block onto the I/P assembly until it clicks in place. 2. Install the wire harness block to the back of the fuse block. NOTE: Refer to Fastener Notice in Service Precautions. 3. Install the bolt. Tighten Tighten the bolt to 6 N.m (53 lb in). 4. Install the turn signal relay to the back of the fuse block. 5. Using the wiring diagram on the cover of the fuse panel, install the fuses. 6. Install the electrical connectors. 7. Install the knee bolster. Page 7253 Control Module References Part 3 OnStar(R) - Analog/Digital Ready System Digital Upgrade Technical Service Bulletin # 05-08-46-006Q Date: 081028 OnStar(R) - Analog/Digital Ready System Digital Upgrade INFORMATION Bulletin No.: 05-08-46-006Q Date: October 28, 2008 Subject: Information on Upgrading Certain OnStar(R) Analog/Digital-Ready Systems to OnStar(R) Generation 6 Digital-Capable System Models Supercede: This bulletin is being revised to update the upgrade kit installation information for the 2001 Chevrolet Impala and Monte Carlo. Please discard Corporate Bulletin Number 05-08-46-006P (Section 08 - Body and Accessories). This bulletin is being issued to provide dealer personnel with information and procedures to follow should an owner wish to upgrade their OnStar(R) Analog/Digital-Ready system to an OnStar(R) Generation 6 Digital-Capable system. Disclaimer Program Overview Program Overview To upgrade their vehicle to an OnStar(R) Generation 6 Digital-Capable system, all that a customer must do is: ^ Take their vehicle to their dealer for the system upgrade. Page 2699 Relay Block - I/P C10 Part 2 Page 1195 Driver Door Module (DDM) - C5 (Memory/Heated Seat Switch) Part 2 Page 14112 Driver Door Module (DDM) - C2 (With RPO Code YE9) Part 2 Page 10371 Stabilizer Bushing: Service and Repair Rear Suspension Stabilizer Shaft Insulator Replacement Removal Procedure 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Remove the stabilizer shaft insulator bracket mounting bolts, 15/25 series shown, 35 series similar. 3. Remove the stabilizer shaft insulators brackets. 4. Lower the stabilizer shaft and remove the stabilizer shaft insulators. 5. Inspect all of the parts for wear or damage. Installation Procedure 1. Important: Place the stabilizer shaft insulators on the stabilizer bar with the slits facing toward the front of the vehicle. Install the stabilizer shaft insulators to the stabilizer bar. 2. Install the stabilizer shaft insulator brackets to the rear axle, 15/25 series shown, 35 series similar. 3. Notice: Refer to Fastener Notice in Service Precautions. Install the stabilizer shaft bracket mounting bolts. ^ Tighten the insulator bracket bolts to 33 Nm (24 ft. lbs.). 4. Lower the vehicle. Drivetrain - Service 4WD Light/DTC C0374 Set Speed Sensor: All Technical Service Bulletins Drivetrain - Service 4WD Light/DTC C0374 Set TECHNICAL Bulletin No.: 05-04-21-003C Date: April 15, 2008 Subject: Service 4WD Light Illuminated, DTC C0374 Set (Inspect Wiring Harness to Transfer Case Speed Sensors,, Replace Wiring Harness) Models: 2004-2007 Buick Rainier 2003-2006 Chevrolet Avalanche, Suburban, Tahoe 2003-2007 Chevrolet Silverado Classic, TrailBlazer, TrailBlazer EXT 2003-2006 GMC Yukon, Yukon XL 2003-2007 GMC Envoy, Envoy XL, Sierra Classic 2003-2004 Oldsmobile Bravada 2005-2007 Saab 9-7X With Four Wheel Drive or All-Wheel Drive and Active All-Wheel Drive (RPO NP4) or Active Two-Speed (RPO NP8) Transfer Case Supercede: This bulletin is being revised to update the Model and Warranty Information. Please discard Corporate Bulletin Number 05-04-21-003B (Section 04 - Driveline/Axle). Condition Some customers may comment on intermittent illumination of the Service 4WD light. Upon investigation, the technician may find DTC C0374 set. The customer may also comment on intermittent erratic operation of the 4WD or AWD system after driving through rain/snow or simply going through a car wash. Cause The speed sensor signal may have become corrupted. Possible openings in the speed sensor wire insulation (twisted pairs) can allow water intrusion. Also wire connections contaminated by water may result in short circuits and erroneous speed sensor readings. This most often occurs on the rear speed sensor circuit. Correction Inspect the wiring harness to the transfer case speed sensors. On Rainier, TrailBlazer, Envoy and 9-7X models, fabricate a replacement speed sensor harness between the C101 connector and the speed sensors. Completely inspect and test all wiring. Refer to Speed Signal Front Axle Actuator and Indicators schematic in SI. Replace the affected twisted pairs. Do not over-twist the two wires in the replacement harness. Wires should be twisted at a rate of 9 revolutions per foot. Use service connector pack, P/N 88987993 at the speed sensor end and terminal, P/N 15326267, at C101. Terminal testing tools and service terminals can be found in Terminal Repair Kit J 38125. Terminals are available from SPX/Kent-Moore. The smaller transfer case harness splices into the larger chassis harness a few inches in front of the crossmember. The chassis harness routes along the left side of the frame under the driver door area. Use nylon tie straps to secure the fabricated harness to the main chassis harness between the transfer case and C101. On the full-size pickup and full-size utility models, replace the 2.2 m (88 in) pigtail harness that runs from the C151 connector under the hood to the transfer case. Use either harness P/N 15832722 or 15224663 depending on vehicle equipment. Refer to Propshaft Speed Sensors Front Axle Actuator and Transfer Case Shift Control Switch schematic in SI. Important: Technicians should verify the integrity of the splice joints after the repair. All splice joints and connections should seal properly against water or a repeat condition can occur. Page 12330 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground TESTING FOR SHORT TO GROUND NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting With A Digital Multimeter TROUBLESHOOTING WITH A DIGITAL MULTIMETER NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TROUBLESHOOTING WITH A TEST LAMP Page 4512 If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Sir/SRS Wiring Repairs SIR/SRS WIRING REPAIRS TOOLS REQUIRED J 38125-D Terminal Repair Kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-D contains the following items: - Special sealed splices - in order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping tool - A heat torch - An instruction manual The sealed splices have the following 2 critical features: - A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-D also serves as a generic terminal repair kit. The kit contains the following items: - A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors Page 13197 For vehicles repaired under warranty use, the table. Disclaimer Page 15841 4. Close the endgate. 5. Inspect the operation. Page 12118 2. Click on the Analog-to-Digital Program link to start the ordering process. 3. To order a kit, you will need the information shown above. 4. After submitting the order, the "Terms and Conditions of Your OnStar(R) Service" page will display. This is your confirmation that the upgrade kit order has been created. U.S. Dealers will also receive an e-mail from Autocraft within several hours of ordering an upgrade kit (Canadian Dealers will receive an e-mail from MASS Electronics). 5. Print the "Terms and Conditions of Your OnStar(R) Service" page, and have the customer sign a copy. 6. A copy of this form should be stapled to the customer's copy of the Repair Order and one copy should be retained in the customer service folder. 7. If the kit you ordered is available, you will receive the upgrade kit within 4 business days of entering your order through the OnStar(R) Online Enrollment webpage. 8. To check on kit availability or the status of your order, U.S. Dealers can log onto the distributor's website at www.autocraft.com. Canadian dealers can call MASS Electronics at 877-410-6277. Upgrade Kit Installation 1. Skip to the next step if the vehicle to be upgraded is not shown above. Steering - 'Service Rear Wheel Steering' Message Body Control Module: Customer Interest Steering - 'Service Rear Wheel Steering' Message Bulletin No.: 05-02-118-002 Date: February 03, 2005 TECHNICAL Subject: DTC C0455, "Service Rear Wheel Steering", System Jumps from 4-Wheel Steer to 2-Wheel Steer (Reprogram BCM) Models: 2003-2005 Chevrolet Silverado, Suburban 2003-2005 GMC Sierra, Yukon XL with 4-Wheel Steer (RPO NYS) Condition Some customers may comment that the system will jump from 4-wheel steer to 2-wheel steer and the DIC displays the message "Service Rear Wheel Steering". Diagnosis will show DTC C0455-Front Steering Position Sensor malfunction. Cause This condition may be caused by a Class2 communication issue. Correction Reprogram the BCM. 2005 Model Year Vehicles: New software calibration, P/N 15248410, was released on TIS version 12 - broadcast to dealers on December 4, 2004. 2003-2004 Model Year Vehicles: New software calibration, P/N 15259330 ('03 Model Year) and P/N 15259331 ('04 04 Model Year), was released on TIS version 1.75 - broadcast to dealers on January 24, 2005. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 16161 - Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-D in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-D if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Page 10959 For vehicles repaired under warranty, use the table. Disclaimer Page 8876 Auxiliary Power Outlet: Diagnostic Aids Basic Knowledge Required BASIC KNOWLEDGE REQUIRED Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the Service Data. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories CHECKING AFTERMARKET ACCESSORIES Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: - Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions INDUCING INTERMITTENT FAULT CONDITIONS In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: - Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. Page 4338 Body Control Module (BCM) - C4 Part 1 Page 4122 Page 7542 2. Fill the transfer case to the bottom of the fill plug hole with DEXRON® III, GM P/N 12346143 (Canadian P/N 10952622). 3. Install the fill plug. ^ Tighten the plug to 20 Nm (15 ft. lbs.). 4. Install the transfer case shield, if equipped. 5. Lower the vehicle. Page 14357 Refer to the table as a guide in selecting the correct test adapter for frontprobing connectors: Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure SCAN TOOL SNAPSHOT PROCEDURE Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: - Snapshot - taken from the Snapshot menu choice - Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information Procedures Body Control Module: Procedures BODY CONTROL MODULE (BCM) PROGRAMMING/RPO CONFIGURATION INTRODUCTION The procedures below are designed to set-up the body control module (BCM) correctly during BCM related service. Before you start, read these procedures carefully and completely. IMPORTANT: The following procedures must be followed: 1. Programming the BCM. 2. Programming Theft Deterrent System Components, if equipped with Passlock System. PROGRAMMING THE BCM IMPORTANT: After the procedure is completed, the personalization settings of the BCM are set to a default setting. Inform the customer that the personalization must be set again. Perform the BCM special function Request BCM Info. for service programming system (SPS), then follow the SPS instructions. Refer to Service Programming System (SPS) in Programming. PROGRAMMING THEFT DETERRENT SYSTEM COMPONENTS IMPORTANT: This procedure has to be performed only for vehicles equipped with Passlock System. Perform the Programming Theft Deterrent System Components in Theft Deterrent after successfully finishing the Setup New BCM procedure. If the Programming Theft Deterrent System Components in the Theft Deterrent procedure is not performed after a BCM replacement, one of the following conditions will occur: The vehicle will not be protected against theft by the PASSLOCK system. - The engine will not crank or start. IMPORTANT: After programming, perform the following to avoid future misdiagnosis: 1. Turn the ignition OFF for 10 seconds. 2. Connect the scan tool to the data link connector. 3. Turn the ignition ON, with the engine OFF. 4. Use the scan tool in order to retrieve history DTCs from all modules. 5. Clear all history DTCs. Page 472 Electrical Symbols Part 10 Page 6366 13. Disconnect the transmission oil cooler lines. 14. Plug the transmission oil cooler line fittings. 15. Remove the indicator tube nut. 16. Remove the indicator tube bolt, if equipped with RPO HP2. Interior - Front Heated Seat(s) Inoperative Seat Heater Switch: Customer Interest Interior - Front Heated Seat(s) Inoperative Bulletin No.: 04-08-50-007 Date: March 12, 2004 INFORMATION Subject: Service Information for Front Heated Seat Inoperative/Cold Models: 2003-2004 Cadillac Escalade/ESV/EXT 2003-2004 Chevrolet Avalanch/Silverado/Suburban/Tahoe 2003-2004 GMC Denali/Sierra/Yukon/Yukon XL 2003-2004 Hummer H2 The purpose of this bulletin is to provide the technician with the following service information: ^ Heated Seats Switch Operation ^ Heated Seats Switch Diagnostics ^ Heated Seats Switch Customer Information Switch Operation 1. The engine must be running for the heated seat feature to work. The heated seats will shut off automatically when the ignition is turned off. 2. Two buttons, located on the door, are used to control the heated seat. ^ Press the horizontal (RH) button to heat the entire seat, back and cushion. ^ Press the vertical (LH) button to heat ONLY the seat back. ^ The three light bars are an indicator of the level of heat selected for either the entire seat (horizontal button) or ONLY the seat back (vertical button). 3. To heat both the seat back and seat cushion at the same time, press the horizontal (RH) button with the heated seat symbol one time. ^ All 3 light bars will glow indicating the HIGH temperature setting. ^ The horizontal (RH) button does NOT have an ON/OFF indicator light. Page 4312 6. Use fingers to squeeze the 2 locking legs of the cover. 7. Apply pressure and gently rock the cover until one locking leg is unseated. 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. Page 14221 Disclaimer Page 14807 Front Passenger Door Page 6672 16. Install the manual shaft detent roller and spring (3) and bolts. 17. Install the 2 wiring harness clips (1) and bolts (2). 18. Install the wiring harness clip (1) and bolts (2). 19. Install the lube oil pipe (5) with the short end into the valve body. 20. Install the lube oil pipe retainer (7) and the bolt (6). 21. Notice: Refer to Fastener Notice in Service Precautions. Install the valve body bolts and tighten in the order shown. ^ Tighten the bolts to 11 Nm (97 inch lbs.). 22. Install the remaining valve body bolts. ^ Tighten the bolts to 11 Nm (97 inch lbs.). 23. Connect the internal wiring harness to the valve body electrical components. 24. Install the transmission filter. Electrical - Instrument Panel & General Wiring Repair Wiring Harness: All Technical Service Bulletins Electrical - Instrument Panel & General Wiring Repair Bulletin No.: 06-08-45-004 Date: May 02, 2006 INFORMATION Subject: Instrument Panel (I/P), Body and General Wiring Harness Repair Models: 2007 and Prior GM Cars and Trucks 2003-2007 HUMMER H2 2006-2007 HUMMER H3 Important: A part restriction has been implemented on all Body and I/P harnesses and is being administered by the PQC. If a body or I/P harness replacement is required, it can take 12-28 weeks for a harness to be built and delivered to a dealer. The dealer technician is expected to repair any harness damage as the first and best choice before replacing a harness. In an effort to standardize repair practices, General Motors is requiring that all wiring harnesses be repaired instead of replaced. If there is a question concerning which connector and/or terminal you are working on, refer to the information in the appropriate Connector End Views in SI. The Instruction Manual J 38125-620, which is sent with each new update of the J 38125 Terminal Repair Kit, also has terminal crimping and terminal remove information. Important: There are some parts in the J 38125 Terminal Repair Kit (i.e. SIR connector CPAs and heat shrink tube (used in high heat area pigtail replacement) and some TPAs that are not available from GMSPO. It is vitally important that each update to the J 38125 Terminal Repair Kit be done as soon as it arrives at the dealer. Utilize the Terminal Repair Kit (J 38125) to achieve an effective wiring repair. The Terminal Repair Kit has been an essential tool for all GM Dealers since 1987. Replacement terminals and tools for this kit are available through SPX/Kent Moore. Refer to Corporate Bulletin Number 06-08-45-001 for more information. The Instruction Manual J 38125-620, which is sent with each new update to the J 38125 Terminal Repair Kit, also has terminal crimping and terminal removal information. U.S. Dealers Only - Training courses (including Tech Assists, Emerging Issues, Web, IDL and Hands-on) are available through the GM Training website. Refer to Resources and then Training Materials for a complete list of available courses. Canadian Dealers Only - Refer to the Training section of GM infoNet for a complete list of available courses and a copy of the J 38125 Terminal Repair Kit Instruction Manual. Wiring repair information is also available in Service Information (SI). The Wiring Repair section contains information for the following types of wiring repairs: - Testing for intermittent conditions and poor conditions - Flat wire repairs - GMLAN wiring repairs - High temperature wiring repairs - Splicing copper wire using splice clips - Splicing copper wire using splice sleeves - Splicing twisted or shielded cable - Splicing inline harness diodes Page 4292 Electrical Symbols Part 10 Page 7717 Page 7979 Parts Information Warranty Information (excluding Saab U.S. Models) Warranty Information (Saab U.S. Models) Page 4598 Heated Oxygen Sensor (HO2S) Bank 2 Sensor 1 Page 2926 Disclaimer Page 8768 Electrical - Aftermarket Fuse Warning Fuse: All Technical Service Bulletins Electrical - Aftermarket Fuse Warning Bulletin No.: 07-08-45-002 Date: September 05, 2007 ADVANCED SERVICE INFORMATION Subject: Service Alert: Concerns With Aftermarket Fuses in GM Vehicles Models: 2008 and Prior GM Passenger Cars and Light Duty Trucks (including Saturn) 2008 and Prior HUMMER H2, H3 2008 and Prior Saab 9-7X Concerns with Harbor Freight Tools "Storehouse" Branded Blade Type Fuses General Motors has become aware of a fuse recall by Harbor Freight Tools/Storehouse for a variety of aftermarket fuses. In two cases, these fuses have not provided protection for the wiring system of the vehicles they were customer installed in. Upon testing the 15 amp version, it was found that the fuse still would not "open" when shorted directly across the battery terminals. How to Identify These Fuses Packed in a 120 piece set, the fuse has a translucent, hard plastic, blue body with the amperage stamped into the top. There are no white painted numbers on the fuse to indicate amperage. There are no identifying marks on the fuse to tell who is making it. The fuses are known to be distributed by Harbor Freight Tools but there may be other marketers, and packaging of this style of fuse. It would be prudent to replace these fuses if found in a customers vehicle. Likewise, if wiring overheating is found you should check the fuse panel for the presence of this style of fuse. All GM dealers should use genuine GM fuses on the vehicles they service. You should also encourage the use of GM fuses to your customers to assure they are getting the required electrical system protection. GM has no knowledge of any concerns with other aftermarket fuses. If additional information becomes available, this bulletin will be updated. Disclaimer Page 9727 C201 Steering Column Harness To I/P Harness Part 2 Brakes - ABS Lamp ON/DTC's C0265/C0201/U1041 Set Grounding Point: Customer Interest Brakes - ABS Lamp ON/DTC's C0265/C0201/U1041 Set TECHNICAL Bulletin No.: 04-05-25-002E Date: March 11, 2009 Subject: ABS Light On, DTCs C0265, C0201, U1041 Set and/or Loss of Communication with Brake Module (Reground EBCM Ground) Models Supercede: This bulletin is being revised to add step 2 to the procedure and update the Parts and Warranty Information. Please discard Corporate Bulletin Number 04-05-25-002D (Section 05 - Brakes). Condition Some customers may comment that the ABS light is on. Upon further inspection, DTCs C0265 and C0201 may be set in the brake module. It is also possible for DTC U1041 to set in other modules. There may also be a loss of communication with the brake module. Cause A poor connection at the EBCM ground is causing unnecessary replacement of brake modules. Important: The EBCM ground is different for each application. Refer to the list below for the proper ground reference: ^ Midsize Utilities = Ground 304 ^ SSR = Ground 400 ^ Fullsize Trucks and Utilities = Ground 110 Correction Important: Do not replace the brake module to correct this condition. Perform the following repair before further diagnosis of the EBCM. Perform the following steps to improve the connection of the EBCM Ground: 1. Remove the EBCM Ground. The EBCM Ground is located on the frame beneath the driver's side door. If multiple grounds are found in this location, the EBCM ground can be identified as the heavy (12-gauge) wire. 2. If the original fastener has a welded on nut, remove the nut from the frame, and if required, enlarge the bolt hole to accommodate the new bolt and nut. 3. Clean the area, front and back, using a tool such as a *3M(TM) Scotch-Brite Roloc disc or equivalent. A/T - 4L60/65E, No Reverse/2nd or 4th Gear Sun Gear: Customer Interest A/T - 4L60/65E, No Reverse/2nd or 4th Gear TECHNICAL Bulletin No.: 00-07-30-022D Date: June 10, 2008 Subject: No Reverse, Second Gear or Fourth Gear (Replace Reaction Sun Shell with More Robust Heat Treated Parts) Models: 1993 - 2005 GM Passenger Cars and Light Duty Trucks 2003 - 2005 HUMMER H2 with 4L60/65-E Automatic Transmission (RPOs M30 or M32) Supercede: This bulletin is being revised to add 2005 model year to the parts information. Please discard Corporate Bulletin Number 00-07-30-022C (Section 07 - Transmission/Transaxle). Condition Some customers may comment on a no reverse, no second or no fourth gear condition. First and third gears will operate properly. Cause The reaction sun gear (673) may not hold inside the reaction sun shell (670). Correction Important: There are FOUR distinct groups of vehicles and repair procedures involved. Vehicles built in the 2001 model year and prior that make use of a reaction shaft to shell thrust washer: ^ The sun shell can be identified by four square holes used to retain the thrust washer. Use reaction sun shell P/N 24228345, reaction carrier to shell thrust washer (699B) P/N 8642202 and reaction sun gear shell thrust washer (674) P/N 8642331er (674) P/N 8642331along with the appropriate seals and washers listed below. ^ Vehicles built in the 2001 model year and prior that have had previous service to the reaction sun shell: It is possible that some 2001 and prior model year vehicles have had previous service to the reaction sun shell. At the time of service, these vehicles may have been updated with a Reaction Sun Shell Kit (Refer to Service Bulletin 020730003) without four square holes to retain the thrust washer. If it is found in a 2001 model year and prior vehicles that the reaction sun shell DOES NOT have four square holes to retain the thrust washer, these vehicles must be serviced with P/Ns 24229825 (674), 24217328 and 8642331 along with the appropriate seals and washers listed below. ^ Vehicles built in the 2001 model year and later that make use of a reaction shaft to shell thrust bearing: The sun shell can be identified by no holes to retain the thrust washer. Use reaction sun shell, P/N 24229825, reaction carrier shaft to shell thrust bearing (669A), P/N 24217328 and reaction sun gear shell thrust washer (674), P/N 8642331 along with the appropriate seals and washers listed below. ^ Vehicles built from November, 2001 through June, 2002: These vehicles should have the reaction carrier shaft replaced when the sun shell is replaced. Use shell kit P/N 24229853, which contains a sun shell (670), a reaction carrier shaft (666), a reaction carrier shaft to shell thrust bearing (669A) and a reaction sun gear shell thrust washer (674). The appropriate seals and washers listed below should also be used. When servicing the transmission as a result of this condition, the transmission oil cooler and lines MUST be flushed. Refer to Corporate Bulletin Number 02-07-30-052. Follow the service procedure below for diagnosis and correction of the no reverse, no second, no forth condition. Important: If metallic debris is found on the transmission magnet, the transmission must be completely disassembled and cleaned. Metallic debris is defined as broken parts and pieces of internal transmission components. This should not be confused with typical "normal" fine particles found on all transmission magnets. Failure to properly clean the transmission case and internal components may lead to additional repeat repairs. 1. Remove the transmission oil pan and inspect the magnet in the bottom of the pan for metal debris. Refer to SI Document ID # 825141. Page 5613 Camshaft Position (CMP) Sensor Page 12333 Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA and/or the secondary locks. Micro .64 Connectors MICRO .64 CONNECTORS TOOLS REQUIRED J 38125-D Terminal Repair Kit REMOVAL PROCEDURE Follow the steps below in order to remove terminals from Micro 64 connectors. 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. 2. Disconnect the connector from the component. Page 2291 1. Install the inlet heater hose (3) to the auxiliary water pump (1). 2. Position the inlet heater hose clamp (2) to the auxiliary water pump (1). 3. Connect the inlet heater hose to the heater core. 4. Firmly push the quick connect onto the heater core pipe until you hear an audible click. 5. Fill the cooling system. Refer to Draining and Filling Cooling System (with HP2)Draining and Filling Cooling System (without HP2) in Cooling System. Page 977 Engine Control Module: Description and Operation Powertrain Control Module (PCM) POWERTRAIN CONTROL MODULE (PCM) DESCRIPTION POWERTRAIN The powertrain has electronic controls to reduce exhaust emissions while maintaining excellent driveability and fuel economy. The powertrain control module (PCM) is the control center of this system. The PCM monitors numerous engine and vehicle functions. The PCM constantly looks at the information from various sensors and other inputs, and controls the systems that affect vehicle performance and emissions. The PCM also performs the diagnostic tests on various parts of the system. The PCM can recognize operational problems and alert the driver via the malfunction indicator lamp (MIL). When the PCM detects a malfunction, the PCM stores a diagnostic trouble code (DTC). The problem area is identified by the particular DTC that is set. The control module supplies a buffered voltage to various sensors and switches. Review the components and wiring diagrams in order to determine which systems are controlled by the PCM. The following are some of the functions that the PCM controls: The engine fueling - The ignition control (IC) - The knock sensor (KS) system - The evaporative emissions (EVAP) system - The secondary air injection (AIR) system (if equipped) - The exhaust gas recirculation (EGR) system - The automatic transmission functions - The generator - The A/C clutch control - The cooling fan control POWERTRAIN CONTROL MODULE FUNCTION The PCM constantly looks at the information from various sensors and other inputs and controls systems that affect vehicle performance and emissions. The PCM also performs diagnostic tests on various parts of the system. The PCM can recognize operational problems and alert the driver via the malfunction indicator lamp (MIL). When the PCM detects a malfunction, the PCM stores a diagnostic trouble code (DTC). The problem area is identified by the particular DTC that is set. The control module supplies a buffered voltage to various sensors and switches. The input and output devices in the PCM include analog-to-digital converters, signal buffers, counters, and output drivers. The output drivers are electronic switches that complete a ground or voltage circuit when turned on. Most PCM controlled components are operated via output drivers. The PCM monitors these driver circuits for proper operation and, in most cases, can set a DTC corresponding to the controlled device if a problem is detected. MALFUNCTION INDICATOR LAMP (MIL) OPERATION Page 3907 Steps 1 - 3 Page 8421 5. Connect the park brake warning lamp connector. 6. Install the MID-bussed electrical center to the bracket. 7. Install the left side hinge pillar panel. Refer to Trim Panel Replacement - Hinge Pillar in Interior Trim. 8. Raise and support the vehicle. Refer Vehicle Lifting 9. For 15 series vehicles, install the park brake cable to the equalizer by pulling down on the park brake cable in front of the equalizer then installing the cable to the equalizer bar. 10. For 25/35 series vehicles, enable the park brake cable automatic adjuster. Refer to Enabling the Park Brake Cable Automatic Adjuster. 11. Remove the safety stands and lower the vehicle. 12. Connect the negative battery cable. Page 12926 Amplifier: Description and Operation Amplifier AMPLIFIER The amplifier in early build vehicles is a class 2 device that communicates with the scan tool on the Class 2 bus. The Class 2 amplifier will set a U100 in the radio if there is a communication problem. The late build vehicles have a NON-Class 2 amplifier that does not communicate over the Class 2 bus and therefore the NON-Class 2 amplifier will not set codes. Both amplifiers have similar operating characteristics, therefore, there are not separate diagnostics for the NON-Class 2 amplifier. Page 4287 Electrical Symbols Part 4 Page 3577 1. Install the coolant air bleed hose (1) onto the pipe (2). 2. Important: Install the gaskets properly onto the pipe and covers. Position the O-ring seal onto the nipple portion of the pipe. Install the gaskets onto the coolant air bleed pipe and covers. Page 11804 Antenna Cable: Service and Repair Coaxial Cable Replacement - Digital Radio (Extension) COAXIAL CABLE REPLACEMENT - DIGITAL RADIO (EXTENSION) REMOVAL PROCEDURE 1. Remove the upper trim panel from the instrument panel (I/P). 2. Disconnect the digital radio antenna cable (1). 3. Fully open the I/P storage compartment in order to access the digital receiver (3). 4. Disconnect the antenna cable (2) from the digital receiver (3). 5. Disengage the antenna cable clips (4, 6) from the I/P. 6. Remove the digital radio antenna extension cable (5). INSTALLATION PROCEDURE Page 3273 3. If vehicle is a 2 wheel drive (2WD), raise the vehicle to a height to work through the front wheelhouse opening. 4. If vehicle is a 4 wheel drive (4WD), raise the vehicle in order to remove the front tires and wheels. 5. Remove the left front tire and wheel. 6. Remove the wheelhouse inner panel push pin retainers (2). 7. Remove the wheelhouse inner panel (1). 8. Remove the engine shield bolts. 9. Remove the engine shield. Important: DO NOT raise and/or support the engine by the crankshaft balancer, or oil pan. 10. Raise and suitably support the engine using adjustable (screw type) jack stands. 11. Remove the engine mount bolts. 12. For vehicles with 4WD, remove the front propeller shaft. 13. Remove the left engine mount. Installation Procedure OnStar(R) - Number Incorrect/Incorrectly Assigned Emergency Contact Module: Customer Interest OnStar(R) - Number Incorrect/Incorrectly Assigned INFORMATION Bulletin No.: 05-08-46-004C Date: December 23, 2010 Subject: OnStar(R) Phone Number Concerns (Phone Number Incorrect/Assigned to Another Vehicle/Phone) That Occur During Diagnosis of OnStar(R) System Models: 2000-2011 GM Passenger Cars and Trucks Equipped with OnStar(R) (RPO UE1) Supercede: This bulletin is being revised to update model years up to 2011. Please discard Corporate Bulletin Number 05-08-46-004B (Section 08 - Body and Accessories). During diagnosis of an OnStar(R) concern, the technician may be told that the OnStar(R) phone number is incorrect or tied to another vehicle and/or phone of some kind. To resolve these concerns, the Tech 2(R) with software version 22.005 (or higher), has the capability to change the OnStar(R) phone number. Service Procedure 1. With the Tech 2(R), build the vehicle to specifications within the Diagnostics area of the Tech 2(R). 2. For vehicles with physical-based diagnostics - under Body, go to the OnStar(R) section. Then select the Special Functions menu. For vehicles with functional-based diagnostics - under Body and Accessories, go to the Cellular Communication section. Select Module Setup and then Vehicle Communication Interface Module. 3. Locate the Program Phone Number prompt and select it. The original phone number will be displayed on the Tech 2(R) screen. 4. Contact the OnStar(R) team at the GM Technical Assistance Center (TAC) to obtain a new phone number. 5. Highlight the digits of the phone number one at a time and enter the new phone number using the number keys on the Tech 2(R). 6. Press the Soft key at the base of the screen for Done once these numbers have been changed on the screen. 7. Press the Soft key for Done again. The area code or new phone number has now been programmed into the phone. 8. Cycle the ignition to Off and open the driver's door. 9. Press the blue OnStar(R) button to make sure that a normal connection can be made to the OnStar(R) call center. If applicable, make sure the Hands-Free Calling (HFC) works properly by making a phone call. 10. If the system is working properly, fax or voicemail a case closing into the OnStar(R) team at TAC with the results. Dealers in Canada should submit case closing information through the GM infoNET. Please follow this diagnostic process thoroughly and complete each step. If the condition exhibited is resolved WITHOUT completing every step, the remaining steps do not need to be performed. If the procedure above does not resolve the condition, you must contact TAC for further assistance. This diagnostic approach was developed specifically for this condition and should not automatically be used for other vehicles with similar symptoms. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use: Warranty Information (Saab Models) For vehicles repaired under warranty, use the table. Brakes/Wheels - Excessive Debris Build Up Mud Flap: Customer Interest Brakes/Wheels - Excessive Debris Build Up Bulletin No.: 04-05-23-005 Date: June 22, 2004 INFORMATION Subject: Availability of Rear Wheel Mud Flaps to Reduce Debris Build-up on Rear Brake Calipers and/or Rear Wheels Models: 1999-2004 Chevrolet Silverado Pickup Models 1999-2004 GMC Sierra Pickup Models This bulletin is to inform dealers of the release of rear wheel mud flaps. The above models that are exposed to extensive off-paved roads may benefit from the mud flaps. The mud flaps have been developed to minimize the amount of stones and/or mud that can impact and collect on the rear caliper and/or wheel rim. Please advise customers that the installation of these mud flaps and following the recommended off-road driving information provided in their Owner's Manual should greatly reduce the possibility of accelerated rear brake component wear and/or rim damage. Install the mud flap forward of each rear wheel using the following procedure. Important: Always work from outboard to inboard, drilling one hole at a time and securing with a fastener. Follow the sequence of the procedure. This will prevent distortion of the mud flap. 1. Raise the vehicle. Support the vehicle. 2. Locate the pickup box side panel rear brace. 3. Remove the existing outboard upper fastener on the brace. 4. Install the mud flap through the "V" of the brace. Install the previously removed fastener in the hole (2) of the mud flap to the brace. Do not tighten the fastener at this time. 5. Using the mud flap as a template, locate and mark the location of the hole (1) in the pickup box wheel house. Page 2608 Application Table Page 1999 7. Insert the J 38125-13A (GM P/N 12031876-1) tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the Terminal Repair Kit to ensure that the correct release tool is used. 8. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. REPAIR PROCEDURE Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. Page 4966 Extended Cab Short Box Shown Below, Other Configurations Similar 6. Install the new canister vent valve solenoid to the fuel tank clip or mounting bracket as shown above. The valve port closest to the electrical connector must point towards the canister. 7. Cut bulk 5/8" heater hose to a length of approximately 76 mm (3 in). Install the hose between the solenoid and the canister pipe and secure using clamps. 8. Attach bulk 5/8" heater hose to the vent port and secure using a clamp. Run a length as needed along the frame rail routing to the area above the transmission. 9. Cut the hose to determined length and install the supplied filter box. Secure using a clamp. 10. Remove the transmission support and lower the transmission assembly as necessary to allow for access to the new filter box location. 11. Secure the filter box to the transmission vent hose just forward of the hose tee-section using a tie strap. DO NOT pinch or restrict the transmission vent hose. The filter box opening should be pointing downward. 12. Raise the transmission and reinstall the transmission support. 13. Connect the EVAP canister vent valve electrical connector. 14. Tie strap the hose as needed along the frame rail in order to keep the hose away from pinch-points and heat sources. 15. Lower the vehicle. Correction (2007-2010 New Style Models) After following the published SI diagnostics and determining that the EVAP canister vent valve is the cause of the MIL light, replace the EVAP canister vent valve assembly and relocate the remote filter box. To ensure correct installation, follow the procedures below. Important DO NOT replace the EVAP canister assembly for this concern unless it fails the leak test. Use Service Kit P/N 19207763 1. Raise the vehicle. Suitably support the vehicle. 2. Disconnect the EVAP canister vent valve electrical connector. Page 4749 5. Remove the PCM cover. 6. Loosen the PCM electrical connector bolts (2). NOTE: Refer to PCM and ESD Notice in Service Precautions. - In order to prevent internal damage to the PCM, the ignition must be OFF when disconnecting or reconnecting the PCM connector. 7. Disconnect the PCM electrical connectors. 8. Release the spring latch from the PCM. 9. Release the PCM mounting tabs from the PCM. 10. Remove the PCM. INSTALLATION PROCEDURE Campaign - Deactivation Of Analog OnStar(R) Technical Service Bulletin # 08089C Date: 081118 Campaign - Deactivation Of Analog OnStar(R) # 08089C: Special Coverage Adjustment - Analog OnStar Deactivation (Nov 18, 2008) Subject: 08089C -- SPECIAL COVERAGE ADJUSTMENT - ANALOG ONSTAR(R) DEACTIVATION Page 901 Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips SPLICING COPPER WIRE USING SPLICE CLIPS IMPORTANT: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. TOOLS REQUIRED J 38125-D Terminal Repair Kit 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-D in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. Page 2749 Location View Location View Page 11913 Important: Secure the wiring harness so that there is no risk of chafing and rattling. 9.4. Fold back the wiring harness and tape over the connectors (C). Fold back the wiring harness once more and secure with cable ties (D). 9.5. Install the right-hand rear luggage compartment in accordance with WIS - 8. Body - Interior equipment - Adjustment/Replacement. 10. Install the ground cable to the battery's negative terminal. 11. Clear the diagnostic trouble codes. 12. Set the date and time, see WIS - 3. Electrical system - Information display (SID_ - Technical description. 2003-2005 Saab 9-3 (9400) 4D/5D; 2004-2005 Saab 9-3 (9400) CV 2003-2005 Saab 9-3 (9440) 4D/5D; 2004-2005 Saab 9-3 (9440) CV Notice: Handle the fiber optic cables with care or the signal may be distorted. ^ It is very important that the two leads in the connector are not confused with one another. ^ Do not splice the cables. ^ Do not bend the cable in a radius smaller than 25 mm (1 in). ^ Do not expose the cable to temperatures exceeding 185°F (85°C). ^ Keep the cable ends free from dirt and grime. ^ Do not expose the cable to impact as this may cause the transparent plastic to whiten, thereby reducing the intensity of the light and causing possible communication interruptions. ^ The cable should not lie against any sharp edges as this may cause increased signal attenuation. 1. Remove the ECU CU with a Tech 2(R) according to the following: Fault diagnosis - Select model year - Select Saab 9-3 Sport (9440) - All - Add/Remove - Control Module - CU/PU - Remove. 2. Remove the ground cable from the battery's negative terminal. 3. Remove the floor console in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 4. Pry out the signal line from the SRS control module to the OnStar(R) control module and secure it: Page 1197 Heated Seat Switch - Front Passenger (FPDM C5) Page 5347 14. Install the fuel line clips to the brackets on the transmission. 15. Install the HO2S sensor connector to the bracket. 16. Install the fuel pipe bracket to the bellhousing stud. 17. Install the fuel pipe bracket nut. Tighten Tighten the nut to 10 N.m (89 lb in). 18. Lower the vehicle. 19. Remove the caps from the fuel rail and EVAP line. 20. Connect the fuel feed line (1) at the engine. 21. Connect the EVAP canister purge tube line (2). 22. Install the fuel fill cap. 23. Connect the negative battery cable. 24. Use the following procedure in order to inspect for leaks: 24.1. Turn the ignition ON, with the engine OFF, for 2 seconds. 24.2. Turn the ignition OFF for 10 seconds. 24.3. Turn the ignition ON, with the engine OFF. 24.4. Inspect for fuel leaks. Page 3299 Engine Oil: Fluid Type Specifications Engine Oil API Classification ................................................................................................................................. ........................................ Look for Starburst Symbol Above -18° C (0° F) ......................................... .......................................................................................................................... 10W-30, 5W-30 (preferred) Below -29° C (-20° F) ................................................................................................................................................. 5W-30 synthetic (preferred) , 0W-30 Page 3669 Radiator Hose: Service and Repair Radiator Hose Quick Connect Fitting Radiator Hose Quick Connect Fitting Removal Procedure 1. Using a bent-tip screwdriver or equivalent, pull on one of the open ends of the retaining ring in order to rotate the retaining ring. 2. Rotate the retaining ring (3) around the quick connector until the retaining ring is out of position and can be completely removed. 3. Remove the radiator outlet hose (2) from the quick connector fitting at the radiator (1). Installation Procedure 1. Important: Do not install the retaining ring (3) onto the fitting by pushing the retaining ring down over the fitting. Hook one of the open ends of the retaining ring (3) in one of the slots in the quick connector. 2. Rotate the retaining ring (3) around the connector until the retaining ring is positioned with all 3 ears through the 3 slots. Page 3892 5. Remove the PCM cover. 6. Loosen the PCM electrical connector bolts (2). NOTE: Refer to PCM and ESD Notice in Service Precautions. - In order to prevent internal damage to the PCM, the ignition must be OFF when disconnecting or reconnecting the PCM connector. 7. Disconnect the PCM electrical connectors. 8. Release the spring latch from the PCM. 9. Release the PCM mounting tabs from the PCM. 10. Remove the PCM. INSTALLATION PROCEDURE Page 13809 5. Remove the cable handle underneath the instrument panel (I/P). 6. Remove the cable end from the handle. 7. Use needle nose pliers in order to squeeze the tabs in order to remove the cable end from the hood latch assembly. 8. Lift the cable from the lock. 9. Partially remove the park brake pedal assembly to gain access to the hood release cable. Refer to Park Brake Pedal Assembly Replacement in Park Brake. 10. Pull the cable in toward the cable handle through the hole in the cowl. 11. Remove the radiator air baffle and deflector. 12. Detach the cable from the retainer clips. Page 8139 Brake Caliper: Specifications Brake Caliper Mounting Bolt Front ....................................................................................................................................................... 108 Nm (80 ft. lbs.) Brake Caliper Mounting Bolt Rear (15 series) ......................................................................................................................................... 42 Nm (31 ft. lbs.) Brake Caliper Mounting Bolt Rear (25/35 series) .................................................................................................................................. 108 Nm (80 ft. lbs.) Caliper Mounting Bracket Bolt Rear (JC5/JH5) ................................................................................................................................... 200 Nm (148 ft. lbs.) Caliper Mounting Bracket Bolt Rear (JH6) .......................................................................................................................................... 165 Nm (122 ft. lbs.) Caliper Mounting Bracket Bolt Rear (JH7) .......................................................................................................................................... 300 Nm (221 ft. lbs.) Caliper Mounting Bracket Bolt Rear (NYS) ........................................................................................................................................ 200 Nm (148 ft. lbs.) Caliper Mounting Bracket to Knuckle, Front (15 series) ...................................................................................................................... 175 Nm (129 ft. lbs.) Caliper Mounting Bracket to Knuckle, Front (25/35 series) ................................................................................................................. 300 Nm (221 ft. lbs.) Page 10012 9. Remove the steering knuckle (2) from the vehicle. Installation Procedure 1. Install the steering knuckle (2) to the vehicle. 2. Install the upper ball joint. 3. Install the lower ball joint. 4. Notice: Refer to Fastener Notice in Service Precautions. Install the park brake cable retaining bolt (3) to the steering knuckle. ^ Tighten the bolt to 65 Nm (48 ft. lbs.). 5. Install the wheel hub and bearing. Page 15257 4. Wait 1 minute before working on the system. Enabling Procedure - Air Bag Fuse 1. Place the ignition in the OFF position. 2. Install the fuse(s) supplying power to the SDM. 3. Turn the ignition switch to the ON position. The AIR BAG indicator will flash then turn OFF. 4. Perform the Diagnostic System Check - Vehicle if the AIR BAG warning indicator does not operate as described. Disabling Procedure - Negative Battery Cable 1. Turn the steering wheel so that the vehicles wheels are pointing straight ahead. 2. Place the ignition in the OFF position. 3. Disconnect the negative battery cable from the battery. 4. Wait 1 minute before working on system. Enabling Procedure - Negative Battery Cable 1. Place the ignition in the OFF position. 2. Connect the negative battery cable to the battery. 3. Turn the ignition switch to the ON position. The AIR BAG indicator will flash then turn OFF. 4. Perform the Diagnostic System Check - Vehicle if the AIR BAG warning indicator does not operate as described. Page 6829 10. Install the propeller shaft universal joint (2) to the pinion yoke (1).Align the reference marks made during removal. 11. Install the yoke retainers (7) and the yoke retainer bolts (6) to the pinion yoke (1). ^ Tighten the yoke retainer bolts to 25 Nm (18 ft. lbs.). 12. Inspect the axle lubricant level, and add, if necessary. 13. Install the differential carrier assembly shield, if equipped. 14. Install the brake calipers. 15. Install the tire and wheel assemblies. 16. Lower the vehicle. Page 496 circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links CIRCUIT PROTECTION - FUSIBLE LINKS Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Flat Wire Repairs FLAT WIRE REPAIRS NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Heated Oxygen Sensor (HO2S) Wiring Repairs HEATED OXYGEN SENSOR (HO2S) WIRING REPAIRS TOOLS REQUIRED J 38125-D Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: - Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-D. Repairing Damaged Wire Insulation REPAIRING DAMAGED WIRE INSULATION Component Locations Torque Converter Clutch Solenoid: Component Locations Automatic Transmission - 4L60-E/4L65-E Automatic Transmission Electronic Component Views (M30/M32) Electronic Components Page 14295 WA815K/91 - WA817K/63 Page 10379 3. Install the stabilizer shaft link nut and bolt to the frame bracket. Notice: Refer to Fastener Notice in Service Precautions. 1. Tighten the link to frame bracket nut to 65 Nm (48 ft. lbs.). 2. Tighten the ball stud to stabilizer shaft nut to 65 Nm (48 ft. lbs.). 4. Lower the vehicle. Page 13269 4.1. Unplug the SRS control module's connector (A). 4.2. Cut off the cable tie (B), detach the connector's rear end face (C), and pull out the connecting rail (D). 4.3. Extract pin 15, cut off the cable terminal and insulate the end with tape (E). Fold back the cable and secure it with tape (F). 4.4. Fit the connecting rail and end face. 4.5. Plug in the connector (A) and secure the cables with cable ties (B). 5. Remove the parcel shelf trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6. M03: Replace the optic cable on the right-hand side Page 5883 Disclaimer Page 15924 You MUST use a silver-bearing solder to make the solder joint. DO NOT attempt this repair with conventional tin/lead alloy solders. Most suppliers have this type of solder available and it is available nationally at Radio Shack(R)*. It is sold in several diameters and either are acceptable for this repair. 5. For this step, it is permitted that two technicians be used if required. Heat the new connector on the surface of the buss bar that is to be soldered. Long nose pliers are suggested to hold the electrical connector and the defroster tab in place. Keep the solder ready and begin flowing out the solder as soon as the melting temperature has been reached. Tip If a single technician is attempting this repair, it is beneficial to wrap one turn of the solder around the new contacts base. In this manner, as the melting point of the solder is reached, a layer is deposited on the bottom side of the contact. Important Try to align the new contact so that it is positioned with the same orientation as the original contact. 6. The above illustrates an ideal finished solder joint. Additional stray solder will not harm the performance of the bond; however, while it is unlikely that customers may refer to the appearance of the rear window defroster and its components as a positive styling feature of the vehicle interior, it is easy to elicit the opposite reaction due to a poor cosmetic application. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Parts Information Acrysol(TM) can be ordered directly from Kent Automotive at 1-800-654-6333 (in Canada, 1-800-563-1717). Radio Shack(R) products can be found nationally at retail locations, www.radioshack.com, or at 1-800-843-7422. All other parts can be ordered through GMSPO or SSPO. Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use: Warranty Information (Saab U.S. Models) Page 2117 Spark Plug: Application and ID SPARK PLUG TYPE: AC P/N ................................................................................................................................................. .............................................................. 25171803 NGK P/N .............................................................................................................................................. .............................................................. 12567759 Page 9424 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly, Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Pull to Seat Connectors PULL TO SEAT CONNECTORS TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Page 504 IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. Splicing Twisted or Shielded Cable SPLICING TWISTED OR SHIELDED CABLE Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. - Rewrap the conductors with the mylar tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with mylar tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Control Module References Restraints - Passenger Presence System Information Seat Occupant Sensor: All Technical Service Bulletins Restraints - Passenger Presence System Information INFORMATION Bulletin No.: 06-08-50-009F Date: December 23, 2010 Subject: Information on Passenger Presence Sensing System (PPS or PSS) Concerns With Custom Upholstery, Accessory Seat Heaters or Other Comfort Enhancing Devices Models: 2011 and Prior GM Passenger Cars and Trucks Equipped with Passenger Presence Sensing System Supercede: This bulletin is being revised to update the model years. Please discard Corporate Bulletin Number 06-08-50-009E (Section 08 - Body and Accessories). Concerns About Safety and Alterations to the Front Passenger Seat Important ON A GM VEHICLE EQUIPPED WITH A PASSENGER SENSING SYSTEM, USE THE SEAT COVERS AND OTHER SEAT-RELATED EQUIPMENT AS RELEASED BY GM FOR THAT VEHICLE. DO NOT ALTER THE SEAT COVERS OR SEAT-RELATED EQUIPMENT. ANY ALTERATIONS TO SEAT COVERS OR GM ACCESSORIES DEFEATS THE INTENDED DESIGN OF THE SYSTEM. GM WILL NOT BE LIABLE FOR ANY PROBLEMS CAUSED BY USE OF SUCH IMPROPER SEAT ALTERATIONS, INCLUDING ANY WARRANTY REPAIRS INCURRED. The front passenger seat in many GM vehicles is equipped with a passenger sensing system that will turn off the right front passenger's frontal airbag under certain conditions, such as when an infant or child seat is present. In some vehicles, the passenger sensing system will also turn off the right front passenger's seat mounted side impact airbag. For the system to function properly, sensors are used in the seat to detect the presence of a properly-seated occupant. The passenger sensing system may not operate properly if the original seat trim is replaced (1) by non-GM covers, upholstery or trim, or (2) by GM covers, upholstery or trim designed for a different vehicle or (3) by GM covers, upholstery or trim that has been altered by a trim shop, or (4) if any object, such as an aftermarket seat heater or a comfort enhancing pad or device is installed under the seat fabric or between the occupant and the seat fabric. Aftermarket Seat Heaters, Custom Upholstery, and Comfort Enhancing Pads or Devices Important ON A GM VEHICLE EQUIPPED WITH A PASSENGER SENSING SYSTEM, USE ONLY SEAT COVERS AND OTHER SEAT-RELATED EQUIPMENT RELEASED AS GM ACCESSORIES FOR THAT VEHICLE. DO NOT USE ANY OTHER TYPE OF SEAT COVERS OR SEAT-RELATED EQUIPMENT, OR GM ACCESSORIES RELEASED FOR OTHER VEHICLE APPLICATIONS. GM WILL NOT BE LIABLE FOR ANY PROBLEMS CAUSED BY USE OF SUCH IMPROPER SEAT ACCESSORIES, INCLUDING ANY WARRANTY REPAIRS MADE NECESSARY BY SUCH USE. Many types of aftermarket accessories are available to customers, upfitting shops, and dealers. Some of these devices sit on top of, or are Velcro(R) strapped to the seat while others such as seat heaters are installed under the seat fabric. Additionally, seat covers made of leather or other materials may have different padding thickness installed that could prevent the Passenger Sensing System from functioning properly. Never alter the vehicle seats. Never add pads or other devices to the seat cushion, as this may interfere with the operation of the Passenger Sensing System and either prevent proper deployment of the passenger airbag or prevent proper suppression of the passenger air bag. Disclaimer Automatic Transmission - 4L60-E/4L65-E Page 9044 Junction Block - I/P - C8 Page 354 Involved are certain vehicles within the VIN breakpoints shown above. PARTS INFORMATION -- Saab US Only Customer Notification General Motors will notify customers of this special coverage on their vehicles (see copy of typical customer letter shown in this bulletin - actual divisional letter may vary slightly). OnStar(R) - Analog/Digital Ready System Digital Upgrade Technical Service Bulletin # 05-08-46-006Q Date: 081028 OnStar(R) - Analog/Digital Ready System Digital Upgrade INFORMATION Bulletin No.: 05-08-46-006Q Date: October 28, 2008 Subject: Information on Upgrading Certain OnStar(R) Analog/Digital-Ready Systems to OnStar(R) Generation 6 Digital-Capable System Models Supercede: This bulletin is being revised to update the upgrade kit installation information for the 2001 Chevrolet Impala and Monte Carlo. Please discard Corporate Bulletin Number 05-08-46-006P (Section 08 - Body and Accessories). This bulletin is being issued to provide dealer personnel with information and procedures to follow should an owner wish to upgrade their OnStar(R) Analog/Digital-Ready system to an OnStar(R) Generation 6 Digital-Capable system. Disclaimer Program Overview Program Overview To upgrade their vehicle to an OnStar(R) Generation 6 Digital-Capable system, all that a customer must do is: ^ Take their vehicle to their dealer for the system upgrade. Page 16128 Electrical Symbols Part 3 Page 2280 6. Leak test the fitting(s) of the repaired or reinstalled component using the J 39400-A. 7. Install the air cleaner. Page 14098 Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips SPLICING COPPER WIRE USING SPLICE CLIPS IMPORTANT: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. TOOLS REQUIRED J 38125-D Terminal Repair Kit 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-D in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. Page 12865 9. Erase the diagnostic trouble codes. 10. Set the date and time, see WIS - 3. Electrical system - Information display (SID) - Technical description. Page 12671 these systems will then completely power OFF. OnStar(R) Module Expected Current Draw The expected current draw of the OnStar(R) module in various ignition modes are as follows: ^ Ignition ON ‐ 240 to 400 mA ^ Ignition OFF ‐ 3 to 20 mA for 48 hours ^ Ignition OFF ‐ 0.2 to 0.8 mA after 48 hours (120 hours on specified vehicle communication platforms (VCPs)). Note During extended voltage testing for battery parasitic draw, it is possible to observe a voltage spike caused by the following: ^ A cellular registration call that was triggered by the local cellular system. ^ The OnStar(R) system has set a monthly trigger for a vehicle data upload call for the OnStar(R) Vehicle Diagnostic E‐mail upload. OnStar(R) System States of Readiness The OnStar(R) system will use the following 4 states of readiness, depending upon the type of cellular market the vehicle is in when the ignition is turned OFF. ^ High power ^ Low power ^ Sleep ^ Digital standby The high power state is in effect whenever the ignition is in the ON or RUN position, retained accessory power (RAP) is enabled, and/or the OnStar(R) system is sending or receiving calls or when the system is performing a remote function. The low power state is in effect when the OnStar(R) system is idle with the ignition in the ON or RUN position, or with RAP enabled. The sleep state is entered after the vehicle has been shut OFF and the RAP has timed out. At a predetermined time recorded within the VCIM, the system re-enters the low power state to listen for a call from the OnStar(R) Call Center for 1 minute. After this interval, the system will again return to the sleep state for 9 minutes. If a call is sent during the 1 minute interval, the OnStar(R) system will receive the call and immediately go into the high power mode to perform any requested functions. If a call is not received during the 1 minute interval, the system will go back into the sleep mode for another 9 minutes. This process will continue for up to 48 hours, after which the OnStar(R) system will turn OFF until the ignition is turned to the ON or RUN position. The digital standby power state is entered after the vehicle has been shut off and the RAP has timed out while in a digital cellular area. When in digital standby mode, the OnStar(R) module is able to perform all remote functions as commanded by an OnStar(R) advisor at any time, for a continuous 48 hours. After 48 hours, the OnStar(R) module will go into sleep mode until a wake up signal from the vehicle is seen by the CIM. If the OnStar module loses the digital cellular signal it will revert to analog mode and follow the standard sleep state (9 minutes OFF, 1 minute standby) based on the time of the GPS signals, this will continue until a digital cellular signal is again received. If the OnStar(R) system loses battery power while the system is in a standby or sleep mode, the system will remain OFF until battery power is restored and the ignition is turned to the ON or RUN position. Deactivated OnStar(R) Accounts In the event that a customer has not upgraded their vehicle to a digital system, the account has been deactivated. The customers have been previously notified of the steps required to upgrade their vehicles. After the OnStar(R) account has been deactivated, customers will experience the following: ^ The OnStar(R) status LED will not illuminate ^ The OnStar(R) system will NOT attempt to connect to the OnStar(R) Call Center in the event of a collision or if the vehicle's front air bags deploy for any other reason. ^ An emergency button press will result in a demo message being played, indicating the service has been deactivated and needs to be upgraded. Page 10199 Steering Column Position Sensor: Service and Repair Inflatable Restraint Steering Wheel Module Coil Centering Inflatable Restraint Steering Wheel Module Coil Centering 1. Notice: The new SIR coil assembly will be centered. Improper alignment of the SIR coil assembly may damage the unit, causing an inflatable restraint malfunction. Important: If double wire harness strap is installed onto the wire harness assembly and column, you must reuse the holder for the wire straps during installation. Remove the wire harness strap(s) where necessary. Verify the following conditions before centering the SIR coil: ^ The wheels on the vehicle are straight ahead. ^ The block tooth (1) of the steering shaft assembly is in the 12 o'clock position. ^ The ignition switch is in the LOCK position. 2. If the front (5) of the SIR coil has a centering window (4), and the back side (2) includes a spring service lock (1), perform the following steps: 1. Hold the SIR coil with the face up. 2. While depressing the spring service lock, rotate the coil hub clockwise until the coil ribbon stops. 3. Rotate the coil hub slowly, counterclockwise, until the centering window appears yellow and both arrows (3) line up. 4. Release spring service lock between the locking tab. The SIR coil is now centered. 5. Align the centered SIR coil with the horn tower and slide onto the steering shaft assembly. 3. If the front (4) of the SIR coil has a centering window (3), and the back side (1) includes NO spring service lock, perform the following steps: 0. Hold the SIR coil with the face up. 1. Rotate the coil hub clockwise until the coil ribbon stops. Page 4416 results from the alteration or modification of a vehicle using non-GM approved parts or accessories. Dealers should be especially cautious of accessory companies that claim the installation of their product will not void the factory warranty. Many times these companies have even given direction on how to quickly disassemble the accessory in an attempt to preclude the manufacturer from finding out that is has been installed. Any suspect repairs should be reviewed by the Fixed Operations Manager (FOM), and in Canada by the Warranty Manager (WM) for appropriate repair direction. If it is decided that a goodwill repair is to be made on the vehicle, even with the installation of such non-GM approved components, the customer is to be made aware of General Motors position on this issue and is to sign the appropriate goodwill documentation required by General Motors. It is imperative for dealers to understand that by installing such devices, they are jeopardizing not only the warranty coverage, but also the performance and reliability of the customer's vehicle. Disclaimer Page 14952 9.1. Push the mud flap to make contact with the front side of the underbody cross sill and mark location of the hole (5) of the mud flap. 9.2. Center punch the marked location and drill a 5.159 mm (13/64 in) hole. 9.3. Install the screw. Tighten Tighten the screw to 4 N.m (35 lb in). 9.4. Repeat the above steps for hole location 6. 10. Repeat the above steps for the opposite side. Parts Information Parts are expected to be available from GMSPO on June 30, 2004. Warranty Information Please advise the customer that the mud flaps can be purchased as an accessory. Installation and/or cost of the mud flaps will not be covered under the vehicle's warranty. Disclaimer 4L60/4L60-E/4L65-E Transmission Tow/Haul Switch: Testing and Inspection 4L60/4L60-E/4L65-E Transmission Tow/Haul Switch/Indicator Always On or Inoperative Circuit Description Tow/haul mode enables the operator to achieve enhanced shift performance when towing or hauling a load. When tow/haul mode is selected, the tow/haul switch input signal to the body control module (BCM) is momentarily toggled to zero volts. This signals the powertrain control module (PCM) to extend the length of time between upshifts and increase transmission line pressure. Cycling the tow/haul switch again disables tow/haul mode and returns the transmission to a normal shift pattern. Diagnostic Aids If the electrical circuit tests are OK and the tow/haul shift pattern is not occurring, there may be a mechanical/hydraulic condition that prevents tow/haul operation. Refer to Symptoms - Automatic Transmission. Page 5077 Important The new canister vent valve will be installed in a new location, outside of the frame. 7. Position and secure the new valve assembly to the frame bracket on the outside of the frame using the existing hole and mounting bolt. Tighten Tighten the bracket mounting bolt to 12 Nm (106 lb in). 8. Connect the vent valve pipe to the EVAP canister. 9. Install the two vent valve pipe clips into the existing underbody holes. 10. Connect the EVAP canister vent valve electrical connector, if equipped. 11. Attach bulk 5/8" heater hose to the vent valve port and secure using a clamp. Run a length as needed along the frame rail routing to the area above the transmission. 12. Cut the hose to determined length and install the supplied filter box. Secure using a clamp. 13. Remove the transmission support and lower the transmission assembly as necessary to allow for access to the new filter box location. 14. Secure the filter box to the transmission vent hose just forward of the hose tee-section using a tie strap. DO NOT pinch or restrict the transmission vent hose. The filter box opening should be pointing downward. 15. Raise the transmission and reinstall the transmission support. 16. Tie strap the hose as needed along the frame rail in order to keep the hose away from pinch-points and heat sources. 17. Lower the vehicle. 2004-2007 Model Year (Use Service Kit P/N 19152349) 1. Raise the vehicle. Suitably support the vehicle. 2. Disconnect the EVAP canister vent valve electrical connector. 3. Disconnect the canister pipe from the vent valve. 4. Push in the retainer and remove the existing canister vent valve from the fuel tank clip or mounting bracket. Discard the old valve. 5. Cut back the existing canister pipe approximately 51 mm (2 in) to remove the quick connect end. Crew Cab Short Box Shown Below, Other Configurations Similar Page 9677 15. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 16. Install the electrical ground wire terminal to the rivet stud. 17. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 18. Install the M6 conductive nut to the rivet stud and: Tighten Tighten to 8 Nm (71 lb in). 19. Verify proper system operation. M6 Weld Nut Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M6 weld nut at the electrical ground location is damaged or stripped, a M7 conductive self-threading bolt may be used to secure the ground wire terminal. 2. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the weld nut and allow to dry. 3. Remove any loose metal particles from the damaged or stripped weld nut with a stiff brush. 4. Select a M7 conductive self-threading bolt. Refer to the Parts Information section of this bulletin 5. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M7 conductive self-threading bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 6. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 7. Install the electrical ground wire terminal to the M7 conductive self-threading bolt. 8. Install the M7 conductive self-threading bolt and: Tighten Tighten to 9 Nm (80 lb in). 9. Verify proper system operation. M6 Weld Nut Alternative Repair Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the electrical ground location is accessible from both sides of the panel, a M6 conductive bolt and a M6 conductive nut may be used to secure the electrical ground wire terminal. Refer to the Parts Information section of this bulletin. 2. Select a location adjacent the damaged M6 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the new electrical ground site. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the ground location and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 8.5 mm (0.33 in) diameter hole through the panel. 5. Remove paint and primer from the area surrounding the 8.5 mm (0.33 in) hole until bare metal is visible. 6. Select a M6 conductive bolt. Refer to the Parts Information section of this bulletin. 7. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 8. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 9. Install the electrical ground wire terminal and the M6 conductive bolt to the ground location. 10. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 11. Install the M6 conductive nut to the bolt and: Page 15994 Steps 1-5 Page 909 Control Module References Part 4 Page 3737 9. If vehicle is a crew cab pick-up truck, remove the exhaust heat shield nuts. 10. Remove the exhaust heat shields from the studs. Installation Procedure 1. If vehicle is a crew cab pick-up truck, install the exhaust heat shields to the studs. 2. Notice: Refer to Fastener Notice in Service Precautions. Install the exhaust heat shield nuts. Tighten the exhaust heat shield nuts to 9 Nm (80 inch lbs.). 3. If vehicle is a extended cab pick-up truck, install the exhaust heat shield (1, 2) to the studs. 4. Install the exhaust heat shield nuts. Tighten the exhaust heat shield nuts to 9 Nm (80 inch lbs.). Page 15676 1. Connect the electrical connectors. 2. Install the headlamp switch by snapping the headlamps switch into place. 3. Install the bezel to the instrument panel. Campaign - Unwanted Repeat Calls to OnStar(R) Technical Service Bulletin # 10037 Date: 100420 Campaign - Unwanted Repeat Calls to OnStar(R) CUSTOMER SATISFACTION Bulletin No.: 10037 Date: April 20, 2010 Subject: 10037 - Unwanted Repeat Calls to OnStar(R) Models: 2003 Buick LeSabre 2004-2006 Buick Rendezvous 2005 Buick LeSabre, Terraza 2005-2006 Buick LaCrosse/Allure 2006-2008 Buick Lucerne 2008 Buick LaCrosse/Allure 2008-2009 Buick Enclave 2003 Cadillac CTS 2004 Cadillac Escalade 2004-2005 Cadillac CTS-V, Deville 2005 Cadillac Escalade ESV, SRX 2005-2006 Cadillac STS 2005-2008 Cadillac CTS 2006-2008 Cadillac DTS 2007 Cadillac Escalade, Escalade EXT 2007-2008 Cadillac Escalade ESV 2008 Cadillac SRX, STS 2002 Chevrolet Impala 2003-2008 Chevrolet Suburban 2003-2009 Chevrolet Silverado 2004-2008 Chevrolet Impala 2005 Chevrolet Colorado, Corvette, Malibu 2005-2006 Chevrolet Uplander 2005-2008 Chevrolet Avalanche, Tahoe, TrailBlazer 2006 Chevrolet HHR, Monte Carlo 2006-2008 Chevrolet Equinox 2007-2008 Chevrolet Corvette 2008 Chevrolet HHR 2008-2009 Chevrolet Cobalt, Colorado, Malibu, Uplander 2003 GMC Envoy XL, Sierra, Yukon XL 2004-2008 GMC Yukon 2005-2009 GMC Sierra 2005-2008 GMC Yukon XL 2006-2008 GMC Envoy 2007 GMC Canyon 2007-2009 GMC Acadia 2006 HUMMER H2 2006-2008 HUMMER H3 2008 HUMMER H2 2003 Oldsmobile Silhouette 2005 Montana SV6 2005-2008 Pontiac Grand Prix 2006 Pontiac G6, Vibe 2007 Pontiac Montana SV6 2007-2008 Pontiac Solstice 2008 Pontiac G6, Torrent 2008-2009 Pontiac G5, G8 2009 Pontiac G3, Montana SV6 2005-2007 Saturn ION 2006-2009Saturn VUE 2007-2008 Saturn AURA, OUTLOOK, SKY Equipped with OnStar(R) (RPO UE1) Page 9406 Electrical Symbols Part 4 Service and Repair Oil Pressure Sensor: Service and Repair Engine Oil Pressure Sensor and/or Switch Replacement ^ Tools Required J 41712 Oil Pressure Switch Socket Removal Procedure 1. If necessary, remove the engine sight shield. 2. Disconnect the oil pressure sensor electrical connector (1). 3. Using J 41712 or equivalent, remove the oil pressure sensor. Installation Procedure Page 14330 Radiator Support: Service and Repair Tie Bar Replacement - Upper Removal Procedure 1. Disconnect the negative battery cable. 2. Remove the upper radiator baffle. 3. Remove the headlamps. 4. Remove the upper condenser mounting bolts. 5. Remove the bolts from the front end diagonal brace. 6. Remove the front end diagonal brace. 7. Remove the fan shroud. 8. Remove the tie bar to radiator brace bolts (1). Access the bolts from the rear of the upper radiator support using an extension. Page 4783 Left Side Of Engine Page 2704 Application Tabel Part 2 Location View A/C - Ticking Noise From Instrument Panel/DTC's Set Control Module HVAC: Customer Interest A/C - Ticking Noise From Instrument Panel/DTC's Set Bulletin No.: 06-01-38-003 Date: April 27, 2006 TECHNICAL Subject: Intermittent Ticking Noise from I/P, Poor A/C Performance, HVAC DTCs B0229, B0414, B0424, B3770 (Reprogram HVAC Control Module) Models: 2004-2006 Cadillac Escalade Models 2004-2006 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2004-2006 GMC Sierra Models, Yukon Models with Air Conditioning (RPOs CJ2, CJ3) Condition Some customers may comment on one or more of the following concerns: ^ Intermittent ticking/clicking noise from the instrument panel. ^ Recirculation mode does not work or Air Conditioning (A/C) system performance is poor during high ambient temperatures. ^ Unable to control the driver side temperature. ^ Unable to control the passenger side temperature. ^ Unable to change the front system modes. Cause This condition may be caused by the Heating, Ventilation and Air Conditioning (HVAC) actuators that may hunt for the correct commanded position. This cycling may cause a clicking or ticking noise. An overtravel of the HVAC system control doors may cause one or more of the concerns listed above. If an overtravel occurs, a Diagnostic Trouble Code (DTC) will be set, and the door will go to a preset default position. When a system door defaults, that door will stay at the default position until the DTC is cleared. After the DTC is cleared, the door will operate properly until the overtravel condition re-occurs. The table lists the HVAC system doors and the DTC associated with it. Correction Technicians are to perform the normal diagnostic procedures in SI for these concerns. If diagnostics show that the HVAC system door(s) travel below 5 counts (out of the lower range) or above 250 counts (out of the upper range), then update the software calibrations in the HVAC control module. The new calibrations were made available to dealerships as part of TIS2000 incremental satellite update version 2.5, which was broadcast to dealers in February 2006. Page 14313 WA929L/15 - WA931L/68 Page 8553 Claim Information Refer to the General Motors WINS Claims Processing Manual for details on Product Recall Claim Submission. Customer Notification -- For US and Canada General Motors will notify customers of this recall on their vehicle (see copy of customer letter shown in this bulletin). Customer Notification -- For Letters will be sent to known owners of record located within areas covered by the US National Traffic and Motor Vehicle Safety Act. For owners outside these areas, dealers should notify customers using the sample letter. Dealer Recall Responsibility -- For US and Export (US States, Territories and Possessions) The US National Traffic and Motor Vehicle Safety Act provides that each vehicle which is subject to a recall of this type must be adequately repaired within a reasonable time after the customer has tendered it for repair. A failure to repair within sixty days after tender of a vehicle is prima facie evidence Page 1145 For vehicles repaired under warranty, use the table. Disclaimer Page 1309 Ambient Temperature Sensor / Switch HVAC: Description and Operation AIR TEMPERATURE SENSORS The air temperature sensors are a 2-wire negative temperature co-efficient thermistor. The vehicle uses the following air temperature sensors: Ambient Air Temperature Sensor - Inside Air Temperature Sensor Assembly - Upper Left Air Temperature Sensor - Upper Right Air Temperature Sensor - Lower Left Air Temperature Sensor - Lower Right Air Temperature Sensor A signal and a low-reference circuit enables the sensor to operate. As the air temperature surrounding the sensor increases, the sensor resistance decreases. The sensor signal voltage decreases as the resistance decreases. The sensor operates within a temperature range between -40°C (-40°F) to 101°C (215°F). The sensor signal varies between 0.5 volts. The input of the duct air temperature sensors are different from the ambient and inside sensors. The HVAC control module converts the signal to a range between 0-255 counts. As the air temperature increases the count value will decrease. If the HVAC control module detects a malfunctioning sensor, then the control module software will use a defaulted air temperature value. The default value for the ambient and inside air temperature sensors will be displayed on the scan tool. The default value for the duct air temperature sensors will not be displayed on the scan tool. The scan tool parameter for the duct air temperature sensors are the actual state of the signal circuit. The default action ensures that the HVAC system can adjust the inside air temperature near the desired temperature until the condition is corrected. The ambient air temperature sensor mounts underhood and can be affected by city traffic, by idling, and by restarting a hot engine. Therefore, the HVAC control module filters the value of the ambient air temperature sensor for temperature display. The ambient air temperature value is updated under the above conditions. The scan tool has the ability to update the displayed ambient air temperature. To update the ambient air temperature display on the HVAC control module, perform the following procedure: Simultaneously press the MODE, FRONT DEFROST and REAR DEFROST switches. 1. Turn ON the ignition. 2. Simultaneously press the MODE, FRONT DEFROST and REAR DEFROST switches. Drivetrain - Service 4WD Light/DTC C0374 Set Speed Sensor: Customer Interest Drivetrain - Service 4WD Light/DTC C0374 Set TECHNICAL Bulletin No.: 05-04-21-003C Date: April 15, 2008 Subject: Service 4WD Light Illuminated, DTC C0374 Set (Inspect Wiring Harness to Transfer Case Speed Sensors,, Replace Wiring Harness) Models: 2004-2007 Buick Rainier 2003-2006 Chevrolet Avalanche, Suburban, Tahoe 2003-2007 Chevrolet Silverado Classic, TrailBlazer, TrailBlazer EXT 2003-2006 GMC Yukon, Yukon XL 2003-2007 GMC Envoy, Envoy XL, Sierra Classic 2003-2004 Oldsmobile Bravada 2005-2007 Saab 9-7X With Four Wheel Drive or All-Wheel Drive and Active All-Wheel Drive (RPO NP4) or Active Two-Speed (RPO NP8) Transfer Case Supercede: This bulletin is being revised to update the Model and Warranty Information. Please discard Corporate Bulletin Number 05-04-21-003B (Section 04 - Driveline/Axle). Condition Some customers may comment on intermittent illumination of the Service 4WD light. Upon investigation, the technician may find DTC C0374 set. The customer may also comment on intermittent erratic operation of the 4WD or AWD system after driving through rain/snow or simply going through a car wash. Cause The speed sensor signal may have become corrupted. Possible openings in the speed sensor wire insulation (twisted pairs) can allow water intrusion. Also wire connections contaminated by water may result in short circuits and erroneous speed sensor readings. This most often occurs on the rear speed sensor circuit. Correction Inspect the wiring harness to the transfer case speed sensors. On Rainier, TrailBlazer, Envoy and 9-7X models, fabricate a replacement speed sensor harness between the C101 connector and the speed sensors. Completely inspect and test all wiring. Refer to Speed Signal Front Axle Actuator and Indicators schematic in SI. Replace the affected twisted pairs. Do not over-twist the two wires in the replacement harness. Wires should be twisted at a rate of 9 revolutions per foot. Use service connector pack, P/N 88987993 at the speed sensor end and terminal, P/N 15326267, at C101. Terminal testing tools and service terminals can be found in Terminal Repair Kit J 38125. Terminals are available from SPX/Kent-Moore. The smaller transfer case harness splices into the larger chassis harness a few inches in front of the crossmember. The chassis harness routes along the left side of the frame under the driver door area. Use nylon tie straps to secure the fabricated harness to the main chassis harness between the transfer case and C101. On the full-size pickup and full-size utility models, replace the 2.2 m (88 in) pigtail harness that runs from the C151 connector under the hood to the transfer case. Use either harness P/N 15832722 or 15224663 depending on vehicle equipment. Refer to Propshaft Speed Sensors Front Axle Actuator and Transfer Case Shift Control Switch schematic in SI. Important: Technicians should verify the integrity of the splice joints after the repair. All splice joints and connections should seal properly against water or a repeat condition can occur. Specifications Brake Pad: Specifications Replace the disc brake pads when the friction surface is worn to within 0.76 mm (0.030 inch) of the mounting plates. Page 13158 9. Erase the diagnostic trouble codes. 10. Set the date and time, see WIS - 3. Electrical system - Information display (SID) - Technical description. Page 4557 Knock Sensor (KS) Page 6671 8. Install the manual valve (1) into the valve body. 9. To aid in alignment and assembly, install J 25025-5. 10. Install the valve body gasket (6). 11. Install the valve body (5). Attach the manual valve to the detent lever while installing the valve body. 12. Install the transmission fluid pressure manual valve position switch (2). 13. Install the transmission fluid pressure manual valve position switch bolts (1) finger tight. 14. Tighten the bolts in the order shown. ^ Tighten the bolts to 11 Nm (97 inch lbs.). 15. Remove J 25025-5. Page 11395 Solar Sensor: Service and Repair SUN LOAD SENSOR REPLACEMENT REMOVAL PROCEDURE 1. Remove the instrument panel (I/P) upper trim panel. 2. Remove the sun load sensor (2) from the upper trim panel. 3. Disconnect the electrical connector. INSTALLATION PROCEDURE 1. Connect the electrical connector. 2. Install the sun load sensor (2) to the upper trim panel. 3. Install the I/P upper trim panel- Page 12517 Vehicles Built with Upgradeable OnStar(R) System Analog Modules Note: Page 12750 For vehicles repaired under warranty use, the table. Disclaimer Page 3588 Contamination Mixing conventional green coolant with DEX-COOL(R) will degrade the service interval from 5 yrs./150,000 miles (240,000 km) to 2 yrs./30,000 miles (50,000 km) if left in the contaminated condition. If contamination occurs, the cooling system must be flushed twice immediately and re-filled with a 50/50 mixture of DEX-COOL(R) and clean water in order to preserve the enhanced properties and extended service interval of DEX-COOL(R). After 5 years/150,000 miles (240,000 km) After 5 yrs/150,000 miles (240,000 km), the coolant should be changed, preferably using a coolant exchanger. If the vehicle was originally equipped with DEX-COOL(R) and has not had problems with contamination from non-DEX-COOL(R) coolants, then the service interval remains the same, and the coolant does not need to be changed for another 5 yrs/150,000 miles (240,000 km) Equipment (Coolant Exchangers) The preferred method of performing coolant replacement is to use a coolant exchanger. A coolant exchanger can replace virtually all of the old coolant with new coolant. Coolant exchangers can be used to perform coolant replacement without spillage, and facilitate easy waste collection. They can also be used to lower the coolant level in a vehicle to allow for less messy servicing of cooling system components. It is recommended that you use a coolant exchanger with a vacuum feature facilitates removing trapped air from the cooling system. This is a substantial time savings over repeatedly thermo cycling the vehicle and topping-off the radiator. The vacuum feature also allows venting of a hot system to relieve system pressure. Approved coolant exchangers are available through the GMDE (General Motors Dealer Equipment) program. For refilling a cooling system that has been partially or fully drained for repairs other than coolant replacement, the Vac-N-Fill Coolant Refill Tool (GE-47716) is recommended to facilitate removal of trapped air from the cooling system during refill. Disclaimer Page 7621 Pay particular attention to the terminal connections at the module. Spread or open terminal connections may create an intermittent contact. Do a pin drag test. Refer to the terminal testing information in the table shown. ^ After repairs are complete, ALWAYS clear DTCs from the module prior to a system function test. If codes are not cleared first, the system will not function after repair. The technician may erroneously think that the system is still down and that further repairs are needed. Warranty Dealers who unnecessarily replace the TCCM that are found to have No Trouble Found (NTF) at the WPC will be returned to the AVM (Area Service Manager), or the DSM (District Service Manager) in Canada, through the Regional Feedback Process and may be charged back for the repair through the WINS system. Disclaimer Page 11137 Parts Information Important The Cooling Coil Coating listed below is the only GM approved product for use under warranty as an evaporator core disinfectant and for the long term control of evaporator core microbial growth. Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Page 4510 Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses CIRCUIT PROTECTION - FUSES The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the Page 12961 Speaker - LF - Tweeter - With RPO Code UQ3 Page 4597 Heated Oxygen Sensor (HO2S) Bank 1 Sensor 2 Page 1576 Fuel Level Sensor: Description and Operation Fuel System Description (Cab Chassis) FUEL LEVEL SENSOR The fuel level sensor is a part of the fuel sender assembly. The position of the float arm indicates the fuel level. The fuel level sensor contains a variable resistor which changes resistance in correspondence with the amount of fuel in the fuel tank. On models that are equipped with a single fuel tank, the fuel level sensor is wired directly to the instrument panel (IP) cluster. On models equipped with dual fuel tanks, both fuel level sensors are wired to the PCM. The PCM calculates the total fuel level in both tanks. The instrument panel (IP) fuel gage displays the total fuel level in both fuel tanks. Page 9038 Junction Block - I/P - C2 Part 2 Capacity Specifications Fluid - Transfer Case: Capacity Specifications Information not supplied by the manufacturer. Seat Bolster Motor/Position Sensor - Driver (With RPO Code AN3) Seat Bolster Motor/Position Sensor - Driver (With RPO Code AN3) Page 9814 5. Push on the tab (3) so that the electrical center can be rotated on the studs located at (2). 6. Remove all connectors by removing the bolt (1) for each connector. 7. Disconnect all connectors from the electrical center block. 8. Push on the tabs (2) in order to lift the electrical center (1) out of the housing. 9. To replace the engine electrical center bracket remove the 4 retaining bolts (1). 10. Remove the engine electrical center bracket assembly from the fender. INSTALLATION PROCEDURE Page 10058 1. Install the gear inlet hose to the gear (4). Notice: Refer to Installing Hoses Without Twists or Bends Notice in Service Precautions. Important: Following this sequence ensures correct routing and orientation. 2. Install the booster inlet hose to the pump. Important: Ensure that the hose contacts the power steering pump as shown. Page 9766 C321 Seat Jumper Harness To Seat Harness (With RPO Code AN3) Part 1 Manual Transmission - NV 3500 Vehicle Speed Sensor: Service and Repair Manual Transmission - NV 3500 Vehicle Speed Sensor (VSS) Replacement Removal Procedure 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. Disconnect the vehicle speed sensor (VSS) electrical connector (1). 3. Remove the VSS and O-ring seal. Installation Procedure Page 4310 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Micro-Pack 100W Connectors MICRO-PACK 100W CONNECTORS TOOLS REQUIRED J 38125-D Terminal Repair Kit REMOVAL PROCEDURE There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2)has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. IMPORTANT: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Page 983 5. Remove the PCM cover. 6. Loosen the PCM electrical connector bolts (2). NOTE: Refer to PCM and ESD Notice in Service Precautions. - In order to prevent internal damage to the PCM, the ignition must be OFF when disconnecting or reconnecting the PCM connector. 7. Disconnect the PCM electrical connectors. 8. Release the spring latch from the PCM. 9. Release the PCM mounting tabs from the PCM. 10. Remove the PCM. INSTALLATION PROCEDURE Page 8498 cloth below the booster supply port in order to capture any fluid exiting the hydro-boost unit. 10. Install the inlet port adapter, CH 47950-2 (2) into the booster supply port. 11. Using a torque wrench, slowly tighten the inlet port adapter to 16 N.m (12 lb-ft). If the clear tube was removed from the inlet port adapter assembly, be sure it is reinstalled. 12. Before each use of the accumulator pressure clamp, CH 47950-1, be sure to grease the clamp bolt and anti rotation washer with wheel bearing grease. 13. Install the accumulator pressure clamp, CH 47950-1 (1), by sliding it over the accumulator and straddling the hydro-boost housing. 14. Confirm that the accumulator pressure clamp is squarely seated onto the booster housing and accumulator, and place the 3/4 inch containment bolt into the fixture. Install the nut hand-tight onto the containment bolt. 15. Check and make sure that the fixture washer is correctly positioned between the end of the accumulator, and that the pin is engaged in the end of the bolt. The tab on the washer should be rotated clockwise so it is located below the master cylinder mounting flange ear. Caution: Incorrect installation of the washer will result in damage to the accumulator end. 16. Hand-tighten the accumulator pressure clamp bolt. Make sure the clamp is level and the tube is square to the end of the accumulator. 17. Place a shop cloth next to the opening of the inlet port adapter in order to capture any fluid exiting the hydro-boost unit. Important: Do not exceed 65 N.m (48 lb-ft) torque. Important: A torque wrench must be used to tighten the fixture clamp bolt 18. Slowly tighten the fixture clamp bolt while monitoring the inlet port adapter tube for signs of power steering fluid. Stop tightening of the bolt when either fluid is observed (below the maximum 65 N.m (48 lb-ft) torque) OR The 65 N.m (48 lb-ft) maximum bolt torque is achieved (with no fluid Page 3215 22. Remove and discard the old gasket (1). 23. Remove the oil fill tube from the rocker cover, if required. 24. If required, clean and inspect the rocker arm cover. Installation Procedure Important: ^ All gasket surfaces should be free of oil or other foreign material during assembly. ^ DO NOT reuse the valve rocker arm cover gasket. ^ If the oil fill tube has been removed from the rocker arm cover, install a NEW fill tube during assembly. 1. Lubricate the O-ring seal of the NEW oil fill tube with clean engine oil. 2. Insert the NEW oil fill tube into the rocker arm cover.Rotate the tube clockwise until locked in the proper position. 3. Install the oil fill cap into the tube.Rotate the cap clockwise until locked in the proper position. Page 2406 Page 10825 Air Door Actuator / Motor: Diagrams HVAC System - Manual Air Temperature Actuator - Left A/C - Ticking Noise From Instrument Panel/DTC's Set Control Module HVAC: Customer Interest A/C - Ticking Noise From Instrument Panel/DTC's Set Bulletin No.: 06-01-38-003 Date: April 27, 2006 TECHNICAL Subject: Intermittent Ticking Noise from I/P, Poor A/C Performance, HVAC DTCs B0229, B0414, B0424, B3770 (Reprogram HVAC Control Module) Models: 2004-2006 Cadillac Escalade Models 2004-2006 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2004-2006 GMC Sierra Models, Yukon Models with Air Conditioning (RPOs CJ2, CJ3) Condition Some customers may comment on one or more of the following concerns: ^ Intermittent ticking/clicking noise from the instrument panel. ^ Recirculation mode does not work or Air Conditioning (A/C) system performance is poor during high ambient temperatures. ^ Unable to control the driver side temperature. ^ Unable to control the passenger side temperature. ^ Unable to change the front system modes. Cause This condition may be caused by the Heating, Ventilation and Air Conditioning (HVAC) actuators that may hunt for the correct commanded position. This cycling may cause a clicking or ticking noise. An overtravel of the HVAC system control doors may cause one or more of the concerns listed above. If an overtravel occurs, a Diagnostic Trouble Code (DTC) will be set, and the door will go to a preset default position. When a system door defaults, that door will stay at the default position until the DTC is cleared. After the DTC is cleared, the door will operate properly until the overtravel condition re-occurs. The table lists the HVAC system doors and the DTC associated with it. Correction Technicians are to perform the normal diagnostic procedures in SI for these concerns. If diagnostics show that the HVAC system door(s) travel below 5 counts (out of the lower range) or above 250 counts (out of the upper range), then update the software calibrations in the HVAC control module. The new calibrations were made available to dealerships as part of TIS2000 incremental satellite update version 2.5, which was broadcast to dealers in February 2006. Page 6018 Vehicle Speed Sensor(VSS) Page 2314 2. Install the suction hose to the accumulator using new sealing washers. NOTE: Refer to Fastener Notice in Service Precautions. 3. Install the suction hose nut to the accumulator. Tighten Tighten the nut to 16 N.m (12 lb ft). 4. Install the suction hose (2) to the compressor using new sealing washers. 5. Install the suction hose mounting bolt to the A/C compressor. Tighten Tighten the bolt to 16 N.m (12 lb ft). 6. Evacuate and recharge the A/C system. Refer to Refrigerant Recovery and Recharging. 7. Leak test the fittings of the component using the J 39400-A. Page 4543 Steps 18 - 20 Page 7616 For vehicles repaired under warranty, use the table. Disclaimer Page 8305 1. Remove all traces of the original adhesive patch. 2. Clean the threads of the bolts with brake parts cleaner or the equivalent and allow to dry. 3. Apply Threadlocker GM P/N 12345493 (Canadian P/N 10953488) to the threads of the bolts. 6. Install the brake caliper to the brake caliper mounting bracket. 7. Install the 2 brake caliper mounting bolts. ^ Tighten the 2 brake caliper mounting bolts to 42 Nm (31 ft. lbs.). 8. Install the quarter shaft shield. 9. Install the quarter shaft shield nut and the bolt. ^ Tighten the quarter shaft shield nut and the bolt to 25 Nm (18 ft. lbs.). 10. Install the tire and wheel assembly. 11. Lower the vehicle. 12. With the engine OFF gradually apply the brake pedal to approximately 2/3 of it's travel distance. 13. Slowly release the brake pedal. 14. Wait 15 seconds then repeat steps 12-13 until a firm pedal is obtained. This will properly seat the brake caliper pistons and brake pads. Disc Brake Hardware Replacement - Front Disc Brake Hardware Replacement - Front Caution: Refer to Brake Dust Caution in Service Precautions. Removal Procedure 1. Raise and support the vehicle. Refer Vehicle Lifting 2. Remove the tire and wheel assembly. 3. Notice: Support the brake caliper with heavy mechanic's wire, or equivalent, whenever it is separated from its mount and the hydraulic flexible brake hose is still connected. Failure to support the caliper in this manner will cause the flexible brake hose to bear the weight of the caliper, which may cause damage to the brake hose and in turn may cause a brake fluid leak. Remove the caliper from the mounting bracket and support the caliper with heavy mechanic's wire or equivalent. DO NOT disconnect the hydraulic brake flexible hose from the caliper. Refer to Brake Caliper Replacement Front. 4. Remove the disc brake pads from the disc brake caliper mounting bracket. 5. Remove the disc brake pad retainers from the disc brake caliper mounting bracket. 6. Inspect the disc brake hardware. Refer to Disc Brake Mounting and Hardware Inspection - Front. Page 14099 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Page 754 HVAC Control Module - C1 Part 2 Page 13543 circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links CIRCUIT PROTECTION - FUSIBLE LINKS Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Flat Wire Repairs FLAT WIRE REPAIRS NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Heated Oxygen Sensor (HO2S) Wiring Repairs HEATED OXYGEN SENSOR (HO2S) WIRING REPAIRS TOOLS REQUIRED J 38125-D Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: - Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-D. Repairing Damaged Wire Insulation REPAIRING DAMAGED WIRE INSULATION Wheels/Tires - 20 Inch Wheels Available From GM Wheels: All Technical Service Bulletins Wheels/Tires - 20 Inch Wheels Available From GM Bulletin No.: 03-03-10-006F Date: September 27, 2006 INFORMATION Subject: 20" Wheels Available Through GM Accessories Models: 1999-2007 Chevrolet Silverado 1500 Series Only (Classic) 1999-2007 GMC Sierra 1500 Series Only (Classic) Excludes 1999-2000 Vehicles with 4.3L Engine (VIN W - RPO L35) Excludes Vehicles with Quadrasteer (RPO NYS) Excludes Parallel Hybrid Truck (RPO HP2) Excludes 2001-2004 Vehicles with Traction Control (RPO NW7) combined with 3.42 Axle Ratio (RPO GU6) Campaign - HVAC Blower Not Functional Runs Continuously Control Module HVAC: All Technical Service Bulletins Campaign - HVAC Blower Not Functional Runs Continuously SPECIAL COVERAGE Bulletin No.: 11046 Date: April 07, 2011 Subject: 11046 - Special Coverage Adjustment - Heating, Ventilation, and Air Conditioning Blower Not Fully Functional on All Blower Speeds, Inoperative, or Runs Continuously with the Ignition Off Models: 2003-2006 Chevrolet Avalanche, Suburban, Tahoe 2003-2007 Chevrolet Silverado 2003-2006 GMC Yukon, Yukon XL 2003-2007 GMC Sierra Equipped with Manual HVAC (CJ3) or Heavy Duty Heater (C42) Due to part availability, owner letters will be released in phases starting with older model year first. Owners for model year vehicles not included in first phase owner mailing will receive an owner advisory letter. The letter will inform the customer that parts are not yet available and that another letter will be sent to them when parts become available. A copy of this letter will be attached to the dealer message announcing this bulletin. In the meantime, if a customer brings their vehicle to the dealership with the condition described in this bulletin, repair the vehicle using the parts called out in this bulletin. Condition On some 2003-2006 model year Chevrolet Avalanche, Suburban, Tahoe; GMC Yukon, Yukon XL; and 2003-2007 model year Chevrolet Silverado and GMC Sierra vehicles equipped with a manual heating, ventilation, and air conditioning (HVAC) system (CJ3) or heavy duty heater (C42), the interface between the electrical terminals of the relay resistor module and the wiring connector that powers the module may be incapable of conducting higher current levels for sustained periods of blower motor operation. In addition, moisture and other contaminants may enter the fresh air intake plenum and contact the internal circuit of the module or corrode the terminals. Either of the above may cause the relay resistor module or wiring connector to overheat, resulting in one or more of the following symptoms: - The HVAC blower may not function on certain or all blower speed settings - A burning plastic smell or smoke may be present in the vehicle - The HVAC blower may run continually with the ignition in the OFF position In very rare events, if the above symptoms are ignored, a fire could occur. Special Coverage Adjustment This special coverage covers the condition described above for a period of 10 years or 240,000 km, whichever occurs first, from the date the vehicle was originally placed in service, regardless of ownership. Dealers are to install a new blower motor resistor and resistor module connector. The repairs will be made at no charge to the customer. For vehicles covered by Vehicle Service Contracts, all eligible claims with repair orders on or after April 8, 2011 are covered by this special coverage and must be submitted using the labor operation codes provided with this bulletin. Claims with repair orders prior to April 8, 2011 must be submitted to the Service Contract provider. Vehicles Involved Involved are certain 2003-2006 model year Chevrolet Avalanche, Suburban, Tahoe; GMC Yukon, Yukon XL; and 2003-2007 model year Chevrolet Silverado and GMC Sierra vehicles equipped with a manual HVAC (CJ3) or heavy duty heater (C42). Important Dealers are to confirm vehicle eligibility prior to beginning repairs by using the Applicable Warranties section in the Global Warranty Management system. Parts Information Page 6681 Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use the table. Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table. Disclaimer Page 9551 Fuse Block - Underhood C1 Part 5 Fuse Block - Underhood C2 Engine - Rough Idle/Misfire/MIL ON/DTC P0300 Intake Air Plenum Gasket: Customer Interest Engine - Rough Idle/Misfire/MIL ON/DTC P0300 Bulletin No.: 05-06-04-029A Date: June 24, 2005 TECHNICAL Subject: Flexible Fuel (RPO L59) Rough Idle, Misfire, MIL DTC P0300 (Install Intake Manifold Gaskets With Teal Green Gasket Material) Models: 2002-2004 Chevrolet Silverado, Suburban, Tahoe 2002-2004 GMC Sierra, Yukon, Yukon XL with 5.3L Engine and Flexible Fuel (VIN Z - RPO L59) This bulletin may apply to the following engines using regular fuel: 4.8L, 5.3L, 6.0L (VINs V, T, P, U, N - RPOs LR4, LM7, LM4, LQ4, LQ9). Supercede: This bulletin is being revised to add additional diagnostic information. Please discard Corporate Bulletin Number 05-06-04-029 (Section 06 - Engine/Propulsion System). Important: Always begin your diagnosis with the Diagnostic System Check - Engine Controls (SI Document ID # 1289827) for any MIL or driveability concern. The Diagnostic System Check directs you to the next logical step in your diagnosis. Follow the instructions in this bulletin should the rough idle, misfire, or DTC P0300 diagnostic procedure point to an air leak in the intake manifold gasket. Following the published diagnostic procedures will improve diagnostic accuracy and support our fix it right the first time approach. Condition Some customers may comment that the vehicle may have a rough idle, misfires and/or a MIL illuminated with a stored DTC P0300. Cause The L59 engine is calibrated for ethanol fuel (E85). Due to the low volatility of ethanol, the PCM provides higher fuel flow through the injector, which may pool on the upper manifold to head gasket material. Overtime (usually 12 months and longer), the gasket material may degrade resulting in an unmetered air leak. Correction Replace the upper intake manifold gaskets with the teal green gasket material, P/N 89017589. Important: Do not replace the upper intake manifold gaskets with the original orange gasket material, P/N 17113557. Inspect Intake Manifold to Cylinder head Deck for Warpage Page 15476 Fuel Gauge Sender: Diagrams Fuel Pump/Sender Assembly - Primary Page 13402 Steering Mounted Controls Transmitter: Diagnostic Aids Basic Knowledge Required BASIC KNOWLEDGE REQUIRED Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the Service Data. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories CHECKING AFTERMARKET ACCESSORIES Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: - Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions INDUCING INTERMITTENT FAULT CONDITIONS In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: - Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. Page 11674 2. Install the rear seat belt retractor to body bolt (1). Tighten Tighten the bolt to 53 N.m (39 lb ft). 3. Install the rear quarter trim panel. 4. Install the rear seat belt to body bolts (2). Tighten Tighten the bolts to 53 N.m (39 lb ft). 5. Install the seat belt guide cover (1). Page 4992 3. Disconnect the vent valve pipe quick connect from the canister. 4. Either cut the existing valve vent pipe and leave the remaining section of pipe in the vehicle or remove along with the valve. 5. Push in the retainer and remove the existing canister vent valve from the fuel tank clip or mounting bracket. 6. Cut back the existing canister pipe approximately 51 mm (2 in) and retain the pipe for use with new valve. 7. Connect the canister pipe quick connect to the canister. 2500 Crew Cab Short Box Shown Below, Other Configurations Similar 1500 Extended Cab Short Box Shown Below, Other Configurations Similar 8. Install the new canister vent valve solenoid to the fuel tank clip or mounting bracket as shown above. The valve port closest to the electrical connector must point towards the canister. 9. Cut bulk 5/8" heater hose to a length of approximately 76 mm (3 in). Install the hose between the solenoid and the canister pipe and secure using clamps. 10. Attach bulk 5/8" heater hose to the vent port and secure using a clamp. Run a length as needed along the frame rail routing to the passenger side area above the transmission. 11. Cut the hose to determined length and install the supplied filter box. Secure using a clamp. 12. Remove the transmission heat shield, if necessary. 13. Remove the transmission support and lower the transmission assembly as necessary to allow for access to the new filter box location. 14. Secure the filter box to the transmission vent hose just forward of the hose tee-section using a tie strap. DO NOT pinch or restrict the transmission vent hose. The filter box opening should be pointing downward. 15. Raise the transmission and reinstall the transmission support. 16. Reinstall the transmission heat shield. 17. Connect the EVAP canister vent valve electrical connector. 18. Tie strap the hose as needed along the frame rail in order to keep the hose away from pinch-points and heat sources. 19. Lower the vehicle. Parts Information Page 2149 Steps 14 - 15 The number(s) below refer to the step(s) in the diagnostic table. 2. The chirping noise may not be engine related. This step is to verify that the engine is making the noise. If the engine is not making the noise do not proceed any further in this table. 3. The noise may be an internal engine noise. Remove the drive belt(s) and operate the engine for a few seconds, this will verify if the chirping noise is related to the drive belt(s) or not. With the drive belt(s) removed the water pump will not operate and the engine may overheat. Also diagnostic trouble codes (DTCs) may set when the engine is operated with the drive belt(s) removed. 4. Inspect the drive belt(s) for signs of pilling. Pilling is the small balls, pills, or strings in the drive belt grooves caused by the accumulation of rubber dust. 6. Misalignment of the accessory drive pulley(s) may be caused from improper mounting or incorrect installation of an accessory drive component, or the pulley may be bent inward or outward from a previous repair. Test for a misaligned accessory drive pulley using a straight edge in the pulley grooves across two or three pulleys. If a misaligned pulley is found, refer to that accessory drive component for the proper removal and installation procedure for that pulley. 10. Inspection of the fasteners can eliminate the possibility that a incorrect bolt, nut, spacer, or washer was installed. 12. Inspection of the accessory drive pulley(s) should include inspecting for bends, dents, or other damage to the pulley(s) that would prevent the drive belt(s) from seating properly in the pulley grooves or on the smooth surface of the pulley when the back side of the drive belt is used to drive the pulley. 14. Replacing the drive belt(s) when it is not damaged or there is not excessive pilling will only be a temporary repair. Drive Belt Excessive Wear Drive Belt Excessive Wear Diagnosis Diagnostic Aids Excessive wear on a drive belt(s) is usually caused by incorrect installation or the incorrect drive belt(s) for the application. Minor misalignment of the accessory drive pulley(s) will not cause excessive wear, but will probably cause the drive belt(s) to make a noise or fall off. Excessive misalignment of the accessory drive pulley(s) will cause excessive wear and may also make the drive belt(s) fall off. Test Description Page 4811 Fuel Tank Pressure (FTP) Sensor Driveline - Bump/Clunk/Squawking Noises Slip Yoke: All Technical Service Bulletins Driveline - Bump/Clunk/Squawking Noises Bulletin No.: 01-04-17-004B Date: January 05, 2005 TECHNICAL Subject: Clunk, Bump or Squawk when Vehicle Comes to Complete Stop or Accelerating from Complete Stop (Replace Rear Drive Shaft Nickel-Plated Slip Yoke) Models Supercede: This bulletin is being revised to add Cadillac Escalade (Old Style) to the Models section. Please discard Corporate Bulletin Number 01-04-17-004A (Section 04 - Driveline/Axle). Condition Some customers may comment on a clunk, bump or squawk noise when the vehicle comes to a stop or when accelerating from a complete stop. Cause A slip/stick condition between the transfer case output shaft and the driveshaft slip yoke may cause this condition. Diagnostic Tips There are several resources in the electronic Service Information System which can provide the technician with information on diagnosis and repair of clunk conditions, and fix the customer's vehicle right the first time without unnecessary parts replacement. Some of the documents available in SI include: ^ Symptoms - Propeller Shaft Page 13179 networks, and will not require an upgrade in connection with the cellular industry's transition to the digital network. In order to verify the type of OnStar(R) Hardware in a vehicle, type the VIN into the VIN look-up tool, which is available at the OnStar(R) Online Enrollment website within GM GlobalConnect (for U.S. dealers) or InfoNet (for Canadian dealers). Disclaimer Page 16050 Control Module References Part 4 Page 3248 Steps 1 - 6 The number(s) below refer to the step(s) in the diagnostic table. 2. This inspection is to verify that the drive belt(s) is correctly installed on all of the accessory drive pulleys. Wear on the drive belt(s) may be caused by mis-positioning the drive belt(s) by one or more grooves on a pulley(s). 3. The installation of a drive belt(s) that is too wide or too narrow will cause wear on the drive belt(s). The drive belt(s) ribs should match all of the grooves on the pulleys. 4. This inspection is to verify that the drive belt(s) is not contacting any part of the engine or body while the engine is operating. There should be sufficient clearance when the accessory drive components load varies. The drive belt(s) should not come in contact with an engine or a body component when snapping the throttle. Drive Belt Falls Off Drive Belt Falls Off Diagnosis Diagnostic Aids If the drive belt(s) repeatedly falls off the accessory drive pulley(s), this may be caused by a pulley misalignment. An extra load that is quickly applied or released by an accessory drive component may also cause the drive belt(s) to fall off. Verify that the accessory drive component(s) are operating properly. If the drive belt(s) is the incorrect length, the drive belt tensioner may not maintain the proper tension on the drive belt(s). Test Description Page 16088 9. Use J 38125-12A to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. REPAIR PROCEDURE The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. 1. Cut the wire as close to the terminal as possible. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. Page 3804 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. REPLACEMENT PROCEDURE After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Insure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the Terminal Removal Procedure. Repairing Connector Terminals REPAIRING CONNECTOR TERMINALS TOOLS REQUIRED J 38125-D Terminal Repair Kit Use the following repair procedures in order to repair the following: - Push to Seat terminals - Pull to Seat terminals - Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-D contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100 World terminals. Soldering Micro-Pack 100 World terminals may damage the terminal. Circuit Protection - Circuit Breakers CIRCUIT PROTECTION - CIRCUIT BREAKERS A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Page 12594 12.2. Cars with brackets for e.g. an amplifier: Remove the pin strap (A) from the bracket and remove the tape (B) holding the optic cables. 12.3. Remove the locking strip (C) on the 2-pin connector (H2-9). Open the terminal housing with a screwdriver. Remove the secondary catch (E) on the connector and remove the optic cables coming from the OnStar(R) control modules. 12.4. Loosen one of the optic cables remaining in H2-9 (F), connect it to the connector and fit the secondary catch (E). Connect the connector so that the optic cables are opposite each other (G). Connect the terminal housing (D) and refit the locking strip (C). Page 5599 Steps 1 - 3 Page 9898 Disclaimer Page 10048 Power Steering Line/Hose: Service and Repair Power Brake Booster Inlet Hose Replacement Power Brake Booster Inlet Hose Replacement Removal Procedure 1. Notice: Refer to Power Steering Hose Disconnected Notice in Service Precautions. Install a drain pan under the vehicle. 2. Remove the brake booster inlet hose (1) from the brake booster (2). 3. Remove the brake booster inlet hose from the power steering pump. 4. Remove the brake booster inlet hose from the vehicle. Installation Procedure 1. Notice: Refer to Installing Hoses Without Twists or Bends Notice in Service Precautions. Route the hose in the same position the hose occupied prior to removal. 2. Install the brake booster inlet hose (1) to the brake booster (2). Hand tighten only. 3. Notice: Refer to Fastener Notice in Service Precautions. Install the brake booster inlet hose to the power steering pump. ^ Tighten the brake booster inlet hose fittings to 28 Nm (20 ft. lbs.). 4. Remove the drain pan from under the vehicle. 5. Bleed the power steering system. Refer to Bleeding the Power Steering System. Page 5264 Fuel Injector: Diagrams Fuel Injector 1 Page 7639 1. If a NEW control module is being installed, program the new module. 2. Install the shift control module to the bracket. 3. Connect the shift control module electrical connectors. 4. Start the engine and test the automatic transfer case system for proper shift operation. Transfer Case Control Module Reprogramming Transfer Case Control Module Reprogramming Set-up for Module Programming/Reprogramming Important: Ensure that the vehicle battery is fully charged and that a battery charger is no longer connected. If performing this procedure for module replacement, install a new module before proceeding. Before reprogramming, close the doors and wait two minutes to allow other modules to stop communicating via the class 2 data line. Failure to do so could result in a failed reprogramming procedure. ^ Turn OFF all accessories. ^ Turn ON the ignition, with the engine OFF. Page 9776 C388 Seat Motor Jumper Harness To Passenger Seat Harness (With RPO Code AG2) Page 9777 C396 Body Harness To Right Rear Door Harness (Crew Cab) Part 1 Page 3554 - Worn ignition wires - Incorrect spark plug gap - Excessive idling or slow speeds under light loads can keep spark plug temperatures so low that normal combustion deposits may not burn off. - Deposit fouling - Oil, coolant, or additives that include substances such as silicone, very white coating, reduces the spark plug intensity. Most powdery deposits will not affect spark plug intensity unless they form into a glazing over the electrode. Page 937 Electronic Throttle Control Module: Service and Repair THROTTLE ACTUATOR CONTROL (TAC) MODULE REPLACEMENT REMOVAL PROCEDURE 1. Disconnect the instrument panel (I/P) harness electrical connector (2). 2. Release the red connector position assurance (CPA) retainer. 3. Disconnect the engine wiring harness electrical connector (1). 4. Remove the throttle actuator control (TAC) module nuts. 5. Remove the TAC module. INSTALLATION PROCEDURE Page 5781 8. Connect the PNP switch electrical connector (2). 9. If equipped with 4WD, install the front propeller shaft. 10. Lower the vehicle. 11. Check the switch for proper operation. The engine must start in the park (P) or neutral (N) positions only. If proper operation of the switch can not be obtained, replace the switch. Transfer Case - NVG 246-NP8 Four Wheel Drive Selector Switch: Service and Repair Transfer Case - NVG 246-NP8 Transfer Case Shift Control Switch Replacement Removal Procedure 1. Remove the instrument panel (I/P) cluster bezel. 2. Using a flat-tipped screwdriver, gently pry the retaining clips open on the housing. 3. Slide out the selector switch until the electrical connector are accessible. 4. Disconnect the selector switch electrical connectors (2, 3). 5. Remove the selector switch from the housing. Installation Procedure 1. Position the selector switch close to the housing so the electrical connectors can be connected. Page 12957 Speaker: Diagrams Speaker - RF Door Speaker - RF Door - With RPO Code UQ5 Page 4663 circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links CIRCUIT PROTECTION - FUSIBLE LINKS Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Flat Wire Repairs FLAT WIRE REPAIRS NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Heated Oxygen Sensor (HO2S) Wiring Repairs HEATED OXYGEN SENSOR (HO2S) WIRING REPAIRS TOOLS REQUIRED J 38125-D Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: - Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-D. Repairing Damaged Wire Insulation REPAIRING DAMAGED WIRE INSULATION Page 8559 Use clean, new power steering fluid only. 12. Fill the pump reservoir with fluid to the FULL COLD level. 13. Attach J 43485, Power Steering Bleeder Adapter, to J 35555, Metal Mityvac, or equivalent. 14. Place J 43485 on or in the pump reservoir filler neck. 15. Apply a vacuum of 68 kPa (20 in Hg) maximum. 16. Wait 1 minute. 17. Remove J 43485 and J 35555. 18. Reinstall the pump reservoir cap. 19. Start the engine. Allow the engine to idle. 20. Turn the steering wheel 180-360 degrees in both directions 5 times. 21. Switch the ignition off 22. Verify the fluid level. 23. Release the park brake and unblock the wheels. Hydro-Boost(R) Replacement -- Kodiak, TopKick Tools Required ^ J 35555 Metal Mityvac ^ J 43485 Power Steering Bleeder Adapter Removal 1. Block the wheels. 2. Disconnect the electrical connectors from the electrohydraulic pump and the flow switch. Page 8286 13. Remove the caliper guide pin bolts. 14. Remove the brake caliper from the vehicle. 15. Inspect the caliper assembly. Refer to Brake Caliper Inspection. Installation Procedure 1. Important: Use denatured alcohol to clean the outside surface of caliper boot before installing new brake pads. If you are installing new brake pads, use a C-clamp in order to compress the piston to the bottom of the caliper bore. Use the old brake pad, a metal plate or a wooden block across the face of the piston in order to protect the piston and the caliper boot. 2. Important: Use a small flat-bladed tool and lift the inner edge caliper boot next to the piston to release any trapped air. Ensure that the piston boot is below the level of the piston face. 3. Install the caliper to the caliper mounting bracket. 4. Perform the following procedure before installing the caliper guide pin bolts (15 Series pickups only). 1. Remove all traces of the original adhesive patch. 2. Clean the threads of the bolt with brake parts cleaner or the equivalent and allow to dry. 3. Apply Threadlocker GM P/N 12345493 (Canadian P/N 10953488) to the threads of the bolt. Junction Block - I/P Relay Box: Application and ID Junction Block - I/P Location View Location View Page 3695 7. Install the outlet hose to the water pump. 8. Position the outlet hose clamp at the water pump. 9. Install the accessory drive belt. Replacement - Accessory (4.8L, 5.3L, and 6.0L Engines) Drive Belt Replacement - Accessory (5.3L Engine w/RPO HP2) in Engine Mechanical - 4.8L, 5.3L, and 6.0L. 10. Install the fan blade. 11. Install the inlet hose to the water pump. 12. Position the inlet hose clamp at the water pump. 13. Install the engine vent inlet hose to the radiator hose clips. 14. If necessary, install the engine sight shield. 15. Important: Align the arrow at the throttle body end of the duct with the throttle body attaching stud. Install the air cleaner outlet duct. Page 4444 Engine Control Module: Description and Operation Throttle Actuator Control (Tac) System POWERTRAIN CONTROL MODULE The PCM determines the driver's intent, then calculates the appropriate throttle response. This information is sent to the TAC module through a dedicated serial data line. Page 6093 3. Install the transmission filter. Page 2795 Malfunction Indicator Lamp: Service and Repair SERVICE VEHICLE SOON INDICATOR The "SERVICE VEHICLE SOON" light will come on if there are certain non-emission related vehicle problems. These problems may not be obvious and may affect vehicle performance or durability. The light will come on briefly when the ignition is turned on to show that it is working properly. This light does NOT come on at certain mileage intervals. There is probably a PCM or a BCM Code set that will aid you in diagnosis. RESET PROCEDURE The only way to get the light to go off is to clear the PCM or BCM code(s). This light can NOT be reset or shut off any other way. PCM/BCM codes should be read & repaired before clearing them. Page 11971 ^ An OnStar(R) Call Center button press WILL NOT connect the vehicle with OnStar(R). The vehicle must be upgraded to reactivate the account. The customer will hear a demo message stating that there is not a current OnStar(R) subscription for the vehicle. The message will also instruct the customer how to upgrade and reactivate services. ^ OnStar(R) personal calling (OPC) will not be available, as this feature requires the customer to have a current OnStar(R) account. Attempts to use this feature will result in cellular connection failure messages and the inability to connect to the number dialed. Note For deactivated vehicles, a no connect response should be considered normal system operation. Further diagnosis and subsequent repair is only necessary should the customer elect to become an active OnStar(R) subscriber and upgrade the account subscription. OnStar(R) Cellular, GPS, and Diagnostic Limitations The proper operation of the OnStar(R) System is dependent on several elements outside the components integrated into the vehicle. These include the National Cellular Network Infrastructure, the cellular telephone carriers within the network, and the GPS. The cellular operation of the OnStar(R) system may be inhibited by factors such as the users range from a digital cellular tower, the state of the cellular carrier's equipment, and the location where the call is placed. Making an OnStar(R) key press in areas that lack sufficient cellular coverage or have a temporary equipment failure will result in either the inability of a call to complete with a data transfer or the complete inability to connect to the OnStar(R) Call Center. The OnStar(R) system may also experience connection issues if the identification numbers for the module, station identification number (STID), electronic serial number (ESN) or manufacturers electronic ID (MEID), are not recognized by the cellular carriers local signal receiving towers. The satellites that orbit earth providing the OnStar system with GPS data have almost no failures associated with them. In the event of a no GPS concern, the failure will likely lie with the inability of the system to gain GPS signals because of its location, i.e. in a parking structure, hardware failure, or being mistaken with an OnStar(R) call which has reached the Call Center without vehicle data. During diagnostic testing of the OnStar(R) system, the technician should ensure the vehicle is located in an area that has a clear unobstructed view of the open sky, and preferably, an area where digital cellular calls have been successfully placed. These areas can be found by successfully making an OnStar(R) keypress in a known good OnStar(R) equipped vehicle and confirming success with the OnStar(R) Call Center advisor. Such places can be used as a permanent reference for future OnStar(R) testing. Mobile Identification Number and Mobile Directory Number The vehicle communication interface module (VCIM) utilizes 2 numbers for cellular device identification, call routing and connection. They are: ^ A mobile identification number (MIN) ^ A mobile directory number (MDN) Note The MIN represents the number used by the cellular carrier for call routing purposes. The MDN represents the number dialed to reach the cellular device. Diagnostic Information Symptoms - Cellular Communication The following steps must be completed before using the symptom table. 1. Perform the Diagnostic System Check - Vehicle, before using the Symptom Tables in order to verify that the following are true: ^ There are no DTCs set. ^ The control modules can communicate via the serial data link. 2. Review the system operation in order to familiarize yourself with the system functions. Refer to Radio/Audio System Description and Operation in SI. Diagnostic Starting Point - Displays and Gages Begin the displays and gages system diagnosis with Diagnostic System Check - Vehicle or the audible warning system diagnosis with Diagnostic System Page 16016 Electrical Symbols Part 12 Page 11609 2. Install the seat belt buckle bolt. Tighten Tighten the bolt to 53 N.m (39 lb ft). 3. Install the seat belt latch assembly to the center front seat. 4. Install the seat belt latch bolt. Tighten Tighten the bolt to 53 N.m (39 lb ft). Page 14094 circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links CIRCUIT PROTECTION - FUSIBLE LINKS Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Flat Wire Repairs FLAT WIRE REPAIRS NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Heated Oxygen Sensor (HO2S) Wiring Repairs HEATED OXYGEN SENSOR (HO2S) WIRING REPAIRS TOOLS REQUIRED J 38125-D Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: - Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-D. Repairing Damaged Wire Insulation REPAIRING DAMAGED WIRE INSULATION Description and Operation Electronic Throttle Control Module: Description and Operation THROTTLE ACTUATOR CONTROL MODULE The TAC module is the control center for the throttle actuator control system. The TAC system is self-diagnosing and provides diagnostic information to the PCM through a dedicated serial data line. The TAC achieves throttle positioning by providing a pulse width modulated voltage to the TAC, as directed by the PCM. Page 6462 15. Remove the cable clip on the transfer case, if equipped. 16. Remove the range selector cable end (2) from the transmission range selector lever ball stud (1). 17. Depress the tangs and remove the cable from the bracket. 18. Lower the vehicle and ensure that the steering column shift lever is still in the park position. Installation Procedure 1. Ensure that the transmission manual shaft lever is in the mechanical park position. 2. Align and install the cable to the bracket. 3. Install the range selector cable end (2) to the transmission range selector lever ball stud (1). 4. Install the cable clip on the transfer case, if equipped. 5. Install the retainer that secures the cable to the bracket. 6. Install the clips on the cable to the floor panel reinforcement. Page 9735 C214 I/P Harness To Headliner Harness (With RPO Code U42) Part 1 Page 14348 Electrical Symbols Part 9 Brakes/Wheels - Excessive Debris Build Up Mud Flap: All Technical Service Bulletins Brakes/Wheels - Excessive Debris Build Up Bulletin No.: 04-05-23-005 Date: June 22, 2004 INFORMATION Subject: Availability of Rear Wheel Mud Flaps to Reduce Debris Build-up on Rear Brake Calipers and/or Rear Wheels Models: 1999-2004 Chevrolet Silverado Pickup Models 1999-2004 GMC Sierra Pickup Models This bulletin is to inform dealers of the release of rear wheel mud flaps. The above models that are exposed to extensive off-paved roads may benefit from the mud flaps. The mud flaps have been developed to minimize the amount of stones and/or mud that can impact and collect on the rear caliper and/or wheel rim. Please advise customers that the installation of these mud flaps and following the recommended off-road driving information provided in their Owner's Manual should greatly reduce the possibility of accelerated rear brake component wear and/or rim damage. Install the mud flap forward of each rear wheel using the following procedure. Important: Always work from outboard to inboard, drilling one hole at a time and securing with a fastener. Follow the sequence of the procedure. This will prevent distortion of the mud flap. 1. Raise the vehicle. Support the vehicle. 2. Locate the pickup box side panel rear brace. 3. Remove the existing outboard upper fastener on the brace. 4. Install the mud flap through the "V" of the brace. Install the previously removed fastener in the hole (2) of the mud flap to the brace. Do not tighten the fastener at this time. 5. Using the mud flap as a template, locate and mark the location of the hole (1) in the pickup box wheel house. Page 11658 Seat Belt Latch: Service and Repair Seat Belt Buckle and Latch - Rear (Crew Cab) SEAT BELT BUCKLE AND LATCH REPLACEMENT - REAR (CREW CAB) REMOVAL PROCEDURE 1. Remove the rear seat cushion and cover. 2. Remove the bolt (13) that retains the buckle assembly (14) to the seat frame. 3. Remove the buckle assembly INSTALLATION PROCEDURE Page 6666 19. Connect the internal wiring harness electrical connectors to the following components: ^ The transmission fluid pressure manual valve position switch (1) ^ The 1-2 shift solenoid (2) ^ The 2-3 shift solenoid (3) ^ The pressure control solenoid (4) ^ The TCC PWM solenoid (5) ^ The 3-2 shift solenoid (6) 20. Install the auxiliary pump, if equipped with RPO HP2. 21. Install the transmission filter. Page 373 Important: The optic cable must not be bent with a radius less than 25 mm (1 in). 12.5. Cars with brackets for e.g. an amplifier: Fit the cable tie (11 900 515) to the wiring harness approx. 100 mm (4 in) from H2-9, fit the cable tie (H) to the bracket. Gather the optic cable in a gentle loop (I) and then place the loop behind the bracket. Important: The optic cable must not be bent with a radius less than 25 mm (1 in). 12.6. Cars without brackets for e.g. an amplifier: Gather the optic cable in a gentle loop (J) and secure with cable tie. 13. CV: Fit the left-hand, rear side hatch trim in accordance with WIS - 8. Body - Interior equipment - Adjustment/Replacement. 14. Fit the ground cable to the battery's negative terminal. 15. Carry out procedures after disconnecting the battery, see WIS - 3. Electrical System - Charging system - Adjustment/Replacement. Important: Follow Tech 2(R) on-screen instructions. 16. Add ECU ICM, choose without OnStar(R). See WIS-General-Tech 2(R) - Description and Operation - Add/Remove. 2000-2004 Saab 9-5 2000-2004 Saab 9-5 Page 1451 Brake Light Switch: Service and Repair STOP LAMP SWITCH REPLACEMENT REMOVAL PROCEDURE 1. Disconnect the electrical connector from the stop lamp switch (2). 2. Remove the pushrod retaining clip (4). 3. Remove the stop lamp switch (2). INSTALLATION PROCEDURE 1. Install the stop lamp switch (2). 2. Install the pushrod retaining clip (4). 3. Connect the electrical connector to the stop lamp switch (2). Page 6580 1. Lubricate the input speed sensor seal with automatic transmission fluid. 2. Install the input speed sensor (1). Notice: Refer to Fastener Notice in Service Precautions. 3. Install the input speed sensor bolt. ^ Tighten the bolt to 11 Nm (96 inch lbs.). 4. Connect the input speed sensor electrical connector (1). 5. Lower the vehicle. Suspension - Shock Absorber/Strut Leakage Information Suspension Strut / Shock Absorber: All Technical Service Bulletins Suspension - Shock Absorber/Strut Leakage Information INFORMATION Bulletin No.: 05-03-08-002C Date: October 16, 2009 Subject: Information on Replacement of Shock Absorbers and Struts Due to Fluid Leaks Models: 2010 and Prior GM Passenger Cars and Trucks (Including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X Supercede: This bulletin is being revised to add the 2010 model year and Inspection Procedures. Please discard Corporate Bulletin Number 05-03-08-002B (Section 03 - Suspension). This bulletin is intended to help identify the severity of shock absorber and strut fluid seepage. Improper diagnosis may lead to components being replaced that are within the manufacturer's specification. Shock absorbers and strut assemblies are fluid-filled components and will normally exhibit some seepage. Seepage is defined as oil film or dust accumulation on the exterior of the shock housing. Shock absorbers and struts are not to be replaced under warranty for seepage. Use the following information to determine if the condition is normal acceptable seepage or a defective component. Important Electronically controlled shock absorbers (MR) may have a tendency to attract dust to this oil film. Often this film and dust can be wiped off and will not return until similar mileage is accumulated again. Inspection Procedure Note The shock absorber or strut assembly DOES NOT have to be removed from the vehicle to perform the following inspection procedure. Use the following descriptions and graphics to determine the serviceability of the component. Shock Absorbers Do Not Replace shock absorbers displaying condition 1 or 2 levels of seepage. 1. Oil or fluid residue only on the bottom or top of the shock absorber and not originating from the shaft seal (the upper part of the lower shock tube). 2. Light film/residue on approximately 1/3 (a) or less of the lower shock tube (A) and originating from the shaft seal. Replace shock absorbers displaying conditions 3 and 4 levels of leaks. 3. Oil drip or trail down the lower shock tube and originating from the shaft seal. 4. An extreme wet film of oil covering more than 1/3 (b) of the lower shock tube and originating from the shaft seal. Coil-over Shock Absorber Page 11751 Steps 6-7 The numbers below refer to the step numbers on the diagnostic table. 2. Lack of communication may be due to a partial malfunction of the class 2 serial data circuit or due to a total malfunction of the class 2 serial data circuit. The specified procedure will determine the particular condition. 3. This step tests for valid system power moding in all ignition switch positions. 5. The presence of DTCs which begin with "U" indicate some other module is not communicating. The specified procedure will compile all the available information before tests are performed. Page 11582 Page 9289 4. Connect the wire connectors to the lower portion of the electrical center block. 5. Connect the wire connectors with the bolts to the electrical center block. Tighten Tighten all connector bolts (1) to 9 N.m (80 lb in). 6. Ensure all wire connectors are securely connected. 7. Set the electrical center block in its resting position till the tabs (3) locks in place. 8. Install the lower part of the cover (1). 9. With the cover (2) off, use the fuse location information to install all fuses and relays. 10. Install the cover. 11. Install the fender upper brace. 12. Install the 4 fender upper brace bolts. Tighten Tighten the 4 retaining bolts to 25 N.m (18 lb ft). 13. Connect the negative battery cable. 14. Start vehicle and ensure all components function properly. Page 4434 Engine Control Module: Diagrams Powertrain Control Module (PCM) C2 Page 11222 Refrigerant: Service and Repair REFRIGERANT RECOVERY AND RECHARGING TOOLS REQUIRED - J 43600 ACR 2000 Air Conditioning Service Center - J 45037 A/C Oil Injector CAUTION: Avoid breathing the A/C Refrigerant 134a (R-134a) and the lubricant vapor or the mist. Exposure may irritate the eyes, nose, and throat. Work in a well ventilated area. In order to remove R-134a from the A/C system, use service equipment that is certified to meet the requirements of SAE J 2210 (R-134a recycling equipment). If an accidental system discharge occurs, ventilate the work area before continuing service. Additional health and safety information may be obtained from the refrigerant and lubricant manufacturers. - For personal protection, goggles and gloves should be worn and a clean cloth wrapped around fittings, valves, and connections when doing work that includes opening the refrigerant system. If R-134a comes in contact with any part of the body severe frostbite and personal injury can result. The exposed area should be flushed immediately with cold water and prompt medical help should be obtained. NOTE: R-134a is the only approved refrigerant for use in this vehicle. The use of any other refrigerant may result in poor system performance or component failure. - To avoid system damage use only R-134a dedicated tools when servicing the A/C system. - Use only Polyalkylene Glycol Synthetic Refrigerant Oil (PAG) for internal circulation through the R-134a A/C system and only 525 viscosity mineral oil on fitting threads and O-rings. If lubricants other than those specified are used, compressor failure and/or fitting seizure may result. - R-12 refrigerant and R-134a refrigerant must never be mixed, even in the smallest of amounts, as they are incompatible with each other. If the refrigerants are mixed, compressor failure is likely to occur. Refer to the manufacturer instructions included with the service equipment before servicing. The J 43600 is a complete air conditioning service center for R-134a. The ACR 2000 recovers, recycles, evacuates and recharges A/C refrigerant quickly, accurately and automatically. The unit has a display screen that contains the function controls and displays prompts that will lead the technician through the recover, recycle, evacuate and recharge operations. R-134a is recovered into and charged out of an internal storage vessel. The ACR 2000 automatically replenishes this vessel from an external source tank in order to maintain a constant 5.45-6.82 kg (12-15 lbs) of A/C refrigerant. The ACR 2000 has a built in A/C refrigerant identifier that will test for contamination, prior to recovery and will notify the technician if there are foreign gases present in the A/C system. If foreign gases are present, the ACR 2000 will not recover the refrigerant from the A/C system. The ACR 2000 also features automatic air purge, single pass recycling and an automatic oil drain. Refer to the J 43600 ACR 2000 manual for operation and setup instruction. Always recharge the A/C System with the proper amount of R-134a. Refer to Refrigerant System Capacities for the correct amount. A/C REFRIGERANT SYSTEM OIL CHARGE REPLENISHING If oil was removed from the A/C system during the recovery process or due to component replacement, the oil must be replenished. Oil can be injected into a charged system using J 45037 . For the proper quantities of oil to add to the A/C refrigerant system, refer to Refrigerant System Capacities. Page 4293 Electrical Symbols Part 11 Page 1872 Tow/Haul Switch: Testing and Inspection 4L80-E/4L85-E Transmission Tow/Haul Switch/Indicator Always On or Inoperative Circuit Description Tow/haul mode enables the operator to achieve enhanced shift performance when towing or hauling a load. When tow/haul mode is selected, the tow/haul switch input signal to the body control module (BCM) is momentarily toggled to zero volts. This signals the powertrain control module (PCM) to extend the length of time between up shifts and increase transmission line pressure. Cycling the tow/haul switch again disables tow/haul mode and returns the transmission to a normal shift pattern. Diagnostic Aids If the electrical circuit checks are OK and the tow/haul shift pattern is not occurring, there may be a mechanical/hydraulic condition that prevents tow/haul operation. Refer to Symptoms - Automatic Transmission. CKP System Variation Learn Procedure Crankshaft Position Sensor: Service and Repair CKP System Variation Learn Procedure CKP SYSTEM VARIATION LEARN PROCEDURE 1. Install a scan tool. 2. Monitor the powertrain control module (PCM) for DTCs with a scan tool. If other DTCs are set, except DTC P0315, refer to Diagnostic Trouble Code (DTC) List for the applicable DTC that set. 3. Select the crankshaft position (CKP) variation learn procedure with a scan tool. 4. The scan tool instructs you to perform the following: 4.1. Accelerate to wide open throttle (WOT). 4.2. Release throttle when fuel cut-off occurs. 4.3. Observe fuel cut-off for applicable engine. 4.4. Engine should not accelerate beyond calibrated RPM value. 4.5. Release throttle immediately if value is exceeded. 4.6. Block drive wheels. 4.7. Set parking brake. 4.8. DO NOT apply brake pedal. 4.9. Cycle ignition from OFF to ON. 4.10. Apply and hold brake pedal. 4.11. Start and idle engine. 4.12. Turn A/C OFF. 4.13. Vehicle must remain in Park or Neutral. 4.14. The scan tool monitors certain component signals to determine if all the conditions are met to continue with the procedure. The scan tool only displays the condition that inhibits the procedure. The scan tool monitors the following components: - CKP sensors activity-If there is a CKP sensor condition, refer to the applicable DTC that set. - Camshaft position (CMP) sensor activity-If there is a CMP sensor condition, refer to the applicable DTC that set. - Engine coolant temperature (ECT)-If the ECT is not warm enough, idle the engine until the engine coolant temperature reaches the correct temperature. 5. Enable the CKP system variation learn procedure with a scan tool. IMPORTANT: While the learn procedure is in progress, release the throttle immediately when the engine starts to decelerate. The engine control is returned to the operator and the engine responds to throttle position after the learn procedure is complete. 6. Accelerate to WOT. 7. Release when the fuel cut-off occurs. 8. Test in progress 9. The scan tool displays Learn Status: Learned this ignition. If the scan tool indicates that DTC P0315 ran and passed, the CKP variation learn procedure is complete. If the scan tool indicates DTC P0315 failed or did not run, refer to DTC P0315. If any other DTCs set, refer to Diagnostic Trouble Code (DTC) List for the applicable DTC that set. 10. Turn OFF the ignition for 30 seconds after the learn procedure is completed successfully. 11. The CKP system variation learn procedure is also required when the following service procedures have been performed, regardless of whether DTC P0315 is set: - A CKP sensor replacement - An engine replacement - A PCM replacement - A harmonic balancer replacement - A crankshaft replacement - Any engine repairs which disturb the CKP sensor relationship Page 14888 Power Seat Switch: Diagrams Seat Adjuster Switch - Driver (With RPO Code AN3) Part 1 Interior - Seat Memory Feature Appears Inoperative Memory Positioning Module: All Technical Service Bulletins Interior - Seat Memory Feature Appears Inoperative Bulletin No.: 04-08-50-003 Date: February 26, 2004 INFORMATION Subject: Enabling Memory Seat Feature via DIC If Feature Appears Inoperative Models: 2003-2004 Cadillac Escalade, Escalade ESV, Escalade EXT 2003-2004 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2003-2004 GMC Sierra, Yukon, Yukon Denali, Yukon Denali XL 2003-2004 HUMMER H2 with Steering Wheel Controls (RPO UK3) (standard on H2) If the memory seat feature appears inoperative, check the Driver Information Center (DIC). Many of the memory seat modules that were returned through the Warranty Parts Center for a condition of inoperative have shown No Trouble Found. The Driver Information Center (DIC), programmed for Seat Entry and Exit, is set to the default "Off" mode at the assembly plant. DO NOT REPLACE THE MEMORY SEAT MODULE. Perform the following procedure. Important: The following procedure will need to be completed for each Remote/Key selection. Using the DIC menu, do the following steps: 1. Set the "Seat Recall" to either "At Key In" or "On Remote" based on the customer's preference. 2. Set the "Exit Seat" to "On". 3. Adjust the following items: Memory Seat: 3.1. Driver's Seat (including the seat back, recliner, lumbar, and side wings) 3.2. Throttle and Brake Pedals (not available on H2 or Silverado and Sierra Trucks) 3.3. Outside Mirrors 3.4. Radio Station Presets 3.5. Last Chosen Climate Control System Settings (not available on Silverado or Sierra Trucks) 3.6. Press and hold the "1" or "2" (for driver 1 or 2) button of the memory control for three seconds. A double chime will sound to let you know that the position has been stored. Easy Exit Seat: 3.1. Press and release the 1 or 2 button or press the unlock button on the desired remote keyless entry transmitter. The seat will move to the stored memory position. 3.2. Adjust the seat to the desired exit position. 3.3. Press and hold the exit button of the memory control (located on the door) for three seconds. A double chime will sound to let you know that the position has been stored for the identified driver (1 or 2). Page 1455 Cargo Lamp Switch: Service and Repair LAMP SWITCH ASSEMBLY REPLACEMENT - FRONT FOG LAMP AND CARGO LAMP REMOVAL PROCEDURE 1. Remove the instrument cluster bezel. 2. Remove the fog lamp switch and cargo switch from the housing. 3. Disconnect the electrical connector(s) from the fog lamp switch. 4. Remove the fog lamp and cargo lamp switch from the housing. INSTALLATION PROCEDURE 1. Connect the electrical connector(s) to the fog lamp and cargo lamp switch. 2. Install the fog lamp switch into the housing. 3. Install the IP trim bezel to the instrument panel. Page 7070 Page 14841 Pedal Positioning Switch: Service and Repair Brake Pedal Position Sensor Replacement Removal Procedure 1. Important: Once the Brake Pedal Position Sensor bolt is removed for any reason, a new 4 mm bolt, with fresh LOCTITETM will need to be installed. Remove the brake pedal position sensor bolt (1). 2. Remove the brake pedal position sensor (2) from the mounting bracket. 3. Disconnect the brake pedal position sensor electrical connector (1). 4. Remove the brake pedal position sensor (2) from the vehicle Installation Procedure Page 7318 1. If a NEW control module is being installed, program the new module. 2. Install the shift control module to the bracket. 3. Connect the shift control module electrical connectors. 4. Start the engine and test the automatic transfer case system for proper shift operation. Transfer Case Control Module Reprogramming Transfer Case Control Module Reprogramming Set-up for Module Programming/Reprogramming Important: Ensure that the vehicle battery is fully charged and that a battery charger is no longer connected. If performing this procedure for module replacement, install a new module before proceeding. Before reprogramming, close the doors and wait two minutes to allow other modules to stop communicating via the class 2 data line. Failure to do so could result in a failed reprogramming procedure. ^ Turn OFF all accessories. ^ Turn ON the ignition, with the engine OFF. ABS Automated Bleed Procedure Brake Bleeding: Service and Repair ABS Automated Bleed Procedure ABS Automated Bleed Procedure Notice: When adding fluid to the brake master cylinder reservoir, use only Delco Supreme 11®, GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. The use of any type of fluid other than the recommended type of brake fluid, may cause contamination which could result in damage to the internal rubber seals and/or rubber linings of hydraulic brake system components. Notice: Refer to Brake Fluid Effects on Paint and Electrical Components Notice in Service Precautions. Important: This procedure may be performed on all vehicles EXCEPT those equipped with option code JL4, Vehicle Stability Enhancement System (VSES). Important: The base hydraulic brake system must be bled before performing this automated bleeding procedure. If you have not yet performed the base hydraulic brake system bleeding procedure, refer to Hydraulic Brake System Bleeding (Manual) Hydraulic Brake System Bleeding (Pressure) in Hydraulic Brakes before proceeding. 1. Install a scan tool to the vehicle. 2. Start the engine and allow the engine to idle. 3. Depress the brake pedal firmly and maintain steady pressure on the pedal. 4. Using the scan tool, begin the automated bleed procedure. 5. Follow the instructions on the scan tool to complete the automated bleed procedure. Release the brake pedal between each test sequence. 6. Turn the ignition OFF. 7. Remove the scan tool from the vehicle. 8. Fill the brake master cylinder reservoir to the maximum-fill level with Delco Supreme 11® GM P/N 12377967 (Canadian P/N 992667) or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. 9. Bleed the hydraulic brake system. Refer to Hydraulic Brake System Bleeding (Manual) Hydraulic Brake System Bleeding (Pressure) in Hydraulic brakes. 10. With the ignition OFF, apply the brakes 3-5 times, or until the brake pedal becomes firm, in order to deplete the brake booster power reserve. 11. Slowly depress and release the brake pedal. Observe the feel of the brake pedal. 12. If the brake pedal feels spongy, repeat the automated bleeding procedure. If the brake pedal still feels spongy after repeating the automated bleeding procedure inspect the brake system for external leaks. Refer to Brake System External Leak Inspection in Hydraulic Brakes. 13. Turn the ignition key ON, with the engine OFF; check to see if the brake system warning lamp remains illuminated. 14. If the brake system warning lamp remains illuminated, DO NOT allow the vehicle to be driven until it is diagnosed and repaired. Refer to Symptoms - Hydraulic Brakes. 15. Drive the vehicle to exceed 13 kph (8 mph) to allow ABS initialization to occur. Observe brake pedal feel. 16. If the brake pedal feels spongy, repeat the automated bleeding procedure until a firm brake pedal is obtained. Page 15959 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. REPLACEMENT PROCEDURE After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Insure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the Terminal Removal Procedure. Repairing Connector Terminals REPAIRING CONNECTOR TERMINALS TOOLS REQUIRED J 38125-D Terminal Repair Kit Use the following repair procedures in order to repair the following: - Push to Seat terminals - Pull to Seat terminals - Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-D contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100 World terminals. Soldering Micro-Pack 100 World terminals may damage the terminal. Circuit Protection - Circuit Breakers CIRCUIT PROTECTION - CIRCUIT BREAKERS A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Engine Controls - MIL ON/Misfire/Misfire DTC's Set Engine Control Module: Customer Interest Engine Controls - MIL ON/Misfire/Misfire DTC's Set Bulletin No.: 06-06-04-046 Date: September 12, 2006 INFORMATION Subject: Information on Engine Misfire MIL/SES Light Illuminated or Flashing DTC P0300, P0301, P0302, P0303, P0304, P0305, P0306, P0307, P0308, P0420 or P0430 Models: 1999-2007 Cadillac, Chevrolet, GMC Full-Size Pickup and/or Utility Trucks with 4.8L, 5.3L, 5.7L, 6.0L or 6.2L VORTEC GEN III, GEN IV, V-8 Engine (VINs V, C, T, Z, B, 3, M, 0, J, R, U, N, Y, K, 8 - RPOs LR4, LY2, LM7, L59, L33, LC9, LH6, LMG, LY5, L31, LQ4, LQ9, L76, LY6, L92) with Active Fuel Management(TM) and E85 Flex Fuel If you encounter vehicles that exhibit the above conditions, refer to SI for the appropriate DTC(s) set. If no trouble is found, the cause may be due to an ECM ground terminal that has corroded with rust over time. Inspect the main engine wiring harness ground terminal (G103) for this condition. The wire terminal (G103) attaches either to the front or to the rear of the right side cylinder head, depending on the model year of the Full Size Pickup and/or Utility Trucks. If the ECM ground terminal has been found to be corroded, then follow the service procedure outlined in this bulletin to correct the corrosion issue. Remove either the nut or bolt securing the main engine wiring harness ground terminal (G103) to the right cylinder head. Refer to the above illustration to determine where the ground is located on the vehicle (1). Page 4667 Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips SPLICING COPPER WIRE USING SPLICE CLIPS IMPORTANT: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. TOOLS REQUIRED J 38125-D Terminal Repair Kit 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-D in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. Page 435 Important The following information MUST be documented on the repair order. Failure to do so may result in a chargeback. - Customer vehicle condition. - Was a Service Lamp or Service Message illuminated? If yes, specify which Service Lamp or Service Message. - Was a DTC(s) set? If yes, specify which DTC(s) were set. - After following the procedure contained within this bulletin, could the condition be duplicated? ‹› If the condition was not duplicated, then document the affected module/component connector name and number on the repair order. - If the condition was duplicated after the procedure contained within this bulletin was followed, and additional diagnosis led to the replacement of a module or component, the SI Document ID Number MUST be written on the repair order. Parts Information Alternate Distributor For All of North America Note NyoGel(R) 760G Lubricant* is equivalent to GMSPO P/N 12377900, and P/N 10953529 (Canada), specified for use to correct the condition in this bulletin. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to: Warranty Information (Saab Models) Interior - Intermittent Seat Heater Operation Seat Heater: Customer Interest Interior - Intermittent Seat Heater Operation Bulletin No.: 05-08-50-008 Date: August 19, 2005 TECHNICAL Subject: Intermittent Heated Seats Inoperative, DTC B3941 Set (Reprogram Driver Seat Module) Models: 2003-2005 Cadillac Escalade, Escalade ESV, Escalade EXT 2003-2005 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2003-2005 GMC Sierra, Yukon, Yukon XL, Yukon Denali All with Seat FRT, Individual (Non BKT) (RPO AN3) 2003-2005 HUMMER H2 with Seat, Front Bucket Deluxe (RPO AR9) Condition Some customers may comment that occasionally the seat heater will not operate when activated. If the ignition key is cycled OFF and back ON again, the heated seat will operate correctly. Also, on some LB7 diesel engine vehicles, the seat heater may turn itself off during the first 10 minutes of operation. This occurs only with the first activation for the day and works correctly with subsequent activations immediately after the event. These conditions are intermiffent and DTC B3941 may be set. Correction Technicians are to reprogram the driver seat module with an updated software calibration. This new service calibration was released with TIS satellite data update version 6.5 available June 13, 2005. As always, make sure your Tech 2(R) is updated with the latest software version. Warranty Information Description and Operation Shift Indicator: Description and Operation PRNDL DISPLAY The IPC displays the selected gear position as determined by the PCM. The IPC receives a class 2 message from the PCM indicating the gear position. The PRNDL display blanks if: - The IPC receives a class 2 message indicating the park position and the column park switch indicates a position other than park, open input. - The IPC detects a loss of class 2 communications with the PCM. Page 10921 Control Module References Part 2 Page 15142 Electrical Symbols Part 5 Page 15929 Electrical Symbols ELECTRICAL SYMBOLS Electrical Symbols Part 1 Page 14338 Front Passenger Door Page 8585 Use clean, new power steering fluid only. 12. Fill the pump reservoir with fluid to the FULL COLD level. 13. Attach J 43485, Power Steering Bleeder Adapter, to J 35555, Metal Mityvac, or equivalent. 14. Place J 43485 on or in the pump reservoir filler neck. 15. Apply a vacuum of 68 kpa (20 in Hg) maximum. 16. Wait 1 minute. 17. Remove 1 J43485 and J 35555. 18. Reinstall the pump reservoir cap. 19. Start the engine. Allow the engine to idle. 20. Turn the steering wheel 180-360 degrees in both directions 5 times. 21. Switch the ignition off 22. Verify the fluid level. 23. Release the park brake and unblock the wheels. Page 11700 Inflatable Restraint Side Impact Sensor (SIS) - Right (With RPO Code HP2) Instruments - Unable to Reset Oil Life Monitor Oil Change Reminder Lamp: All Technical Service Bulletins Instruments - Unable to Reset Oil Life Monitor Bulletin No.: 04-06-04-043 Date: June 17, 2004 TECHNICAL Subject: Unable to Reset Engine Oil Life Monitor (Reprogram PCM) Models: 2004 Buick Rainier 2004 Cadillac Escalade, Escalade ESV, Escalade EXT 2004 Chevrolet Avalanche, Express, SSR, Silverado, Suburban, Tahoe, Trailblazer 2004 GMC Envoy, Savana, Sierra, Yukon, Yukon XL with V8 Engine (VINs G, N, P, T, U, V, Z - RPOs L18, LQ9, LM4, LM7, LQ4, LR4, L59) and Electronic Throttle Control Condition Some owners may comment that they are unable to reset the Engine Oil Life Monitor. Correction Reprogram the PCM with calibration operating system P/N 12587603 or later. The new calibration was released beginning with TIS satellite data update version 8.0 for 2003, available August 2003. As always, make sure your TECH2(R) is updated with the latest software version. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 12703 Diagnostic Tips Review # 2 - Delphi Legacy Navigation Radio Page 9213 C220 I/P Harness To Infotainment Jumper Harness (With RPO Code UQ7 & Without RPO Code Y91) Part 2 Page 14651 Seat Bolster/Lumbar Switch - Front Passenger (With RPO Code AN3) Page 7593 21. With the trunnion seated in the bearing cup, press the bearing cup into the yoke until the bearing cup is flush with the yoke ear. 22. Install the opposite bearing cup part way into the yoke ear. 23. Ensure that the trunnions start straight and true into both bearing cups. 24. Press the opposite bearing cup into the yoke ear while working the cross all the time in order to inspect for free unbinding movement of the trunnions in the bearing cups. Important: If there seems to be a hang up or binding, stop pressing. Inspect the needle bearings for misalignment in the bearing cup. 25. Press the bearing cup into the yoke until the bearing cup retainer groove is visible over the top of the bearing cup. 26. Assemble the bearing retainer in the retainer groove. 27. Continue pressing until both retainers can be snapped into place. 28. If the retainer is difficult to seat, the yoke can be sprung slightly with a firm blow from a soft-faced dead blow hammer. 29. It may be necessary to lubricate the snap ring with a slight amount of chassis grease so that the snap ring seats in the bearing cup groove. 30. Install the slip yoke onto the output shaft in the transfer case. 31. Align the reference marks on the pinion flange and the propeller shaft. 32. Install the yoke retainers and bolts. Tighten Tighten the yoke retainer bolts to 25 N.m (19 lb ft). 33. Lower the vehicle. Page 7659 4. Inspect the rear output shaft bushing for scoring or wear. 5. Remove the rear output shaft bushing if required, using the J 45380. ^ Install the finger section of the J 45380 in front of the bushing. ^ Install the tube and forcing screw to the finger section. Ensure the forcing screw is backed out. ^ Using a wrench on the forcing screw, remove the rear output shaft bushing. Installation Procedure 1. Install a NEW rear output shaft bushing, if required, using the J 45380. ^ Install the bushing or the finger section of the J 45380. ^ Install the finger section to the main body of the J 45380. ^ Position the bushing and tool to the case. ^ Using a hammer and the J 45380, install the bushing. Page 15787 Accessory Switch Housing Page 1569 Crankshaft Position Sensor: Service and Repair Crankshaft Position (CKP) Sensor Replacement CRANKSHAFT POSITION (CKP) SENSOR REPLACEMENT REMOVAL PROCEDURE IMPORTANT: Perform the CKP System Variation Learn Procedure whenever the crankshaft position sensor is removed or replaced. 1. Remove the starter. 2. Disconnect the crankshaft position (CKP) sensor electrical connector. 3. Clean the area around the CKP sensor before removal in order to avoid debris from entering the engine. 4. Remove the CKP sensor bolt. 5. Remove the CKP sensor. INSTALLATION PROCEDURE Page 972 Page 3813 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-8 (12085115) crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-8 (12085115) until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes SPLICING INLINE HARNESS DIODES Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate Service Data wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. 9. Tape the diode to the harness or connector using electrical tape. Page 9752 C275 Steering Column Harness To Steering Wheel Module Coil (With RPO Code AL0) Page 11344 5. Install the instrument panel storage tray. 6. Install the instrument cluster trim plate bezel. IMPORTANT: Do not adjust any controls on the HVAC control module while the HVAC control module is calibrating. If interrupted improper HVAC performance will result. 7. Start the vehicle and let run for one minute. Page 15941 Electrical Symbols Part 14 Page 6970 Seals and Gaskets: By Symptom Technical Service Bulletin # 08-07-30-009B Date: 080501 A/T - 4T80E, Slips in Gear/L/H Axle Seal Leaks TECHNICAL Bulletin No.: 08-07-30-009B Date: May 01, 2008 Subject: HYDRA-MATIC(R) Front Wheel Drive 4T80-E (MH1) Left Front Axle Seal Leak, Transmission Slips in Gear (Replace Third Clutch Housing with Revised Service Part) Models: 2001-2008 GM Passenger Cars with HYDRA-MATIC(R) Front Wheel Drive 4T80-E Automatic Transmission (RPO - MH1) Supercede: This bulletin is being updated to revise the Warranty Information. Please discard Corporate Bulletin Number 08-07-30-009A (Section 07 - Transmission/Transaxle). Condition Some customers may comment on a transmission oil leak and/or that the transmission slips in gear. Cause An oil leak may be caused by bushing wear in the third clutch housing, causing excessive fluid build-up at axe sea. Correction Important: DO NOT replace the transmission for above concerns. Replace the third clutch housing with service P/N 8682114, which has revised bushing material to extend life and reduce left front axle seal leaks. Refer to Automatic/Transaxle - 4T80-E Transmission Off-Vehicle Repair Instructions for the replacement of the third clutch housing in SI. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Technical Service Bulletin # 08-07-30-009B Date: 080501 Page 14155 ^ Reinstall the fuse and fuse panel cover. ^ Press the "Enter" button to perform the "Refresh" function. ^ "Test in Progress" will be displayed and the right front passenger door lock will cycle once. ^ The screen will display "Procedure Completed". ^ Press the "Exit" button as necessary to return to the main menu screen. 3. Using the switches in the right front passenger door, verify that the power window and power door lock located in that door function properly. Important: The calibrations required for performing SPS reprogram in the next step are based on the type of exterior rearview mirror the vehicle has. To determine the correct calibration, check the Service Parts Identification Label on the vehicle for the RPO code for exterior mirrors. 4. Follow normal Service Programming System (SPS) to reprogram the passenger door module with the current calibration available in TIS 2000. 5. After reprogramming is complete, using the switches in the right front passenger door, verify that the power window and power door lock located in that door function properly. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 9868 - HVAC Actuator - Inflatable Restraint Sensing and Diagnostic Module (SDM) - Any AIR BAG module - Seatbelt Lap Anchor Pretensioner - Seatbelt Retractor Pretensioner - An SIR system connection or connector condition resulting in the following DTCs being set: B0015, B0016, B0019, B0020, B0022, or B0023 - Powertrain Control Module (PCM) - Remote Control Door Lock Receiver (RCDLR) - Transmission Control Module (TCM) Correction Important DO NOT replace the control module, wiring or component for the following conditions: - The condition is intermittent and cannot be duplicated. - The condition is present and by disconnecting and reconnecting the connector the condition can no longer be duplicated. Use the following procedure to correct the conditions listed above. 1. Install a scan tool and perform the Diagnostic System Check - Vehicle. Retrieve and record any existing history or current DTCs from all of the control modules (refer to SI). ‹› If any DTC(s) are set, refer to Diagnostic Trouble Code (DTC) List - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). ‹› If DTCs are not set, refer to Symptoms - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). 2. When identified, use the appropriate DTC Diagnostics, Symptoms, Schematics, Component Connector End Views and Component Locator documents to locate and disconnect the affected harness connector(s) which are causing the condition. Note Fretting corrosion looks like little dark smudges on electrical terminals and appear where the actual electrical contact is being made. In less severe cases it may be unable to be seen or identified without the use of a magnifying glass. Important DO NOT apply an excessive amount of dielectric lubricant to the connectors as shown, as hydrolock may result when attempting to mate the connectors. Use ONLY a clean nylon brush that is dedicated to the repair of the conditions in this bulletin. 3. With a one-inch nylon bristle brush, apply dielectric lubricant to both the module/component side and the harness side of the affected connector(s). 4. Reconnect the affected connector(s) and wipe away any excess lubricant that may be present. 5. Attempt to duplicate the condition by using the following information: - DTC Diagnostic Procedure - Circuit/System Description - Conditions for Running the DTC - Conditions for Setting the DTC - Diagnostic Aids - Circuit/System Verification ‹› If the condition cannot be duplicated, the repair is complete. ‹› If the condition can be duplicated, then follow the appropriate DTC, Symptom or Circuit/System Testing procedure (refer to SI). Repair Order Documentation Locations Fuel Pump And Sender Assembly Components Transfer Case - NVG 246-NP8 Four Wheel Drive Selector Switch: Service and Repair Transfer Case - NVG 246-NP8 Transfer Case Shift Control Switch Replacement Removal Procedure 1. Remove the instrument panel (I/P) cluster bezel. 2. Using a flat-tipped screwdriver, gently pry the retaining clips open on the housing. 3. Slide out the selector switch until the electrical connector are accessible. 4. Disconnect the selector switch electrical connectors (2, 3). 5. Remove the selector switch from the housing. Installation Procedure 1. Position the selector switch close to the housing so the electrical connectors can be connected. Page 11163 Tighten the screws to 2 N.m (18 lb in). 5. Install the HVAC module assembly. Locations Combination Switch: Locations Steering Wheel and Column Sub-System Components Page 4369 Left Side Of Engine Page 10142 7. Lower the vehicle. 8. Perform a four wheel alignment. Page 10838 3. Connect the electrical connection at the mode actuator (10). 4. Install the Body Control Module. 5. Install the floor air outlet duct extension (1) to the floor air duct (2). Recirculation Actuator RECIRCULATION ACTUATOR REPLACEMENT REMOVAL PROCEDURE 1. Remove the air distribution duct. 2. Disconnect the electrical connection from the recirculation actuator (1). Page 3579 Cooling System Air Bleeder Pipe / Hose: Service and Repair Coolant Air Bleed Hose Replacement Coolant Air Bleed Hose Replacement (4.8L, 5.3L, and 6.0L Engines) Removal Procedure 1. Reposition the coolant air bleed hose clamp at the throttle body. 2. Remove the coolant air bleed hose from the throttle body. 3. Reposition the coolant air bleed hose clamp at the pipe. 4. Remove the coolant air bleed hose (1) from the pipe (2). Installation Procedure Page 6429 Page 6863 Seals and Gaskets: Service and Repair Rear Drive Axle All Except 9.75 Inch Axle Drive Pinion Flange/Yoke and/or Oil Seal Replacement (All Except 9.75 Inch Axle) ^ Tools Required J 8614-01 Flange/Pulley Holding Tool - J 22388 Rear Axle Pinion Oil Seal Installer - Rear (8.6 inch, 9.5 inch axle) - J 44414 Rear Axle Pinion Oil Seal Installer (10.5 inch, 11.5 inch axle) Removal Procedure 1. Important: Observe and mark the positions of all the driveline components, relative to the propeller shaft and the axles, prior to disassembly. These components include the propeller shafts, drive axles, pinion flanges, output shafts, etc. Reassemble all the components in the exact places in which you removed the parts. Follow any specifications, torque values, and any measurements made prior to disassembly. Raise the vehicle. Refer to Vehicle Lifting. 2. Remove the tire and wheel assemblies (8.6 inch, 9.5 inch axles). 3. Remove the rear brake calipers (8.6 inch, 9.5 inch axles). 4. Remove the brake rotors (8.6 inch, 9.5 inch axles). 5. Remove the axle shafts (10.5 inch, 11.5 inch axle). 6. Reference mark the rear propeller shaft (3) to the rear axle pinion yoke (4). 7. Disconnect the propeller shaft from the axle. Wrap the bearing caps with tape in order to prevent the loss of bearing rollers. Support the propeller shaft as necessary. 8. Measure the amount of torque required to rotate the pinion. Use an inch-pound torque wrench. Record this measurement for reassembly. This will give the combined preload for the following components: ^ The pinion bearings ^ The pinion pilot bearing (10.5 inch axle) ^ The pinion oil seal ^ The differential case bearings ^ The axle bearings (8.6 inch, 9.5 inch axles) ^ The axle seals (8.6 inch, 9.5 inch axles) Page 10187 Disclaimer Automatic Transmission - 4L60-E/4L65-E Transmission Position Switch/Sensor: Service and Repair Automatic Transmission 4L60-E/4L65-E Park/Neutral Position Switch Replacement ^ Tools Required J 41364-A Park Neutral Switch Aligner Removal Procedure 1. Apply the park brake. 2. Shift the transmission into neutral. 3. If equipped with 4-wheel drive (4WD), remove the front propeller shaft. 4. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 5. Disconnect the park/neutral position (PNP) switch electrical connector (2). 6. Remove the manual shaft lever nut. Page 1074 Control Module: Service and Repair NVG 263-NP1 Transfer Case Shift Control Module Replacement Transfer Case Shift Control Module Replacement Removal Procedure 1. Disconnect the shift control module electrical connectors. 2. Unsnap and remove the shift control module from the bracket. Installation Procedure Page 12580 1. To receive credit, submit a claim with the information above. Disclaimer 2001 and Older Model Year Vehicles (Except Saab Vehicles) 2001 and Older Model Year Vehicles (Except Saab Vehicles) Important: 2001 and older model year vehicles require the removal of the battery power from the OnStar(R) vehicle interface unit (VIU) to eliminate the possibility of an inadvertent OnStar(R) or emergency/airbag call. 1. Locate and gain access to the OnStar® VIU. Refer to OnStar Vehicle Interface Unit Replacement in SI. Important: Complete removal of the VIU is usually not required. Perform only the steps required to gain access to the C2 32-way blue connector. Residing in the C2 connector are the battery positive (+) circuits. Removal of the C2 connector will deactivate the unit and eliminate the possibility of an inadvertent OnStar(R) or emergency/airbag call. Page 12837 Page 15617 Door Switch: Diagrams Door Latch Assembly (Door Jamb Switch) - LR C2 (Crew Cab Only) Door Latch Assembly (Door Jamb Switch) - LR C2 (Crew Cab Only) Page 2612 Fuse Block - Underhood - Secondary Wire Entry (With RPO Code HP2) Part 2 Page 2319 15. Discard all of the used sealing washers. Cap all of the open connections. INSTALLATION PROCEDURE 1. Install the front evaporator tube to the vehicle. 2. Uncap all of the open connections 3. Install the evaporator tube to the condenser using new sealing washers. NOTE: Refer to Fastener Notice in Service Precautions. 4. Install the evaporator tube nut to the condenser. Tighten Tighten the nut to 16 N.m (12 lb ft). 5. Install the grille to the vehicle. 6. Install the right park/turn signal lamp. Page 9012 Fuse Block - Underhood C2 Part 1 Page 2140 Steps 1 - 13 Page 13172 Page 8391 1. Install the cable. 2. Snap the retainer tabs into the body mount. 3. Connect the front cable to the intermediate cable. 4. Route the cable in through the floor pan and engage the grommet. 5. Remove the safety stands. 6. Lower the vehicle. 7. Roll the carpet into place. 8. Install the park brake pedal. Refer to Park Brake Pedal Assembly Replacement. 9. Adjust the park brake system. (W/O NYS) Park Brake Cable Replacement - Left Rear (w/o NYS) Removal Procedure 1. Release the park brake. 2. Raise and support the vehicle. Refer Vehicle Lifting Page 7814 Page 16036 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. REPLACEMENT PROCEDURE After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Insure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the Terminal Removal Procedure. Repairing Connector Terminals REPAIRING CONNECTOR TERMINALS TOOLS REQUIRED J 38125-D Terminal Repair Kit Use the following repair procedures in order to repair the following: - Push to Seat terminals - Pull to Seat terminals - Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-D contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100 World terminals. Soldering Micro-Pack 100 World terminals may damage the terminal. Circuit Protection - Circuit Breakers CIRCUIT PROTECTION - CIRCUIT BREAKERS A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Page 7585 For vehicles repaired under warranty, use the table. Disclaimer Page 6185 If clutch debris is found, it is also very important to inspect the Pressure Control (PC) solenoid valve (377) fluid screens. Clean or replace the PC solenoid (377) as necessary. It is also important to flush and flow check the transmission oil cooler using J45096. Refer to SI Automatic Transmission Oil Cooler Flushing and Flow Test for the procedure. The notches above each sprag must point up as shown when assembled into the outer race. Bearing Assembly, Input Sun Gear Snap Ring, Overrun Clutch Hub Retaining Hub, Overrun Clutch Wear Plate, Sprag Assembly Retainer and Race Assembly, Sprag Forward Sprag Assembly Retainer Rings, Sprag Assembly Outer Race, Forward Clutch Washer, Thrust (Input Carrier to Race) The following information applies when this sprag is used in 1982-86 transmissions. The new design sprag can be used on models 1982 through 1986, by replacing the entire assembly (637 - 644). Individual components are NOT Page 1163 Front Passenger Seat (1 Of 2) (With RPO Code AN3) Page 13112 The number above refers to the step number on the diagnostic table. DTC U0073 or U2100 DTC Descriptors DTC U0073 00: Control Module Communication Bus Off DTC U0073 71: ECU HS Bus Off DTC U0073 72: ECU LS Bus Off DTC U2100 00: Controller Area Network (CAN) Bus Communication DTC U2100 47: Controller Area Network (CAN) Bus Communication Circuit/System Description The serial data circuits are serial data buses used to communicate information between the control modules. The serial data circuits also connect directly to the data link connector (DLC). Conditions for Running the DTCs Supply voltage at the modules are in the normal operating range. The vehicle power mode requires serial data communications. Conditions for Setting the DTC The module setting the DTC has attempted to establish communications on the serial data circuits more than 3 times. Page 9257 C411 Left Rear Lamp Harness To Chassis Harness (With RPO Code T79) Page 14609 Seat Lumbar Motor - Front Passenger (With RPO Code AN3) Page 905 IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. Splicing Twisted or Shielded Cable SPLICING TWISTED OR SHIELDED CABLE Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. - Rewrap the conductors with the mylar tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with mylar tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Control Module References Page 12370 NON-COMPATIBLE GARAGE DOOR OPENERS Page 268 ^ On 2002 Sevilles and DeVilles, the GPS jumper cable MUST be unclipped from the back seat cross brace, or unplugged from the VCIM first. DO NOT pull back on the mounting bracket until the GPS antenna jumper cable is unclipped from the back seat cross brace or unplugged from the VCIM. The short length of jumper cable does not allow the VCIM mounting bracket to be pulled back very far, and could lead to a break at the VCIM connector. ^ On 2000-2002 Bonnevilles and LeSabres and 2001-2002 Auroras you will need to follow these steps: 1. Remove the 4 nuts that secure the VCU/VIU bracket assembly to the rear seat back brace. Note: Save these nuts for later use. 2. Remove and discard the plastic VCU/VIU bracket assembly from the vehicle. 3. Remove the upper right stud (1) from the rear seat back brace and re-install in the middle lower slot (2) on the brace. Tighten the fastener to 4 Nm (36 lb in). 4. Position the new VCIM in the vehicle over the studs on the rear seat back brace. 5. Install two of the nuts saved from step (1). Tighten the nuts to 4 Nm (36 lb in). 6. Connect the new OnStar jumper harness supplied in the kit to the VCIM (two white connectors) and the body wiring harness (C345 connector). 7. Connect the small coaxial jumper cable supplied in the kit, to the VCIM, with the end that has a blue plastic housing connector. Plug the other end of this coaxial jumper cable to the OnStar Global Positioning Satellite (GPS) antenna coaxial cable at the right angle connector. Note: The GPS cable in the new OnStar jumper harness is not utilized. 8. Connect the cellular coaxial cable to the OnStar VCIM. On 2001 Impala and Monte Carlos you will need to follow these steps: 9. Remove the Vehicle Communications Unit (VCU) and Vehicle Interface Unit (VIU) following the procedures listed in SI. Save the bracket nuts for later use. Remote Control - VCP Remote Control: Description and Operation Remote Control - VCP REMOTE CONTROL To use the remote control, aim it at the infrared window below the video screen and press the desired remote control button. Direct sunlight or very bright light may affect the ability of the entertainment system to receive signals from the remote control. If the remote control does not seem to be working, the batteries may need to be replaced. Objects blocking the line of sight may affect the function of the remote control. Page 7359 Vehicle Speed Sensor (VSS) Tow/Haul Switch Location Page 267 6. See wiring diagram shown above for details. 5. Replace the OnStar(R) Vehicle Communication Interface Module (VCIM) in the vehicle with the provided Digitally-Capable VCIM. Refer to the Communication Interface Module Replacement procedure in the Cellular Communication section of SI. This kit may include a new VCIM bracket. If it does, use this new bracket on the vehicle and discard the original bracket. The kit may also include a small wiring jumper cable. If it does, plug the wiring jumper cable into the connector on the VCIM and the other end to the corresponding vehicle wiring harness connector. ^ For 2001, 2002 and 2003 Chevrolet Impala and Monte Carlo, do not reinstall the black plastic OnStar(R) module cover onto the vehicle after the VCIM and module bracket have been installed. This black plastic cover will no longer fit on the vehicle. ^ The upgrade kit for 2002 Sevilles and DeVilles, and some 2003 Sevilles and DeVilles, will contain a large bracket. To install the new VCIM into this bracket you'll need to carefully line up the notch in the VCIM with the tab in the bracket. Page 15010 report with the recall bulletin. For IPC For dealers with involved vehicles, a Campaign Initiation Detail Report containing the complete Vehicle Identification Number, customer name and address data has been prepared and is being furnished to involved dealers. Dealers that have no involved vehicles currently assigned will not receive a report with the recall bulletin. The Campaign Initiation Detail Report may contain customer names and addresses obtained from Motor Vehicle Registration Records. The use of such motor vehicle registration data for any other purpose other than follow-up necessary to complete this recall is a violation of law in several states/provinces/countries. Accordingly, you are urged to limit the use of this report to the follow-up necessary to complete this program. Parts Information Parts required to complete this recall are to be obtained from General Motors Service Parts Operations (GMSPO). Please refer to your "involved vehicles listing" before ordering parts. Normal orders should be placed on a DRO = Daily Replenishment Order. In an emergency situation, parts should be ordered on a CSO = Customer Special Order. Customer Reimbursement - For US All customer requests for reimbursement for previous repairs for the recall condition will be handled by the Customer Assistance Center, not by dealers. Page 4518 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-8 (12085115) crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-8 (12085115) until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes SPLICING INLINE HARNESS DIODES Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate Service Data wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. 9. Tape the diode to the harness or connector using electrical tape. Page 7207 C104, C114, C150, C151, C153, C154, And PTO Relay Page 5407 7. Remove the fuel tank ground wire bolt (2). 8. Reposition the fuel tank fill pipe ground wire. 9. Loosen the fuel tank fill pipe clamp (3) at the fuel tank. 10. Loosen the vent hose clamp (1) at the fuel tank. 11. Remove the fuel tank fill pipe. 12. Cap the opening on the fuel tank in order to prevent possible system contamination. INSTALLATION PROCEDURE 1. Remove the cap from the opening on the fuel tank. 2. Install the fuel tank fill pipe. NOTE: Refer to Fastener Notice in Service Precautions. 3. Tighten the vent hose clamp (1) at the fuel tank. 4. Tighten the fuel tank fill pipe clamp (3) at the fuel tank. Tighten Tighten the clamps to 2.5 N.m (22 lb in). 5. Position the fuel tank fill pipe ground wire. 6. Install the fuel tank ground wire bolt (2). Tighten Tighten the bolt to 9 N.m (80 lb in). Page 13138 Claim Information - GM, Saturn Canada and Saab Canada Only Claim Information - Saturn US Only Customer Reimbursement Claims - Special Attention Required Customer reimbursement claims must have entered into the "technician comments" field the CSO # (if repair was completed at a Saturn Retail Facility) date, mileage, customer name, and any deductibles and taxes paid by the customer. Claim Information - Saab US Only Description and Operation Electronic Throttle Control Module: Description and Operation THROTTLE ACTUATOR CONTROL MODULE The TAC module is the control center for the throttle actuator control system. The TAC system is self-diagnosing and provides diagnostic information to the PCM through a dedicated serial data line. The TAC achieves throttle positioning by providing a pulse width modulated voltage to the TAC, as directed by the PCM. Page 14806 Seat Heater Switch: Locations Driver Door Page 12908 1. Connect the brake pedal position sensor (2) electrical connector (1). 2. Align the brake pedal position sensor (1) with the actuation arm (2) on the brake pedal and the brake pedal position sensor mounting bracket. Audio - Inadvertent Steering Wheel Button Activation Remote Switch: Technical Service Bulletins Audio - Inadvertent Steering Wheel Button Activation INFORMATION Bulletin No.: 08-08-44-028 Date: August 28, 2008 Subject: Information On Inadvertent Steering Wheel Control (SWC) Button Press Causing Radio Anomalies Models: 2009 and Prior GM Passenger Cars and Trucks (Including Saturn) 2009 and Prior HUMMER H2, H3 Models 2009 and Prior Saab 9-7X All Vehicles with Steering Wheel Controls This bulletin is being issued to provide a recommendation for vehicles with a customer concern of the radio station tuning changing by itself, volume changing by itself, radio changing by itself, or radio muting or going silent when driving and turning the steering wheel. The switches on the right hand side of the steering wheel are easily pressed and may inadvertently be pressed when turning the steering wheel. These concerns may be affected by the location of the steering wheel controls. Recommendation Do Not Replace The Radio 1. Please determine that the switch controls on the steering wheel are functioning correctly. 2. Ask the customer if their hand was in close proximity to the steering wheel controls when the condition happened. Explain to the customer that bumping the controls would have caused this undesired action. Explain to the customer the proper use and function of the steering wheel controls. Disclaimer Connector Views Parking Lamp: Connector Views Park/Turn Signal Lamp - LF Page 8507 Page 13919 1. Install the crossmember to the vehicle. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the bolts retaining the crossmember to the frame. Tighten the crossmember retaining bolts to 120 N.m (88 lb ft). 3. Install the differential carrier shield. 4. Lower the vehicle. Speaker Replacement - Front Floor Console Speaker: Service and Repair Speaker Replacement - Front Floor Console SPEAKER REPLACEMENT - FRONT FLOOR CONSOLE (SUBWOOFER SPEAKER) REMOVAL PROCEDURE 1. Remove the 2 front seats. 2. Move the center console rearward slightly in order to disconnect the wire connector. 3. Move the console rearward to gain access to the subwoofer speaker. 4. Remove the 4 retaining bolts from the speaker. 5. Disconnect the wire connector. 6. Remove the speaker from the subwoofer assembly. INSTALLATION PROCEDURE 1. Install the speaker into the subwoofer assembly. 2. Connect the wire connector. NOTE: Refer to Fastener Notice in Service Precautions. 3. Install the 4 retaining screws. Ensure the screw follows the same thread in the screw boss so that a new thread is not formed. Tighten Tighten the screws to 6 N.m (53 lb in). 4. Move the console forward in order to connect the wire connector. 5. Install the console to the I/P. 6. Install the 2 front seats. Tire/Wheel - Spare Tire Is Non-Matching To Other Tires Spare Tire: All Technical Service Bulletins Tire/Wheel - Spare Tire Is Non-Matching To Other Tires INFORMATION Bulletin No.: 02-03-10-001E Date: November 01, 2010 Subject: Spare Tire is a Different Size than Other Tires Models: 2002-2011 Cadillac Escalade Models 1999-2007 Chevrolet Silverado (Classic) 2000-2011 Chevrolet Suburban, Tahoe 2002-2011 Chevrolet Avalanche 1999-2007 GMC Sierra (Classic) 2001 GMC Sierra C3 2001-2011 GMC Yukon Models 2002-2011 GMC Sierra Denali Supercede: This bulletin is being revised to update the model years. Please discard Corporate Bulletin Number 02-03-10-001D (Section 03 - Suspension). This bulletin is being issued to supply additional information concerning the spare tire on the above vehicles. You or your customers may have noticed that the spare tire has a 16-inch diameter steel wheel or 17-inch diameter aluminum wheel while the road tires have a 17-inch, 18-inch, 20-inch or 22-inch diameter aluminum wheel. Although the spare tire has a different wheel diameter and may be a different brand, the rolling circumference is nearly identical to the road tires. The size difference will not cause a concern because the spare and the other tires will travel the same distance in one revolution. This combination of non-matching tires is used most often on full-size trucks. These vehicles use a road tire and wheel combination that may be too large to conveniently fit the storage compartment space of the vehicle. The customer may not be able to easily remove the spare tire/wheel from the storage area because of its size and/or weight. A steel spare wheel, rather than an aluminum one, may be used since the spare is stowed under the vehicle where it is exposed to road and weather elements. A steel wheel is less likely to incur cosmetic damage while in the stowed position for long periods of time. Please provide this information to your customers. Also, remind your customers of the importance of following the tire maintenance schedule as listed in their Owner Manual. Additional tire care information can be found by visiting www.gmtiresafety.com or contacting GM toll-free. Disclaimer Page 2000 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Weather Pack Connectors WEATHER PACK CONNECTORS The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. Diagrams Coolant Level Switch Page 6036 Torque Converter Clutch Solenoid: Connector Locations Passlock Function Engine Control Module: Description and Operation Passlock Function VEHICLE/POWERTRAIN CONTROL MODULE The VCM/PCM communicates with the BCM over the Class 2 serial data line. When the BCM determines a no start condition, it sends a Class 2 serial data password to the VCM/PCM in order to disable the fuel injection system. If the BCM receives the expected voltage from the Passlock(TM) sensor, the BCM sends a class 2 serial data password to the VCM/PCM in order to enable the fuel injection system. The VCM/PCM then allows the vehicle to start correctly. If the Class 2 serial data password from the BCM to the VCM/PCM is not within the Vehicle Security Status Message, the fuel injectors will shut OFF during a start attempt. The SECURITY telltale will be illuminated for 10 minutes. If the VCM/PCM does not receive the same password from the BCM as the last learned one, the vehicle will start and then stalls due to the Fuel Lockout. Page 6942 5. Insert the inner race (1) into the cage (2), by rotating the inner race (1) downward. 6. Insert the cage (4) and inner race into the outer race (1). 7. Place a brass drift against the CV joint cage (1). 8. Tap gently on the brass drift with a hammer in order to tilt the cage (1). 9. Install the first chrome alloy ball (2) when the CV joint cage (1) tilts. 10. Tilt the CV joint cage (1) in the opposite direction to install the opposing chrome alloy ball (2). 11. Repeat this process in order to install all six of the balls. Diagrams Throttle Body Page 14987 A General Motors Product Recall Customer Reimbursement Procedure Form is shown. Important: Refer to the GM Service Policies and Procedures Manual, section 6.1.12 for specific procedures regarding customer reimbursement and the form. Customer Reimbursement - For Canada Customer requests for reimbursement of previously paid repairs to correct the condition addressed in this bulletin are to be submitted by January 31, 2006. All reasonable customer paid receipts should be considered for reimbursement. The amount to be reimbursed will be limited to the amount the repair would have cost if completed by an authorized General Motors dealer. When a customer requests reimbursement, they must provide the following: ^ Proof of ownership at time of repair. ^ Original paid receipt confirming the amount of repair expense(s) that were not reimbursed, a description of the repair, and the person or entity performing the repair. Claims for customer reimbursement on previously paid repairs are to be submitted as required by WINS. Important: Refer to the GM Service Policies and Procedures Manual, section 1.6.2, for specific procedures regarding customer reimbursement verification. Courtesy Transportation The General Motors Courtesy Transportation program is intended to minimize customer inconvenience when a vehicle requires a repair that is covered by the New Vehicle Limited Warranty. The availability of courtesy transportation to customers whose vehicles are within the warranty coverage period Page 15980 Heated Glass Element: Description and Operation Compass Calibration and Variance Procedure COMPASS CALIBRATION AND VARIANCE PROCEDURE COMPASS CALIBRATION Before calibrating the compass, drive the vehicle to an open area that is magnetically clean or free of large metallic objects such as high tension power lines or large steel buildings. Verify there are no magnetized roof antennas, magnets on or hanging from the mirror, or any other magnetized objects on the inside or outside of the vehicle close to the mirror. 1. Start the engine. IMPORTANT: Before calibrating the compass, make sure the mirror has the correct zone number. Refer to Compass Magnetic Variation Adjustment. 2. Press and hold the switch for the compass, which may be depicted as COMP, COMPASS, or on/off (w/UE1) depending on the type of mirror on the vehicle, until the letter "C" or "CAL" is displayed. 3. Drive the vehicle in circles at a speed of less than 8 km/h (5 mph) until the "C" or "CAL" is replaced by a proper vehicle heading. The calibration procedure is now complete. COMPASS MAGNETIC VARIATION ADJUSTMENT Magnetic variation adjustments are required when the compass displays a constant error in heading. Variation is the difference between magnetic north and true north due to geographical location. 1. Locate your current geographic location on the World Magnetic Variation Map. 2. Turn ON the ignition, with the engine OFF. 3. Press and hold the switch for the compass, which may be depicted as COMP, COMPASS, or on/off (w/UE1) depending on the type of mirror on the vehicle, until a zone number appears on the compass display. 4. Depress the switch for the compass to select the desired zone number. 5. Wait 5 seconds. The display will return to a compass heading. The variance procedure is now complete. 6. Calibrate the compass. Refer to Compass Calibration mentioned above. I/P Fuse Block Fuse Block: Locations I/P Fuse Block Body Control Module (BCM) Page 1692 3. Connect the VSS electrical connector (3). Lower the vehicle. Page 14372 Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses CIRCUIT PROTECTION - FUSES The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the Page 6573 Vehicle Speed Sensor (VSS) Tow/Haul Switch Location Specifications Valve Clearance: Specifications The manufacturer indicates that this vehicle has hydraulic lifters or adjusters and therefore does not require adjustment. Page 8699 Traction Control Switch: Service and Repair Traction Control Switch Replacement Removal Procedure 1. Remove instrument panel (IP) bezel. 2. Gently lift the switch retaining tabs (1) and remove the traction control switch (2) from the instrument panel (IP) assembly (3). 3. Disconnect the harness connector from the traction control switch. Installation Procedure 1. Connect the harness connector to the traction control switch. 2. Install the traction control switch (2) into the instrument panel (IP) assembly (3), making sure that all of the switch retaining tabs (1) are engaged. 3. Install instrument panel (IP) bezel. Page 6498 The torque specification has changed for the fittings to case. The torque has changed from 38 Nm (28 lb ft) to 32 Nm (23 lb ft). Tighten Tighten the new cooler fittings to 32 Nm (23 lb ft). The converter drain back check ball (420C) has been removed from the cooler line fitting and is now located in the channel plate. If you get a concern of no movement in the morning or after sitting for several hours, the cooler check ball should be inspected. The best way to determine where the check ball is located is to look at the cooler line fittings. The old fittings are different sizes (3/8-18 NPSF & 1/4-18 NPSF) and would contain the cooler check ball. The new fittings are the same size as each other (9/16-18 UNF) and do not have a cooler check ball. Parts Information Disclaimer Component Locations Transmission Temperature Sensor/Switch: Component Locations Automatic Transmission - 4L60-E/4L65-E Automatic Transmission Electronic Component Views (M30/M32) Electronic Components Locations Air Induction Components Door Window Regulator Replacement (Manual) Front Door Window Regulator: Service and Repair Door Window Regulator Replacement (Manual) Window Regulator Replacement - Front Door Removal Procedure 1. Raise and support the window glass. 2. Remove the trim panel. 3. Remove the water deflector. 4. Remove the 2 bolts that hold the window to the regulator. 5. Remove the bolts from the window regulator. 6. Remove the window regulator assembly from the door by folding both sides together. Installation Procedure 1. Install the regulator to the door. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the bolts to the window regulator. Tighten the bolts to 9 N.m (80 lb in). 3. Align the window glass to the regulator. 4. Install the bolts that hold the window to the regulator. Tighten the bolts to 9 N.m (80 lb in). 5. Install the water deflector. 6. Install the trim panel. 7. Lower the window. Inspect the operation. Page 16292 Wiper Blade: Testing and Inspection WIPER BLADE ELEMENT CHECK 1. Remove the wiper blades from the wiper arms. 2. Look down the length of the blade element. 3. Replace the wiper blade element if the rubber element which contacts the glass is not on the centerline of the blade +/-15 degrees. 4. Install the wiper blades on the wiper arms. Page 13114 ^ I/O check Any faults detected during the initialization self-test shall generate a DTC. All nodes also continuously perform a self-test while in an active state. DTCs and their associated telltales will set as a result of unprogrammed or unlearned information. DTCs, which are defined for system configuration (e.g. Vehicle Option Content not programmed) do not support the history status bit (set =0). Warning indicator bit is also set, when applicable, while this DTC is present. Action Taken When the DTCs Sets The module suspends all message transmission. The module uses default values for all parameters received on the serial data circuits. The module inhibits the setting of all other communication DTCs. Conditions for Clearing the DTC A current DTC clears when the malfunction is no longer present. A history DTC clears when the module ignition cycle counter reaches the reset threshold of 50, without a repeat of the malfunction. Circuit/System Verification Refer to Data Link References to determine which serial data system is used for a specific module. The DTCs cannot be retrieved with a current status. Diagnosis is accomplished using the following symptom procedures: Scan Tool Does Not Communicate with High Speed GMLAN Device in SI. OR Scan Tool Does Not Communicate with Low Speed GMLAN Device in SI. DTC U1300, U1301, or U1305 Circuit Description Modules connected to the Class 2 serial data circuit monitor for serial data communications during normal vehicle operation. Operating information and commands are exchanged among the modules. In addition to this, Node Alive messages are transmitted by each module on the Class 2 serial data circuit about once every 2 seconds. When the module detects one of the following conditions on the Class 2 serial data circuit for approximately 3 seconds, the setting of all other Class 2 serial communication DTCs is inhibited and a DTC will set. Conditions for Running the DTCs Voltage supplied to the module is in the normal operating voltage range. The vehicle power mode requires serial data communication to occur. Conditions for Setting the DTCs No valid messages are detected on the Class 2 serial data circuit. The voltage level detected on the Class 2 serial data circuit is in one of the following conditions: Page 9136 Important The M6 conductive rivet stud as shown, can accommodate a panel thickness range of 0.7-4.2 mm (0.03-0.17 in). If there are layers of sheet metal, they should be touching without any air gaps to ensure a good ground. 5. Select a M6 conductive rivet stud. Refer to the Parts Information section of this bulletin. Note Use the GE-50317 rivet stud tool kit. 6. Place the M6 conductive rivet stud (1) in the 10 mm (0.40 in) hole. Assemble the rivet stud tool (2) with the groove and flare side facing the rivet stud, then the washer and the M6 nut (3). 7. Using a wrench on the rivet stud tool, and a socket on the M6 nut, secure the M6 conductive rivet stud. 8. Ensure the rivet stud is securely fastened, WITHOUT ANY detectable movement. 9. Completely wrap the threads of the rivet stud with painters tape or equivalent. Note The rivet stud and surrounding panel area MUST BE properly refinished PRIOR to the installation of the ground wire terminal and conductive nut to maintain a secure, stable and corrosion-free electrical ground. 10. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 11. Allow the refinished repair area to cure sufficiently before removing the protective material applied to the rivet stud threads. 12. Remove the painters tape or equivalent from the rivet stud threads. 13. Using GM approved residue-free solvent or equivalent, thoroughly clean the rivet stud threads to remove any adhesive and allow to dry. 14. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive rivet stud. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. Page 8683 Electronic Brake Control Module (ECBCM) - C2 (10/20 Series w/o HP2 Page 15273 Door Switch: Diagrams Door Latch Assembly (Door Jamb Switch) - RR C2 (Crew Cab Only) Door Latch Assembly (Door Jamb Switch) - RR C2 (Crew Cab Only) Page 9531 Location View Page 1741 Crankshaft Position (CKP) Sensor Page 6918 3. Hold the inner race (1) at 90 degrees to the centerline of the cage (2). 4. Align the lands of the inner race (1) with the windows of the cage (2). 5. Insert the inner race (1) into the cage (2), by rotating the inner race (1) downward. 6. Insert the cage (4) and inner race into the outer race (1). Page 10334 - Tighten the nut to 50 Nm (37 lb ft). 8. Install the retaining bolts for the brake hose and wheel speed sensor brackets. - Tighten the bolts to 9 Nm (80 lb in). 9. Install the tire and wheel. 10. Remove the safety stands. 11. Lower the vehicle. 12. Verify the wheel alignment. Page 15654 5. Remove the bulb from the headlamp assembly by twisting the bulb counterclockwise. INSTALLATION PROCEDURE IMPORTANT: Replace a high beam bulb with another high beam bulb. The high beam bulb has a red gasket. - Replace a low beam bulb with another low beam bulb. The low beam bulb has a gray tip and a yellow gasket at the base. 1. Install the new bulb to the headlamp assembly by twisting the bulb clockwise in order to lock in place. 2. Connect the electrical connector to the bulb. 3. Install the headlamp assembly. Page 11452 Inflatable Restraint Sensing And Diagnostic Module: Service and Repair INFLATABLE RESTRAINT SENSING AND DIAGNOSTIC MODULE REPLACEMENT REMOVAL PROCEDURE CAUTION: Do not strike or jolt the inflatable restraint sensing and diagnostic module (SDM). Before applying power to the SDM, make sure that it is securely fastened with the arrow facing toward the front of the vehicle. Failure to observe the correct installation procedure could cause SIR deployment, personal injury, or unnecessary SIR system repairs. - Refer to SIR Caution in Service Precautions. 1. Disable the SIR system. Refer to SIR Disabling and Enabling Zone 7. 2. Remove the drivers seat. 3. Remove the driver side door sill plate. 4. Fold back the carpet to access the inflatable restraint sensing and diagnostic module (SDM). 5. Remove the connector position assurance (CPA) (1) from the inflatable restraint sensing and diagnostic module (SDM) wiring harness connector (2). 6. Push down the flex lock button (3) and slide the connector locking cover (4) to the open position. Page 14890 Seat Adjuster Switch - Driver (AG1) Page 9670 4. Install the ground, then the washer and then the bolt to the frame. Important: It is important to use the bolts, washers and nuts specified in this bulletin. These parts have been identified due to their conductive finish. 5. Install a washer and nut to the back side of the frame. Tighten Tighten the nut to 9 Nm (79 lb in). 6. Cover the front and back side of the repair area using Rubberized Undercoating. An additional check can be made to ensure a good connection for the battery cable to frame ground. It is possible for this ground to cause similar symptoms with the ABS as described above. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Parts Information Warranty Information Disclaimer Service and Repair Rear Door Window Regulator: Service and Repair Window Regulator Replacement - Rear Door Removal Procedure 1. Raise and support the window glass. 2. Remove the trim panel. 3. Remove the water deflector. 4. Remove the 2 bolts that hold the window to the regulator. 5. Remove the bolts from the window regulator. 6. Remove the window regulator assembly from the door by folding both sides together. Installation Procedure 1. Install the regulator to the door. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the bolts to the window regulator. Tighten the bolts to 9 N.m (80 lb in). 3. Align the window glass to the regulator. 4. Install the bolts that hold the window to the regulator. Tighten the bolts to 9 N.m (80 lb in). 5. Install the water deflector. 6. Install the trim panel. 7. Lower the window. Inspect the operation. Page 2504 3. Remove the rear axle drain plug. 4. Drain the lubricant into a suitable container. 5. Inspect the drain plug for excessive metal particle accumulation. This accumulation is symptomatic of extreme wear. 6. Clean the drain plug. Installation Procedure 1. Notice: Refer to Fastener Notice in Service Precautions. Install the rear axle drain plug. ^ Tighten the rear axle drain plug to 27 Nm (20 ft. lbs.). 2. Fill the rear axle. Use the proper fluid. 3. Install the rear axle fill plug. ^ Tighten the rear axle fill plug to 21 Nm (15 ft. lbs.). 4. Lower the vehicle. 9.5, 10.5, and 11.5 Inch Axles Lubricant Replacement - Rear Drive Axle (9.5, 10.5, and 11.5 Inch Axles) Removal Procedure 1. Raise the vehicle. Refer to Vehicle Lifting. Page 14399 Front Passenger Door Module (FPDM) - C2 (With RPO Code YE9) Part 1 Page 8246 perform the following steps: 1. Inspect the brake system for external leaks. 2. Pressure bleed the hydraulic brake system in order to purge any air that may still be trapped in the system. 22. Turn the ignition key ON, with the engine OFF. Check to see if the brake system warning lamp remains illuminated. 23. Important: If the brake system warning lamp remains illuminated, DO NOT allow the vehicle to be driven until it is diagnosed and repaired. If the brake system warning lamp remains illuminated, refer to Symptoms - Hydraulic Brakes. Page 3134 4. Notice: Refer to Fastener Notice in Service Precautions. Install the valve lifter guide bolt. ^ Tighten the bolt to 12 Nm (106 inch lbs.). 5. Install the cylinder head and gasket. Page 15878 Numerous & Various Size Drops of Water Collecting on the Inside Surface of the Lamp Lens After the Vehicle Has Been Exposed to Rain or a Car Washing Environment - A condition that covers more than half the surface of the lamp lens. - An accumulation of water in the bottom of the lamp assembly. - A condition that WON'T clear when the vehicle is parked in a dry environment, or when the vehicle is driven with the lights ON. - A comparison of the equivalent lamp on the opposing side of the vehicle indicates a different performance. Any of the above conditions would indicate the need to service the lens or lamp assembly. Disclaimer Page 12106 ^ I/O check Any faults detected during the initialization self-test shall generate a DTC. All nodes also continuously perform a self-test while in an active state. DTCs and their associated telltales will set as a result of unprogrammed or unlearned information. DTCs, which are defined for system configuration (e.g. Vehicle Option Content not programmed) do not support the history status bit (set =0). Warning indicator bit is also set, when applicable, while this DTC is present. Action Taken When the DTCs Sets The module suspends all message transmission. The module uses default values for all parameters received on the serial data circuits. The module inhibits the setting of all other communication DTCs. Conditions for Clearing the DTC A current DTC clears when the malfunction is no longer present. A history DTC clears when the module ignition cycle counter reaches the reset threshold of 50, without a repeat of the malfunction. Circuit/System Verification Refer to Data Link References to determine which serial data system is used for a specific module. The DTCs cannot be retrieved with a current status. Diagnosis is accomplished using the following symptom procedures: Scan Tool Does Not Communicate with High Speed GMLAN Device in SI. OR Scan Tool Does Not Communicate with Low Speed GMLAN Device in SI. DTC U1300, U1301, or U1305 Circuit Description Modules connected to the Class 2 serial data circuit monitor for serial data communications during normal vehicle operation. Operating information and commands are exchanged among the modules. In addition to this, Node Alive messages are transmitted by each module on the Class 2 serial data circuit about once every 2 seconds. When the module detects one of the following conditions on the Class 2 serial data circuit for approximately 3 seconds, the setting of all other Class 2 serial communication DTCs is inhibited and a DTC will set. Conditions for Running the DTCs Voltage supplied to the module is in the normal operating voltage range. The vehicle power mode requires serial data communication to occur. Conditions for Setting the DTCs No valid messages are detected on the Class 2 serial data circuit. The voltage level detected on the Class 2 serial data circuit is in one of the following conditions: Page 503 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-8 (12085115) crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-8 (12085115) until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes SPLICING INLINE HARNESS DIODES Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate Service Data wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. 9. Tape the diode to the harness or connector using electrical tape. Transfer Case - NVG 246-NP8 Four Wheel Drive Selector Switch: Service and Repair Transfer Case - NVG 246-NP8 Transfer Case Shift Control Switch Replacement Removal Procedure 1. Remove the instrument panel (I/P) cluster bezel. 2. Using a flat-tipped screwdriver, gently pry the retaining clips open on the housing. 3. Slide out the selector switch until the electrical connector are accessible. 4. Disconnect the selector switch electrical connectors (2, 3). 5. Remove the selector switch from the housing. Installation Procedure 1. Position the selector switch close to the housing so the electrical connectors can be connected. Page 2074 Step 3 Page 3990 Knock Sensor: Description and Operation KNOCK SENSOR (KS) SYSTEM DESCRIPTION PURPOSE The knock sensor (KS) system enables the control module to control the ignition timing for the best possible performance while protecting the engine from potentially damaging levels of detonation. The control module uses the KS system to test for abnormal engine noise that may indicate detonation, also known as spark knock. SENSOR DESCRIPTION This KS system uses one or two broadband one-wire sensors. The sensor uses piezo-electric crystal technology that produces an AC voltage signal of varying amplitude and frequency based on the engine vibration, or noise, level. The amplitude and frequency are dependant upon the level of knock that the KS detects. The control module receives the KS signal through a signal circuit. The KS ground is supplied by the engine block through the sensor housing. One way the control module monitors the system is by output of a bias voltage on the KS signal wire. The bias voltage creates a voltage drop that the control module monitors and uses to help diagnose KS faults. The KS noise signal rides along this bias voltage, and due to the constantly fluctuating frequency and amplitude of the signal, will always be outside of the bias voltage parameters. Another way the control module monitors the system is by learning the average normal noise output from the KS. The control module learns a minimum noise level, or background noise, at idle from the KS and uses calibrated values for the rest of the RPM range. The control module uses the minimum noise level to calculate a noise channel. The control module uses this noise channel, and the KS signal that rides along the noise channel, in much the same way as the bias voltage type does. As engine speed and load change, the noise channel upper and lower parameters will change to accommodate the normal KS signal. In order to determine which cylinders are knocking, the control module only uses KS signal information when each cylinder is near top dead center (TDC) of the firing stroke. If the control module has determined that knock is present, it will retard the ignition timing to attempt to eliminate the knock. The control module will always try to work back to a zero compensation level, or no spark retard. An abnormal KS signal will fall within the noise channel or will not be present. KS diagnostics are calibrated to detect faults with the KS circuitry inside the control module, the KS wiring, or the KS voltage output. Page 15964 - Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-D in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-D if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Page 9912 5. Remove paint and primer from the area surrounding the 10 mm (0.40 in) until bare metal is visible. Important The M6 conductive rivet stud as shown, can accommodate a panel thickness range of 0.7-4.2 mm (0.03-0.17 in). If there are layers of sheet metal, they should be touching without any air gaps to ensure a good ground. 6. Select a M6 conductive rivet stud. Refer to the Parts Information section of this bulletin. Note Use the GE-50317 rivet stud tool kit. 7. Place the M6 conductive rivet stud (1) in the 10 mm (0.40 in) hole. Assemble the rivet stud tool (2) with the groove and flare side facing the rivet stud, then the washer and the M6 nut (3). 8. Using a wrench on the rivet stud tool, and a socket on the M6 nut, secure the M6 conductive rivet stud. 9. Ensure the new rivet stud is securely fastened, WITHOUT ANY detectable movement. 10. Completely wrap the threads of the rivet stud with painters tape or equivalent. Page 7885 1. If a NEW control module is being installed, program the new module. 2. Install the shift control module to the bracket. 3. Connect the shift control module electrical connectors. 4. Start the engine and test the automatic transfer case system for proper shift operation. Page 16138 Electrical Symbols Part 14 NVG 246-NP8 Control Module: Service and Repair NVG 246-NP8 Transfer Case Control Module Reprogramming Transfer Case Control Module Reprogramming Set-up for Module Programming/Reprogramming Important: Ensure that the vehicle battery is fully charged and that a battery charger is no longer connected. If performing this procedure for module replacement, install new module before proceeding. Before reprogramming close the doors and wait two minutes to allow other modules to stop communicating via the class 2 data line. Failure to do so could result in a failed reprogramming procedure. ^ Turn OFF all accessories. ^ Turn ON the ignition, with the engine OFF. Remote Programming Feature 1. Connect the scan tool to the vehicle. 2. Power-up the scan tool and select the Service Programming feature. 3. Select the appropriate vehicle. 4. Press the Request Info button on the scan tool. 5. Disconnect the scan tool from the vehicle and connect the scan tool to the computer station. 6. Follow the menu select items for reprogramming and provide information as to what type of device you are programming and whether you are reprogramming or replacing the electronic control unit (ECU). 7. Select "vehicle" from the selection menu. 8. Select the module you wish to Program. 9. Select "Normal" for Programming Type. 10. Select the applicable software calibrations. 11. Transfer data file to the scan tool. 12. Reconnect the scan tool to the vehicle. 13. Turn ON the ignition, with the engine OFF. 14. Select the Service Programming feature on the scan tool. 15. Press the Program button on the scan tool. Programming Using Scan Tool Pass-Through Connection 1. Connect the scan tool to vehicle and power it up. 2. Connect the computer station to the scan tool. 3. Select "PC Using Scan Tool Connection" from the programming menu on the computer station. 4. Follow the menu select items for reprogramming and provide information as to what type of device you are programming and whether you are reprogramming or replacing the electronic control unit (ECU). 5. Select "vehicle" from the selection menu. 6. Select the module you wish to program. 7. Select "Normal" for Programming Type. 8. Select the applicable software calibrations. 9. Transfer data file to the scan tool. Transfer Case Shift Control Module Replacement Transfer Case Shift Control Module Replacement Removal Procedure Page 14530 Head Rest: Removal and Replacement Head Restraint Replacement Head Restraint Replacement Removal Procedure 1. Raise the head restraint (1) to the full up position. 2. Insert a paper clip or a similar tool in the hole at the side edges of the head restraint retainers. 3. Press in on the tool in order to release the retainer clips (2). 4. Lift the head restraint from the retainers. Installation Procedure 1. Install the head restraint (1) into the retainers. 2. Push the head restraint to the full down position. 3. Pull up in order to ensure that the head restraint engages with the head restraint retainers (2). Head Restraint Retainer Replacement - Front Seat Head Restraint Retainer Replacement - Front Seat Removal Procedure 1. Slide up the seat back trim cover in order to gain access to the rear cardboard panel fasteners. Refer to Seat Back Cover and Pad Replacement Front. 2. Remove the panel fasteners. Pull back the panel in order to gain access to the bushings. Page 7594 Page 845 4. Connect the wiring connectors to the fuse block. Refer to Electrical Center Identification Views to ensure the right connections are made. 5. Install the right side end panel. Page 10714 14. Remove the retaining ring from the wheel hub. 15. Remove the outer hub bearing and bearing cup using the J 24426 (2) and the J 8092 (1). Installation Procedure 1. Lubricate the following with a light coat of high melting point EP bearing lubricant: ^ The outer wheel bearing ^ The inner wheel bearing ^ The outer wheel bearing cup ^ The inner wheel bearing cup ^ The axle housing 2. Install the outer bearing into the wheel hub. 3. Install the outer bearing cup into the wheel hub. 4L60/4L60-E/4L65-E Transmission Tow/Haul Switch: Testing and Inspection 4L60/4L60-E/4L65-E Transmission Tow/Haul Switch/Indicator Always On or Inoperative Circuit Description Tow/haul mode enables the operator to achieve enhanced shift performance when towing or hauling a load. When tow/haul mode is selected, the tow/haul switch input signal to the body control module (BCM) is momentarily toggled to zero volts. This signals the powertrain control module (PCM) to extend the length of time between upshifts and increase transmission line pressure. Cycling the tow/haul switch again disables tow/haul mode and returns the transmission to a normal shift pattern. Diagnostic Aids If the electrical circuit tests are OK and the tow/haul shift pattern is not occurring, there may be a mechanical/hydraulic condition that prevents tow/haul operation. Refer to Symptoms - Automatic Transmission. Page 14271 Use the chemical manufacturers listed below, or equivalent: Auto Magic(R) or Clay Magic(R) products available from: Auto Wax Company, Inc. 1275 Round Table Dr. Dallas, TX 75247 (800) 826-0828 (Toll-Free) or (214) 631-4000 (Local) Fax (214) 634-1342 www.automagic.com [email protected] E038 Fallout Gel or E038E Liquid Fallout Remover II available from: Valvoline Car Brite Company 1910 South State Avenue Indianapolis, In 46203 (800) 347-2439 (Toll Free) or (317) 788-9925 (Local) Fax (317) 788-9930 www.carbrite.com [email protected] *We believe these sources and their products to be reliable. There may be additional manufacturers of such products. General Motors does not endorse, indicate any preference for or assume any responsibility for the products from these firms or for any such items which may be available from other sources. If rail dust remover is not available in your area, call one of the numbers listed above for a distributor near your location. Warranty Information (excluding Saab U.S. Models) Important Refer to the Policy & Procedures Manual, section 1.2.1.7 for detailed information regarding warranty coverage for this condition. Important In certain cases where the vehicle finish is severely damaged and the actual repair time exceeds the published time, the additional time should be submitted in the "Other Labor Hours" field. Warranty Information (Saab U.S. Models) Disclaimer Technical Service Bulletin # 05-08-51-008C Date: 090622 Body - Bumps or Rust Colored Spots in Paint Page 902 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Page 12520 these systems will then completely power OFF. OnStar(R) Module Expected Current Draw The expected current draw of the OnStar(R) module in various ignition modes are as follows: ^ Ignition ON ‐ 240 to 400 mA ^ Ignition OFF ‐ 3 to 20 mA for 48 hours ^ Ignition OFF ‐ 0.2 to 0.8 mA after 48 hours (120 hours on specified vehicle communication platforms (VCPs)). Note During extended voltage testing for battery parasitic draw, it is possible to observe a voltage spike caused by the following: ^ A cellular registration call that was triggered by the local cellular system. ^ The OnStar(R) system has set a monthly trigger for a vehicle data upload call for the OnStar(R) Vehicle Diagnostic E‐mail upload. OnStar(R) System States of Readiness The OnStar(R) system will use the following 4 states of readiness, depending upon the type of cellular market the vehicle is in when the ignition is turned OFF. ^ High power ^ Low power ^ Sleep ^ Digital standby The high power state is in effect whenever the ignition is in the ON or RUN position, retained accessory power (RAP) is enabled, and/or the OnStar(R) system is sending or receiving calls or when the system is performing a remote function. The low power state is in effect when the OnStar(R) system is idle with the ignition in the ON or RUN position, or with RAP enabled. The sleep state is entered after the vehicle has been shut OFF and the RAP has timed out. At a predetermined time recorded within the VCIM, the system re-enters the low power state to listen for a call from the OnStar(R) Call Center for 1 minute. After this interval, the system will again return to the sleep state for 9 minutes. If a call is sent during the 1 minute interval, the OnStar(R) system will receive the call and immediately go into the high power mode to perform any requested functions. If a call is not received during the 1 minute interval, the system will go back into the sleep mode for another 9 minutes. This process will continue for up to 48 hours, after which the OnStar(R) system will turn OFF until the ignition is turned to the ON or RUN position. The digital standby power state is entered after the vehicle has been shut off and the RAP has timed out while in a digital cellular area. When in digital standby mode, the OnStar(R) module is able to perform all remote functions as commanded by an OnStar(R) advisor at any time, for a continuous 48 hours. After 48 hours, the OnStar(R) module will go into sleep mode until a wake up signal from the vehicle is seen by the CIM. If the OnStar module loses the digital cellular signal it will revert to analog mode and follow the standard sleep state (9 minutes OFF, 1 minute standby) based on the time of the GPS signals, this will continue until a digital cellular signal is again received. If the OnStar(R) system loses battery power while the system is in a standby or sleep mode, the system will remain OFF until battery power is restored and the ignition is turned to the ON or RUN position. Deactivated OnStar(R) Accounts In the event that a customer has not upgraded their vehicle to a digital system, the account has been deactivated. The customers have been previously notified of the steps required to upgrade their vehicles. After the OnStar(R) account has been deactivated, customers will experience the following: ^ The OnStar(R) status LED will not illuminate ^ The OnStar(R) system will NOT attempt to connect to the OnStar(R) Call Center in the event of a collision or if the vehicle's front air bags deploy for any other reason. ^ An emergency button press will result in a demo message being played, indicating the service has been deactivated and needs to be upgraded. Page 14066 Electrical Symbols Part 5 Page 9319 Relay Box: Application and ID Relay Block - I/P Location View Page 15936 Electrical Symbols Part 9 Page 15933 Electrical Symbols Part 5 Page 12719 2. Skip to the next step if the vehicle to be upgraded is not shown above. 3. Skip to the next step if the vehicle to be upgraded is not a 2005 Cadillac STS. The 2005 Cadillac STS kit may include a new inside rearview (ISRV) mirror assembly and a new ISRV mirror wiring cover. If the kit you receive includes these parts, please remove the existing ISRV mirror and wire cover from the vehicle and install the ones provided in the kit per the instructions in SI. 4. Skip this step if the vehicle to be upgraded is not listed below. ^ 2003-2004 Saturn L-Series ^ 2003 Saturn ION ^ 2002-2003 Saturn VUE 1. Locate and remove the Right Audio output signal terminal 7 from Connector C2 at the Vehicle Communication Interface Module (VCIM). 2. Remove the terminal end and strip the wire. 3. Locate the Left Audio output signal wire from terminal 1 in Connector C2. 4. Splice the Right Audio output signal wire from terminal 7 with the Left Audio output signal wire from terminal 1. 5. See Wiring Repairs in SI for approved splicing methods. Component Locations Fluid Pressure Sensor/Switch: Component Locations Automatic Transmission - 4L60-E/4L65-E Automatic Transmission Electronic Component Views (M30/M32) Electronic Components Page 11982 Action Taken When the DTCs Sets The module suspends all message transmission. The module uses default values for all parameters received on the serial data circuits. The module inhibits the setting of all other communication DTCs. Conditions for Clearing the DTC A current DTC clears when the malfunction is no longer present. A history DTC clears when the module ignition cycle counter reaches the reset threshold of 50, without a repeat of the malfunction. Circuit/System Verification Refer to Data Link References to determine which serial data system is used for a specific module. This DTC cannot be retrieved with a current status. Diagnosis is accomplished using the following symptom procedures: Scan Tool Does Not Communicate with High Speed GMLAN Device in SI. OR Scan Tool Does Not Communicate with Low Speed GMLAN Device in SI. DTC U0140 - U0184 Circuit Description Modules connected to the GMLAN serial data circuit monitor for serial data communications during normal vehicle operation. Operating information and commands are exchanged among the modules. In addition to this, Node Alive messages are transmitted by each module on the GMLAN serial data circuit. When the module detects one of the following conditions on the GMLAN serial data circuit, a DTC will set. Operating information and commands are exchanged among the modules. In addition to this, Node Alive messages are transmitted by each module on the GMLAN serial data circuit. Conditions for Setting the DTCs Diagnostic algorithms are designed so that a single point failure within a particular node shall result in a single DTC/FTB combination being set. Any recognized faults shall generate one DTC. Recognized faults may include but are not limited to the following: ^ Open or shorted condition on an I/O Circuit outside of normal operation of that circuit. ^ Erratic signal of a circuit, outside of normal operation, which can be readily and repeatedly recognized as erratic. ^ A condition, outside of normal operation, which causes a customer perception of a performance problem. ^ A condition whether hardware or data link error, which causes a device to operate in a default or fail soft mode. ^ A condition which changes or limits system performance. ^ Network supervision/signal supervision errors. ^ ECU Internal errors. ^ Criteria determined by legislation. An initialization or shutdown self-test shall be performed and may include but is not limited to the following: ^ RAM check ^ ROM/EEPROM/Flash check Page 7211 Electrical Symbols Part 2 Page 7276 Steps 1-6 Page 15464 Parts Information Parts are currently available from GMSPO. Warranty Information Page 9235 C310 Body Harness To Left Rear Door Harness (Crew Cab) Part 1 Electrical - MIL ON/DTC's Set By Various Control Modules Wiring Harness: All Technical Service Bulletins Electrical - MIL ON/DTC's Set By Various Control Modules TECHNICAL Bulletin No.: 09-06-03-004D Date: December 08, 2010 Subject: Intermittent No Crank/No Start, No Module Communication, MIL, Warning Lights, Vehicle Messages or DTCs Set by Various Control Modules - Diagnosing and Repairing Fretting Corrosion (Disconnect Affected Connector and Apply Dielectric Lubricant) Models: 2011 and Prior GM Passenger Cars and Trucks Attention: This repair can be applied to ANY electrical connection including, but not limited to: lighting, body electrical, in-line connections, powertrain control sensors, etc. DO NOT over apply lubricant to the point where it prevents the full engagement of sealed connectors. A light coating on the terminal surfaces is sufficient to correct the condition. Supercede: This bulletin is being revised to update the Attention statement and add the 2011 model year. Please discard Corporate Bulletin Number 09-06-03-004C (Section 06 Engine/Propulsion System). Condition Some customers may comment on any of the following conditions: - An intermittent no crank/no start - Intermittent malfunction indicator lamp (MIL) illumination - Intermittent service lamp illumination - Intermittent service message(s) being displayed The technician may determine that he is unable to duplicate the intermittent condition. Cause This condition may be caused by a buildup of nonconductive insulating oxidized debris known as fretting corrosion, occurring between two electrical contact surfaces of the connection or connector. This may be caused by any of the following conditions: - Vibration - Thermal cycling - Poor connection/terminal retention - Micro motion - A connector, component or wiring harness not properly secured resulting in movement On low current signal circuits this condition may cause high resistance, resulting in intermittent connections. On high current power circuits this condition may cause permanent increases in the resistance and may cause a device to become inoperative. Representative List of Control Modules and Components The following is only a representative list of control modules and components that may be affected by this connection or connector condition and DOES NOT include every possible module or component for every vehicle. - Blower Control Module - Body Control Module (BCM) - Communication Interface Module (CIM) - Cooling Fan Control Module - Electronic Brake Control Module (EBCM) - Electronic Brake and Traction Control Module (EBTCM) - Electronic Suspension Control (ESC) Module - Engine Control Module (ECM) - Heating, Ventilation and Air Conditioning (HVAC) Control Module Page 10688 Balancing of the tire and wheel assembly must be performed on a computerized balancer, capable of static and dynamic wheel balance modes. Assemblies should be balanced to within 1/4 ounce on either rim flange. Proper cones and adapters should be used, free of nicks and burrs to ensure proper balancing. Center Cap Install the center cap onto the wheel after the tire has been mounted and balanced, but BEFORE the assembly is installed onto the vehicle. The preferred method for center cap installation is to push in by hand. As an alternate, use a nonmetallic object to push the center cap into place. Attempting to "hammer-on" the caps may result in damage to the cap. Wheel (Lug) Nuts ALUMINUM WHEELS REQUIRE SPECIAL WHEEL NUTS. Each wheel nut should be torqued in the appropriate torque sequence (refer to graphic) and to 190 N.m (140 lb ft). The torque should be re-checked after the first 160 km (100 mi). To help protect the wheels from theft, a wheel lock kit is also available. Incorrect wheel nuts or improperly tightened wheel nuts can cause the wheel to become loose and even come off. This could lead to an accident. Be sure to use the correct wheel nuts. Wheel Nut Caps Install the wheel nut caps after tightening the wheel nuts. Install the wheel nut caps finger tight, plus 1/2 turn. Jounce Bumper This modification is required on all 2WD vehicles EXCEPT the following: Excludes: 2006-2007 2WD Extended Cab - Short Box (model C15553) 2006-2007 2WD Crew Cab - Short Box with Enhanced Trailering (RPO NHT) (model C15543) 2006-2007 2WD Extended Cab - Standard Box with Enhanced Trailering (RPO NHT) (model C15753) It will be required to replace the existing front suspension spring/jounce bumper with Jounce Bumper kit, P/N 12499481. The following procedure should be followed: Raise and support the vehicle. Remove the nut from the spring bumper stud. Remove the spring bumper. Page 11175 6. Remove the outlet heater hose. INSTALLATION PROCEDURE 1. Install the outlet heater hose. 2. Install the outlet heater hose to the engine. 3. Connect the outlet heater hose to the heater core. Firmly push the quick connect onto the heater core pipe until you hear an audible click. 4. Install the heater and surge tank hose to the mounting clip. 5. Install the air intake tube. 6. Fill the cooling system. Refer to Draining and Filling Cooling System (with HP2)Draining and Filling Cooling System (without HP2) in Cooling System. Page 1198 Memory/Heated Seat Switch - Driver (DDM C5) Part 1 Page 14847 Door Lock Switch - Front Passenger (Base Only) Page 12952 Speaker - LF Door - With RPO Code UQ3/UQ7 Page 4917 7. Remove the control lever to the manual shaft nut. 8. Remove the control lever from the manual shaft. 9. Remove the PNP switch bolts. 10. Remove the PNP switch from the manual shaft. If the PNP switch does not slide off the manual shaft, file the outer edge of the manual shaft in order to remove any burrs. Installation Procedure 1. Install the PNP switch to the manual shaft by aligning the switch hub flats with the manual shaft flats. 2. Slide the PNP switch onto the manual shaft until the switch mounting bracket contacts the mounting bosses on the transmission. 3. Important: If a new PNP switch is being installed, the switch will come with a positive assurance bracket. The positive assurance bracket aligns the new switch in its proper position for installation and the use of the park neutral switch aligner will not be necessary. Install the PNP switch bolts finger tight. Page 5027 Floor Panel Heat Shield Replacement Heat Shield: Service and Repair Floor Panel Heat Shield Replacement Floor Panel Heat Shield Replacement Removal Procedure 1. Remove the exhaust manifold pipe, if necessary. 2. Remove the catalytic converter, if necessary. 3. Remove the exhaust front heat shield nuts. 4. Remove the exhaust front heat shield from the studs. 5. If vehicle is a regular cab pick-up truck, remove the exhaust heat shield nuts. 6. Remove the exhaust front heat shield (1) and/or the exhaust heat shield (2) from the studs. 7. If vehicle is a extended cab pick-up truck, remove the exhaust heat shield nuts. 8. Remove the exhaust heat shield (1, 2) from the studs. Page 1779 Impact Sensor: Service and Repair Sensor Replacement Guidelines SENSOR REPLACEMENT GUIDELINES The SIR sensor replacement policy requires replacing sensors in the area of accident damage. The area of accident damage is defined as the portion of the vehicle which is crushed, bent, or damaged due to a collision. For example, a moderate collision where the front of the vehicle impacts a tree. If the vehicle has an SIR sensor mounted forward of the radiator, it must be replaced. - Replace the sensor whether or not the air bags have deployed. - Replace the sensor even if it appears to be undamaged. Sensor damage which is not visible, such as slight bending of the mounting bracket or cuts in the wire insulation, can cause improper operation of the SIR sensing system. Do not try to determine whether the sensor is undamaged, replace the sensor. Also, if you follow a Diagnostic Trouble Code (DTC) table and a malfunctioning sensor is indicated, replace the sensor. Page 12787 ^ An OnStar(R) Call Center button press WILL NOT connect the vehicle with OnStar(R). The vehicle must be upgraded to reactivate the account. The customer will hear a demo message stating that there is not a current OnStar(R) subscription for the vehicle. The message will also instruct the customer how to upgrade and reactivate services. ^ OnStar(R) personal calling (OPC) will not be available, as this feature requires the customer to have a current OnStar(R) account. Attempts to use this feature will result in cellular connection failure messages and the inability to connect to the number dialed. Note For deactivated vehicles, a no connect response should be considered normal system operation. Further diagnosis and subsequent repair is only necessary should the customer elect to become an active OnStar(R) subscriber and upgrade the account subscription. OnStar(R) Cellular, GPS, and Diagnostic Limitations The proper operation of the OnStar(R) System is dependent on several elements outside the components integrated into the vehicle. These include the National Cellular Network Infrastructure, the cellular telephone carriers within the network, and the GPS. The cellular operation of the OnStar(R) system may be inhibited by factors such as the users range from a digital cellular tower, the state of the cellular carrier's equipment, and the location where the call is placed. Making an OnStar(R) key press in areas that lack sufficient cellular coverage or have a temporary equipment failure will result in either the inability of a call to complete with a data transfer or the complete inability to connect to the OnStar(R) Call Center. The OnStar(R) system may also experience connection issues if the identification numbers for the module, station identification number (STID), electronic serial number (ESN) or manufacturers electronic ID (MEID), are not recognized by the cellular carriers local signal receiving towers. The satellites that orbit earth providing the OnStar system with GPS data have almost no failures associated with them. In the event of a no GPS concern, the failure will likely lie with the inability of the system to gain GPS signals because of its location, i.e. in a parking structure, hardware failure, or being mistaken with an OnStar(R) call which has reached the Call Center without vehicle data. During diagnostic testing of the OnStar(R) system, the technician should ensure the vehicle is located in an area that has a clear unobstructed view of the open sky, and preferably, an area where digital cellular calls have been successfully placed. These areas can be found by successfully making an OnStar(R) keypress in a known good OnStar(R) equipped vehicle and confirming success with the OnStar(R) Call Center advisor. Such places can be used as a permanent reference for future OnStar(R) testing. Mobile Identification Number and Mobile Directory Number The vehicle communication interface module (VCIM) utilizes 2 numbers for cellular device identification, call routing and connection. They are: ^ A mobile identification number (MIN) ^ A mobile directory number (MDN) Note The MIN represents the number used by the cellular carrier for call routing purposes. The MDN represents the number dialed to reach the cellular device. Diagnostic Information Symptoms - Cellular Communication The following steps must be completed before using the symptom table. 1. Perform the Diagnostic System Check - Vehicle, before using the Symptom Tables in order to verify that the following are true: ^ There are no DTCs set. ^ The control modules can communicate via the serial data link. 2. Review the system operation in order to familiarize yourself with the system functions. Refer to Radio/Audio System Description and Operation in SI. Diagnostic Starting Point - Displays and Gages Begin the displays and gages system diagnosis with Diagnostic System Check - Vehicle or the audible warning system diagnosis with Diagnostic System Drivetrain - Whine or Click Type Noises from Front Axle Carrier Bearings: Customer Interest Drivetrain - Whine or Click Type Noises from Front Axle TECHNICAL Bulletin No.: 09-04-19-001 Date: April 28, 2009 Subject: Whine or Click Type Noises from Front Axle/New Design Front Axle Side Bearing Adjusters (Inspect/Replace with New Lock Rings) Models: 2002-2009 Cadillac Escalade, Escalade ESV, Escalade EXT 2002-2009 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2002-2009 GMC Sierra, Yukon, Yukon XL All Equipped with 8.25" Front Axle Condition Some customers may comment about whine or click type noises from the front axle. Upon further investigation, disassembly of the front differential may reveal chipped pinion or ring gear teeth. Cause This condition may be caused by an oversize front bearing side adjuster lock ring allowing the adjuster to move. New Design Lock Adjusters Vs Old Design T-Lock Adjusters Note Front axle housings for old-style (Classic - GMT800) and new-style (GMT900) vehicles are not interchangeable. The new design eliminates the side bearing adjusters movement. The lock adjusters are retained by a pressed in lock ring that maintains the adjuster setting for backlash and side bearing preload. All front axle housings for all model years will use the new design adjusters, and use the new lock ring. The t-lock adjusters are still available, but if a housing replacement is needed, it is necessary to order the lock ring style housing, two of the new adjusters and two of the lock rings. Part numbers are available through the GM Parts catalog. A newly designed 8.25" front axle is in production. The new design eliminates the t-lock side bearing adjusters. The new adjusters are retained by a pressed in lock ring that maintains the adjuster setting for backlash and side bearing preload. This design was phased into production during September, 2006. As a result, in the 2007 model year, both old-style (Classic - GMT800) and new-style (GMT900) vehicles built before the change have the t-lock design adjusters, and both types of vehicles built after the change have the lock ring design adjusters. Correction If no damage is visible and the concern was a whine or click noise, follow the inspect procedure in this bulletin and replace the lock ring. Complete assembly replacement is not necessary if an oversized slipping lock ring was found. Important The bearing adjuster lock rings are not reusable. Inspect New Replacement Part Prior to Installation Page 6001 ^ The reverse boost valve bushing ^ A new reverse boost valve ^ A new pressure regulator spring retainer ^ The added isolator pressure regulator spring ^ The pressure regulator spring 3. Install the pre-assembled parts into the pump bore. 4. Install the reverse boost valve bushing retainer ring while holding the reverse boost valve bushing in place. Ensure the retainer ring (2) is in the groove. 5. Install the transmission filter. 6. Fill the transmission to the proper level with Dexron® III transmission fluid. Fuse Block - Underhood - Secondary Fuse: Application and ID Fuse Block - Underhood - Secondary Location View Inner Tie Rod End: Service and Repair Inner Rack and Pinion Inner Tie Rod Replacement ^ Tools Required J 34028 Inner Tie Rod Wrench Removal Procedure 1. Raise the vehicle. Support the vehicle with suitable safety stands. Refer to Vehicle Lifting. 2. Remove the tire and wheel assembly from the vehicle. 3. Remove the rack and pinion boot. Refer to Rack and Pinion Boot Replacement - On Vehicle. Notice: Do not change the rack bearing preload adjustment before removing the inner tie rod from the steering rack. This could cause damage to the pinion or the steering rack or both. 4. Remove the shock dampener (2) from the inner tie rod (5). 5. Slide the shock dampener (2) back onto the rack (1). Important: Do not hold the steering rack while removing the inner tie rod if the preload adjustment has not been changed. 6. Remove the inner tie rod (5) from the rack assembly (1) as follows: 1. Place a wrench on the flats of the inner tie rod housing (4) 2. Rotate the inner tie rod housing (4) counterclockwise until the inner tie rod (5) separates from the rack. Page 14582 Disclaimer Page 1811 Seat Sensor/Switch: Diagrams Inflatable Restraint Seat Position Switch - Left (With RPO Code AL0) Electrical - MIL ON/DTC's Set By Various Control Modules Wiring Harness: All Technical Service Bulletins Electrical - MIL ON/DTC's Set By Various Control Modules TECHNICAL Bulletin No.: 09-06-03-004D Date: December 08, 2010 Subject: Intermittent No Crank/No Start, No Module Communication, MIL, Warning Lights, Vehicle Messages or DTCs Set by Various Control Modules - Diagnosing and Repairing Fretting Corrosion (Disconnect Affected Connector and Apply Dielectric Lubricant) Models: 2011 and Prior GM Passenger Cars and Trucks Attention: This repair can be applied to ANY electrical connection including, but not limited to: lighting, body electrical, in-line connections, powertrain control sensors, etc. DO NOT over apply lubricant to the point where it prevents the full engagement of sealed connectors. A light coating on the terminal surfaces is sufficient to correct the condition. Supercede: This bulletin is being revised to update the Attention statement and add the 2011 model year. Please discard Corporate Bulletin Number 09-06-03-004C (Section 06 Engine/Propulsion System). Condition Some customers may comment on any of the following conditions: - An intermittent no crank/no start - Intermittent malfunction indicator lamp (MIL) illumination - Intermittent service lamp illumination - Intermittent service message(s) being displayed The technician may determine that he is unable to duplicate the intermittent condition. Cause This condition may be caused by a buildup of nonconductive insulating oxidized debris known as fretting corrosion, occurring between two electrical contact surfaces of the connection or connector. This may be caused by any of the following conditions: - Vibration - Thermal cycling - Poor connection/terminal retention - Micro motion - A connector, component or wiring harness not properly secured resulting in movement On low current signal circuits this condition may cause high resistance, resulting in intermittent connections. On high current power circuits this condition may cause permanent increases in the resistance and may cause a device to become inoperative. Representative List of Control Modules and Components The following is only a representative list of control modules and components that may be affected by this connection or connector condition and DOES NOT include every possible module or component for every vehicle. - Blower Control Module - Body Control Module (BCM) - Communication Interface Module (CIM) - Cooling Fan Control Module - Electronic Brake Control Module (EBCM) - Electronic Brake and Traction Control Module (EBTCM) - Electronic Suspension Control (ESC) Module - Engine Control Module (ECM) - Heating, Ventilation and Air Conditioning (HVAC) Control Module Page 5860 Speed Sensor: Service and Repair Transfer Case - NVG 246-NP8 Transfer Case Speed Sensor Replacement - Front Transfer Case Speed Sensor Replacement - Front Removal Procedure 1. Remove the transfer case shield, if equipped. 2. Disconnect the front speed sensor electrical connector (5). 3. Remove the front speed sensor. Installation Procedure 1. Notice: Refer to Fastener Notice in Service Precautions. Install the front speed sensor. ^ Tighten the speed sensor to 15 Nm (11 ft. lbs.). Page 2990 Balancing of the tire and wheel assembly must be performed on a computerized balancer, capable of static and dynamic wheel balance modes. Assemblies should be balanced to within 1/4 ounce on either rim flange. Proper cones and adapters should be used, free of nicks and burrs to ensure proper balancing. Center Cap Install the center cap onto the wheel after the tire has been mounted and balanced, but BEFORE the assembly is installed onto the vehicle. The preferred method for center cap installation is to push in by hand. As an alternate, use a nonmetallic object to push the center cap into place. Attempting to "hammer-on" the caps may result in damage to the cap. Wheel (Lug) Nuts ALUMINUM WHEELS REQUIRE SPECIAL WHEEL NUTS. Each wheel nut should be torqued in the appropriate torque sequence (refer to graphic) and to 190 N.m (140 lb ft). The torque should be re-checked after the first 160 km (100 mi). To help protect the wheels from theft, a wheel lock kit is also available. Incorrect wheel nuts or improperly tightened wheel nuts can cause the wheel to become loose and even come off. This could lead to an accident. Be sure to use the correct wheel nuts. Wheel Nut Caps Install the wheel nut caps after tightening the wheel nuts. Install the wheel nut caps finger tight, plus 1/2 turn. Jounce Bumper This modification is required on all 2WD vehicles EXCEPT the following: Excludes: 2006-2007 2WD Extended Cab - Short Box (model C15553) 2006-2007 2WD Crew Cab - Short Box with Enhanced Trailering (RPO NHT) (model C15543) 2006-2007 2WD Extended Cab - Standard Box with Enhanced Trailering (RPO NHT) (model C15753) It will be required to replace the existing front suspension spring/jounce bumper with Jounce Bumper kit, P/N 12499481. The following procedure should be followed: Raise and support the vehicle. Remove the nut from the spring bumper stud. Remove the spring bumper. Page 3646 Heater Hose: Service and Repair Heater Hose Replacement - Inlet (With RPO Code HP2 Front) HEATER HOSE REPLACEMENT - INLET (W/ HP2 FRONT) REMOVAL PROCEDURE 1. Drain the cooling system. Refer to Draining and Filling Cooling System (with HP2)Draining and Filling Cooling System (without HP2) in Cooling System. 2. Loosen the air cleaner outlet duct clamps at the following locations: - Throttle body - Mass airflow/intake air temperature (MAF/IAT) sensor 3. Remove the radiator inlet hose clip from the outlet duct. 4. Remove the air cleaner outlet duct. 5. Reposition the inlet heater hose clamp from the engine. 6. Remove the inlet heater hose from the engine. Page 7168 4. Position the input shaft bearing retainer. Align the bearing retainer oil drain hole with the drain hole in the transmission housing. 5. Notice: Refer to Fastener Notice in Service Precautions. Install the input shaft bearing retainer bolts. ^ Tighten the bolts to 14 Nm (10 ft. lbs.). 6. Install the clutch actuator cylinder and the bolts. ^ Tighten the bolts to 8 Nm (71 inch lbs.) 7. Install the transmission. 8. Lower the vehicle. Transmission Housing Oil Seal Replacement - Rear Transmission Housing Oil Seal Replacement - Rear (4WD) ^ Tools Required J 36825 Output Shaft Oil Seal Remover - J 23907 Slide Hammer - J 36502-2A Output Shaft Oil Seal Protector - J 36502 Extension Housing Seal Installer Removal Procedure Propshaft Speed Sensor - Front Page 9974 7. Lower the vehicle. 8. Perform a four wheel alignment. Page 9206 C206 I/P Harness To Body Harness (With RPO Codes Y91/HP2) Part 2 Page 10576 10. Align the inscribed mark on the tire with the valve stem on the wheel. 11. Reinstall the Tire Pressure Sensor. Refer to Tire Pressure Sensor installation procedure in SI. 12. Mount the tire on the wheel. Refer to Tire Mounting and Dismounting. 13. Pressurize the tire to 276 kPa (40 psi) and inspect for leaks. 14. Adjust tire pressure to meet the placard specification. 15. Balance the tire/wheel assembly. Refer to Tire and Wheel Assembly Balancing - Off-Vehicle. 16. Install the tire and wheel assembly onto the vehicle. Refer to the appropriate service procedure in SI. Parts Information Warranty Information (excluding Saab U.S. Models) Important The Silicone - Adhesive/Sealant comes in a case quantity of six. ONLY charge warranty one tube of adhesive/sealant per wheel repair. For vehicles repaired under warranty, use: One leak repair per wheel. Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table above. Disclaimer Page 3063 1. Install the wheel hub and bearing (3) to the vehicle. 2. Install the wheel hub and bearing retaining bolts. ^ Tighten the bolts to 180 Nm (132 ft. lbs.). 3. Notice: Refer to Fastener Notice in Service Precautions. Install the wheel drive shaft retaining nut. ^ Tighten the nut to 250 Nm (184 ft. lbs.). 4. Install the retainer (3) and cotter pin (2) to the wheel drive shaft nut. 5. Install the dust cap (4). 6. Install the brake rotor. 7. Install the tire and wheel. 8. Lower the vehicle. Page 820 Location View Location View Diagrams Cruise Control Module: Diagrams Cruise Control Module (CCM) Part 1 Page 6058 3. Remove the 4th clutch accumulator piston pin retainer ring (5). 4. Remove the 4th clutch accumulator piston (4) and pin (2) from the accumulator housing (1). 5. Remove the 4th clutch accumulator piston pin (2) from the accumulator housing (1). 6. Remove the 4th clutch accumulator piston seal (3) from the accumulator housing (1). Third and Fourth Clutch Accumulator Assembly 1. Install the 3rd clutch accumulator piston inner (3) and outer (1) seals. Lubricate the 3rd clutch accumulator piston seals (1, 3) with DEXRON® III automatic transmission fluid. 2. Install the 3rd clutch accumulator piston (2). 3. Install the 4th clutch accumulator piston seal (3). Lubricate the 4th clutch accumulator piston seal (3) with DEXRON® III automatic transmission fluid. 4. Assemble the 4th clutch accumulator piston pin (2) with the 4th clutch accumulator piston (4). 5. Install the 4th clutch accumulator piston assembly into the accumulator housing (1). 6. Install the 4th clutch accumulator piston pin retainer ring (5) onto the 4th clutch accumulator piston pin (2). Installation Procedure Page 12683 Action Taken When the DTCs Sets The module suspends all message transmission. The module uses default values for all parameters received on the serial data circuits. The module inhibits the setting of all other communication DTCs. Conditions for Clearing the DTC A current DTC clears when the malfunction is no longer present. A history DTC clears when the module ignition cycle counter reaches the reset threshold of 50, without a repeat of the malfunction. Circuit/System Verification Refer to Data Link References to determine which serial data system is used for a specific module. This DTC cannot be retrieved with a current status. Diagnosis is accomplished using the following symptom procedures: Scan Tool Does Not Communicate with High Speed GMLAN Device in SI. OR Scan Tool Does Not Communicate with Low Speed GMLAN Device in SI. DTC U0140 - U0184 Circuit Description Modules connected to the GMLAN serial data circuit monitor for serial data communications during normal vehicle operation. Operating information and commands are exchanged among the modules. In addition to this, Node Alive messages are transmitted by each module on the GMLAN serial data circuit. When the module detects one of the following conditions on the GMLAN serial data circuit, a DTC will set. Operating information and commands are exchanged among the modules. In addition to this, Node Alive messages are transmitted by each module on the GMLAN serial data circuit. Conditions for Setting the DTCs Diagnostic algorithms are designed so that a single point failure within a particular node shall result in a single DTC/FTB combination being set. Any recognized faults shall generate one DTC. Recognized faults may include but are not limited to the following: ^ Open or shorted condition on an I/O Circuit outside of normal operation of that circuit. ^ Erratic signal of a circuit, outside of normal operation, which can be readily and repeatedly recognized as erratic. ^ A condition, outside of normal operation, which causes a customer perception of a performance problem. ^ A condition whether hardware or data link error, which causes a device to operate in a default or fail soft mode. ^ A condition which changes or limits system performance. ^ Network supervision/signal supervision errors. ^ ECU Internal errors. ^ Criteria determined by legislation. An initialization or shutdown self-test shall be performed and may include but is not limited to the following: ^ RAM check ^ ROM/EEPROM/Flash check Page 8756 6. If necessary, remove the engine sight shield. 7. Unsnap the junction block cover. 8. Remove the positive battery cable (1) from the junction block. 9. If equipped with a 4.8L, 5.3L, or 6.0L engine, remove the negative cable clip from the positive cable clip. 10. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 11. If equipped with a 8.1L engine, remove the negative cable clip from the positive cable clip. 12. Raise and suitably support the vehicle. Refer to Vehicle Lifting. Page 11643 Seat Belt Buckle: Service and Repair Seat Belt Buckle and Latch - Rear (Crew Cab) SEAT BELT BUCKLE AND LATCH REPLACEMENT - REAR (CREW CAB) REMOVAL PROCEDURE 1. Remove the rear seat cushion and cover. 2. Remove the bolt (13) that retains the buckle assembly (14) to the seat frame. 3. Remove the buckle assembly INSTALLATION PROCEDURE Parking Brake Shoe Replacement (Except RPO NYS, 1500HD, 25/35 Series) Parking Brake Shoe: Service and Repair Parking Brake Shoe Replacement (Except RPO NYS, 1500HD, 25/35 Series) Parking Brake Shoe Replacement (Except RPO NYS, 1500HD, 25/35 Series) Removal Procedure Caution: Avoid taking the following actions when you service wheel brake parts: - Do not grind brake linings. - Do not sand brake linings. - Do not clean wheel brake parts with a dry brush or with compressed air. Some models or aftermarket brake parts may contain asbestos fibers which can become airborne in dust. Breathing dust with asbestos fibers may cause serious bodily harm. Use a water-dampened cloth in order to remove any dust on brake parts. Equipment is available commercially in order to perform this washing function. These wet methods prevent fibers from becoming airborne. 1. Raise and support the vehicle. 2. Remove the tire and the wheel. 3. Relieve the tension on the park brake cables by loosening the nut at the equalizer. 4. Remove the park brake cable from the park brake actuator lever. 5. Remove the rotor. Refer to Rear Brake Rotor Replacement in Disc Brakes See: Disc Brake System/Brake Rotor/Disc/Service and Repair. 6. Turn the adjustment screw (1) to the fully home position in the notched adjustment nut. 7. Remove the park brake shoe assembly from the backing plate by removing the tips from the slots and sliding the shoe (2) towards the retaining spring (3) until the shoe disengages from the spring. 8. Remove the park brake shoe assembly from the vehicle by placing one of the open ends of the shoe over the axle flange and rotating the shoe until it has cleared the flange. Installation Procedure 1. Clean the debris and the dust from the park brake components using a clean shop cloth. Page 15953 7. Insert the J 38125-13A (GM P/N 12031876-1) tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the Terminal Repair Kit to ensure that the correct release tool is used. 8. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. REPAIR PROCEDURE Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. Page 15002 Page 1407 Fuel Pump/Sender Assembly - Secondary Page 13551 IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. Splicing Twisted or Shielded Cable SPLICING TWISTED OR SHIELDED CABLE Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. - Rewrap the conductors with the mylar tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with mylar tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Control Module References Page 12615 Labor Time Information Page 12708 Page 4876 Transmission Position Switch/Sensor: Adjustments Automatic Transmission - 4L80-E/4L85-E Park/Neutral Position Switch Adjustment Important: ^ The following procedure is for vehicles that have not had the park/neutral position (PNP) switch removed or replaced. If the switch has been removed or replaced, refer to Park/Neutral Position Switch Replacement for the proper adjustment procedure. ^ Apply the park brake. ^ The engine must start in the park (P) or neutral (N) positions only. ^ Check the PNP switch for proper operation. If adjustment is required, proceed as follows: 1. Place the shift lever in the neutral (N) position. 2. With an assistant in the drivers seat, raise and suitably support the vehicle. Refer to Vehicle Lifting. 3. Loosen the PNP switch bolts. 4. With the vehicle in neutral (N), rotate the PNP switch while the assistant attempts to start the engine. 5. Following a successful start, turn the engine off. 6. Notice: Refer to Fastener Notice in Service Precautions. Tighten the PNP switch bolts. ^ Tighten the bolts to 25 Nm (18 ft. lbs.). 7. Lower the vehicle. 8. Check the PNP switch for proper operation. The engine must start in the park (P) or neutral (N) positions only. 9. Replace the PNP switch if proper operation can not be achieved. Page 12980 1. Connect the electrical connector. 2. Install the speaker. Snap the speaker into place and ensure that the speaker is fully seated. 3. Install the trim panel. 4. Inspect the component's operation. Speaker Replacement - Rear Pillar SPEAKER REPLACEMENT - REAR PILLAR REMOVAL PROCEDURE 1. Remove the trim panel. 2. Remove the speaker by pushing down on the top retainer. Interior - Napped Seat Fabric Repair Seat Cover: All Technical Service Bulletins Interior - Napped Seat Fabric Repair Bulletin No.: 04-08-50-011A Date: May 04, 2006 INFORMATION Subject: Repairing Napped Seat Fabric Models: 2007 Cadillac Escalade, Escalade ESV, Escalade EXT 1999-2006 Chevrolet Silverado 2000-2007 Chevrolet Suburban, Tahoe 2002-2005 Chevrolet Astro 2002-2006 Chevrolet Monte Carlo 2002-2007 Chevrolet Avalanche 2002-2005 GMC Safari 2007 GMC Yukon, Yukon XL 2002-2004 Oldsmobile Alero 1997-2006 Pontiac Grand Prix Supercede: This bulletin is being revised to add model years and models. Please discard Corporate Bulletin Number 04-08-50-011 (Section 08 - Body & Accessories). This bulletin is being issued to advise technicians/dealers on the proper repair required when a customer brings in a trimmed seat with the appearance of being worn, having a bald spot and/or being discolored. The seats in the later vehicles are trimmed with a cloth that has a napped fabric. Under some circumstances, the nap may become crushed down by normal use, giving the appearance of being worn out. If the base material is NOT visible, use a small brass (NOT STEEL) wire brush to carefully fluff and raise the nap. The wire brush (fine bristle brass) is available at most hardware and home stores. If the base material is visible, replace the trim cover. The Astro/Safari van will also have this material on the door trim. Disclaimer Drivetrain - Excessive Effort When Shift 2HI to 4HI Differential Fluid - M/T: All Technical Service Bulletins Drivetrain - Excessive Effort When Shift 2HI to 4HI TECHNICAL Bulletin No.: 09-04-19-002A Date: February 17, 2011 Subject: 4WD System Shift Performance in Cold Ambient Temperatures (Use Synthetic Fluid in Light Duty Front Axles with 8.5" Ring Gears) Models: 1999-2011 Chevrolet Silverado 1500 Series Models 1999-2011 GMC Sierra 1500 Series Models Equipped with 4WD and 8.25" Front Axle Ring Gears (Transfer Case RPOs NP2, NQG) Attention: It is important to determine the RPO for the transfer case in GWM/IVH prior to applying this bulletin. This bulletin applies ONLY to vehicles equipped with 8.25" front axle ring gears, used in conjunction with a manual transfer case (RPOs NP2, NQG). Supercede: This bulletin is being revised to add the 2011 model year. Please discard Corporate Bulletin Number 09-04-19-002 (Section 04 - Driveline/Axle). Condition Some customers may comment about the effort required to shift from 2HI to 4HI in cold ambient temperatures at -6°C (20°F) or below. Cause This condition may be caused by the standard front axle being equipped with conventional mineral oil axle fluid. In cold ambient temperatures, prior to complete warm up, the fluid viscosity is thick. This may affect transfer case shift performance prior to full warm up. Correction Drain the front axle fluid and refill with GM SAE 75W-90 Synthetic Axle Fluid, P/N 89021677 (in Canada, 89021678). Refer to Front Axle Lubricant Replacement in SI. It is important to use synthetic fluid in this 8.25" axle to improve the performance of the 4WD system in cold ambient temperatures. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 5033 supported, only J2534. 1. BEFORE the original IPC is disconnected from the vehicle, record the odometer and engine hour values. 2. Replace the IPC with a replacement part obtained from the ESC. Refer to Instrument Cluster Replacement in SI. 3. Using the TIS2WEB SPS application, select either: J2534 Tech 2 or J2534 MDI, when available and build the vehicle. 4. Select: IPC Setup J2534. 5. After selecting IPC Setup J2534, the user will be prompted to: install the new controller. Ignore this prompt if the new IPC was already installed. This prompt is just to remind the user that this application is only for a new IPC. Important FOR 2003 FULLSIZE TRUCKS, UTILITIES AND H2, THE ENGINE MUST BE STARTED AND RUNNING PRIOR TO ENTERING THE MILEAGE AND ENGINE HOURS. After the odometer value is programmed, the engine must remain running for 6 minutes 15 seconds before the ignition can be turned off. Failure to do so will result in engine hours not being programmed and a new IPC will have to be ordered. 6. Enter the odometer and engine hour values, when applicable. By default the application will be set to miles. For metric units, click the button on the left next to: Kilometers. The IPC odometer and engine hour meter setup procedure is now complete. 7. The IPC calibration files can now be programmed into the IPC. Refer to SPS in SI. Disclaimer Page 8800 6. Use fingers to squeeze the 2 locking legs of the cover. 7. Apply pressure and gently rock the cover until one locking leg is unseated. 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. Steering - 'Service Rear Wheel Steering' Message Body Control Module: Customer Interest Steering - 'Service Rear Wheel Steering' Message Bulletin No.: 05-02-118-002 Date: February 03, 2005 TECHNICAL Subject: DTC C0455, "Service Rear Wheel Steering", System Jumps from 4-Wheel Steer to 2-Wheel Steer (Reprogram BCM) Models: 2003-2005 Chevrolet Silverado, Suburban 2003-2005 GMC Sierra, Yukon XL with 4-Wheel Steer (RPO NYS) Condition Some customers may comment that the system will jump from 4-wheel steer to 2-wheel steer and the DIC displays the message "Service Rear Wheel Steering". Diagnosis will show DTC C0455-Front Steering Position Sensor malfunction. Cause This condition may be caused by a Class2 communication issue. Correction Reprogram the BCM. 2005 Model Year Vehicles: New software calibration, P/N 15248410, was released on TIS version 12 - broadcast to dealers on December 4, 2004. 2003-2004 Model Year Vehicles: New software calibration, P/N 15259330 ('03 Model Year) and P/N 15259331 ('04 04 Model Year), was released on TIS version 1.75 - broadcast to dealers on January 24, 2005. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 15471 Parts Information Parts are currently available from GMSPO. Warranty Information Page 2963 Refer to the appropriate section of SI for specifications and repair procedures that are related to the vibration concern. Disclaimer Page 15750 1. Notice: Refer to Fastener Notice in Service Precautions. Install the backup lamp switch. ^ Tighten the switch to 20 Nm (15 ft. lbs.). 2. If equipped with a 8.1L engine, connect the backup lamp switch electrical connector (4). 3. If equipped with a 6.6L engine, connect the backup lamp switch electrical connector (3). Lower the vehicle. Page 15025 Page 13832 Body Emblem: Service and Repair Emblem/Nameplate Replacement - Door (W/O SS) Emblem/Nameplate Replacement - Door (W/O SS) Tools Required J 25070 Heat Gun Removal Procedure Important: Use the tape for protection and alignment marks for alignment of the new emblem. 1. Apply tape to the area around the door emblem. 2. Heat the emblem/nameplate, using a heat gun J 25070 152 mm (6.0 in) from the surface. 3. Apply the heat using a circular motion for about 30 seconds. Notice: Refer to Exterior Trim Emblem Removal Notice in Service Precautions. 4. Remove the emblem/nameplate from the door surface using a plastic, flat-bladed tool. 5. Remove all adhesive from the door panel surface and the back of the emblem/nameplate using 3M(TM) scotch brite molding adhesive remover disk 3M(TM) P/N 07501 or equivalent. 6. Clean the door surface using varnish makers and painters (VMP) naptha. Installation Procedure 1. If the location of the emblem/nameplate has not been marked apply tape. 2. Warm the door surface with a heat gun J 25070 152 mm (6.0 in) from the surface to a minimum of 21°C (70°F). Important: Do not touch the adhesive backing of the emblem/nameplate. 3. Remove the backing from the front end of the emblem/nameplate. 4. Press the emblem/nameplate to the door panel surface while continuing to remove the backing. 5. Hand roll the emblem/nameplate to the door panel to ensure proper adhesion. 6. Inspect the emblem/nameplate for bonding. 7. Remove the tape from the area around the door emblem. Page 14097 - Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-D in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-D if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Page 10780 ^ Dry or brittle ^ Compression set Installation Procedure 1. Clean all corrosion or contaminates from the steering knuckle bore and the hub and bearing assembly. 2. Lubricate the steering knuckle bore with wheel bearing grease or the equivalent. 3. Install the O-ring (7) to the steering knuckle, the 25/35 series. 4. Notice: Refer to Fastener Notice in Service Precautions. Install the wheel speed sensor mounting bolt to the wheel hub and bearing. ^ Tighten the sensor mounting bolt to 18 Nm (13 ft. lbs.). 5. Install the wheel hub and bearing and splash shield to the vehicle, 25/35 series. 6. Install the wheel hub and bearing (5) and splash shield (6) to the vehicle, 15 series. 7. Install the wheel hub and bearing mounting bolts, the 15 series. 8. Install the wheel hub and bearing mounting bolts, 25/35 series. ^ Tighten the wheel hub to knuckle bolts to 180 Nm (133 ft. lbs.). Page 14440 Disclaimer Page 5331 12. Remove the positive crankcase ventilation (PCV) hose. 13. Disconnect the fuel feed and return pipes (1, 2) from the fuel rail. 14. Disconnect the fuel pressure regulator vacuum line. 15. Remove the fuel rail bolts. NOTE: Remove the fuel rail assembly carefully in order to prevent damage to the injector electrical connector terminals and the injector spray tips. Support the fuel rail after the fuel rail is removed in order to avoid damaging the fuel rail components. - Cap the fittings and plug the holes when servicing the fuel system in order to prevent dirt and other contaminants from entering open pipes and Page 4077 of the possible harness chafing/pinching. Also, on any of the above listed vehicles, the PCM wiring harness may be chafing against the precharge pump bracket or the battery tray. Correction On RPO AN3 vehicles, inspect the routing of the seat wiring harness. Reroute the seat wiring harness and attaching harness fastener (1) to the opposite side of the seat module bracket. Repair the harness as necessary. Refer to Wiring Repairs in the Wiring Systems sub-section of SI. The seat may have to be removed for ease of access and proper repair of the wiring harness. Inspect the routing of the PCM wiring harness at the precharge pump bracket and the battery tray. Repair the harness as necessary. Refer to Wiring Repairs in the Wiring Systems sub-section of SI. If any of the above conditions still remain after this repair, refer to SI for further diagnostic information. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 13529 IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections TESTING FOR INTERMITTENT AND POOR CONNECTIONS TOOLS REQUIRED - J 35616-C GM-Approved Terminal Test Kit - J 38125-D Terminal Repair Kit - J 42675 Flat-Wire Probe Adapter Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector. - Poor terminal to wire connection - Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. - Wire insulation which is rubbed through - This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. - Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. Testing For Proper Terminal Contact It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-D or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-D, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. Page 5268 Fuel Injector 5 Locations Mass Air Flow (MAF) Sensor: Locations Right Side Of The Engine Compartment Page 3680 Engine Coolant Temperature (ECT) Sensor Engine, A/T - Shift/Driveability Concerns/MIL ON Air Filter Element: All Technical Service Bulletins Engine, A/T - Shift/Driveability Concerns/MIL ON Bulletin No.: 04-07-30-013B Date: February 01, 2007 INFORMATION Subject: Automatic Transmission Shift, Engine Driveability Concerns or Service Engine Soon (SES) Light On as a Result of the Use of an Excessively/Over-Oiled Aftermarket, Reusable Air Filter Models: 2007 and Prior GM Cars and Light Duty Trucks 2007 and Prior Saturn Models 2003-2007 HUMMER H2 2006-2007 HUMMER H3 2005-2007 Saab 9-7X Supercede: This bulletin is being revised to add models and model years. Please discard Corporate Bulletin Number 04-07-30-013A (Section 07 - Transmission/Transaxle). The use of an excessively/over-oiled aftermarket, reusable air filter may result in: Service Engine Soon (SES) light on Transmission shift concerns, slipping and damaged clutch(es) or band(s) Engine driveability concerns, poor acceleration from a stop, limited engine RPM range The oil that is used on these air filter elements may be transferred onto the Mass Air Flow (MAF) sensor causing contamination of the sensor. As a result, the Grams per Second (GPS) signal from the MAF may be low and any or all of the concerns listed above may occur. When servicing a vehicle with any of these concerns, be sure to check for the presence of an aftermarket reusable, excessively/over-oiled air filter. The MAF, GPS reading should be compared to a like vehicle with an OEM air box and filter under the same driving conditions to verify the concern. The use of an aftermarket reusable air filter DOES NOT void the vehicle's warranty. If an aftermarket reusable air filter is used, technicians should inspect the MAF sensor element and the air induction hose for contamination of oil prior to making warranty repairs. Transmission or engine driveability concerns (related to the MAF sensor being contaminated with oil) that are the result of the use of an aftermarket reusable, excessively/over-oiled air filter are not considered to be warrantable repair items. Page 7819 6. Connect the internal wiring harness electrical connectors to the following components: ^ Transmission fluid pressure switch (1) ^ 1-2 shift control solenoid (2) ^ 2-3 shift control solenoid (3) ^ Pressure control solenoid (4) ^ TCC PWM solenoid (5) ^ 3-2 control solenoid (6) 7. Install the 1-2 accumulator, if necessary. 8. Install the transmission filter. Page 9244 C324 Lumbar Bolster Harness To Seat Harness (With RPO Code AN3) Page 2637 LR Of The Engine Compartment (With RPO Code 9L4) SRS - Air Bag Lamp ON/DTC B0092 Set Seat Occupant Sensor: All Technical Service Bulletins SRS - Air Bag Lamp ON/DTC B0092 Set Bulletin No.: 02-09-41-002A Date: March 24, 2004 TECHNICAL Subject: Air Bag Lamp On, Passenger Air Bag Indicator Always Reads OFF, DTC B0092 Set (Repair Passenger Presence System (PPS) Sensor Harness) Models: 2003-2004 Cadillac Escalade, Escalade EXT 2003-2004 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2003-2004 GMC Sierra, Yukon, Yukon XL with Sensor Indicator Inflatable Restraint Front Passenger/Child Presence Detector (RPO ALO) Supercede: This bulletin is being revised to add the 2004 model year. Please discard Corporate Bulletin Number 02-09-41-002 (Section 09 - Restraints). Condition Some customers may comment that the Air Bag Lamp is on and the Passenger Air Bag indicator always reads OFF. Upon investigation, the technician may find DTC B0092 set. Cause The cause of this condition may be a shorted Passenger Presence System (PPS) sensor wire. The PPS sensor harness is located under the front passenger seat. This harness may be pinched between the seat frame and the track/riser. Correction Locate the PPS sensor (1) and inspect the harness for proper routing. If the harness is pinched between the seat frame and the track/riser, use the procedure listed below to repair wire(s). 1. Move the front passenger seat to the full rearward and full tilt up position. 2. Loosen the seat frame to track/riser nut and remove the harness. 3. Tighten the seat frame to track/riser nut. 4. Repair any damaged wires. Refer to Wiring Repairs in the Wiring Systems sub-section of the Service Manual. Warranty Information Page 15013 and involved in a product recall is very important in maintaining customer satisfaction. Dealers are to ensure that these customers understand that shuttle service or some other form of courtesy transportation is available and will be provided at no charge. Dealers should refer to the General Motors Service Policies and Procedures Manual for Courtesy Transportation guidelines. Claim Information Page 6934 12. Position the inboard end (tripot end) of the halfshaft assembly into the base of the J-36652-01 for the 1500 models (except 1500 HD) or J 36652-98 for the 1500 HD, 2500, 3500 and Hummer H2 models. 13. Install the top half of the J-36652-01 for the 1500 models (except 1500 HD) or J 36652-98 for the 1500 HD, 2500, 3500 and HUMMER H2 models. 14. Align the swage ring (2) and the swage ring clamp. 15. Insert the bolts. Hand tighten the bolts until the bolts are snug. 16. Align the following during this procedure: ^ The tripot boot (3) ^ The tripot housing (1) ^ The swage ring (2) ^ Tighten each bolt 180 degrees at a time. Alternate between the bolts until both sides of the top half of the tool touch the bottom half . ^ Loosen the bolts and remove the halfshaft assembly from the tool. Page 12535 A current DTC clears when the condition for setting the DTC is no longer present. A history DTC clears after 50 malfunction-free ignition cycles. Circuit/System Testing Without RPO UAV 1. Turn OFF the ignition and all electrical components, including the scan tool. 2. Disconnect the harness connector at the cellular microphone. 3. Test for less than 5 Ohms between the low reference circuit terminal A and ground. ^ If greater than the specified range, test the low reference circuit for an open/high resistance. If the circuit tests normal, replace the VCIM. 4. Ignition ON, test for 9 - 11 volts between the signal circuit terminal B and ground. ^ If greater than the specified range, test the signal circuit for a short to voltage. If the circuit tests normal, replace the VCIM. ^ If less than the specified range, test the signal circuit for a short to ground or an open/high resistance. If the circuit tests normal, replace the VCIM. Refer to the appropriate vehicle in SI. 5. If all circuits test normal, test or replace the cellular microphone. Circuit/System Testing With RPO UAV 1. Turn OFF the ignition and all electrical components, including the scan tool. 2. Disconnect the X4 harness connector at the navigation radio and the harness connector at the cellular microphone. 3. Test for less than 5 Ohms between the low reference circuit terminal A and ground. ^ If greater than the specified range, test the low reference circuit for an open/high resistance. If the circuit tests normal, replace the VCIM. Refer to the appropriate vehicle in SI. 4. Ignition ON, test for 9 - 11 volts between the signal circuit terminal B and ground. ^ If greater than the specified range, test the signal circuit for a short to voltage. If the circuit tests normal, replace the VCIM. ^ If less than the specified range, test the signal circuit for a short to ground or an open/high resistance. If the circuit tests normal, replace the VCIM. 5. If all circuits test normal, test or replace the cellular microphone. 6. Connect the X4 harness connector at the navigation radio. 7. With a scan tool, verify that DTC B2455 is not set as current in the navigation radio. ^ If DTC B2455 is set as current, replace the navigation radio. Refer to the appropriate vehicle in SI. DTC B2462, B2483, or B2484 Circuit/System Description The vehicle communication interface module (VCIM) receives information from a specific navigation antenna located on the outside of the vehicle. The navigation antenna is connected to the VCIM via a shielded coaxial cable. The antenna cable also provides a path for DC current for powering the antenna. DTC Descriptors DTC B2462 02: Global Positioning System (GPS) Antenna Malfunction Short to Ground DTC B2462 04: Global Positioning System (GPS) Antenna Malfunction Open Circuit Page 2134 Disclaimer Page 7074 Parts Information Parts are currently available from GMSPO. Warranty Information Page 9883 For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to refer to the table above. Disclaimer Page 12006 Page 14125 Front Passenger Door Module (FPDM) - C4 (With RPO Code YE9) Part 2 Front Passenger Door Module (FPDM) - C5 (With RPO Code AN3) Part 1 Crossmember Replacement - Front Engine (4WD) Cross-Member: Service and Repair Crossmember Replacement - Front Engine (4WD) Crossmember Replacement - Front Engine (4WD) Removal Procedure 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Remove the differential carrier shield. 3. Remove the bolts retaining the crossmember to the frame. 4. Remove the crossmember from the vehicle. Installation Procedure OnStar(R) - Re-establishing OnStar(R) Communications Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Re-establishing OnStar(R) Communications Bulletin No.: 00-08-46-004C Date: January 17, 2008 INFORMATION Subject: Re-establishing Communications with OnStar(R) Center After Battery Disconnect Models: 2000-2008 GM Passenger Cars and Trucks (Including Saturn and Saab) with Digital OnStar(R) (RPO UE1) Supercede: This bulletin is being revised to add models and model years. Please discard Corporate Bulletin Number 00-08-46-004B (Section 08 - Body and Accessories). When servicing any of the above models and a battery cable is disconnected or power to the OnStar(R) Vehicle Communication Interface Module (VCIM) is interrupted for any reason the following procedure must be performed to verify proper Global Positioning System (GPS) function. Never swap OnStar(R) Vehicle Communication Interface Modules (VCIM) from other vehicles. Transfer of OnStar(R) modules from other vehicles should not be done. Each OnStar(R) module has a unique identification number. The VCIM has a specific Station Identification (STID). This identification number is used by the National Cellular Telephone Network and OnStar(R) systems and is stored in General Motors Vehicle History files by VIN. After completing ALL repairs to the vehicle you must perform the following procedure: Move the vehicle into an open area of the service lot. Sit in the vehicle with the engine running and the radio turned on for five minutes. Press the OnStar(R) button in the vehicle. When the OnStar(R) advisor answers ask the advisor to verify the current location of the vehicle. If the vehicle location is different than the location the OnStar(R) advisor gives contact GM Technical Assistance (TAC) and choose the OnStar(R) prompt. GM OnStar(R) TAC will assist in the diagnosis of a failed VCIM and, if appropriate, order a replacement part. Replacement parts are usually shipped out within 24 hours, and a pre-paid return package label will be included for returning the faulty part. By returning the faulty part, you will avoid a non-return core charge. Disclaimer Component Locations Pressure Regulating Solenoid: Component Locations Automatic Transmission - 4L60-E/4L65-E Automatic Transmission Electronic Component Views (M30/M32) Electronic Components Page 6216 Disclaimer Locations Canister Purge Solenoid: Locations Full Engine View Left Side Keyless Entry - Inoperative Keyless Entry Module: Customer Interest Keyless Entry - Inoperative Bulletin No.: 04-08-52-005 Date: June 15, 2004 TECHNICAL Subject: Remote Keyless Entry (RKE) System Inoperative (Reprogram Passenger Door Module (PDM)) Models: 2004 Cadillac Escalade, Escalade ESV, Escalade EXT 2004 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2004 GMC Sierra, Yukon, Yukon XL Condition Some customers may comment on any of the following conditions: ^ The RKE key fob does not function. ^ The "Service Tire Pressure Monitoring System" message is displayed, if equipped. ^ The passenger door will not unlock from the passenger's or driver's door switches. ^ The passenger door window is inoperative. Correction Reprogram the PDM with the Tech 2(R). Currently the Tech 2(R) software is not available for the 2004 model year. Engineering is aware of this and are working to release a new service calibration. In the meantime, build the Tech 2(R) as a 2003 model year and perform the reprogram using the procedure listed below. 1. Turn the ignition switch to the ON position. 2. Connect the Tech 2(R) to the vehicle's diagnostic link connector (DLC), power it up and press enter. ^ Select: Diagnostics. ^ Select model year: 2003. ^ Select: Light truck. ^ Select: Body. ^ Select the proper Product line. ^ Select the proper HVAC Type. ^ Select the proper Radio System type. ^ Select: Passenger Door Module. ^ Select: Special Functions. ^ Select: Refresh. Important: You must remove the described fuse in the next step for the "Refresh" program to be performed. If you do not remove the fuse for five seconds, the Tech 2 will continue to display "Test in Progress" and the program will not complete. ^ Remove the PDM fuse for 5 seconds from the fuse center located behind the panel on the left end of the instrument panel. Page 5679 Page 7714 Disclaimer Page 6613 Disclaimer Page 4991 Extended Cab Short Box Shown Below, Other Configurations Similar 6. Install the new canister vent valve solenoid to the fuel tank clip or mounting bracket as shown above. The valve port closest to the electrical connector must point towards the canister. 7. Cut bulk 5/8" heater hose to a length of approximately 76 mm (3 in). Install the hose between the solenoid and the canister pipe and secure using clamps. 8. Attach bulk 5/8" heater hose to the vent port and secure using a clamp. Run a length as needed along the frame rail routing to the area above the transmission. 9. Cut the hose to determined length and install the supplied filter box. Secure using a clamp. 10. Remove the transmission support and lower the transmission assembly as necessary to allow for access to the new filter box location. 11. Secure the filter box to the transmission vent hose just forward of the hose tee-section using a tie strap. DO NOT pinch or restrict the transmission vent hose. The filter box opening should be pointing downward. 12. Raise the transmission and reinstall the transmission support. 13. Connect the EVAP canister vent valve electrical connector. 14. Tie strap the hose as needed along the frame rail in order to keep the hose away from pinch-points and heat sources. 15. Lower the vehicle. Correction (2007-2010 New Style Models) After following the published SI diagnostics and determining that the EVAP canister vent valve is the cause of the MIL light, replace the EVAP canister vent valve assembly and relocate the remote filter box. To ensure correct installation, follow the procedures below. Important DO NOT replace the EVAP canister assembly for this concern unless it fails the leak test. Use Service Kit P/N 19207763 1. Raise the vehicle. Suitably support the vehicle. 2. Disconnect the EVAP canister vent valve electrical connector. Page 9422 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground TESTING FOR SHORT TO GROUND NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting With A Digital Multimeter TROUBLESHOOTING WITH A DIGITAL MULTIMETER NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TROUBLESHOOTING WITH A TEST LAMP Page 12184 The number above refers to the step number on the diagnostic table. DTC U0073 or U2100 DTC Descriptors DTC U0073 00: Control Module Communication Bus Off DTC U0073 71: ECU HS Bus Off DTC U0073 72: ECU LS Bus Off DTC U2100 00: Controller Area Network (CAN) Bus Communication DTC U2100 47: Controller Area Network (CAN) Bus Communication Circuit/System Description The serial data circuits are serial data buses used to communicate information between the control modules. The serial data circuits also connect directly to the data link connector (DLC). Conditions for Running the DTCs Supply voltage at the modules are in the normal operating range. The vehicle power mode requires serial data communications. Conditions for Setting the DTC The module setting the DTC has attempted to establish communications on the serial data circuits more than 3 times. Engine Controls - MIL ON/Rough Idle/Misfire/DTC's Set PROM - Programmable Read Only Memory: Customer Interest Engine Controls - MIL ON/Rough Idle/Misfire/DTC's Set Bulletin No.: 05-06-04-063 Date: October 12, 2005 TECHNICAL Subject: LM7, L59 or L33 Engines with Cold Start Rough or Incorrect Idle, Misfire, Malfunction Indicator Lamp (MIL) or Flashing Requiring 02 Sensor Replacement (Reprogram PCM) Models: 2004-2005 Cadillac Escalade 2004-2005 Chevrolet Avalanche, Silverado 1500, Suburban, Tahoe 2005 Chevrolet Silverado Hybrid (HP2) 2004-2005 GMC Sierra 1500, Yukon, Yukon XL 2005 GMC Sierra Hybrid (PH2) with Vortec 5300 5.3L V-8 Engine (VINs T, Z, B - RPOs LM7, L59, L33) Condition Some customers may comment on a Malfunction Indicator Lamp (MIL) On or that the MIL is flashing. An actual engine misfire may or may not be felt along with an incorrect idle speed. Typically this occurs during cold winter months, on cold engine starts. Some vehicles may have been previously serviced for the same condition. Technicians may also find the following DTCs stored with the Tech 2(R) P0131, P0133, P0134, P0137, P0138, P0140, P0151, P0153, P0154, P0157, P1133, which may be in conjunction with P0171, P0174, P0300 and P1138. Cause Water shock occurs when water droplets are present in the exhaust. The water in the exhaust contacts the sensor element inside the H02 sensor, causing the H02 sensor element to crack. Correction Upon diagnostic investigation, the technician may find that the H02 sensor requires replacement. In addition to replacing the affected H02 sensor, these vehicles should also be reflashed with the latest PCM calibration. An updated PCM calibration will be available to dealerships as part of TIS 2000 incremental satellite update 11.0 (NAO version 25.010) or greater. Always, make sure your Tech 2 is updated with the latest software version. Important: If a DTC P0420 or P0430 is stored along with DTC(s) P0300, the catalytic converter diagnostics in Service Information (SI) must be followed to determine if the catalytic converters are operating properly. Warranty Information For vehicles repaired under warranty, use the table. Page 4335 Body Control Module (BCM) - C2 Part 3 Page 502 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves SPLICING COPPER WIRE USING SPLICE SLEEVES TOOLS REQUIRED J 38125-D Terminal Repair Kit IMPORTANT: Use only GM splice sleeves, other splice sleeves may not protect the splice from moisture or a provide good electrical connection. Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. Page 4182 1. Install the knock sensors. Tighten Tighten the sensor to 20 N.m (15 lb ft). 2. Connect the knock sensor electrical connectors. 3. Push down on the rubber covers. 4. Install the intake manifold. Page 14596 Memory Seat Module - C4 Part 2 Wheels - Plastic Wheel Nut Covers Loose/Missing Wheel Fastener: All Technical Service Bulletins Wheels - Plastic Wheel Nut Covers Loose/Missing Bulletin No.: 01-03-10-009A Date: July 27, 2004 TECHNICAL Subject: Plastic Wheel Nut Covers Missing and/or Loose (Replace Missing Covers and Add Sealant to All Covers) Models: 2005 and All Prior Passenger Cars (Except All Cadillac Models and Pontiac GTO) with Plastic Wheel Nut Covers Supercede: This bulletin is being revised to add additional models years. Please discard Corporate Bulletin Number 01-03-10-009. Condition Some customers may comment that the plastic wheel nut covers are missing and/or loose. Correction Important: ^ DO NOT USE a silicone-based adhesive. ^ Do not apply the *permatex(R) around the threads in a circular pattern. ^ Apply a single bead across the threads approximately 10 mm (0.4 in) in length, 5 mm (0.2 in) in height and 5 mm (0.2 in) in width. Replace any missing plastic wheel nut covers with the appropriate covers and apply Permatex(R) # 2 Form A Gasket Sealant(R) to the threads of all the plastic wheel nut covers. Tighten finger tight plus a 1/4 turn with a hand wrench. *We believe this source and their products to be reliable. There may be additional manufacturers of such material. General Motors does not endorse, indicate any preference for or assume any responsibility for the products from this firm or for any other such items which may be available from other sources. Permatex(R) # 2 Form A Gasket Sealant(R) part numbers (available at your local parts supplier) ^ P/N 80009 (2A/2AR) - 44 ml (1.5 oz) tube boxed ^ P/N 80015 (2AR) - 44 ml (1.5 oz) tube carded ^ P/N 80010 (2B/2BR) - 89 ml (3 oz) tube boxed ^ P/N 80016 (2BR) - 89 ml (3 oz) tube carded ^ P/N 80011 (2C) - 325 ml (11 oz) tube boxed Warranty Information For vehicles repaired under warranty, use the table. Page 3082 The wheel hubs illustrated above are intended to provide enough visual details to identify subtle differences between the Gen II and Gen III replacement hubs. The various colors used in the graphics are not indicative of any difference or feature, but are used to increase the detail and clarity of the assembly. The associated part number is listed with each illustration. Please refer to the chart above for the specific application for each hub. Page 4636 Electrical Symbols Part 6 Page 12237 2. Skip to the next step if the vehicle to be upgraded is not shown above. 3. Skip to the next step if the vehicle to be upgraded is not a 2005 Cadillac STS. The 2005 Cadillac STS kit may include a new inside rearview (ISRV) mirror assembly and a new ISRV mirror wiring cover. If the kit you receive includes these parts, please remove the existing ISRV mirror and wire cover from the vehicle and install the ones provided in the kit per the instructions in SI. 4. Skip this step if the vehicle to be upgraded is not listed below. ^ 2003-2004 Saturn L-Series ^ 2003 Saturn ION ^ 2002-2003 Saturn VUE 1. Locate and remove the Right Audio output signal terminal 7 from Connector C2 at the Vehicle Communication Interface Module (VCIM). 2. Remove the terminal end and strip the wire. 3. Locate the Left Audio output signal wire from terminal 1 in Connector C2. 4. Splice the Right Audio output signal wire from terminal 7 with the Left Audio output signal wire from terminal 1. 5. See Wiring Repairs in SI for approved splicing methods. Page 532 Door Control Module Diagram 3 Part 1 Page 11984 High OR Low The above conditions are met for more than 3 seconds. Circuit/System Verification These DTCs cannot be retrieved with a current status. To diagnose use the Scan Tool Does Not Communicate with a Class 2 Device. Refer to SI. An intermittent condition is likely to be caused by a short on the Class 2 serial data circuit. To diagnose use the Scan Tool Does Not Communicate with a Class 2 Device. Refer to SI. DTC B2455 DTC Descriptors DTC B2455 01: Cellular Phone Microphone Circuit Short to Battery DTC B2455 02: Cellular Phone Microphone Circuit Short to Ground DTC B2455 04: Cellular Phone Microphone Circuit Open Circuit Circuit/System Description Without RPO UAV The vehicle communication interface module (VCIM) uses the cellular phone microphone to allow driver communication with OnStar(R). With RPO UAV The vehicle communication interface module (VCIM) and navigation radio use the cellular phone microphone to allow driver communication with OnStar(R), as well as to operate the voice recognition/voice guidance feature of the navigation radio. Conditions for Running the DTC The ignition is in RUN or ACC position. System voltage is between 9.5 - 15.5 volts. The above conditions are met for more than 10 seconds. Conditions for Setting the DTC B2455 01: A short to battery is detected on the cellular microphone signal circuit. B2455 02: A short to ground is detected on the cellular microphone signal circuit. B2455 04: An open circuit is detected on the cellular microphone signal circuit. Action Taken When the DTC Sets The VCIM and/or navigation radio (RPO UAV) will not receive any signal from the microphone. The OnStar(R) status LED turns red. Voice recognition will not function. Conditions for Clearing the DTC Page 14323 Paint: Application and ID Paint Identification Precautions PAINT IDENTIFICATION Caution: Exposure to isocyanates during paint preparation and application processes can cause severe breathing problems. Read and follow all of the instructions from the manufacturers of painting materials, equipment, and protective gear. Important Always refer to the GM Approved Refinish Materials book GM PIN 4901 MD This book identities the paint systems you may use. The basecoat/clearcoat paint is factory applied in the following 4 layers in order to give the finish a high gloss look: 1. A cathodic immersion primer 2. A primer/surfacer 3. A basecoat 4. A clear top coat (clearcoat) Refer to the Service Parts ID Label to identify the type of top coat on the vehicle. This label contains all paint related information for the vehicle. This includes paint technology, paint codes, trim level, and any special order paint colors. Automatic Transmission - 4L60-E/4L65-E Transmission Position Switch/Sensor: Adjustments Automatic Transmission - 4L60-E/4L65-E Park/Neutral Position Switch Adjustment Important: ^ The following procedure is for vehicles that have not had the park/neutral position (PNP) switch removed or replaced. If the PNP switch has been removed or replaced, refer to Park/Neutral Position Switch Replacement for the proper adjustment procedure. ^ Apply the park brake. ^ The engine must start in the park (P) or neutral (N) positions only. ^ Check the PNP switch for proper operation. If adjustment is required, proceed as follows: 1. Place the transmission range selector in the neutral (N) position. 2. With an assistant in the drivers seat, raise and suitably support the vehicle. Refer to Vehicle Lifting. 3. Loosen the park/neutral position (PNP) switch bolts. 4. With the vehicle in the neutral (N) position, rotate the switch while the assistant attempts to start the engine. 5. Following a successful start, turn the engine off. 6. Notice: Refer to Fastener Notice in Service Precautions. ^ Tighten the PNP switch bolts. ^ Tighten the bolts to 25 Nm (18 ft. lbs.). 7. Lower the vehicle. 8. Check the PNP switch for proper operation. The engine must start in the park (P) or neutral (N) positions only. 9. Replace the PNP switch if proper operation can not be achieved. Page 9525 Location View Page 8191 1. Thickness Variation Pulsation is Caused by Lateral Run Out (LRO). LRO on a brake corner assembly is virtually undetectable unless measured (with a dial indicator after the brake service) and will not be detected as brake pulsation during an after brake service test drive. If the brake corner is assembled with excessive LRO (greater than 0.050 mm (0.002 in), thickness variation will develop on the brake rotor over time and miles. Excessive LRO will cause the brake pads to wear the brake rotors unevenly, which causes rotor thickness variation. Pulsation that is the result of excessive Lateral Run Out usually develops in 4,800-16,000 km (3,000-10,000 mi). The more excessive the LRO, the faster the pulsation will develop. LRO can also be induced when uneven torque is applied to wheel nuts (lug nuts). Improper wheel tightening after tire rotation, spare tire usage, brake inspection, etc. can be the cause of brake pulsation. Again, it usually takes 4,800-16,000 km (3,000-10,000 mi) AFTER the service event for the condition to develop. The customer does not usually make the connection between the service event and the awareness of the pulsation. The proper usage of torque wrenches and/or torque sticks (torque limiting sockets) will greatly reduce or eliminate the pulsation conditions after wheel service events. The improper use of impact wrenches on wheel nuts greatly increases the likelihood of pulsation after wheel service. The following are examples of pulsation conditions and reimbursement recommendations: - If the customer noticed the condition between 4,800-16,000 km (3,000-10,000 mi) and it gradually got worse, normally the repair would be covered. The customer may tolerate the condition until it becomes very apparent. - If a GM dealer performed a prior brake service, consider paying for the repair and then strongly reinforce proper brake lathe maintenance. - If the customer had the brake service done outside of a GM dealership, normally GM would not offer any assistance. - If a customer indicated they had wheel service, ask who performed the service. Then; - If a GM dealer performed the service, consider paying for the repair and then strongly reinforce the use of torque sticks at the dealer. Two common size torque sticks cover 90% of all GM products. Each technician needs to use torque sticks properly every time the wheel nuts are tightened. - If the customer had the wheel service done outside of a GM dealership, normally GM would not offer any assistance. 2. Thickness Variation Pulsation Caused by Brake Rotor Corrosion - Rotor corrosion is another form of thickness variation, which can cause a pulsation concern and can be addressed as follows: - Cosmetic Corrosion: In most instances rotor corrosion is cosmetic and refinishing the rotor is unnecessary. - Corrosion - Pulsation Caused by Thickness Variation (Lot Rot / Low Miles - 0-321 km (0-200 mi): At times more extensive corrosion can cause pulsation due to thickness variation. This usually happens when the vehicle is parked for long periods of time in humid type conditions and the braking surface area under the pads corrodes at a different rate compared to the rest of the braking surface area. Cleaning up of braking surfaces (burnishing) can be accomplished by 10 - 15 moderate stops from 56- 64 km/h (35 - 40 mph) with cooling time between stops. If multiple moderate braking stops do not correct this condition, follow the "Brake Rotor Clean-Up Procedure" below. - Corrosion - Pulsation Caused by Thickness Variation (without rotor flaking / higher mileage 3,200-8,000 km (2,000-5,000 mi): In some cases, more extensive corrosion that is not cleaned up by the brake pad over time and miles can cause the same type of pulsation complaint due to thickness variation. In these cases, the rotor surface is usually darker instead of shiny and a brake pad foot print can be seen against the darker surface. This darker surface is usually due to build-up, on the rotor material surface, caused by a combination of corrosion, pad material and heat. To correct this condition, follow the "Brake Rotor Clean-up Procedure" below. - Corrosion - Pulsation Caused by Thickness Variation (with rotor flaking / higher mileage - 8,000 + km (5,000 + miles) : At times, more extensive corrosion over time and miles can cause pulsation due to thickness variation (flaking). This flaking is usually a build up, mostly on the rotor material surface, caused by a combination of corrosion, pad material and heat. When rotor measurements are taken, the low areas are usually close to the original rotor thickness (new rotor) measurement and the high areas usually measure more than the original rotor thickness (new rotor) measurement (depending on mileage and normal wear). To correct this condition, follow the "Brake Rotor Clean-up Procedure" described below. Important In some flaking instances, cleaning-up this type of corrosion may require more rotor material to be removed then desired. Customer consideration should be taken in these situations and handled on a case by case basis, depending on the amount/percentage of rotor life remaining and the vehicle's warranty time and miles. Brake Rotor Clean-Up Procedure Page 13667 Front Door Panel: Service and Repair Water Deflector Replacement - Front Door Water Deflector Replacement - Front Door Removal Procedure Important: Water deflectors seal the inner panel. Water deflectors prevent water from entering into the body. A strip of adhesive between the deflector and the door secures the deflector. 1. Remove the trim panel. 2. Using a flat-blade tool, break the bond between the sealer and the door. 3. Pull the waterproof sealing tape from the deflector. 4. Remove the water deflector. Installation Procedure 1. Using waterproof tape or 3M(R) 777 (or equivalent), install the water deflector to the door. 2. Install the trim panel to the door. Page 878 Body Control Module: Diagnostic Aids Basic Knowledge Required BASIC KNOWLEDGE REQUIRED Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the Service Data. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories CHECKING AFTERMARKET ACCESSORIES Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: - Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions INDUCING INTERMITTENT FAULT CONDITIONS In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: - Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. Page 8300 12. Wait 15 seconds, then repeat steps 10-11 until a firm pedal is obtained. This will properly seat the brake caliper pistons and brake pads. W/O NYS Brake Caliper Bracket Replacement - Rear (15/25 Series w/o NYS) Caution: Refer to Brake Dust Caution in Service Precautions. Removal Procedure 1. Raise and support the vehicle. Refer Vehicle Lifting 2. Remove the tire and wheel assembly. 3. Notice: Support the brake caliper with heavy mechanic's wire, or equivalent, whenever it is separated from its mount and the hydraulic flexible brake hose is still connected. Failure to support the caliper in this manner will cause the flexible brake hose to bear the weight of the caliper, which may cause damage to the brake hose and in turn may cause a brake fluid leak. Remove the brake caliper from the brake caliper mounting bracket and support the brake caliper with heavy mechanic's wire or equivalent. DO NOT disconnect the hydraulic brake hose from the brake caliper. 4. Remove the brake pads from the brake caliper mounting bracket. 5. Remove the anti-rattle clips from the brake caliper bracket. 6. Remove the brake caliper bracket mounting bolts (2). 7. Remove the brake caliper bracket (1). 8. Remove any contaminants or foreign material from the inside ends of the brake caliper bracket. 9. Clean the mounting surface and threads of the brake caliper bracket. Installation Procedure Page 1588 Fuel Tank Pressure Sensor: Service and Repair FUEL TANK PRESSURE SENSOR REPLACEMENT REMOVAL PROCEDURE 1. Remove the fuel tank. 2. Using a slight rocking motion, while pulling straight up, remove the fuel tank pressure sensor (1). INSTALLATION PROCEDURE 1. Install the fuel tank pressure sensor (1). 2. Install the fuel tank. Page 3275 10. Install the engine mount heat shield, if equipped. ^ Tighten the engine mount-to-engine mount bracket bolts to 65 Nm (48 ft. lbs.). 11. Install the left front tire and wheel. 12. Install the wheelhouse inner panel push pin retainers (2). 13. Install the wheelhouse inner panel (1). 14. Lower the vehicle. Right Engine Mount Replacement - Right Removal Procedure 1. Raise the vehicle. 2. Remove the tire and wheel. 3. Remove the wheelhouse panel. 4. Remove the exhaust manifold. 5. Remove the engine protection shield. With Full Floating 10.5 Axle Bearing: Service and Repair With Full Floating 10.5" or 11.5" Ring Gear Rear Axle Hub, Bearing, Cup, and/or Seal Replacement ^ Tools Required J 8092 Universal Driver Handle - 3/4 inch - 10 - J 2222-C Wheel Bearing Nut Wrench - J 24426 Wheel Bearing Race Installer - Outer - J 24427 Wheel Bearing Race Installer - Inner - J 44419 Hub Outer Bearing Race Installer - J 44420 Differential Bearing and Hub Seal Installer Removal Procedure 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Remove the tire and wheel assembly. 3. Remove the brake caliper. 4. Remove the axle shaft. 5. Remove the axle nut retaining ring. 6. Remove the key. 7. Remove the adjusting nut using the J 2222-C. Page 11595 Service Procedure 1. Note the position of the rear seats. 2. Position the seats to gain access to the lower seat belt anchor stud for the rear center seat. 3. Remove any cover necessary to gain access to the lower seat belt anchor point for the rear center seat. 4. Remove the nut (1) retaining the rear center seat's lower seat belt anchor (seat back shown in the up position). 5. Remove the belt anchor point from the stud. 6. Remove the belt from the seat loop on the front of the seat back cushion. 7. Route the belt outside of the seat loop and install it on the lower anchor stud. Be sure that the belt is not twisted. 8. Install the retaining nut to the anchor stud. Tighten Tighten the retaining nut to 53 Nm (39 lb ft). 9. Using an appropriate color of locally obtained upholstery thread and needle (size 16 recommended), sew the retaining loop closed in the center. 10. Reposition the seats to the customer's original position as noted in Step 1 Courtesy Transportation -- for US and Canada The General Motors Courtesy Transportation Program is intended to minimize customer inconvenience when a vehicle requires a repair that is covered by the New Vehicle Limited Warranty. The availability of courtesy transportation to customers whose vehicles are within the warranty coverage period and involved in a product recall is very important in maintaining customer satisfaction. Dealers are to ensure that these customers understand that shuttle service or some other form of courtesy transportation is available and will be provided at no charge. Dealers should refer to the General Motors Service Page 1987 Electrical Symbols Part 14 Page 13249 Models The service procedure in this bulletin has been revised. Step 11 in the procedure for the 2004-2005 Saab 9-3 (9440) Convertible has been revised. Discard all copies of bulletin 08089B, issued September 2008. Condition In November 2002, the U.S. Federal Commissions (FCC) ruled that wireless carriers would no longer be required to support the analog wireless network beginning in 2008. As a result, On Star(R) is unable to continue analog service. OnStar(R) has deactivated most of the systems operating in the analog mode; however, there are some vehicles that OnStar(R) could not deactivate. Although the analog OnStar(R) hardware in these vehicles can no longer communicate with OnStar(R), the hardware in the vehicle is still active. If the OnStar(R) emergency button is pressed, or in the case of an airbag deployment, or near deployment, the customer may hear a recording that OnStar(R) is being contacted. However, since analog service is no longer available, the call will not connect to OnStar(R). To end the call, the customer must press the white phone or white dot button. If the call is not ended, the system will continue to try to connect to OnStar(R) until the vehicle battery is drained. Special Policy Adjustment At the customer's request, dealers/retailers are to deactivate the OnStar(R) system. The service will be made at no charge to the customer. This special coverage covers the condition described above until December 31, 2008 for all non-Saab vehicles; April 30, 2009 for all Saab vehicles. Vehicles Involved Page 8630 Page 14272 TECHNICAL Bulletin No.: 05-08-51-008C Date: June 22, 2009 Subject: Bumps or Rust Colored Spots in Paint Due to Rail or Iron Dust (Remove Rail Dust) Models: 1994-2010 GM Passenger Cars and Trucks (Including Saturn) 2003-2010 HUMMER H2 2006-2010 HUMMER H3 2005-2009 Saab 9-7X Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 05-08-51-008B (Section 08 - Body and Accessories). Condition Visible rust colored spots or bumps on a vehicle's paint surface from rail or iron dust. Cause Rail dust comes from tiny iron particles produced from the friction between train wheels and the tracks and gets deposited on the vehicle surfaces. Iron dust can get deposited on the surface if the vehicle is stored near any operation producing iron dust such as an iron ore yard. Either material can lay on top of, or become embedded in, the paint surface. Correction Because the severity of the condition varies, proper diagnosis of the damage is critical to the success of repairs. Diagnosis should be performed on horizontal surfaces (hood, roof, deck lid, pick up box, etc.) after the vehicle has been properly cleaned. There are two types of repair materials recommended to repair rail dust or iron dust: 1. GEL TYPE OXALIC ACID: - Has the characteristics of the liquid type oxalic acid but stays where you put it because of its gel consistency. 2. CLAY TYPE NON-ACID BASED: - Requires surface lubricant during use. - Has different grades available. Caution Rail dust remover (Oxalic Acid) is an acidic substance containing chemicals that will break down the iron particles embedded in the finish. When working with rail dust remover, use the necessary safety equipment, including gloves and goggles. Follow the chemical manufacturer's directions closely because it may require special handling and disposal. If, upon inspection, some particles are still present, the various chemical manufacturer's processes can be repeated. After the removal process, small pits may remain in the clearcoat and can be corrected, in most cases, with a finesse/polish operation. Procedure 1. Move the vehicle to a cool shaded area and make sure that the vehicle surfaces are cool during the removal process. DO NOT PERFORM THE REMOVAL PROCESS IN DIRECT SUNLIGHT OR ON A VEHICLE WITH HOT OR WARM BODY PANELS. 2. Wash the vehicle with soap and water. Dry it immediately and clean the affected areas with a wax and grease remover. 3. Perform the removal process according to the chemical manufacturer's directions. Once the damage has been repaired, the final step involves a polishing process. Rail Dust Remover Manufacturers Use the chemical manufacturers listed below, or equivalent: Auto Magic(R) or Clay Magic(R) products available from: Auto Wax Company, Inc. Page 9598 Relay Block - I/P C3 Part 2 Page 15062 8. Install the large shoulder (M8) bolts into the reinforcement and front panel (total of 4) and the small (M6) bolts into the reinforcement and side outer panel (total of 6) with the nuts. Tighten ^ Tighten the M8 bolts to 25 Nm (18 lb-ft.). ^ Tighten the M6 bolts to 9 Nm (79 lb-in). 9. Remove all metal shavings from the pickup box afier installation. 10. Install the bedliner if equipped with the aid of an assistant. The bedliner may need to be trimmed in order to obtain the necessary clearance for the reinforcements. Ladder Rack and/or Side Tool Box Applications - Reinforcement Kit Installation 1. Install the LH and RH front L-shaped reinforcements using the procedure above. 2. Remove the LH and RH rear taillamp assemblies. This is necessary to gain access to install the rearmost bolt of the rear reinforcement. 3. Place the LH and RH rear reinforcements into position on the pickup box. 4. Mark the holes necessary for drilling and remove the reinforcements. 5. Drill 7.5 mm (0.30 in) holes into the weld flange of the side outer panel. 6. Apply anti-corrosion material to the drilled holes as necessary. Refer to step 6 under Front Reinforcement Installation procedure. 7. Place the rear reinforcements back onto the pickup box. 8. Install the M6 bolts through the reinforcement and side panel with the nuts. Tighten Tighten the bolts to 9 Nm (79 lb-in). 9. Install the LH and RH rear taillamp assemblies. 10. Place the LH and RH center reinforcement into position on the pickup box. Underhood Fuse Block LR Of The Engine Compartment (With RPO Code 9L4) Page 7328 Page 10155 2. Rotate the coil hub slowly, counterclockwise until the centering window appears yellow and both arrows (2) line up. This is the CENTER position. 3. While holding the coil hub in the CENTER position, align the SIR coil with the horn tower and slide onto the steering shaft assembly. 4. If the front side (3) of the SIR coil has NO centering window, but the back side (2) includes a spring service lock (1), perform the following steps: 0. Hold the SIR coil with the back side up. 1. While depressing the spring service lock, rotate the coil hub in the direction of the arrow (4) until the coil ribbon stops. 2. Still pressing the spring service lock, rotate the coil hub in the opposite direction 21⁄2 revolutions. 3. Release the spring service lock between locking tabs. The SIR coil is now centered. 4. Align the centered SIR coil with the horn tower and slide onto the steering shaft assembly. 5. If the front side (2) of the SIR coil has NO centering window, and the back side (1) includes NO spring service lock, perform the following steps: 0. Hold the SIR coil with the face up. 1. Rotate the coil hub in the direction of the arrow until the coil ribbon stops. 2. Rotate the coil hub, slowly, counterclockwise, for 21⁄2 revolutions. This is the CENTER position. 3. While maintaining the coil hub in the CENTER position, align the centered SIR coil with the horn tower and slide onto the steering shaft assembly. 6. If double wire harness strap is installed onto the wire harness assembly and column, you must route the wires up against the steering column. One wire harness strap will surround one lead from the coil to the steering column. The other wire harness strap will surround all leads to the steering column. Cooling System, A/C - Aluminum Heater Cores/Radiators Heater Core: Technical Service Bulletins Cooling System, A/C - Aluminum Heater Cores/Radiators INFORMATION Bulletin No.: 05-06-02-001A Date: July 16, 2008 Subject: Information On Aluminum Heater Core and/or Radiator Replacement Models: 2005 and Prior GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2005 HUMMER H2 Supercede: This bulletin is being revised to update the Warranty Information. Please discard Corporate Bulletin Number 05-06-02-001 (Section 06 - Engine/Propulsion System). Important: 2004-05 Chevrolet Aveo (Pontiac Wave, Canada Only) does not use DEX-COOL(R). Refer to the flushing procedure explained later in this bulletin. The following information should be utilized when servicing aluminum heater core and/or radiators on repeat visits. A replacement may be necessary because erosion, corrosion, or insufficient inhibitor levels may cause damage to the heater core, radiator or water pump. A coolant check should be performed whenever a heater core, radiator, or water pump is replaced. The following procedures/ inspections should be done to verify proper coolant effectiveness. Caution: To avoid being burned, do not remove the radiator cap or surge tank cap while the engine is hot. The cooling system will release scalding fluid and steam under pressure if the radiator cap or surge tank cap is removed while the engine and radiator are still hot. Important: If the vehicle's coolant is low, drained out, or the customer has repeatedly added coolant or water to the system, then the system should be completely flushed using the procedure explained later in this bulletin. Technician Diagnosis ^ Verify coolant concentration. A 50% coolant/water solution ensures proper freeze and corrosion protection. Inhibitor levels cannot be easily measured in the field, but can be indirectly done by the measurement of coolant concentration. This must be done by using a Refractometer J 23688 (Fahrenheit scale) or J 26568 (centigrade scale), or equivalent, coolant tester. The Refractometer uses a minimal amount of coolant that can be taken from the coolant recovery reservoir, radiator or the engine block. Inexpensive gravity float testers (floating balls) will not completely analyze the coolant concentration fully and should not be used. The concentration levels should be between 50% and 65% coolant concentrate. This mixture will have a freeze point protection of -34 degrees Fahrenheit (-37 degrees Celsius). If the concentration is below 50%, the cooling system must be flushed. ^ Inspect the coolant flow restrictor if the vehicle is equipped with one. Refer to Service Information (SI) and/or the appropriate Service Manual for component location and condition for operation. ^ Verify that no electrolysis is present in the cooling system. This electrolysis test can be performed before or after the system has been repaired. Use a digital voltmeter set to 12 volts. Attach one test lead to the negative battery post and insert the other test lead into the radiator coolant, making sure the lead does not touch the filler neck or core. Any voltage reading over 0.3 volts indicates that stray current is finding its way into the coolant. Electrolysis is often an intermittent condition that occurs when a device or accessory that is mounted to the radiator is energized. This type of current could be caused from a poorly grounded cooling fan or some other accessory and can be verified by watching the volt meter and turning on and off various accessories or engage the starter motor. Before using one of the following flush procedures, the coolant recovery reservoir must be removed, drained, cleaned and reinstalled before refilling the system. Notice: ^ Using coolant other than DEX‐COOL(R) may cause premature engine, heater core or radiator corrosion. In addition, the engine coolant may require changing sooner, at 30,000 miles (50,000 km) or 24 months, whichever occurs first. Any repairs would not be covered by your warranty. Always use DEX‐COOL(R) (silicate free) coolant in your vehicle. ^ If you use an improper coolant mixture, your engine could overheat and be badly damaged. The repair cost would not be covered by your warranty. Too much water in the mixture can freeze and crack the engine, radiator, heater core and other parts. Page 11926 7.2. Remove the console (A). 7.3. Disconnect the connector (B) from the OnStar(R) control module. Important: Secure the cable harness to prevent the risk of scraping and rattling. 7.4. Fold back the cable harness and tape down the connector (C). Fold back the cable harness again and secure with cable ties (D). 7.5. 5D: Assemble the right-hand cover for the luggage compartment floor. 8. Fit the ground cable on the battery's negative cable. Page 11384 A/C Low Pressure Switch And A/C Accumulator Page 3351 7. Remove the transmission cover bolt. 8. If equipped, remove the oil pan skid plate bolts. 9. Remove the oil pan skid plate. 10. Remove the crossbar bolts. 11. Remove the crossbar. 12. Remove the transmission cover bolt and cover. 13. Drain the engine oil and remove the engine oil filter. 14. Re-install the drain plug and oil filter until snug. HVAC System - Automatic Control Module HVAC: Service and Repair HVAC System - Automatic Blower Motor Control Processor Replacement BLOWER MOTOR CONTROL PROCESSOR REPLACEMENT REMOVAL PROCEDURE 1. If equipped, remove the sound insulator panel. 2. Disconnect the electrical connector at the blower motor. 3. Disconnect the electrical connector (4) from the blower motor control processor (2). 4. Remove the blower motor control processor retaining screws (3) from the HVAC module (1). 5. Remove the blower motor control processor (2) from the HVAC module (1). INSTALLATION PROCEDURE Page 14614 Power Seat Motor: Service and Repair SEAT ADJUSTER MOTOR REPLACEMENT - FRONT The seat adjuster motors can not be replaced individually. Therefore if any motor has failed, the seat adjuster needs to be replaced as an assembly. Page 8612 Page 12350 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-8 (12085115) crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-8 (12085115) until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes SPLICING INLINE HARNESS DIODES Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate Service Data wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. 9. Tape the diode to the harness or connector using electrical tape. Diagrams Page 12587 Important: Secure the wiring harness so that there is no risk of chafing or rattling. 6.1. Remove the passenger seat in accordance with WIS 8. Body - Seats Adjustment/Replacement. 6.2. Remove the right-hand B-pillar trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.3. Remove the right-hand C pillar trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.4. Fold the rear seat backrest forward. 6.5. Remove the right-hand side bolster in accordance with WIS - 8. Body - Seats Adjustment/Replacement. 6.6. Remove the A-pillar's lower side piece. 6.7. Open the cover on the right-hand wiring harness channels. 6.8. Loosen the locking strip (A) on the 2-pin connector (H2-11) for the optic cable, located by the right-hand A-pillar. 6.9. Loosen the catch (B) and remove the optic cable that runs backward in the car. 6.10. Dismantle the end cap from the new optic cable (12 783 577) and connect it to the connector H2-11. Push in the optic cable and make sure the catch (B) locks and refit the locking strip (A). 6.11. Secure the connector and the old optic cable using the cable tie for the existing wiring harness (C). Page 9681 For vehicles repaired under warranty, use the table. Disclaimer Page 14764 Heated Seat Element - Front Passenger Cushion Page 14865 Power Seat Motor Position Sensor: Diagrams Seat Bolster Motor/Position Sensor - Driver (With RPO Code AN3) Page 14196 5. Using a wide plastic flat-bladed tool, release the retaining clips on both sides of the door module. 6. Remove the door module from the switch panel bezel. INSTALLATION PROCEDURE 1. Install the door module into the switch panel bezel until it snaps into place. 2. Install the switch panel bezel and module to the door panel. NOTE: Refer to Fastener Notice in Service Precautions. 3. Install the screw that retains the switch panel bezel (1) to the front door panel. Tighten Tighten the screw to 2 N.m (18 lb in). 4. Connect the electrical connectors. Page 7222 Electrical Symbols Part 14 Page 11196 2. Install the suction hose to the accumulator using new sealing washers. NOTE: Refer to Fastener Notice in Service Precautions. 3. Install the suction hose nut to the accumulator. Tighten Tighten the nut to 16 N.m (12 lb ft). 4. Install the suction hose (2) to the compressor using new sealing washers. 5. Install the suction hose mounting bolt to the A/C compressor. Tighten Tighten the bolt to 16 N.m (12 lb ft). 6. Evacuate and recharge the A/C system. Refer to Refrigerant Recovery and Recharging. 7. Leak test the fittings of the component using the J 39400-A. Specifications Clutch Fluid: Specifications HYDRAULIC CLUTCH FLUID 5-SPEED TRANS. Hydraulic Clutch Fluid (GM Part No. U.S. 12345347, in Canada 10953517) or equivalent DOT-3 brake fluid. 6-SPEED TRANS. Hydraulic Clutch Fluid. Use only GM Part No. U.S. 88958860, in Canada 88901244, DOT-4 brake fluid. Page 534 Door Module: Service and Repair DOOR CONTROL MODULE PROGRAMMING AND SETUP Driver Door Module After replacing the driver door module (DDM), perform the programing procedure. Refer to Service Programming System (SPS). See: Testing and Inspection/Programming and Relearning Passenger Door Module After replacing the passenger door module (PDM), perform the following programing and setup procedures: ‹› Service Programming System (SPS). See: Testing and Inspection/Programming and Relearning ‹› Transmitter Programming. See: Testing and Inspection/Programming and Relearning ‹› Control Module Setup. See: Testing and Inspection/Programming and Relearning Page 8752 Positive: Service and Repair Replacement Procedure- Battery Relay to Starter - Auxiliary BATTERY POSITIVE CABLE REPLACEMENT - BATTERY RELAY TO STARTER - AUXILIARY REMOVAL PROCEDURE CAUTION: Refer to Battery Disconnect Caution in Service Precautions. 1. Disconnect the auxiliary battery negative cable. 2. Reposition the boot. 3. Remove the auxiliary positive battery cable nut. 4. Remove the auxiliary positive battery cable from the auxiliary relay. 5. Remove the auxiliary positive battery cable clip from the battery tray. 6. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 7. Remove the auxiliary cable clip bolt from the frame. Page 9178 C103 I/P Harness To Forward Lamp Harness (Export) Page 4095 5. If equipped with a 6.0L engine, disconnect the HO2S electrical connector. 6. Remove the HO2S. INSTALLATION PROCEDURE IMPORTANT: A special anti-seize compound is used on the HO2S threads. The compound consists of liquid graphite and glass beads. The graphite tends to burn away, but the glass beads remain, making the sensor easier to remove. New, or service replacement sensors already have the compound applied to the threads. If the sensor is removed from an exhaust component and if for any reason the sensor is to be reinstalled, the threads must have anti-seize compound applied before the reinstallation. 1. If reinstalling the old sensor, coat the threads with anti-seize compound GM P/N 12377953, or equivalent. NOTE: Refer to Component Fastener Tightening Notice in Service Precautions. 2. Install the HO2S. Tighten Tighten the sensor to 42 N.m (31 lb ft). Page 13174 Labor Time Information Brakes - ABS Lamp ON/DTC's C0265/C0201/U1041 Set Electronic Brake Control Module: All Technical Service Bulletins Brakes - ABS Lamp ON/DTC's C0265/C0201/U1041 Set TECHNICAL Bulletin No.: 04-05-25-002E Date: March 11, 2009 Subject: ABS Light On, DTCs C0265, C0201, U1041 Set and/or Loss of Communication with Brake Module (Reground EBCM Ground) Models Supercede: This bulletin is being revised to add step 2 to the procedure and update the Parts and Warranty Information. Please discard Corporate Bulletin Number 04-05-25-002D (Section 05 - Brakes). Condition Some customers may comment that the ABS light is on. Upon further inspection, DTCs C0265 and C0201 may be set in the brake module. It is also possible for DTC U1041 to set in other modules. There may also be a loss of communication with the brake module. Cause A poor connection at the EBCM ground is causing unnecessary replacement of brake modules. Important: The EBCM ground is different for each application. Refer to the list below for the proper ground reference: ^ Midsize Utilities = Ground 304 ^ SSR = Ground 400 ^ Fullsize Trucks and Utilities = Ground 110 Correction Important: Do not replace the brake module to correct this condition. Perform the following repair before further diagnosis of the EBCM. Perform the following steps to improve the connection of the EBCM Ground: 1. Remove the EBCM Ground. The EBCM Ground is located on the frame beneath the driver's side door. If multiple grounds are found in this location, the EBCM ground can be identified as the heavy (12-gauge) wire. 2. If the original fastener has a welded on nut, remove the nut from the frame, and if required, enlarge the bolt hole to accommodate the new bolt and nut. 3. Clean the area, front and back, using a tool such as a *3M(TM) Scotch-Brite Roloc disc or equivalent. Page 15589 Clearance Lamp - RR (With RPO Code NYS Or E63) Page 10998 Blower Motor Resistor: Service and Repair Blower Motor Replacement (Visteon) BLOWER MOTOR REPLACEMENT (VISTEON) REMOVAL PROCEDURE 1. Remove the sound insulator panel. 2. Disconnect the electrical connector (2) from the blower motor (1). 3. Remove the screws from the blower motor (1). 4. Remove the blower motor (1) from the HVAC module (3). 5. Remove the retainer from the blower motor impeller. Discard the retainer. 6. Remove the blower motor impeller from the blower motor (1). INSTALLATION PROCEDURE 1. Install the blower motor impeller to the blower motor (1). 2. Install the new retainer to the blower motor impeller. 3. Install the blower motor (1) to the HVAC module (3). NOTE: Refer to Fastener Notice in Service Precautions. 4. Install the screws to the blower motor (1) Tighten Tighten the screws to 2 N.m (18 lb in). 5. Connect the electrical connector (2) to the blower motor (1). 6. Install the sound insulator panel. A/C - Ticking Noise From Instrument Panel/DTC's Set Air Door Actuator / Motor: All Technical Service Bulletins A/C - Ticking Noise From Instrument Panel/DTC's Set Bulletin No.: 06-01-38-003 Date: April 27, 2006 TECHNICAL Subject: Intermittent Ticking Noise from I/P, Poor A/C Performance, HVAC DTCs B0229, B0414, B0424, B3770 (Reprogram HVAC Control Module) Models: 2004-2006 Cadillac Escalade Models 2004-2006 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2004-2006 GMC Sierra Models, Yukon Models with Air Conditioning (RPOs CJ2, CJ3) Condition Some customers may comment on one or more of the following concerns: ^ Intermittent ticking/clicking noise from the instrument panel. ^ Recirculation mode does not work or Air Conditioning (A/C) system performance is poor during high ambient temperatures. ^ Unable to control the driver side temperature. ^ Unable to control the passenger side temperature. ^ Unable to change the front system modes. Cause This condition may be caused by the Heating, Ventilation and Air Conditioning (HVAC) actuators that may hunt for the correct commanded position. This cycling may cause a clicking or ticking noise. An overtravel of the HVAC system control doors may cause one or more of the concerns listed above. If an overtravel occurs, a Diagnostic Trouble Code (DTC) will be set, and the door will go to a preset default position. When a system door defaults, that door will stay at the default position until the DTC is cleared. After the DTC is cleared, the door will operate properly until the overtravel condition re-occurs. The table lists the HVAC system doors and the DTC associated with it. Correction Technicians are to perform the normal diagnostic procedures in SI for these concerns. If diagnostics show that the HVAC system door(s) travel below 5 counts (out of the lower range) or above 250 counts (out of the upper range), then update the software calibrations in the HVAC control module. The new calibrations were made available to dealerships as part of TIS2000 incremental satellite update version 2.5, which was broadcast to dealers in February 2006. Page 8753 8. Remove the starter lead nut. 9. Remove the auxiliary positive battery cable from the starter stud. 10. Remove the auxiliary positive battery cable. INSTALLATION PROCEDURE 1. Install the auxiliary positive battery cable. 2. Install the auxiliary positive battery cable to the starter stud. NOTE: Refer to Fastener Notice in Service Precautions. 3. Install the starter lead nut. Tighten Tighten the nut to 9 N.m (80 lb in). Page 12000 Page 4967 3. Disconnect the vent valve pipe quick connect from the canister. 4. Either cut the existing valve vent pipe and leave the remaining section of pipe in the vehicle or remove along with the valve. 5. Push in the retainer and remove the existing canister vent valve from the fuel tank clip or mounting bracket. 6. Cut back the existing canister pipe approximately 51 mm (2 in) and retain the pipe for use with new valve. 7. Connect the canister pipe quick connect to the canister. 2500 Crew Cab Short Box Shown Below, Other Configurations Similar 1500 Extended Cab Short Box Shown Below, Other Configurations Similar 8. Install the new canister vent valve solenoid to the fuel tank clip or mounting bracket as shown above. The valve port closest to the electrical connector must point towards the canister. 9. Cut bulk 5/8" heater hose to a length of approximately 76 mm (3 in). Install the hose between the solenoid and the canister pipe and secure using clamps. 10. Attach bulk 5/8" heater hose to the vent port and secure using a clamp. Run a length as needed along the frame rail routing to the passenger side area above the transmission. 11. Cut the hose to determined length and install the supplied filter box. Secure using a clamp. 12. Remove the transmission heat shield, if necessary. 13. Remove the transmission support and lower the transmission assembly as necessary to allow for access to the new filter box location. 14. Secure the filter box to the transmission vent hose just forward of the hose tee-section using a tie strap. DO NOT pinch or restrict the transmission vent hose. The filter box opening should be pointing downward. 15. Raise the transmission and reinstall the transmission support. 16. Reinstall the transmission heat shield. 17. Connect the EVAP canister vent valve electrical connector. 18. Tie strap the hose as needed along the frame rail in order to keep the hose away from pinch-points and heat sources. 19. Lower the vehicle. Parts Information Page 6238 Fluid - A/T: Technical Service Bulletins A/T - Water Or Coolant Contamination Information INFORMATION Bulletin No.: 08-07-30-035B Date: November 01, 2010 Subject: Information on Water or Ethylene Glycol in Transmission Fluid Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks with Automatic Transmission Supercede: This bulletin is being revised to update model years. Please discard Corporate Bulletin Number 08-07-30-035A (Section 07 - Transmission/Transaxle). Water or ethylene glycol in automatic transmission fluid (ATF) is harmful to internal transmission components and will have a negative effect on reliability and durability of these parts. Water or ethylene glycol in ATF will also change the friction of the clutches, frequently resulting in shudder during engagement or gear changes, especially during torque converter clutch engagement. Indications of water in the ATF may include: - ATF blowing out of the transmission vent tube. - ATF may appear cloudy or, in cases of extreme contamination, have the appearance of a strawberry milkshake. - Visible water in the oil pan. - A milky white substance inside the pan area. - Spacer plate gaskets that appear to be glued to the valve body face or case. - Spacer plate gaskets that appear to be swollen or wrinkled in areas where they are not compressed. - Rust on internal transmission iron/steel components. If water in the ATF has been found and the source of the water entry has not been identified, or if a leaking in-radiator transmission oil cooler is suspected (with no evidence of cross-contamination in the coolant recovery reservoir), a simple and quick test kit is available that detects the presence of ethylene glycol in ATF. The "Gly-Tek" test kit, available from the Nelco Company, should be obtained and the ATF tested to make an accurate decision on the need for radiator replacement. This can help to prevent customer comebacks if the in-radiator transmission oil cooler is leaking and reduce repair expenses by avoiding radiator replacement if the cooler is not leaking. These test kits can be obtained from: Nelco Company Test kits can be ordered by phone or through the website listed above. Orders are shipped standard delivery time but can be shipped on a next day delivery basis for an extra charge. One test kit will complete 10 individual fluid sample tests. For vehicles repaired under warranty, the cost of the complete test kit plus shipping charges should be divided by 10 and submitted on the warranty claim as a net item. The transmission should be repaired or replaced based on the normal cost comparison procedure. Important If water or coolant is found in the transmission, the following components MUST be replaced. - Replace all of the rubber-type seals. - Replace all of the composition-faced clutch plates and/or bands. - Replace all of the nylon parts. - Replace the torque converter. - Thoroughly clean and rebuild the transmission, using new gaskets and oil filter. Important The following steps must be completed when repairing or replacing. Flush and flow check the transmission oil cooler using J 45096. Refer to Corporate Bulletin Number 02-07-30-052F- Automatic Transmission Oil Cooler Flush and Flow Test Essential Tool J 45096 TransFlow. - Thoroughly inspect the engine cooling system and hoses and clean/repair as necessary. Page 1565 Crankshaft Position (CKP) Sensor Page 9255 C405 Right Clearance Lamp Harness To License Lamp Harness (With RPO Codes NYS Or R05) Page 6933 10. For the 1500 models (except 1500 HD), assemble the bolts and the support plate to the base of the J-36652-01 and secure the base in a vise. 11. For the 1500 HD, 2500, 3500, and HUMMER H2 models, assemble the bolts and the support plate to the base of the J 36652-98 and secure the base in a vise. Page 13152 10.4. Remove the end cap from the new optic cable, connect to the connector and refit the secondary catch (D). Fit the terminal housing (C) to the connector and refit the locking strip (B). 10.5. Secure the old optic cable together with the new one (E). Important: The optic cable must not be bent with a radius less than 25 mm (1 in). Important: Secure the wiring harness so that there is no risk of chafing and rattling. 11. CV: Remove the rear seat in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. The O-bus connector H2-9 is located behind the left speaker. 12. M04-05: Disconnect the optic cables on the OnStar(R) control modules and join the cables: 12.1. Cut off the cable tie holding the connector (H2-9) against REC. Locations Hazard Warning Switch: Locations Upper Steering Column Page 12728 Labor Time Information Page 5390 1. Remove the fuel tank. 2. Disconnect and remove the fuel feed (1) line from the sending unit and retaining clips. 3. Cap the fuel feed/return, and evaporative emission (EVAP) lines in order to prevent possible fuel/EVAP system contamination. INSTALLATION PROCEDURE 1. Remove the caps from the fuel feed/return, and EVAP lines. 2. Install and connect the fuel feed (1) line to the sending unit and retaining clips. 3. Install the fuel tank. Page 5270 Fuel Injector 7 Page 12710 Diagnostic Tips Review # 4 - Denso legacy Navigation Radio Page 3074 The torque specification for the wheel drive shaft nut has been revised as shown in the table. Disclaimer Page 10832 Air Door Actuator / Motor: Service and Repair HVAC System - Automatic Air Temperature Actuator Replacement - Left AIR TEMPERATURE ACTUATOR REPLACEMENT - LEFT REMOVAL PROCEDURE 1. Remove the I/P insulator panel. 2. Disconnect the electrical connector (1) from the left air temperature actuator (2). 3. Remove the screws from the left air temperature actuator (2). 4. Remove the left air temperature actuator (2) from the HVAC module assembly (3). INSTALLATION PROCEDURE 1. Install the left air temperature actuator (2) to the HVAC module assembly (3). NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the screws to the left air temperature actuator (2). Tighten Tighten the screws to 2 N.m (18 lb ft). 3. Install the electrical connector (1) to the left air temperature actuator (2). 4. Install the I/P insulator panel. 5. Reprogram the left air temperature actuator. Refer to Re-Calibrating Actuators. See: Testing and Inspection/Component Tests and General Diagnostics Air Temperature Actuator Replacement - Right Interior - Front Heated Seat(s) Inoperative Seat Heater Switch: All Technical Service Bulletins Interior - Front Heated Seat(s) Inoperative Bulletin No.: 04-08-50-007 Date: March 12, 2004 INFORMATION Subject: Service Information for Front Heated Seat Inoperative/Cold Models: 2003-2004 Cadillac Escalade/ESV/EXT 2003-2004 Chevrolet Avalanch/Silverado/Suburban/Tahoe 2003-2004 GMC Denali/Sierra/Yukon/Yukon XL 2003-2004 Hummer H2 The purpose of this bulletin is to provide the technician with the following service information: ^ Heated Seats Switch Operation ^ Heated Seats Switch Diagnostics ^ Heated Seats Switch Customer Information Switch Operation 1. The engine must be running for the heated seat feature to work. The heated seats will shut off automatically when the ignition is turned off. 2. Two buttons, located on the door, are used to control the heated seat. ^ Press the horizontal (RH) button to heat the entire seat, back and cushion. ^ Press the vertical (LH) button to heat ONLY the seat back. ^ The three light bars are an indicator of the level of heat selected for either the entire seat (horizontal button) or ONLY the seat back (vertical button). 3. To heat both the seat back and seat cushion at the same time, press the horizontal (RH) button with the heated seat symbol one time. ^ All 3 light bars will glow indicating the HIGH temperature setting. ^ The horizontal (RH) button does NOT have an ON/OFF indicator light. Page 2320 7. Position the SGCM coolant pump (1) to the radiator core support (3). 8. Install the bolts (2) to the SGCM coolant pump (1). Tighten Tighten the nut to 16 N.m (12 lb ft). 9. Install the push pin to the right side radiator air baffle. 10. Install the air cleaner assembly. 11. Install the rear evaporator tube (3) to the vehicle. 12. Connect the nut to the evaporator tube fitting. Tighten Tighten the nut to 9 N.m (80 lb in). 13. Install the evaporator tube to the evaporator. Page 1736 Camshaft Position Sensor: Description and Operation CAMSHAFT POSITION (CMP) SENSOR The CMP sensor is also a magneto resistive sensor, with the same type of circuits as the CKP sensor. The CMP sensor signal is a digital ON/OFF pulse, output once per revolution of the camshaft. The CMP sensor information is used by the PCM to determine the position of the valve train relative to the CKP. Page 6867 6. Remove the washer. 7. Install the J 8614-2 (2) and the J 8614-3 (3) into the J 8614-01 (1) as shown. 8. Remove the pinion yoke by turning the J 8614-3 (3) clockwise while holding the J 8614-01 (1).Use a container in order to retrieve the lubricant. 9. Remove the pinion oil seal. Use a suitable seal removal tool. Do not damage the axle housing. Installation Procedure 1. Apply a light coat of axle lubricant, GM P/N 12378557 or equivalent meeting GM Specification 9986207, to the lip of the pinion seal. 2. Install the new seal using the J 45710. 3. Install the pinion yoke. 4. Notice: Refer to Pinion Flange/Yoke Installation Notice in Service Precautions. Inner Joint and Seal Replacement Constant Velocity Joint Boot: Service and Repair Inner Joint and Seal Replacement Wheel Drive Shaft Inner Joint and Seal Replacement ^ Tools Required J 35910 Seal Clamp Tool - J 36652 Drive Axle Clamp Swage Tool - J 36652-98 Axle Swage Tool Disassembly Procedure 1. Use a hand grinder in order to cut through the swage ring (2). Important: Use caution when using the hand grinder by the tripot housing (1). 2. Remove the tripot housing (1) from the halfshaft. 3. Wipe the grease off of the housing (1). 4. Thoroughly degrease the tripot housing (1). 5. Allow the tripot housing (1) to dry prior to assembly. Page 9274 Junction Block - Rear Lamps - C4 Body - Polypropylene Energy Absorber Replacement Rear Bumper Reinforcement: Technical Service Bulletins Body - Polypropylene Energy Absorber Replacement Bulletin No.: 07-08-63-001 Date: April 17, 2007 INFORMATION Subject: Information on Repair of Polypropylene Energy Absorbers Models: 2007 and Prior GM Passenger Cars and Trucks (including Saturn) 2007 and Prior HUMMER H2, H3 2005-2007 Saab 9-7X Supercede: This bulletin is being revised to change the repair information. Please discard Corporate Bulletin Number 63-20-02 (Section 8 - Body and Accessories). Because the energy absorbers are relatively low in cost to replace, it is now more cost efficient to replace the energy absorbers whenever they are damaged. Disclaimer Front End Sensors Impact Sensor: Description and Operation Front End Sensors INFLATABLE RESTRAINT FRONT END SENSORS The front end sensors are equipped on vehicles to supplement the SIR system performance. The front end sensors are electronic and are not part of the deployment loops, but instead provide inputs to the sensing and diagnostic module (SDM). The front end sensors can assist in determining the severity of some frontal collisions. The SDM uses the input from the front end sensors to assist in determining the severity of a frontal collision further supporting air bag deployment. If the SDM determines a deployment is warranted, the SDM will cause current to flow through the deployment loops deploying the frontal air bags. Page 3415 Important: The intake plenum should also be checked for excessive warpage that may cause an uneven clamping pressure of the seal. If the plenum is found to be warped it will need to be replaced. Service Information states, "An intake manifold with warpage in excess of 3 mm (0.118 in) over a 200 mm (7.87 in) area should be replaced." Intake warpage is measured at the gasket sealing surfaces and should be measured within a 200 mm (7.87 in) area. This measurement is across only two of the intake runner port openings. Measurements taken across the entire distance of all four intake runner ports will lead to unnecessary manifold replacements. Important: Measurements taken across the entire distance of all four intake runner ports will lead to unnecessary intake manifold replacements. 1. Locate a straight edge across the intake manifold cylinder head deck surface. Position the straight edge across two runner port openings. 2. Insert a feeler gauge between the intake manifold and the straight edge. An intake manifold with warpage in excess of 3 mm (0.118 in) over a 200 mm (7.87 in) area is warped and should be replaced. Do not replace intake manifolds with warpage that measures less than 3 mm (0.118 in) over a 200 mm (7.87 in). Parts Information Warranty Information For vehicles repaired under warranty, use the table. Page 13557 Control Module References Part 6 Page 4560 1. Install the knock sensors. Tighten Tighten the sensor to 20 N.m (15 lb ft). 2. Connect the knock sensor electrical connectors. 3. Push down on the rubber covers. 4. Install the intake manifold. Page 13280 4.2. Release the back end of the connector (C) and remove from the contact rail (D). 4.3. M00-01: Disconnect pin 39, cut off the cable terminal and insulate the end using tape (E). Fold back the cable and secure using tape (F). 4.4. M02-04: Disconnect pin 58, cut off the cable terminal and insulate the end using tape (E). Fold back the cable and secure using tape (F). 4.5. Assemble the contact rail and end. 4.6. Connect connector (A) and secure the cable using a cable tie (B). 5. Assemble the gear shift housing (A). AUT: Connect connector (B). 6. Assemble the center console, see WIS - Body - Interior. 7. Remove the OnStar(R) control module and secure the cable harness: 7.1. 5D: Remove the right-hand cover from the luggage compartment floor. Page 6850 7. Install the differential assembly. 8. Fill the axle with lubricant. Use the proper fluid. 9. Lower the vehicle. Page 16143 When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage TESTING FOR A SHORT TO VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity TESTING FOR CONTINUITY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents TESTING FOR ELECTRICAL INTERMITTENTS Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground - Testing for Continuity - Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 msRECORD and emits an audible tone (beep). Page 5801 Transmission Speed Sensor: Service and Repair Output Shaft Speed Sensor Replacement Output Shaft Speed Sensor Replacement Removal Procedure Important: This procedure is for 2-wheel drive (2WD) vehicles only. If the vehicle is equipped with 4-wheel drive (4WD), the output speed sensor is located on the transfer case. 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. Disconnect the output speed sensor (2) electrical connector. 3. Remove the output speed sensor bolt. 4. Remove the output speed sensor (2). 5. Inspect the output speed sensor (2) for any evidence of damage. Installation Procedure Capacity Specifications Refrigerant Oil: Capacity Specifications REFRIGERANT OIL CAPACITIES ACCUMULATOR REPLACEMENT NOTE: Add 60 ml (2 oz) of PAG oil, plus the equal amount of oil drained from the accumulator. COMPRESSOR REPLACEMENT ......................................................................................................................................................... 60 ml (2.0 oz) NOTE:The Denso replacement compressor is precharged with 237 ml (8.0 oz) of PAG oil. CONDENSER REPLACEMENT ............................................................................................................................................................ 30 ml (1.0 oz) EVAPORATOR REPLACEMENT ......................................................................................................................................................... 90 ml (3.0 oz) NOTE: If more than the specified amount of PAG oil was drained from a component, add the equal amount drained. TOTAL SYSTEM PAG OIL CAPACITY ............................................................................................................................................ 240 ml (8.0 oz) Page 14476 Memory Seat Module - C3 Part 3 Page 4915 8. Connect the PNP switch electrical connector (2). 9. If equipped with 4WD, install the front propeller shaft. 10. Lower the vehicle. 11. Check the switch for proper operation. The engine must start in the park (P) or neutral (N) positions only. If proper operation of the switch can not be obtained, replace the switch. Page 899 SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-D. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: - The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair Tools Required J 38125-D Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-D. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Page 3631 Flushing Procedures using DEX-COOL(R) Important: The following procedure recommends refilling the system with DEX-COOL(R), P/N 12346290 (in Canada, use P/N 10953464), GM specification 6277M. This coolant is orange in color and has a service interval of 5 years or 240,000 km (150,000 mi). However, when used on vehicles built prior to the introduction of DEX-COOL(R), maintenance intervals will remain the same as specified in the Owner's Manual. ^ If available, use the approved cooling system flush and fill machine (available through the GM Dealer Equipment Program) following the manufacturer's operating instructions. ^ If approved cooling system flush and fill machine is not available, drain the coolant and dispose of properly following the draining procedures in the appropriate Service Manual. Refill the system using clear, drinkable water and run the vehicle until the thermostat opens. Repeat and run the vehicle three (3) times to totally remove the old coolant or until the drained coolant is almost clear. Once the system is completely flushed, refill the cooling system to a 50%-60% concentration with DEX‐COOL(R), P/N 12346290 (in Canada, use P/N 10953464), GM specification 6277M, following the refill procedures in the appropriate Service Manual. If a Service Manual is not available, fill half the capacity of the system with 100% DEX-COOL(R), P/N 12346290 (in Canada, use P/N 10953464), GM specification 6277M. Then slowly add clear, drinkable water (preferably distilled) to the system until the level of the coolant mixture has reached the base of the radiator neck. Wait two (2) minutes and reverify the coolant level. If necessary, add clean water to restore the coolant to the appropriate level. Once the system is refilled, reverify the coolant concentration using a Refractometer J 23688 (Fahrenheit scale) or J 26568 (centigrade scale) coolant tester, or equivalent. The concentration levels should be between 50% and 65%. Flushing Procedures using Conventional Silicated (Green Colored) Coolant Important: 2004-2005 Chevrolet Aveo (Pontiac Wave, Canada Only) does not use DEX‐COOL(R). The Aveo and Wave are filled with conventional, silicated engine coolant that is blue in color. Silicated coolants are typically green in color and are required to be drained, flushed and refilled every 30,000 miles (48,000 km). The Aveo and Wave are to be serviced with conventional, silicated coolant. Use P/N 12378560 (1 gal) (in Canada, use P/N 88862159 (1 L). Refer to the Owner's Manual or Service Information (SI) for further information on OEM coolant. Important: Do not mix the OEM orange colored DEX-COOL(R) coolant with green colored coolant when adding coolant to the system or when servicing the vehicle's cooling system. Mixing the orange and green colored coolants will produce a brown coolant which may be a customer dissatisfier and will not extend the service interval to that of DEX-COOL(R). Conventional silicated coolants offered by GM Service and Parts Operations are green in color. ^ If available, use the approved cooling system flush and fill machine (available through the GM Dealer Equipment Program) following the manufacturer's operating instructions. ^ If approved cooling systems flush and fill machine is not available, drain coolant and dispose of properly following the draining procedures in appropriate Service Manual. Refill the system using clear, drinkable water and run vehicle until thermostat opens. Repeat and run vehicle three (3) times to totally remove old coolant or until drained coolant is almost clear. Once the system is completely flushed, refill the cooling system to a 50%-60% concentration with a good quality ethylene glycol base engine coolant, P/N 12378560, 1 gal (in Canada, use P/N 88862159 1 L), conforming to GM specification 1825M, or recycled coolant conforming to GM specification 1825M, following the refill procedures in the appropriate Service Manual. If a Service Manual is not available, fill half the capacity of the system with 100% good quality ethylene glycol base (green colored) engine coolant, P/N 12378560 1 gal., (in Canada, use P/N 88862159 1 L) conforming to GM specification 1825M. Then slowly add clear, drinkable water (preferably distilled) to system until the level of the coolant mixture has reached the base of the radiator neck. Wait two (2) minutes and recheck coolant level. If necessary, add clean water to restore coolant to the appropriate level. Once the system is refilled, recheck the coolant concentration using a Refractometer J 23688 (Fahrenheit scale) or J 26568 (centigrade scale) coolant tester, or equivalent. Concentration levels should be between 50% and 65%. Parts Information Warranty Information Page 8040 Electronic Brake Control Module (ECBCM) - C2 (10/20 Series w/o HP2 Diagrams Headlamp Switch: Diagrams Headlamp Switch Part 1 Page 1762 Air Bag Deactivation Switch: Service and Repair INFLATABLE RESTRAINT INSTRUMENT PANEL (I/P) MODULE DISABLE SWITCH REPLACEMENT REMOVAL PROCEDURE CAUTION: Refer to SIR Caution in Service Precautions. 1. Remove the instrument panel trim bezel. 2. Remove the I/P module switch from the lower right opening of the switch plate panel. 3. Disconnect the I/P module switch electrical connector. INSTALLATION PROCEDURE 1. Connect the I/P module switch electrical connector. 2. Install the I/P module switch into the lower right opening of the switch plate panel. 3. Install the instrument panel trim bezel. Page 7225 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors USING CONNECTOR TEST ADAPTERS IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-B Connector Test Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Page 15024 Notice: When installing the new support cable, make sure that the left side (LS) is installed on the left (driver's) side of the vehicle, and the right side (RS) is installed on the right (passenger) side. The support cables are marked with an LS or RS on the end of the cable that attaches to the tailgate. Installing a support cable on the incorrect side of the vehicle may result in the cable getting damaged when the tailgate is closed. 9. Install one new flat washer on the bolt followed by a new support cable. The end of the support cable should go over the washer and onto the shoulder of the bolt. 10. Install the bolt, flat washer, and cable assembly into the latch and tailgate. Tighten Tighten the bolt to 25 Nm (18 lb-ft). 11. If the other bolt was loosened earlier, Tighten Tighten the bolt to 25 Nm (18 lb-ft). 12. Verify that the support cable end rotates freely on the bolt. 13. Attach the opposite end of the support cable to the pickup box. 14. Repeat the procedure on the other support cable~ Important: Depending on the condition of the tailgate and related parts, one of the two new support cables (either left or right) may NOT be tight (taut) when the tailgate is fully open. This condition may be caused by several factors including a damaged hinge, pickup box, or the tailgate itself may be slightly bent due to overloading at some previous time. Replacing either or both support cables a second time will NOT correct this condition. Replacement of any additional parts to correct this condition will NOT be covered under this recall. 15. Remove the tailgate support, close, open and re-close the tailgate. Verify that the support cables fold properly. Locations Upper Steering Column Page 16224 Front Door Window Glass Weatherstrip: Service and Repair Door Window Weatherstrip Weatherstrip Replacement - Front Door Window Removal Procedure 1. Remove the door trim panel. 2. Remove the water deflector. 3. Remove the window. 4. Remove the screws. 5. Pull the weatherstrip from the following locations: * The front of the glass run channel * The top of the window frame flange * The rear of the glass run channel 6. Remove the weatherstrip from the door. Installation Procedure 1. Install the weatherstrip to the following locations: * The front of the glass run channel * The top of the window frame flange * The rear of the glass run channel Notice: Refer to Fastener Notice in Service Precautions. 2. Install the bolts. Tighten to 6 N.m (53 lb in). 3. Install the window. 4. Install the water deflector. 5. Install the door trim panel. 6. Inspect operation of window. Page 2517 Fluid - Transfer Case: Service and Repair Transfer Case - NVG 261-NP2 Transfer Case Fluid Replacement Removal Procedure Important: When performing the following service procedures, use only hand tools in order to remove and install the fill or drain plugs. Always start the plugs by hand in order to prevent cross threading. 1. Remove the transfer case shield, if equipped. 2. Remove the fill plug. 3. Remove the drain plug. Installation Procedure Notice: Refer to Fastener Notice in Service Precautions. Important: If the drain or fill plug have to be replaced, use only aluminum replacement drain plugs. Steel plugs will react with the magnesium of the transfer case. 1. Install the drain plug. ^ Tighten the plug to 20 Nm (15 ft. lbs.). 2. Fill the transfer case to the bottom of the fill plug hole with the approved transfer case fluid. Page 10881 Electrical Symbols Part 3 Specifications Parking Brake Backing Plate: Specifications Backing Plate Bolts .............................................................................................................................. ................................................ 135 Nm (100 ft. lbs.) Interior - Loose/Unwanted Seat Movement Seat Track: All Technical Service Bulletins Interior - Loose/Unwanted Seat Movement Bulletin No.: 05-08-50-012A Date: July 24, 2006 TECHNICAL Subject: Unwanted/Loose Seat Movement (Apply Adhesive and Install New Bolts in Seat Mounting Rails) Models: 2002-2006 Cadillac Escalade, Escalade EXT 2003-2006 Cadillac ESV 1999-2007 Chevrolet Silverado Pickup Models (Classic) 2000-2006 Chevrolet Suburban, Tahoe 2002-2006 Chevrolet Avalanche 1999-2007 GMC Sierra Pickup Models (Classic) 2000-2006 GMC Yukon, Yukon XL 2003-2006 HUMMER H2 with Power Driver Front Seat Power Adjuster (RPO AG1) and/or Passenger Seat Power Adjuster (RPO AG2) Supercede: This bulletin is being revised to add model years and additional Warranty Information. Please discard Corporate Bulletin Number 05-08-50-012 (Section 08 - Body and Accessories). Condition Some customers may comment on unwanted seat movement in the front power bucket seat (driver or passenger) during fast acceleration or hard braking. A metal to metal clicking noise is often heard at seat "stops." Cause The threads of the two zinc nut retainers (one on each side of the seat adjuster) may creep over time, causing a loss of self-rolling screw clamp load and ultimately causes relative rail and vehicle seat motion. Correction Apply adhesive and install new bolts in seat mounting rails using the following procedure. 1. Remove the front seat and invert onto a flat surface covered with a clean, non-scratch material (soft cloth or similar). Refer to the applicable Seats sub-section in SI. Adjust so that the seat mounting rails are at 45 degrees. 2. Remove the upper M8 mounting bolt from one rail and discard. Leave the other bolt intact as this will hold the track in place while working. Wipe the bolt hole area with a clean rag. Important: Only use the adhesive provided in the repair kit. Do not substitute with other adhesives. Page 7656 Seals and Gaskets: Service and Repair Transfer Case - NVG 261-NP2 Transfer Case Output Shaft Seal Replacement - Front Transfer Case Output Shaft Seal Replacement - Front ^ Tools Required J 8092 Drive Handle - J 43484 Output Shaft Seal Installer Removal Procedure 1. Remove the transfer case shield, if equipped. 2. Remove the front propeller shaft. 3. Insert a flat-tipped screwdriver into the inner race. 4. Pry the inner race back. 5. Insert a small pry bar into the inner race. 6. Remove the inner part of the seal. Service and Repair Global Positioning System Module: Service and Repair COMMUNICATION INTERFACE MODULE REPLACEMENT REMOVAL PROCEDURE IMPORTANT: The vehicle communication interface module (VCIM) has a specific set of unique numbers that tie the module to each vehicle. These numbers, the 10-digit station identification (STID) and the 11-digit electronic serial number (ESN), are used by the National Cellular Network and Onstar(R) to identify the specific vehicle. Because these numbers are tied to the vehicle identification number of the vehicle, you must never exchange these parts with those of another vehicle. 1. Remove the instrument panel (I/P) top trim panel. 2. Disconnect the wire connectors (2) from the module. 3. Disconnect the coaxial cable (3) from the module. 4. Remove the nuts (2) retaining the module to the bracket. 5. Remove the module (3) from the vehicle. INSTALLATION PROCEDURE 1. If replacing the VCIM, record the 10-digit STID number, and the 11-digit ESN number from the labels on the new module. Page 4826 2. Connect the MAP sensor electrical connector (1). 3. Install the engine sight shield. Page 13433 Control Module References Part 4 Page 7191 1. Install the control lever insulator, if removed. 2. Install the control lever boot to the control lever, if removed. 3. Install the control lever. 4. If alignment of the control lever is necessary, or if the shift lever assembly was replaced perform the following: 1. The nut must be seated at the bottom of the thread runout on the shift lever. 2. Seat the control lever against the shift lever assembly adjustment nut. 3. Back the control lever off the nut in order to align the index mark on the control lever perpendicular to the edge of the control lever boot retainer. 4. Ensure that the index mark is located on the passenger side and that the shift pattern is aligned parallel to the vehicle centerline or rotated no more than 6 degrees clockwise. 5. Notice: Refer to Fastener Notice in Service Precautions. Hold the control lever and tighten the shift lever assembly nut against the control lever. ^ Tighten the nut to 37 Nm (27 inch lbs.). 5. Seat the control lever boot to the floor. 6. Install the control lever boot screws, if removed. ^ Tighten the screws to 1.6 Nm (14 inch lbs.). 7. Install the control lever boot retainer, if removed. 8. Install the control lever boot retainer plastic retainers, if removed. Page 6895 7. On axles with a locking differential, remove the shaft part way. Rotate the case until the pinion shaft touches the housing. 8. On axles with a locking differential, use a screwdriver, or a similar tool, in order to enter the differential case and rotate the lock (1) until the lock aligns with the thrust block (2). 9. Push the flange of the axle shaft (1) toward the differential. 10. Remove the C-lock (4) from the button end of the axle shaft (1). 11. Important: When removing the axle shaft, do not rotate the shaft. Rotating the shaft will misalign the gears. Misaligning the gears will make the assembly difficult. Remove the axle shaft (1) from the housing (5). Page 4893 Page 3614 Engine Coolant Temperature (ECT) Sensor Page 4067 For vehicles repaired under warranty, use the table. Disclaimer Page 15316 Parts Information Parts are currently available from GMSPO. Warranty Information Page 1003 Steps 15 - 18 Striker Replacement - Lower Rear Door Striker: Service and Repair Striker Replacement - Lower Striker Replacement - Lower Removal Procedure 1. Open the side access door. 2. Remove the lower door striker bolts. 3. Remove the lower door striker from the vehicle. Installation Procedure 1. Install the lower door striker to the vehicle. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the lower door striker bolts. Tighten the lower door striker bolts to 24 N.m (18 lb ft). Page 13036 Page 7627 Pay particular attention to the terminal connections at the module. Spread or open terminal connections may create an intermittent contact. Do a pin drag test. Refer to the terminal testing information in the table shown. ^ After repairs are complete, ALWAYS clear DTCs from the module prior to a system function test. If codes are not cleared first, the system will not function after repair. The technician may erroneously think that the system is still down and that further repairs are needed. Warranty Dealers who unnecessarily replace the TCCM that are found to have No Trouble Found (NTF) at the WPC will be returned to the AVM (Area Service Manager), or the DSM (District Service Manager) in Canada, through the Regional Feedback Process and may be charged back for the repair through the WINS system. Disclaimer Page 7758 2. Connect the speed sensor electrical connector (4). 3. Lower the vehicle. Page 1702 Accelerator Pedal Position (APP) Sensor Part 2 Page 8195 Brake Rotor/Disc: Specifications Page 14216 Disclaimer Interior - Front Seat Arm Rest Hinge Broken Arm Rest: All Technical Service Bulletins Interior - Front Seat Arm Rest Hinge Broken Bulletin No.: 06-08-50-004A Date: July 28, 2006 TECHNICAL Subject: Front Seat Armrest Hinge Breaking (Replace Lid) Models: 2003-2006 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2003-2006 GMC Sierra, Yukon, Yukon XL with Front Split Seat (RPO AE7) Supercede: This bulletin is being revised to include RPO Code and interior trim color code information. Please discard Corporate Bulletin Number 06-08-50-004 (Section 08 - Body and Accessories). Condition Some customers may comment that the lid for the armrest is broken. Correction Replace the armrest lid using the procedure below. 1. Open the armrest lid. 2. Remove the armrest inner panel. Use a flat-bladed screwdriver and place it between the two panels and pull to separate. 3. Fold the seat backs to gain access to the hinge pin. Using a punch, push the hinge pin out. 4. Install the two springs into the new armrest lid. 5. Align the two springs and the lid to the armrest and install the pin. 6. Install the inner lid to the armrest and close the lid. 7. Place the seat back in the upright position. Page 10703 Wheel Bearing: Testing and Inspection Wheel Bearings Diagnosis Test 1-7 Page 9705 C103 I/P Harness To Forward Lamp Harness (Export) Page 11779 Disclaimer Page 6871 20. Remove the collapsible spacer. 21. Remove the inner pinion bearing from the pinion using the J 22912-01 and a hydraulic press. 22. Remove the outer pinion bearing cup using a hammer and a brass drift in the slots provided.Move the drift back and forth between one side of the cup and the other in order to work the cups out of the retainer evenly. 23. Remove the inner pinion bearing cup using a hammer and a brass drift in the slots provided.Move the drift back and forth between one side of the cup and the other in order to work the cups out of the retainer evenly. Installation Procedure Page 912 Control Module References Part 7 Page 13854 Page 7477 Case: Service and Repair Transfer Case - NVG 246-NP8 Transfer Case Shield Replacement Removal Procedure 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. If the vehicle is a 1500 series, remove the transfer case shield bolts, if equipped. 3. Remove the transfer case shield, if equipped. 4. If the vehicle is a 2500 series, remove the transfer case shield screws, if equipped. 5. Remove the transfer case shield, if equipped. Installation Procedure 1. If the vehicle is a 2500 series, position the transfer case shield, if equipped. 2. Install the transfer case shield screws, if equipped. Page 12577 Page 829 Junction Block - I/P Wire Entry Part 3 Page 513 Driver Door Module (DDM) - C2 (With RPO Code YE9) Part 1 Page 1539 Air Induction Components Electrical - Aftermarket Fuse Warning Fuse: All Technical Service Bulletins Electrical - Aftermarket Fuse Warning Bulletin No.: 07-08-45-002 Date: September 05, 2007 ADVANCED SERVICE INFORMATION Subject: Service Alert: Concerns With Aftermarket Fuses in GM Vehicles Models: 2008 and Prior GM Passenger Cars and Light Duty Trucks (including Saturn) 2008 and Prior HUMMER H2, H3 2008 and Prior Saab 9-7X Concerns with Harbor Freight Tools "Storehouse" Branded Blade Type Fuses General Motors has become aware of a fuse recall by Harbor Freight Tools/Storehouse for a variety of aftermarket fuses. In two cases, these fuses have not provided protection for the wiring system of the vehicles they were customer installed in. Upon testing the 15 amp version, it was found that the fuse still would not "open" when shorted directly across the battery terminals. How to Identify These Fuses Packed in a 120 piece set, the fuse has a translucent, hard plastic, blue body with the amperage stamped into the top. There are no white painted numbers on the fuse to indicate amperage. There are no identifying marks on the fuse to tell who is making it. The fuses are known to be distributed by Harbor Freight Tools but there may be other marketers, and packaging of this style of fuse. It would be prudent to replace these fuses if found in a customers vehicle. Likewise, if wiring overheating is found you should check the fuse panel for the presence of this style of fuse. All GM dealers should use genuine GM fuses on the vehicles they service. You should also encourage the use of GM fuses to your customers to assure they are getting the required electrical system protection. GM has no knowledge of any concerns with other aftermarket fuses. If additional information becomes available, this bulletin will be updated. Disclaimer Page 12769 THIS PROGRAM IS IN EFFECT UNTIL APRIL 30, 2011. Condition Certain 2002-2009 model year vehicles equipped with OnStar(R) may have a condition in which the vehicle's OnStar(R) system repeatedly makes incomplete calls to OnStar(R) without the vehicle's occupant(s) input or knowledge. Customer initiated Blue Button call, Emergency calls, and Automatic Crash Notification calls will also fail to establish a data connection with the OnStar(R) Call Center. Eventually, the customer's call will connect as a voice only line and the customer will be able to talk with an OnStar(R) advisor; however, the advisor will not get crucial customer data such as vehicle identification and location. Correction Dealers/retailers are to replace the OnStar(R) module (VCIM). Vehicles Involved Involved are certain 2002-2009 model year vehicles equipped with OnStar(R), and built within these VIN breakpoints: Note: Some model years/models have only one vehicle involved. Important Dealers/retailers are to confirm vehicle eligibility prior to beginning repairs by using GMVIS (dealers/retailers using WINS) or the Investigate Vehicle History link (dealers/retailers using GWM). Not all vehicles within the above breakpoints may be involved. For dealers/retailers with involved vehicles, a listing with involved vehicles containing the complete vehicle identification number, customer name, and address information has been prepared and will be provided to dealers/retailers through the GM GlobalConnect Recall Reports. Dealers/retailers will not have a report available if they have no involved vehicles currently assigned. The listing may contain customer names and addresses obtained from Motor Vehicle Registration Records. The use of such motor vehicle registration data for any purpose other than follow-up necessary to complete this program is a violation of law in several states/provinces/countries. Accordingly, you are urged to limit the use of this report to the follow-up necessary to complete this program. Parts Information US: OnStar(R) modules required for this program are to be obtained by contacting Autocraft Electronics via the web at www.autocraft.com, and selecting the catalog item that contains bulletin number 10037 (or PIC 4893B), or by calling 1-800-336-3998. Dealer must provide the VIN, R.O. number, and the current vehicle mileage. Canada: OnStar(R) modules required for this program are to be obtained by contacting MASS Electronics at 1-877-410-6277. Dealer must provide the VIN, R.O. number, and the current vehicle mileage. DO NOT ORDER ONSTAR(R) MODULES FROM GENERAL MOTORS CUSTOMER CARE AND AFTERSALES (GMCC&A;), SATURN SERVICE PARTS OPERATION (SSPO), OR THE TECHNICAL ASSISTANCE CENTER (TAC). Courtesy Transportation The General Motors Courtesy Transportation program is intended to minimize customer inconvenience when a vehicle requires a repair that is covered by the New Vehicle Limited Warranties. The availability of courtesy transportation to customers whose vehicles are within the warranty coverage period and involved in a product program is very important in maintaining customer satisfaction. Dealers/retailers are to ensure that these customers understand that shuttle service or some other form of courtesy transportation is available and will be provided at no charge. Dealers should refer to the General Motors Service Policies and Procedures Manual for Courtesy Transportation guidelines. Claim Information 1. Submit a claim using the table below. 2. Courtesy Transportation - For dealers/retailers using WINS, submit using normal labor code; for dealers/retailers using GWM - submit as Net Item under the repair labor code. Body - Dimple In Body Side Molding(s) Upper Side Moulding / Trim: All Technical Service Bulletins Body - Dimple In Body Side Molding(s) Bulletin No.: 04-08-111-002B Date: October 26, 2006 TECHNICAL Subject: Dimple in Body Side Molding (Replace Moldings) Models: 2004 Chevrolet Avalanche without Body Hardware (RPO WBH) 2004 Chevrolet Silverado, Suburban, Tahoe with Body/Side Exterior-Molding-in-Color (RPO B85) Supercede: This bulletin is being revised to change the Warranty and add a revised parts information statement. Please discard Corporate Bulletin Number 04-08-111-002A (Section 08 - Body and Accessories). Condition Some customers may comment on a raised surface or a dimple in the exterior molded-in-color body side door moldings. This condition may be more pronounced in warmer climates. This does not apply to standard colored keyed black body side moldings. Cause Engineering has determined that this condition may be caused by a bar code label on the backside of the molding that dimples the molding. Correction Replace ALL of the exterior body side door moldings. Refer to Molding Replacement-Body Side procedure in SI. Dealer Action Please contact all customers that were told they would be called when a repair became available. Parts Information NV 3500 Fluid - M/T: Service and Repair NV 3500 Transmission Fluid Replacement ^ Tools Required J 36511 Oil Fill/Drain Plug Hex Bit (17 MM) Removal Procedure 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. Using J 36511 remove the oil fill plug. 3. Place a suitable drain pan under the transmission in order to catch the drained transmission fluid. 4. Using J 36511 remove the oil drain plug. 5. Remove any old sealant from the transmission housing. Installation Procedure Description and Operation Speedometer Head: Description and Operation SPEEDOMETER The IPC displays the vehicle speed on the analog speedometer based on the vehicle speed signal from the PCM. The PCM converts the data from the vehicle speed sensor to a 4,000 pulses/mile signal. The IPC uses the vehicle speed signal circuit from the PCM in order to calculate the vehicle speed. The speedometer defaults to 0 km/h (0 mph) if a malfunction in the vehicle speed signal circuit exists. Page 7108 5. Notice: Refer to Fastener Notice in Service Precautions. Install the engine flywheel bolts. 1. Tighten the bolts a first pass in sequence to 20 Nm (15 ft. lbs.). 2. Tighten the bolts a second pass in sequence to 50 Nm (37 ft. lbs.). 3. Tighten the bolts a final pass in sequence to 100 Nm (74 ft. lbs.). 6. Install the clutch, if equipped with a manual transmission. 7. Install the automatic transmission, if equipped. Page 5695 7. Remove the pressure control solenoid retainer bolt (364A) and retainer (378). 8. Remove the pressure control solenoid (377). 9. Remove the TCC solenoid bolts and the valve body bolts which retain the internal wiring harness. 10. Using J 28458 , release the pass-through electrical connector from the transmission case. 1. Use the small end of the J 28458 over the top of the connector. 2. Twist in order to release the four tabs retaining the connector. 3. Pull the harness connector down through the transmission case. 11. Remove the TCC solenoid (with O-ring seal) and wiring harness. Page 7194 Shift Boot: Service and Repair ZF S6-650 Control Lever and/or Boot Replacement Removal Procedure 1. Remove the control lever. Important: Loosen DO NOT remove the shift lever assembly adjustment nut if replacing the control lever. 2. Remove the control lever boot retainer plastic retainers, if necessary. 3. Remove the control lever boot retainer, if necessary. 4. Remove the control lever boot screws, if necessary. 5. Remove the control lever boot, if necessary. 6. Remove the control lever insulator, if necessary. Installation Procedure Page 1063 Pay particular attention to the terminal connections at the module. Spread or open terminal connections may create an intermittent contact. Do a pin drag test. Refer to the terminal testing information in the table shown. ^ After repairs are complete, ALWAYS clear DTCs from the module prior to a system function test. If codes are not cleared first, the system will not function after repair. The technician may erroneously think that the system is still down and that further repairs are needed. Warranty Dealers who unnecessarily replace the TCCM that are found to have No Trouble Found (NTF) at the WPC will be returned to the AVM (Area Service Manager), or the DSM (District Service Manager) in Canada, through the Regional Feedback Process and may be charged back for the repair through the WINS system. Disclaimer Page 9269 Application Table Page 12320 Electrical Symbols Part 11 Page 384 2. Skip to the next step if the vehicle to be upgraded is not shown above. 3. Skip to the next step if the vehicle to be upgraded is not a 2005 Cadillac STS. The 2005 Cadillac STS kit may include a new inside rearview (ISRV) mirror assembly and a new ISRV mirror wiring cover. If the kit you receive includes these parts, please remove the existing ISRV mirror and wire cover from the vehicle and install the ones provided in the kit per the instructions in SI. 4. Skip this step if the vehicle to be upgraded is not listed below. ^ 2003-2004 Saturn L-Series ^ 2003 Saturn ION ^ 2002-2003 Saturn VUE 1. Locate and remove the Right Audio output signal terminal 7 from Connector C2 at the Vehicle Communication Interface Module (VCIM). 2. Remove the terminal end and strip the wire. 3. Locate the Left Audio output signal wire from terminal 1 in Connector C2. 4. Splice the Right Audio output signal wire from terminal 7 with the Left Audio output signal wire from terminal 1. 5. See Wiring Repairs in SI for approved splicing methods. Page 3925 Accelerator Pedal Position Sensor: Service and Repair ACCELERATOR PEDAL POSITION (APP) SENSOR REPLACEMENT REMOVAL PROCEDURE NOTE: Handle the electronic throttle control components carefully. Use cleanliness in order to prevent damage. Do not drop the electronic throttle control components. Do not roughly handle the electronic throttle control components. Do not immerse the electronic throttle control components in cleaning solvents of any type. 1. Remove the connector position assurance (CPA) retainer. 2. Disconnect the accelerator pedal position (APP) sensor electrical connector. 3. Reposition the carpet to access the lower nut. 4. Remove the accelerator pedal nuts. 5. Remove the accelerator pedal assembly. INSTALLATION PROCEDURE Page 2619 Fuse: Application and ID Fuse Block - Underhood Location View Page 2753 Junction Block - Rear Lamps - C4 Page 15322 Fuel Pump/Sender Assembly - Secondary Service and Repair Grille: Service and Repair Grille Replacement (Chevrolet) Removal Procedure 1. Open the hood. 2. Remove the upper air baffle. 3. Remove the headlamp. 4. Release the side grille retainer (1) from the fender (2). Remove the grille from the vehicle. 5. Release the upper grille retainer (1) and the lower grille retainer (2) from the vehicle. Installation Procedure Page 15977 Heated Glass Element: Electrical Diagrams Defogger Diagram Page 779 The 1999 though early 2003 wiring harness jumper that plugs into the relay block will have a reddish/brown 6-way connector and a tag with the last four digits of the wiring harness part number. Second design 2003-05 may have a white plastic connector with part number 5418 as well. ^ The 1999 jumper is/was P/N 12171982 with a pink/purple tag identifier of 1982. This number has been superseded to 15366255, with a pink/purple tag identifier of 6255. ^ The 2000 jumper harness is P/N 15366255. The pink/purple tag identifier is 6255. ^ The 2001-2002 jumper is P/N 15086884. The orange tag identifier is 6884. ^ The 2003-05 jumper is P/N 15085418. The orange tag identifier is 5418. When transferring the brake controller with the wiring jumper attached from a 2001-2002 vehicle to a 2003-05 vehicle, a change to the jumper harness connector must be performed. Page 6407 1. Lubricate the output speed sensor seal with automatic transmission fluid. 2. Install the output speed sensor (2). Notice: Refer to Fastener Notice in Service Precautions. 3. Install the output speed sensor bolt. ^ Tighten the bolt to 11 Nm (96 inch lbs.). 4. Connect the output speed sensor (2) electrical connector. 5. Lower the vehicle. Page 9697 For vehicles repaired under warranty, use the table. Disclaimer Page 6059 1. Install J 25025 into the valve body bolt hole where the manual shaft detent roller and spring is mounted. 2. Install the valve body gasket (2) onto the accumulator housing (1). 3. Install the valve body spacer plate (3) onto the valve body gasket (2). 4. Install the third and fourth clutch accumulator housing gasket (3). 5. Install the third clutch accumulator piston spring (1). This spring is the longer of the two springs. 6. Install the fourth clutch accumulator piston spring (4). 7. Install the third and fourth clutch accumulator housing assembly (5) onto the control valve body assembly (2). 8. Install the six accumulator housing bolts (6). Start the bolts finger tight and work towards the opposite end. 9. Notice: Refer to Fastener Notice in Service Precautions. Tighten the accumulator housing bolts sequentially. ^ Tighten the bolts to 11 Nm (97 inch lbs.). 10. Remove the J 25025. 11. Install the valve body. Page 2485 Fluid - M/T: Service and Repair NV 4500 Transmission Fluid Replacement Removal Procedure 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. Remove the oil fill plug. 3. Place a suitable drain pan under the transmission in order to catch the drained transmission fluid. 4. Remove the oil drain plug. 5. Remove any old sealant from the transmission housing. Installation Procedure 1. Apply a thin bead of sealant GM P/N 12346004 (Canadian P/N 10953480), or equivalent to the oil drain and fill plug threads. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the oil drain plug. ^ Tighten the plug to 37 Nm (27 ft. lbs.). Page 8344 3. Important: Install a rubber cap or plug to the exposed brake pipe fitting ends in order to prevent brake fluid loss and contamination. Disconnect the brake pipes from the master cylinder. 4. Plug the open brake pipe ends. 5. Remove the master cylinder mounting nuts. 6. Remove the master cylinder from the vehicle. 7. Remove the master cylinder reservoir. Installation Procedure 1. Install the master cylinder reservoir. 2. Bench bleed the master cylinder. 3. Install the master cylinder to the vehicle. 4. Notice: Refer to Fastener Notice in Service Precautions. Install the master cylinder mounting nuts. ^ Tighten the nuts to 33 Nm (24 ft. lbs.). 5. Remove the rubber cap or plug from the exposed brake pipe fitting ends. 6. Connect the brake pipes. ^ Tighten the pipe fittings to 25 Nm (18 ft. lbs.). 7. Connect the electrical connector to the brake fluid level sensor. 8. Bleed the hydraulic brake system. Page 15958 9. Use J 38125-12A to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. REPAIR PROCEDURE The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. 1. Cut the wire as close to the terminal as possible. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. Page 7306 Pay particular attention to the terminal connections at the module. Spread or open terminal connections may create an intermittent contact. Do a pin drag test. Refer to the terminal testing information in the table shown. ^ After repairs are complete, ALWAYS clear DTCs from the module prior to a system function test. If codes are not cleared first, the system will not function after repair. The technician may erroneously think that the system is still down and that further repairs are needed. Warranty Dealers who unnecessarily replace the TCCM that are found to have No Trouble Found (NTF) at the WPC will be returned to the AVM (Area Service Manager), or the DSM (District Service Manager) in Canada, through the Regional Feedback Process and may be charged back for the repair through the WINS system. Disclaimer Locations Canister Vent Valve: Locations Evaporative Emission (EVAP) Canister Vent Solenoid Page 4528 Information Bus: Electrical Diagrams Data Link Connector (DLC) Diagram 1 Page 6907 6. Install the tripot spider assembly (3) onto the halfshaft bar (2). 7. Install the spacer ring (1) in the groove at the end of the halfshaft bar (2). Page 2975 Disclaimer Page 8245 Brake Bleeding: Service and Repair Hydraulic Brake System Bleeding (Manual) Hydraulic Brake System Bleeding (Manual) Caution: Refer to Brake Fluid Irritant Caution in Service Precautions. Notice: Refer to Brake Fluid Effects on Paint and Electrical Components Notice in Service Precautions. Notice: When adding fluid to the brake master cylinder reservoir, use only Delco Supreme 11, GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. The use of any type of fluid other than the recommended type of brake fluid, may cause contamination which could result in damage to the internal rubber seals and/or rubber linings of hydraulic brake system components. 1. Place a clean shop cloth beneath the brake master cylinder to prevent brake fluid spills. 2. With the ignition Off and the brakes cool, apply the brakes 3-5 times, or until the brake pedal effort increases significantly, in order to deplete the brake booster power reserve. 3. If you have performed a brake master cylinder bench bleeding on this vehicle, or if you disconnected the brake pipes from the master cylinder, you must perform the following steps: 1. Ensure that the brake master cylinder reservoir is full to the maximum-fill level. If necessary add Delco Supreme 11, GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container.If removal of the reservoir cap and diaphragm is necessary, clean the outside of the reservoir on and around the cap prior to removal. 2. With the rear brake pipe installed securely to the master cylinder, loosen and separate the front brake pipe from the front port of the brake master cylinder. 3. Allow a small amount of brake fluid to gravity bleed from the open port of the master cylinder. 4. Reconnect the brake pipe to the master cylinder port and tighten securely. 5. Have an assistant slowly depress the brake pedal fully and maintain steady pressure on the pedal. 6. Loosen the same brake pipe to purge air from the open port of the master cylinder. 7. Tighten the brake pipe, then have the assistant slowly release the brake pedal. 8. Wait 15 seconds, then repeat steps 3.3-3.7 until all air is purged from the same port of the master cylinder. 9. With the front brake pipe installed securely to the master cylinder - after all air has been purged from the front port of the master cylinder loosen and separate the rear brake pipe from the master cylinder, then repeat steps 3.3-3.8. 10. After completing the final master cylinder port bleeding procedure, ensure that both of the brake pipe-to-master cylinder fittings are properly tightened. 4. Fill the brake master cylinder reservoir with Delco Supreme 11, GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. Ensure that the brake master cylinder reservoir remains at least half-full during this bleeding procedure. Add fluid as needed to maintain the proper level.Clean the outside of the reservoir on and around the reservoir cap prior to removing the cap and diaphragm. 5. Install a proper box-end wrench onto the RIGHT REAR wheel hydraulic circuit bleeder valve. 6. Install a transparent hose over the end of the bleeder valve. 7. Submerge the open end of the transparent hose into a transparent container partially filled with Delco Supreme 11, GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. 8. Have an assistant slowly depress the brake pedal fully and maintain steady pressure on the pedal. 9. Loosen the bleeder valve to purge air from the wheel hydraulic circuit. 10. Tighten the bleeder valve, then have the assistant slowly release the brake pedal. 11. Wait 15 seconds, then repeat steps 8-10 until all air is purged from the same wheel hydraulic circuit. 12. With the right rear wheel hydraulic circuit bleeder valve tightened securely - after all air has been purged from the right rear hydraulic circuit install a proper box-end wrench onto the LEFT REAR wheel hydraulic circuit bleeder valve. 13. Install a transparent hose over the end of the bleeder valve, then repeat steps 7-11. 14. With the left rear wheel hydraulic circuit bleeder valve tightened securely - after all air has been purged from the left rear hydraulic circuit - install a proper box-end wrench onto the RIGHT FRONT wheel hydraulic circuit bleeder valve. 15. Install a transparent hose over the end of the bleeder valve, then repeat steps 7-11. 16. With the right front wheel hydraulic circuit bleeder valve tightened securely - after all air has been purged from the right front hydraulic circuit install a proper box-end wrench onto the LEFT FRONT wheel hydraulic circuit bleeder valve. 17. Install a transparent hose over the end of the bleeder valve, then repeat steps 7-11. 18. After completing the final wheel hydraulic circuit bleeding procedure, ensure that each of the 4 wheel hydraulic circuit bleeder valves are properly tightened. 19. Fill the brake master cylinder reservoir to the maximum-fill level with Delco Supreme 11, GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. 20. Slowly depress and release the brake pedal. Observe the feel of the brake pedal. 21. If the brake pedal feels spongy, repeat the bleeding procedure again. If the brake pedal still feels spongy after repeating the bleeding procedure, Page 11920 8.5. Close the luggage compartment floor. 9. Fold down the left-hand rear side hatch in the luggage compartment. 10. M03: Replace the optic cable on the left-hand rear side: 10.1. Place the optic cable so that it is positioned behind the terminal housing on top of REC (A). 10.2. Remove the locking strip (B) on the 2-pin connector (H2-9) for the optic cable. 10.3. Open the terminal housing (C) with a screwdriver. Remove the secondary catch (D) on the connector and disconnect the optic cable coming from the OnStar(R) control modules. Locations Mass Air Flow (MAF) Sensor: Locations Right Side Of The Engine Compartment Page 13228 Diagnostic Trouble Codes DTC U1000 and U1255 Circuit/System Description Modules connected to the Class 2 serial data circuit monitor for serial data communications during normal vehicle operation. Operating information and commands are exchanged among the modules. When a module receives a message for a critical operating parameter, the module records the identification number of the module which sent the message for State of Health monitoring. A critical operating parameter is one which, when not received, requires that the module use a default value for that parameter. When a module does not associate an identification number with at least one critical parameter within 5 seconds of beginning serial data communication, DTC U1000 or U1255 DTC is set. When more than one critical parameter does not have an identification number associated with it, the DTC will only be reported once. The Class 2 serial data communications circuit on this vehicle are in a hybrid ring and star configuration. Each module on the ring has 2 serial data circuits connected to it, except the following modules which have only 1 serial data circuit connected them: Page 10267 Steering Mounted Controls Transmitter: Electrical Diagrams Steering Wheel Controls Diagram Page 9580 Junction Block - I/P - C4 Part 2 Page 12422 Memory/Heated Seat Switch - Driver (DDM C5) Part 2 A/T - No Movement in Drive or 3rd Gear Clutch: Customer Interest A/T - No Movement in Drive or 3rd Gear TECHNICAL Bulletin No.: 08-07-30-027 Date: June 04, 2008 Subject: No Movement When Transmission is Shifted to Drive or Third - Normal Operation When Shifted to Second, First or Reverse (Replace Forward Sprag Assembly) Models: 1982 - 2005 GM Passenger Cars and Light Duty Trucks 2006 - 2007 Buick Rainier 2006 Cadillac Escalade, Escalade ESV, Escalade EXT 2006 Chevrolet SSR 2006 - 2008 Chevrolet Avalanche, Colorado, Express, Silverado Classic, Silverado, Suburban, Tahoe, TrailBlazer 2006 GMC Yukon Denali, Yukon Denali XL 2006 - 2008 GMC Canyon, Envoy, Savana, Sierra Classic, Sierra, Yukon, Yukon XL 2006 Pontiac GTO 2006 - 2007 HUMMER H2 2006 - 2008 HUMMER H3 2006 - 2008 Saab 9-7X with 4L60, 4L60E, 4L65E or 4L70E Automatic Transmission (RPOs MD8, M30, M32, M33 or M70) Condition Some customers may comment that the vehicle has no movement when the transmission is shifted to DRIVE or THIRD position, but there is normal operation when it is shifted to SECOND, FIRST or REVERSE position. Cause This condition may be caused by a damaged forward sprag assembly (642). Correction When inspecting the sprag, it is important to test the sprag for proper operation by holding the outer race (644) with one hand while rotating the input sun gear (640) with the other hand. The sun gear should rotate only in the counterclockwise direction with the input sun gear facing upward. If the sprag rotates in both directions or will not rotate in either direction, the sprag elements should be inspected by removing one of the sprag assembly retaining rings (643). Refer to SI Unit Repair section for forward clutch sprag disassembly procedures. If the sprag is found to be damaged, make repairs to the transmission as necessary. A new forward roller clutch sprag assembly is now available from GMSPO. Page 14645 Power Seat Switch: Diagrams Seat Adjuster Switch - Driver (With RPO Code AN3) Part 1 Page 8917 Auxiliary Power Outlet: Electrical Diagrams Cigar Lighter/Auxiliary Outlets Diagram 1 Description and Operation Evaporative System Service Port: Description and Operation EVAP SERVICE PORT The EVAP service port is located in the EVAP purge pipe between the EVAP purge solenoid valve and the EVAP canister. The service port is identified by a green colored cap. Page 10492 Do not reuse the nut. A new nut must be used when installing the wheel drive shaft. Remove the wheel driveshaft assembly retaining nut (2) and washer (3) from the wheel driveshaft. 7. Disengage the wheel drive shaft from the wheel hub and bearing using J 45859 or equivalent. 8. Remove the wheel hub and the 15-series bearing mounting bolts (4). 9. Remove the wheel hub and bearing (4) mounting bolts, 25/35 series. 10. Remove the wheel hub and bearing and splash shield from the vehicle. 11. Remove the O-ring seal from the steering knuckle bore, 25/35 series. 12. Remove the wheel speed sensor mounting bolt (5). 13. Clean and inspect the O-ring seal, 25/35 series. 14. Replace the seal if the following conditions exist: ^ Nicks ^ Cuts Electrical - Trailer Brakes Apply With Headlamps ON Trailer Lighting Module: Customer Interest Electrical - Trailer Brakes Apply With Headlamps ON Bulletin No.: 02-05-22-004C Date: April 05, 2005 TECHNICAL Subject: Trailer Brakes Applied When Headlights/Park Lamps Are On, Brake Controller Illumination (Modify Brake Controller Wiring Harness) Models: 2002-2005 Cadillac Escalade, Escalade EXT 1999-2005 Chevrolet Silverado 2000-2005 Chevrolet Suburban, Tahoe 2002-2005 Chevrolet Avalanche 1999-2005 GMC Sierra 2000-2005 GMC Yukon, Yukon XL 2003-2005 HUMMER H2 Supercede: This bulletin is being revised to add additional model years. Please discard Corporate Bulletin Number 02-05-22-004B (Section 05 - Brakes). Condition Some customers may comment that when the headlamps or park lamps are on, the brakes on the trailer are always applied, or that the back lighting for the trailer brake controller only illuminates when the brakes are applied. Cause The cause of this condition may be due to wiring changes within the vehicle electrical system for the 2003 model year. Correction Inspect the brake controller wiring harness jumper that is plugged into the vehicle relay block-body. The relay block-body is located under the left side of the instrument panel near the left kick panel, behind a plastic cover. Page 6844 17. Determine the selective shim thickness for the pinion gear bearing retainer. 18. Apply sealant, GM P/N 1052942 (Canadian P/N 10953466) or equivalent, to sealing surface of the pinion gear bearing retainer. 19. Install the selective shim.Align the tab on the shim with the unmachined surface of the pinion gear bearing retainer. 20. Apply sealant, GM P/N 1052942 (Canadian P/N 10953466) or equivalent, to surface of the selective shim. 21. Install the pinion gear bearing retainer. 22. Install the pinion gear bearing retainer bolts. ^ Tighten the pinion gear bearing retainer bolts to 88 Nm (65 ft. lbs.). 23. Measure the rotating torque of the pinion and the ring gear. Compare this measurement with the rotating torque recorded during removal. The rotating torque of the pinion and the ring gear should be between 3.9-6.2 Nm (30-55 inch lbs.) for new bearings or 2.8-5.6 Nm (25-50 inch lbs.) for used bearings. 24. If the rotating torque of the pinion and the ring gear is not within specifications, adjust the preload of the pinion or the differential side bearings as necessary. 25. Install the propeller shaft (3) to the pinion yoke (4).Align the reference marks made during removal. 26. Install the propeller shaft yoke retaining clamps and the bolts. ^ Tighten the propeller shaft yoke retaining clamp bolts to 25 Nm (18 ft. lbs.). 27. Install the axle shafts. 28. Fill the axle with axle lubricant. 29. Lower the vehicle. Page 5556 Ignition Cable: Service and Repair SPARK PLUG WIRE REPLACEMENT REMOVAL PROCEDURE 1. Remove the spark plug wire from the spark plug. 1.1. Twist the spark plug wire boot a 1/2 turn. 1.2. Pull only on the boot in order to remove the wire from the spark plug. 2. Remove the spark plug wire from the ignition coil. 2.1. Twist the spark plug wire boot a 1/2 turn. 2.2. Pull only on the boot in order to remove the wire from the ignition coil. IMPORTANT: The Melco(R) spark plug wires MUST be used only with the Melco(R) coils and bracket, like wise the Delphi(R) spark plug wires MUST be used only with Delphi(R) coils and bracket. The components are NOT interchangeable. 3. There are 2 different manufacturers for the spark plug wire, ignition coils and coil brackets. They are as follows: 4. The Melco(R) spark plug wire (1) will have a blue foil mark on it, and the wire is 145 mm (5.70 in) in length from cable seal to cable seal. 5. The Delphi(R) spark plug wire (2) will have a white foil mark on it, and the wire is 110 mm (4.30 in) in length cable seal to cable seal. OnStar(R) - Analog/Digital Ready System Digital Upgrade Technical Service Bulletin # 05-08-46-006Q Date: 081028 OnStar(R) - Analog/Digital Ready System Digital Upgrade INFORMATION Bulletin No.: 05-08-46-006Q Date: October 28, 2008 Subject: Information on Upgrading Certain OnStar(R) Analog/Digital-Ready Systems to OnStar(R) Generation 6 Digital-Capable System Models Supercede: This bulletin is being revised to update the upgrade kit installation information for the 2001 Chevrolet Impala and Monte Carlo. Please discard Corporate Bulletin Number 05-08-46-006P (Section 08 - Body and Accessories). This bulletin is being issued to provide dealer personnel with information and procedures to follow should an owner wish to upgrade their OnStar(R) Analog/Digital-Ready system to an OnStar(R) Generation 6 Digital-Capable system. Disclaimer Program Overview Program Overview To upgrade their vehicle to an OnStar(R) Generation 6 Digital-Capable system, all that a customer must do is: ^ Take their vehicle to their dealer for the system upgrade. Below Rear Seat (HP2) Below Rear Seat (HP2) Page 5961 Page 13240 A current DTC clears when the condition for setting the DTC is no longer present. A history DTC clears after 50 malfunction-free ignition cycles. Circuit/System Testing Without RPO UAV 1. Turn OFF the ignition and all electrical components, including the scan tool. 2. Disconnect the harness connector at the cellular microphone. 3. Test for less than 5 Ohms between the low reference circuit terminal A and ground. ^ If greater than the specified range, test the low reference circuit for an open/high resistance. If the circuit tests normal, replace the VCIM. 4. Ignition ON, test for 9 - 11 volts between the signal circuit terminal B and ground. ^ If greater than the specified range, test the signal circuit for a short to voltage. If the circuit tests normal, replace the VCIM. ^ If less than the specified range, test the signal circuit for a short to ground or an open/high resistance. If the circuit tests normal, replace the VCIM. Refer to the appropriate vehicle in SI. 5. If all circuits test normal, test or replace the cellular microphone. Circuit/System Testing With RPO UAV 1. Turn OFF the ignition and all electrical components, including the scan tool. 2. Disconnect the X4 harness connector at the navigation radio and the harness connector at the cellular microphone. 3. Test for less than 5 Ohms between the low reference circuit terminal A and ground. ^ If greater than the specified range, test the low reference circuit for an open/high resistance. If the circuit tests normal, replace the VCIM. Refer to the appropriate vehicle in SI. 4. Ignition ON, test for 9 - 11 volts between the signal circuit terminal B and ground. ^ If greater than the specified range, test the signal circuit for a short to voltage. If the circuit tests normal, replace the VCIM. ^ If less than the specified range, test the signal circuit for a short to ground or an open/high resistance. If the circuit tests normal, replace the VCIM. 5. If all circuits test normal, test or replace the cellular microphone. 6. Connect the X4 harness connector at the navigation radio. 7. With a scan tool, verify that DTC B2455 is not set as current in the navigation radio. ^ If DTC B2455 is set as current, replace the navigation radio. Refer to the appropriate vehicle in SI. DTC B2462, B2483, or B2484 Circuit/System Description The vehicle communication interface module (VCIM) receives information from a specific navigation antenna located on the outside of the vehicle. The navigation antenna is connected to the VCIM via a shielded coaxial cable. The antenna cable also provides a path for DC current for powering the antenna. DTC Descriptors DTC B2462 02: Global Positioning System (GPS) Antenna Malfunction Short to Ground DTC B2462 04: Global Positioning System (GPS) Antenna Malfunction Open Circuit Page 9973 Maintain the sensor position. Do not turn the sensor. Remove the rear wheel position sensor (2) from the steering gear. Installation Procedure 1. Important: Make sure the O-ring (1) is installed. Install the rear wheel position sensor (2) to the steering gear. 2. Important: Be careful to maintain the position of the replacement sensor. Remove the pin retaining the position of the new sensor and immediately install the sensor to the steering gear. 3. Notice: Refer to Fastener Notice in Service Precautions. Install the rear wheel position sensor retaining bolts. Apply LOCTITE 242 blue. ^ Tighten the bolts to 4 Nm (35 inch lbs.). 4. Install the rear wheel position sensor cover (4). 5. Connect the electrical connector (1). 6. Install the steering gear protection shield (1) and retaining bolts (3). ^ Tighten the steering gear protection shield retaining bolts to 180 Nm (132 ft. lbs.). Page 14113 Driver Door Module (DDM) - C3 (With RPO Code YE9) Part 1 Color Compatibility Guide (Paint Codes) Paint: Application and ID Color Compatibility Guide (Paint Codes) COLOR COMPATIBILITY GUIDE (Paint Codes) Page 12947 Remote Control: Description and Operation Steering Wheel Controls STEERING WHEEL CONTROLS Some audio functions are available using the steering wheel controls. The steering wheel controls consist of multiple momentary contact switches that connect a series of resistors. When a steering wheel control button is pressed, a specific resistance value is noted by the body control module (BCM). This results in a generated voltage, unique to the particular button. The BCM alerts the radio that the button has been pressed, and the radio responds, just as if the corresponding radio front panel button had been pressed. Page 12415 1. Position the module into the vehicle. 2. Connect the lower electrical harness connectors (2). 3. Slide the module (2) to the left to engage the lower retainers. NOTE: Refer to Fastener Notice in Service Precautions. 4. Install the module retaining screws (3). Tighten Tighten the screws to 3 N.m (26 lb in). 5. Connect the upper electrical harness connectors (3). 6. Install the seat cushion. 7. If a new memory seat module was installed, calibrate the seat. Refer to Memory Seat Calibration Procedure. Discharge Hose Replacement Hose/Line HVAC: Service and Repair Discharge Hose Replacement DISCHARGE HOSE REPLACEMENT TOOLS REQUIRED J 39400-A Halogen Leak Detector REMOVAL PROCEDURE 1. Recover the refrigerant. Refer to Refrigerant Recovery and Recharging. 2. Remove the discharge hose mounting bolt (2) from the A/C compressor. 3. Remove the discharge hose (1) from the A/C compressor. 4. Remove the upper radiator baffle. 5. Remove the discharge hose nut from the condenser. 6. Remove the discharge hose from the condenser. 7. Disconnect the electrical connector from the A/C recirculation switch. 8. Remove the discharge hose from the vehicle. 9. Discard all of the used sealing washers. Cap the system openings. INSTALLATION PROCEDURE Page 2051 Alignment: Technical Service Bulletins Steering/Suspension - Revised Caster/Camber Adjustment Info - Revised Front Caster and Camber Adjustment Procedure # 02-03-07-002A - (Mar 24, 2005) Models: 1999-2000 Cadillac Escalade 2002-2005 Cadillac Escalade, Escalade EXT 1999-2005 Chevrolet Express, Silverado, Suburban, Tahoe 2002-2005 Chevrolet Avalanche 1999 GMC Suburban 1999-2005 GMC Savana, Sierra, Yukon, Yukon XL, Yukon XL Denali This bulletin is being revised to add model years and clarify the information. Please discard Corporate Bulletin Number 02-03-07-002 (Section 03 - Suspension). When performing a wheel alignment on any of the above vehicles, please refer to the Front Caster and Camber Adjustment Procedure in SI before contacting the GM Technical Assistance Center (TAC) with issues concerning adjustments, caster out-of-spec, etc. Disclaimer Page 2192 Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 7172 1. Position a NEW oil seal in the input shaft bearing retainer. 2. Using J 38801, install the oil seal. 3. Apply a thin bead of RTV sealer GM P/N 12345739 (Canadian P/N 10953472), or equivalent to the input shaft bearing retainer mating surface. 4. Position the input shaft bearing retainer. 5. Align the bearing retainer oil drain hole at the top dead center position. 6. Apply threadlock GM P/N 12345493 (Canadian P/N 10953488), or equivalent to the input shaft bearing retainer bolts. Notice: Refer to Fastener Notice in Service Precautions. 7. Install the input shaft bearing retainer bolts. ^ Tighten the bolts to 22 Nm (16 inch lbs.). Fuel Pressure Gage Installation and Removal Fuel Pressure Release: Service and Repair Fuel Pressure Gage Installation and Removal FUEL PRESSURE GAGE INSTALLATION AND REMOVAL INSTALLATION PROCEDURE TOOLS REQUIRED J 34730-1A Fuel Pressure Gage CAUTION: - Refer to Gasoline/Gasoline Vapors Caution in Service Precautions. - Refer to Fuel Gage Leak Caution in Service Precautions. 1. Remove the engine sight shield. 2. Remove the fuel rail pressure fitting cap. 3. Connect the J 34730-1A to the fuel pressure valve. Wrap a shop towel around the fitting while connecting the gage in order to avoid spillage. 4. Install the bleed hose on J 34730-1A into an approved container. REMOVAL PROCEDURE 1. Remove the bleed hose on the J 34730-1A from the approved container. 2. Remove the shop towel from around the fitting and discard into an approved container. 3. Disconnect the J 34730-1A from the fuel pressure valve. 4. Install the fuel rail pressure fitting cap. 5. Install the engine sight shield. Page 15239 Control Module References Part 5 Page 2021 Control Module References Part 6 Page 5636 Spark Plug: Specifications Spark Plug Torque ............................................................................................................................... ........................................................ 15 Nm (11 lb ft) Spark Plug Gap ................................................ ........................................................................................................................................ 1.01 mm (0.040 in) Page 10051 1. Notice: Refer to Power Steering Hose Disconnected Notice in Service Precautions. Install a drain pan under the vehicle. 2. Remove the power steering gear inlet hose (1) from the brake booster. 3. Remove the power steering gear inlet hose from the power steering gear. 4. Remove the power steering gear inlet hose from the vehicle. Installation Procedure 1. Notice: Refer to Installing Hoses Without Twists or Bends Notice in Service Precautions. Route the hose in the same position the hose occupied prior to removal. 2. Install the power steering gear inlet hose (1) to the brake booster (2). Hand tighten only. 3. Notice: Refer to Fastener Notice in Service Precautions. Install the power steering gear inlet hose to the power steering gear. ^ Tighten both power steering gear inlet hose fittings to 28 Nm (20 ft. lbs.). 4. Remove the drain pan from under the vehicle. 5. Bleed the power steering system. Refer to Bleeding the Power Steering System. (Without Hydroboost) Power Steering Gear Inlet Pipe/Hose Replacement (Without Hydroboost) Removal Procedure 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Remove the engine protection shield. Page 908 Control Module References Part 3 Page 13134 Page 2676 Junction Block - I/P - C7 Page 898 If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Sir/SRS Wiring Repairs SIR/SRS WIRING REPAIRS TOOLS REQUIRED J 38125-D Terminal Repair Kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-D contains the following items: - Special sealed splices - in order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping tool - A heat torch - An instruction manual The sealed splices have the following 2 critical features: - A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-D also serves as a generic terminal repair kit. The kit contains the following items: - A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors Page 9730 C202 I/P Harness To Brake/Clutch Harness Part 1 Page 4410 Remove all rust from the ground terminal, the cylinder head and the retaining nut or bolt. Position the main engine wiring harness ground terminal and install the nut or bolt. Tighten: Tighten the retaining nut or bolt to 16 N.m (12 lb ft). Apply some type of electrical moisture sealant to protect the harness terminal from further corrosion. Disclaimer Page 2334 3. Notice: Refer to Power Steering Hose Disconnected Notice in Service Precautions. Install a drain pan under the vehicle. 4. Remove the power steering gear inlet hose (3) from the power steering pump (1). 5. Remove the power steering gear inlet hose from the power steering gear. 6. Remove the power steering gear inlet hose from the vehicle. Installation Procedure 1. Notice: Refer to Installing Hoses Without Twists or Bends Notice in Service Precautions. Route the hose in the same position the hose occupied prior to removal. 2. Install the power steering gear inlet hose (3) to the power steering pump (1). Hand tighten only. 3. Notice: Refer to Fastener Notice in Service Precautions. Install the power steering gear inlet hose to the power steering gear. ^ Tighten both power steering gear inlet hose fittings to 28 Nm (20 ft. lbs.). 4. Remove the drain pan from under the vehicle. 5. Install the engine protection shield. 6. Lower the vehicle. 7. Bleed the power steering system. Refer to Bleeding the Power Steering System. (Recirculating Ball) Power Steering Gear Outlet Pipe/Hose Replacement (Recirculating Ball) Removal Procedure Page 15776 Door Latch Assembly (Door Jamb Switch) - Driver - C2 Transfer Case - NVG 149-NP3 Speed Sensor: Service and Repair Transfer Case - NVG 149-NP3 Transfer Case Speed Sensor Replacement Removal Procedure 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. Disconnect the speed sensor electrical connector (4). 3. Remove the speed sensor. Installation Procedure 1. Install the speed sensor. ^ Tighten the sensor to 15 Nm (11 ft. lbs.). Notice: Refer to Fastener Notice in Service Precautions. Page 6842 1. Install the inner pinion bearing cup into the pinion gear bearing retainer using the J 37624 (2) and the J 8092 (1). 2. Install the outer pinion bearing cup into the pinion gear bearing retainer using the J 8608 (2) and the J 8092 (1). 3. Install the inner pinion bearing using the J 24433.Press the bearing on until the cone seats on the pinion. 4. Install a new collapsible spacer. 5. Lubricate the pinion bearings with axle lubricant. Use the proper fluid. 6. Install the pinion into the pinion gear bearing retainer. 7. Install the outer pinion bearing onto the pinion. Page 9076 Application Table Part 3 Page 9465 Steps 3-4 Page 12674 Diagnostic Trouble Codes DTC U1000 and U1255 Circuit/System Description Modules connected to the Class 2 serial data circuit monitor for serial data communications during normal vehicle operation. Operating information and commands are exchanged among the modules. When a module receives a message for a critical operating parameter, the module records the identification number of the module which sent the message for State of Health monitoring. A critical operating parameter is one which, when not received, requires that the module use a default value for that parameter. When a module does not associate an identification number with at least one critical parameter within 5 seconds of beginning serial data communication, DTC U1000 or U1255 DTC is set. When more than one critical parameter does not have an identification number associated with it, the DTC will only be reported once. The Class 2 serial data communications circuit on this vehicle are in a hybrid ring and star configuration. Each module on the ring has 2 serial data circuits connected to it, except the following modules which have only 1 serial data circuit connected them: Page 12833 Page 4654 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the cover up until the dress cover releases. Repeat this procedure for the other locking tab. 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. 5. If the connector has a nose piece, use a small flat-blade tool to remove the nose piece by inserting the blade into the slot on the front of the connector and prying up on the nose piece. IMPORTANT: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 6. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. IMPORTANT: Be careful not to angle or rock the J 38125-13A tool when inserting it into the connector or the tool may break. Page 16024 IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections TESTING FOR INTERMITTENT AND POOR CONNECTIONS TOOLS REQUIRED - J 35616-C GM-Approved Terminal Test Kit - J 38125-D Terminal Repair Kit - J 42675 Flat-Wire Probe Adapter Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector. - Poor terminal to wire connection - Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. - Wire insulation which is rubbed through - This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. - Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. Testing For Proper Terminal Contact It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-D or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-D, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. Page 15934 Electrical Symbols Part 6 Automatic Transmission - 4L60-E/4L65-E Transmission Position Switch/Sensor: Adjustments Automatic Transmission - 4L60-E/4L65-E Park/Neutral Position Switch Adjustment Important: ^ The following procedure is for vehicles that have not had the park/neutral position (PNP) switch removed or replaced. If the PNP switch has been removed or replaced, refer to Park/Neutral Position Switch Replacement for the proper adjustment procedure. ^ Apply the park brake. ^ The engine must start in the park (P) or neutral (N) positions only. ^ Check the PNP switch for proper operation. If adjustment is required, proceed as follows: 1. Place the transmission range selector in the neutral (N) position. 2. With an assistant in the drivers seat, raise and suitably support the vehicle. Refer to Vehicle Lifting. 3. Loosen the park/neutral position (PNP) switch bolts. 4. With the vehicle in the neutral (N) position, rotate the switch while the assistant attempts to start the engine. 5. Following a successful start, turn the engine off. 6. Notice: Refer to Fastener Notice in Service Precautions. ^ Tighten the PNP switch bolts. ^ Tighten the bolts to 25 Nm (18 ft. lbs.). 7. Lower the vehicle. 8. Check the PNP switch for proper operation. The engine must start in the park (P) or neutral (N) positions only. 9. Replace the PNP switch if proper operation can not be achieved. Page 12843 Page 11917 Important: The optic cable must not be bent with a radius less than 25 mm (1 in). 6.17. Fold back the wiring harness and tape over the connectors (G). Fold back the wiring harness once more and secure with cable ties (H). 6.18. Secure the new optic cable on the parcel shelf along the existing wiring harness by the ordinary securing points and by the speaker (I). 6.19. Thread the optic cable down next to the old cable from the parcel shelf to the left-hand wheel housing, next to REC. The cable is secured in the existing clips. 6.20. Fit the right-hand C-pillar trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.21. Fit the parcel shelf trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.22. Fit the passenger seat in accordance with WIS - 8. Body - Seats - Adjustment/Replacement. 6.23. Fit the right-hand side bolster in accordance with WIS - 8. Body - Seats Adjustment/Replacement. 6.24. Fold up the rear seat backrest. 6.25. Fit the right-hand B-pillar trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.26. Fit the A-pillar's lower side piece. 7. M04-05, 4D: Removing the OnStar® control modules and securing the wiring: Page 5281 Steps 7 - 8 The numbers below refer to the step numbers on the diagnostic table. Fuel Injector Balance Test Example (Typical) 6. If the pressure drop value for each fuel injector is within 10 kPa (1.5 psi) of the average pressure drop value, the fuel injectors are flowing properly. Calculate the pressure drop value for each fuel injector by subtracting the second pressure reading from the first pressure reading. Refer to the illustration. Page 13148 Important: The optic cable must not be bent with a radius less than 25 mm (1 in). 6.17. Fold back the wiring harness and tape over the connectors (G). Fold back the wiring harness once more and secure with cable ties (H). 6.18. Secure the new optic cable on the parcel shelf along the existing wiring harness by the ordinary securing points and by the speaker (I). 6.19. Thread the optic cable down next to the old cable from the parcel shelf to the left-hand wheel housing, next to REC. The cable is secured in the existing clips. 6.20. Fit the right-hand C-pillar trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.21. Fit the parcel shelf trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.22. Fit the passenger seat in accordance with WIS - 8. Body - Seats - Adjustment/Replacement. 6.23. Fit the right-hand side bolster in accordance with WIS - 8. Body - Seats Adjustment/Replacement. 6.24. Fold up the rear seat backrest. 6.25. Fit the right-hand B-pillar trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.26. Fit the A-pillar's lower side piece. 7. M04-05, 4D: Removing the OnStar® control modules and securing the wiring: Page 8816 Control Module References Part 4 Page 6979 Seals and Gaskets: Service and Repair Rear Axle Shaft and/or Gasket Replacement Rear Axle Shaft and/or Gasket Replacement Removal Procedure 1. Remove the flange bolts. 2. Lightly tap the axle shaft with a soft-faced hammer in order to loosen the shaft. 3. Grip the rib on the axle shaft flange with a locking pliers. Twist the axle shaft flange in order to start the axle shaft removal. 4. Remove the axle shaft from the tube. 5. Remove the gasket. 6. Clean the axle shaft flange and the outside face of the hub assembly. Installation Procedure 1. Install the gasket onto the axle shaft. 2. Install the gasket and the axle shaft into the axle tube. 1. Ensure the shaft splines mesh into the differential side gear. 2. Align the holes in the axle flange and the gasket with the holes in the hub. 3. Notice: Refer to Fastener Notice in Service Precautions. Install the axle flange bolts. ^ For the 10.5 inch axle, tighten the rear axle flange bolts to 156 Nm (115 ft. lbs.). ^ For the 11.5 inch axle, tighten the rear axle flange bolts to 200 Nm (148 ft. lbs.). 4. Inspect and add axle lubricant to the axle housing, if necessary. Page 2757 Junction Block - I/P Wire Entry Part 2 Page 12317 Electrical Symbols Part 8 Interior - Erratic Memory Seat Operation Memory Positioning Module: Customer Interest Interior - Erratic Memory Seat Operation Bulletin No.: 04-08-50-016C Date: August 12, 2005 TECHNICAL Subject: Memory Seat May Not Return to Requested Position (Reprogram Driver Seat Module) Models: 2003-2005 Cadillac Escalade, Escalade ESV, Escalade EXT 2003-2005 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2003-2005 GMC Sierra, Yukon, Yukon XL, Yukon Denali All with Seat FRT, Individual (Non BKT) (RPO AN3) 2003-2005 HUMMER H2 with Seat, Front Bucket Deluxe (RPO AR9) Supercede: This bulletin is being revised to update the correction information. Please discard Corporate Bulletin Number 04-08-50-016B (Section 08 - Body and Accessories). Condition Some customers may comment that with repeated cycling of the memory seat between the "exit" and one of the "presets", the position of the seat may "creep" forward or rearward out of expected adjustment. Cause There is a coding deficiency in the software for the memory seat module. Correction Technicians are to reprogram the driver seat module with an updated software calibration. The previous bulletin stated to use a service calibration that was released with TIS satellite data update version 4.5. Feedback has proved that calibration to be ineffective in eliminating the memory seat creep condition. An updated service calibration was released with TIS satellite data update version 6.5 available June 13, 2005. This new calibration has additional memory seat creep protection. As always, make sure your Tech 2(R) is updated with the latest software version. Important: After programming is complete, move the seat all the way rearward and down, then bump the seat slightly forward and up. This position will be just off the end of travel hard stops. Reset both memory seat exit positions at this position. Having the seat set at just off the hard stops will aid in reducing the creep condition. Warranty Information Page 1551 Camshaft Position Sensor: Service and Repair CAMSHAFT POSITION (CMP) SENSOR REPLACEMENT REMOVAL PROCEDURE IMPORTANT: Clean the area around the CMP sensor before removal in order to prevent debris from entering the engine. 1. Remove the camshaft position (CMP) sensor bolt. 2. Remove the CMP sensor. INSTALLATION PROCEDURE 1. Install the CMP sensor. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the CMP sensor bolt. Tighten Tighten the bolt to 29 N.m (21 lb ft). Page 11114 Air Temperature Sensor - Lower Right Locations Mass Air Flow (MAF) Sensor: Locations Right Side Of The Engine Compartment Page 11556 Inflatable Restraint Sensing And Diagnostic Module: Description and Operation INFLATABLE RESTRAINT SENSING AND DIAGNOSTIC MODULE (SDM) The sensing and diagnostic module (SDM) is a microprocessor and the control center for the SIR system. The SDM contains internal sensors along with several external sensors, if equipped, mounted at various locations on the vehicle. In the event of a collision, the SDM performs calculations using the signals received from the internal and external sensors. The SDM compares the results of the calculations to values stored in memory. When these calculations exceed the stored value, the SDM will cause current to flow through the appropriate deployment loops to deploy the air bags. The SDM records the SIR system status when a deployment occurs and requests the instrument panel cluster (IPC) to turn the AIR BAG indicator ON. The SDM performs continuous diagnostic monitoring of the SIR system electrical components and circuitry when the ignition is turned ON. If the SDM detects a malfunction, a DTC will be stored and the SDM will request the IPC to turn the AIR BAG indicator ON. In the event that ignition 1 voltage is lost during a collision, the SDM maintains a 23-volt loop reserve (23 VLR) for deployment of the air bags. It is important to note, when disabling the SIR system for servicing or rescue operations to allow the 23 VLR to dissipate, which could take up to 1 minute. Page 13224 OnStar(R) Microphone The OnStar(R), or cellular microphone, can be a part of the rearview mirror assembly, or on some vehicle lines, a separate, stand alone unit. In either case, the VCIM supplies approximately 10 volts to the microphone on the cellular microphone signal circuit, and voice data from the user is sent back to the VCIM over the same circuit. A cellular microphone low reference circuit or a drain wire provides a ground for the microphone. Cellular and GPS Antennas The vehicle will be equipped with one of the following types of antennas: ^ Separate, stand-alone cellular and navigation (GPS) antennas. ^ A combination cellular and navigation (GPS) antenna, which brings the functions of both into a single part. ^ A cellular, GPS, and digital radio receiver (DRR) antenna, which also incorporates the functionality of the DRR satellite antenna (XM). The cellular antenna is the component that allows the OnStar(R) system to send and receive data using electromagnetic waves by means of cellular technology. The antenna is connected at the base to a coax cable that plugs directly into the VCIM. The GPS antenna is used to collect the signals of the orbiting GPS satellites. Within the antenna is housed a low noise amplifier that allows for a more broad and precise reception of this data. The antenna is connected at the base to a coax cable that plugs directly into the VCIM. The cable also provides a path for DC current for powering the antenna. The OnStar(R) Call Center also has the capability of communicating with the vehicle during an OnStar(R) call to retrieve the latest GPS location and transmit it to the OnStar(R) Call Center. A history location of the last recorded position of the vehicle is stored in the module and marked as aged, for as long as the module power is not removed. Actual GPS location may take up to 10 minutes to register in the event of a loss of power. Audio System Interface When the OnStar(R) requires audio output, a serial data message is sent to the audio system to mute all radio functions and transmit OnStar(R) originated audio. The OnStar(R) audio is transmitted to the vehicle audio system by a dedicated signal circuit and a low reference circuit. The audio system will mute and an audible ring will be heard though the speakers if the vehicle receives a call with the radio ON. On some vehicles, the HVAC blower speed may be reduced when the OnStar(R) system is active to aid in reducing interior noise. When the system is no longer active, the blower speed will return to its previous setting. OnStar(R) Steering Wheel Controls Some vehicles may have a button on the steering wheel, that when pushed can engage the OnStar(R) system. The button may be a symbol of a face with sound waves, or may say MUTE, or be a symbol of a radio speaker with a slash through it. By engaging the OnStar(R) system with this feature, the user can interact with the system by use of voice commands. A complete list of these commands is supplied in the information provided to the customer. If the information is not available for reference, at any command prompt, the user can say "HELP" and the VCIM will return an audible list of available commands. The steering wheel controls consist of multiple momentary contact switches and a resistor network. The switches and resistor network are arranged so that each switch has a different resistance value. When a switch is pressed, a voltage drop occurs in the resistor network. This produces a specific voltage value unique to the switch selected, to be interpreted by the radio or the body control module (BCM). OnStar(R) Power Moding (DRX or Sleep Cycle) The OnStar(R) system uses a unique sleep cycle to allow the system to receive cellular calls while the ignition is in the OFF position and retained accessory power (RAP) mode has ended. A green status LED on the OnStar(R) keypad normally indicates an active OnStar(R) account. The OnStar(R) system will stay powered up after ignition off for an extended time in order to allow for remote services like door unlock, horn honk, light flash, etcetera to take place as requested by the customer. Power cycle (also referred to as DRX) times vary depending on the generation of the OnStar(R) system. Technicians may identify the OnStar(R) system generation by using a Tech 2 and following this menu path: (Body>VCIM>Module ID Information>Module Information 2) or by accessing www.onstarenrollment.com All Generation 6 digital systems are powered up continuously for 48 hours from ignition OFF. After 48 hours, the Generation 6 systems will enter a 9 minute OFF, 1 minute ON power cycle for an additional 72 hours. At the beginning and end of the 1 minute ON stage, you may or may not experience a short spike of current at the beginning and at the end. This allows for calls from OnStar to be received by the system. After 120 hours from ignition OFF, Page 6879 5. Tighten the wheel bearing adjusting nut using the J 2222-C. ^ Rotate the hub in the opposite direction to the way the adjuster nut is turning. ^ Ensure the inner bearing and the seal seats against the spindle shoulder. TIGHTEN ^ Adjusting nut to 70 Nm (52.0 lb ft). 6. Turn the adjusting nut counterclockwise until the nut is loose using the J 2222-C. 7. Turn the adjusting nut clockwise until the nut contacts the bearing cone. Torque on the nut must be zero to finger tight. 8. Insert the adjusting nut lock key into the keyway using one of the following procedures: ^ If the adjusting nut slot is in alignment with the keyway in the axle spindle, insert the adjusting nut lock key into the keyway in the axle spindle. IMPORTANT: Do not turn the adjusting nut more than one slot counterclockwise in order to align the adjusting nut slot with the keyway in the axle spindle. ^ If the adjusting nut slot is not aligned with the keyway in the axle spindle, turn the adjusting nut counterclockwise until the adjusting nut slot is in alignment with the keyway in the axle spindle and insert the adjusting nut lock key. Description and Operation Electronic Throttle Control Module: Description and Operation THROTTLE ACTUATOR CONTROL MODULE The TAC module is the control center for the throttle actuator control system. The TAC system is self-diagnosing and provides diagnostic information to the PCM through a dedicated serial data line. The TAC achieves throttle positioning by providing a pulse width modulated voltage to the TAC, as directed by the PCM. Page 13979 The GM Vehicle Care Odor Eliminator product is an effective odor elimination product when used properly. It must come into direct contact with the odor source. It should be used in conjunction with diagnostic procedures to first eliminate the root cause of the odor. Some procedures for use after odor root cause correction are: STEP TWO: ^ Use the trigger spray head. ^ Put a drop of dish soap the size of a quarter in the bottom of a bottle. ^ Add 8 oz. of GM Vehicle Care Odor Eliminator (1 cup) to the dish soap and top off the bottle with tap water. ^ This formula should be used on hard surfaces (dash, interior plastic molding, and floor pan) STEP THREE: The third step to neutralizing the vehicle is a light to medium treatment of all carpeting and upholstered seats with the GM Vehicle Care Odor Eliminator formula and a wide fan spray setting (at full strength) (i.e.: carpeting on the driver's side requires 4-5 triggers pulls for coverage). The headliner and trunk should be sprayed next. Lightly brushing the formula into the carpeting and upholstery is a recommended step for deep odor problems. The dash and all hard surfaces should be sprayed with dish soap/water mixture. Let stand for 1-2 minutes then wipe off the surface. STEP FOUR: (vehicle ventilation system treatment) The ventilation system is generally the last step in the treatment of the vehicle. a. Spray the GM Vehicle Care Odor Eliminator formula into all dash vents. (1-2 trigger pulls per vent). b. Start the vehicle and turn the vehicle fan on high cool (not A/C setting). c. Spray the formula (10 trigger pulls) into the outside fresh air intake vent (cowl at base of windshield) d. Enter the vehicle after 1 minute and wipe off the excess formula spurting out of the dash vents. e. Smell the air coming from the dash vents. If odors are still present, spray another 5 triggers into the cowl, wait another minute and smell the results. Once you have obtained a fresh, clean smell coming from the vents, turn the system to the A/C re-circulation setting. Roll up the windows, spray 3-5 pumps into the right lower IP area and let the vehicle run with the fan set on high for 5-7 minutes. Please follow this diagnosis process thoroughly and complete each step. If the condition exhibited is resolved without completing every step, the remaining steps do not need to be performed. If these steps do not resolve the condition, please contact GM TAC for further diagnostic assistance. Additional Suggestions to Increase Customer Satisfaction Here are some additional ideas to benefit your dealership and to generate greater customer enthusiasm for this product. ^ Keep this product on-hand for both the Service Department and the Used Car lot. Add value to your used car trades; treat loaner and demo cars during service and at final sale to eliminate smoke, pet, and other common odors offensive to customers. Make deodorizing a vehicle part of your normal vehicle detailing service. ^ Consider including GM Vehicle Care Odor Eliminator as a give-away item with new vehicle purchases. Many dealers give away as "gifts" various cleaning supplies at time of delivery. GM Odor Eliminator is one of a few products GM offers that has as many uses in the home as in the vehicle. Customers may find this product can be used for a host of recreational activities associated with their new vehicle, such as deodorizing a boat they tow, or a camper. ^ GM Odor Eliminator and many of the GM Vehicle Care products offer you the chance to increase dealership traffic as these superior quality products cannot be purchased in stores. Many Dealerships have product displays at the parts counter. Consider additional displays in the Customer Service Lounge, the Showroom and at the Service Desk or Cashier Window. Many customers who purchase vehicles and receive regular maintenance at your dealership may never visit the parts counter, and subsequently are not exposed to the variety and value that these products offer. Parts Information Page 6109 In some cases, the customer may not comment about a vibration but it is important to test drive the vehicle while using the electronic vibration analysis tool in an attempt to locate the cause of the torsional vibration. Refer to the Vibration Diagnosis and Correction sub-section of the appropriate Service Manual for more details on diagnosing and correcting vibrations. Disclaimer Page 11857 Cellular Phone Microphone: Service and Repair MICROPHONE REPLACEMENT - RADIO VOLUME COMPENSATOR INTERIOR REMOVAL PROCEDURE 1. Remove the floor console bezel. 2. Remove the floor console cupholder. 3. Remove the floor console storage bin. 4. Remove the floor console end panel. 5. Move the drivers seat fully forward. 6. Reposition the inboard seat track trim (1) in order to gain access to the rear console side panel screw (2). 7. Remove the rear console side panel screw. 8. Move the drivers seat to the fully rearward. 9. Remove the front console side panel screw (1). IMPORTANT: The floor console drivers side trim panel can not be removed until the noise compensation microphone electrical connector hold down clip is released from the console. 10. Carefully pull outward on the trim panel to release the trim panel clips. Page 6999 8. Remove the adjusting nut. 9. Remove the hub from the axle housing. 10. Remove the rotor, if necessary. 11. Remove the oil seal from the wheel hub using a suitable seal removal tool. 12. Remove the inner hub bearing. 13. Remove the inner hub bearing cup using a brass drift and a hammer. Page 14118 Driver Door Module (DDM) - C5 (With RPO Code AN3) Part 2 A/C - Ticking Noise From Instrument Panel/DTC's Set Control Module HVAC: All Technical Service Bulletins A/C - Ticking Noise From Instrument Panel/DTC's Set Bulletin No.: 06-01-38-003 Date: April 27, 2006 TECHNICAL Subject: Intermittent Ticking Noise from I/P, Poor A/C Performance, HVAC DTCs B0229, B0414, B0424, B3770 (Reprogram HVAC Control Module) Models: 2004-2006 Cadillac Escalade Models 2004-2006 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2004-2006 GMC Sierra Models, Yukon Models with Air Conditioning (RPOs CJ2, CJ3) Condition Some customers may comment on one or more of the following concerns: ^ Intermittent ticking/clicking noise from the instrument panel. ^ Recirculation mode does not work or Air Conditioning (A/C) system performance is poor during high ambient temperatures. ^ Unable to control the driver side temperature. ^ Unable to control the passenger side temperature. ^ Unable to change the front system modes. Cause This condition may be caused by the Heating, Ventilation and Air Conditioning (HVAC) actuators that may hunt for the correct commanded position. This cycling may cause a clicking or ticking noise. An overtravel of the HVAC system control doors may cause one or more of the concerns listed above. If an overtravel occurs, a Diagnostic Trouble Code (DTC) will be set, and the door will go to a preset default position. When a system door defaults, that door will stay at the default position until the DTC is cleared. After the DTC is cleared, the door will operate properly until the overtravel condition re-occurs. The table lists the HVAC system doors and the DTC associated with it. Correction Technicians are to perform the normal diagnostic procedures in SI for these concerns. If diagnostics show that the HVAC system door(s) travel below 5 counts (out of the lower range) or above 250 counts (out of the upper range), then update the software calibrations in the HVAC control module. The new calibrations were made available to dealerships as part of TIS2000 incremental satellite update version 2.5, which was broadcast to dealers in February 2006. Page 8165 1. Remove all traces of the original adhesive patch. 2. Clean the threads of the bolts with brake parts cleaner or the equivalent and allow to dry. 3. Apply Threadlocker GM P/N 12345493 (Canadian P/N 10953488) to the threads of the bolts. 6. Install the brake caliper to the brake caliper mounting bracket. 7. Install the 2 brake caliper mounting bolts. ^ Tighten the 2 brake caliper mounting bolts to 42 Nm (31 ft. lbs.). 8. Install the quarter shaft shield. 9. Install the quarter shaft shield nut and the bolt. ^ Tighten the quarter shaft shield nut and the bolt to 25 Nm (18 ft. lbs.). 10. Install the tire and wheel assembly. 11. Lower the vehicle. 12. With the engine OFF gradually apply the brake pedal to approximately 2/3 of it's travel distance. 13. Slowly release the brake pedal. 14. Wait 15 seconds then repeat steps 12-13 until a firm pedal is obtained. This will properly seat the brake caliper pistons and brake pads. Disc Brake Hardware Replacement - Front Disc Brake Hardware Replacement - Front Caution: Refer to Brake Dust Caution in Service Precautions. Removal Procedure 1. Raise and support the vehicle. Refer Vehicle Lifting 2. Remove the tire and wheel assembly. 3. Notice: Support the brake caliper with heavy mechanic's wire, or equivalent, whenever it is separated from its mount and the hydraulic flexible brake hose is still connected. Failure to support the caliper in this manner will cause the flexible brake hose to bear the weight of the caliper, which may cause damage to the brake hose and in turn may cause a brake fluid leak. Remove the caliper from the mounting bracket and support the caliper with heavy mechanic's wire or equivalent. DO NOT disconnect the hydraulic brake flexible hose from the caliper. Refer to Brake Caliper Replacement Front. 4. Remove the disc brake pads from the disc brake caliper mounting bracket. 5. Remove the disc brake pad retainers from the disc brake caliper mounting bracket. 6. Inspect the disc brake hardware. Refer to Disc Brake Mounting and Hardware Inspection - Front. Interior - Erratic Memory Seat Operation Memory Positioning Module: All Technical Service Bulletins Interior - Erratic Memory Seat Operation Bulletin No.: 04-08-50-016C Date: August 12, 2005 TECHNICAL Subject: Memory Seat May Not Return to Requested Position (Reprogram Driver Seat Module) Models: 2003-2005 Cadillac Escalade, Escalade ESV, Escalade EXT 2003-2005 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2003-2005 GMC Sierra, Yukon, Yukon XL, Yukon Denali All with Seat FRT, Individual (Non BKT) (RPO AN3) 2003-2005 HUMMER H2 with Seat, Front Bucket Deluxe (RPO AR9) Supercede: This bulletin is being revised to update the correction information. Please discard Corporate Bulletin Number 04-08-50-016B (Section 08 - Body and Accessories). Condition Some customers may comment that with repeated cycling of the memory seat between the "exit" and one of the "presets", the position of the seat may "creep" forward or rearward out of expected adjustment. Cause There is a coding deficiency in the software for the memory seat module. Correction Technicians are to reprogram the driver seat module with an updated software calibration. The previous bulletin stated to use a service calibration that was released with TIS satellite data update version 4.5. Feedback has proved that calibration to be ineffective in eliminating the memory seat creep condition. An updated service calibration was released with TIS satellite data update version 6.5 available June 13, 2005. This new calibration has additional memory seat creep protection. As always, make sure your Tech 2(R) is updated with the latest software version. Important: After programming is complete, move the seat all the way rearward and down, then bump the seat slightly forward and up. This position will be just off the end of travel hard stops. Reset both memory seat exit positions at this position. Having the seat set at just off the hard stops will aid in reducing the creep condition. Warranty Information Page 10894 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors USING CONNECTOR TEST ADAPTERS IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-B Connector Test Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Page 3127 7. Remove the camshaft sprocket bolts. 8. Notice: Do not turn the crankshaft assembly after the timing chain has been removed in order to prevent damage to the piston assemblies or the valves. Remove the camshaft sprocket and reposition the timing chain. 9. Remove the camshaft retainer bolts and retainer. 10. Notice: All camshaft journals are the same diameter, so care must be used in removing or installing the camshaft to avoid damage to the camshaft bearings. Remove the camshaft. 1. Install three M8-1.25 x 100 mm (M8-1.25 x 4.0 inch) bolts to the bolt holes in the front of the camshaft. 2. Using the bolts as a handle, carefully rotate and pull the camshaft out of the engine block. 3. Remove the three bolts from the camshaft. Page 8987 Application Table Part 1 Recall - Aftermarket Leather Seat Cover Kit Technical Service Bulletin # 06102B Date: 071019 Recall - Aftermarket Leather Seat Cover Kit Subject: Product Safety - Aftermarket Leather Seat Cover Kits # 06102B - (10/19/2007) 2005-2006 Buick LaCrosse, Rendezvous 2004 Chevrolet Silverado 2005 Chevrolet Tahoe 2005-2006 Chevrolet TrailBlazer, TrailBlazer EXT 2006 Chevrolet HHR, Malibu 2005 GMC Sierra 2005-2006 GMC Envoy 2006 GMC Envoy XL 2006 HUMMER H3 2005 Pontiac Montana 2006 Pontiac G6 The telephone number for contacting General Motors has been changed. To assist customers with initiating the vehicle repurchase process, dealers should contact the GM Reacquired Vehicle Disclosure Center (RVDC). With dealer assistance, the RVDC will work with the customer to reach an agreement on the purchase and physical transfer of the vehicle. Condition General Motors has decided that a defect that relates to motor vehicle safety exists in aftermarket front passenger leather cover kits that were installed at its request on certain vehicles with the Passenger Sensing System. Recently, testing on these seat covers indicated that they can cause the Passenger Sensing system to malfunction. If the Passenger Sensing System malfunctions, the front airbag on the passenger side may be disabled when it should be enabled, or enabled when it should be disabled. In either case, in the event of a crash that requires airbag deployment, a front passenger's level of injury may be increased. The airbag status indicator displays the status of the airbag. Whenever the front passenger seat is occupied, the driver should always check the airbag indicator to see if the airbag is on or off as explained in the owner manual. If it is not correct for the situation, the passenger should be moved to a different seat. Correction Because a replacement leather seat cover that is compatible with the Passenger Sensing System is not available, General Motors will repurchase the vehicle for the full price the customer paid for it (not exceeding the fair market value at the time the customer purchased it), including taxes and fees, if the vehicle is returned to General Motor's possession by January 31, 2007. There will be no deductions for mileage or use unless the vehicle has sustained substantial damage beyond normal wear and tear. General Motors reserves the right to handle each transaction on a case-by-case basis relative to the application of a reasonable depreciation allowance for mileage or use and/or reduction in repurchase price if the vehicle has sustained substantial damage beyond normal wear and tear. General Motors will also pay for the removal of any aftermarket accessories the customer may have installed before they were notified of this recall and return them to the customer. If they no longer have a use for those accessories or they cannot be removed, General Motors will reimburse the customer for the purchase price of those accessories. The customer's local GM dealer will contact General Motors to begin the repurchase process. General Motors will work with the customer to reach an agreement on the purchase of the vehicle. Dealers will be asked by General Motors to assist in the removal of any aftermarket accessories, inspection of the vehicle, obtaining titles and other documentation required to transfer ownership to General Motors, presenting the customer with a check for the purchase, and taking possession of the vehicle. General Motors will arrange for transportation of the vehicle from the dealer. If any of these vehicles are in the used car inventory of your dealership or were sold by you, or a customer brings in an involved vehicle for service, please contact the GM Reacquired Vehicle Disclosure Center (RVCD). If any of these vehicles are in the used car inventory of your dealership or were sold by you, please contact General Motors. Page 9729 C201 Steering Column Harness To I/P Harness Part 4 Page 10719 8. Separate the wheel drive shaft from the wheel hub and bearing using J 45859 (2) or equivalent. 9. Remove the wheel hub and bearing (1) from the vehicle. Installation Procedure OnStar(R) - Incorrect GPS Position Reported During Call Navigation System: All Technical Service Bulletins OnStar(R) - Incorrect GPS Position Reported During Call Bulletin No.: 02-08-46-006C Date: January 08, 2008 INFORMATION Subject: Incorrect OnStar(R) Global Positioning System (GPS) Location Reported During OnStar(R) Call Models: 2000-2008 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2008 HUMMER H2 2006-2008 HUMMER H3 2005-2008 Saab 9-7X with OnStar(R) Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 02-08-46-006B (Section 08 - Body and Accessories). A small number of the above-mentioned vehicles may exhibit a condition in which the vehicle reports an inaccurate location to the OnStar(R) Call Center. This condition can only be identified via a button press to the OnStar(R) Call Center by the customer. Call Center personnel will be able to identify this inaccurate location condition. Customers will then be notified through the mail by OnStar(R) if their vehicle exhibits this condition. Once this condition has been identified OnStar(R) will instruct the customer to return to the dealership to have this condition corrected. It is not necessary to reconfigure the vehicle after the following procedure. In order to correct this condition you must cycle power to the OnStar(R) system. This can be done by either removing the fuses powering the OnStar(R) system or disconnecting the OnStar(R) module (VCIM) from the vehicle. As a last resort you can disconnect the vehicle's battery. The power needs to be removed from the system for approximately 15 minutes. After completing this procedure the vehicle should be taken to an area with an unobstructed view of the sky. The vehicle should be kept running for approximately 10 minutes to allow the vehicle to reacquire the global positioning system (GPS). Then contact the OnStar(R) Call Center via the blue OnStar(R) button and ask the advisor to verify the GPS position. If the OnStar(R) advisor still has an inaccurate GPS location refer to the Navigation Systems and Cellular Communications sub-sections in the Service Manual in order to diagnose and repair the concern. If the normal diagnostics lead to module replacement you will need to contact Technical Assistance (TAC) and choose the OnStar(R) prompt. GM OnStar(R) TAC will assist in the diagnosis and if appropriate order a replacement part. Replacement parts are usually shipped out within 24 hours and a pre-paid return package label will be included for returning the faulty part. By returning the faulty part you will avoid a significant non-return core charge. Warranty Information (excluding Saab US Models) For vehicles repaired under warranty, use the table. Warranty Information (Saab US Models) Page 1281 Coolant Temperature Sensor/Switch (For Computer): Service and Repair ENGINE COOLANT TEMPERATURE (ECT) SENSOR REPLACEMENT REMOVAL PROCEDURE NOTE: Use care when handling the coolant sensor. Damage to the coolant sensor will affect the operation of the fuel control system. 1. Drain the cooling system to a level below the engine cooling temperature (ECT) sensor. Refer to Draining and Filling Cooling System in Cooling System. 2. Disconnect the ECT sensor electrical connector (5). 3. Remove the ECT sensor. INSTALLATION PROCEDURE NOTE: Replacement components must be the correct part number for the application. Components requiring the use of the thread locking compound, lubricants, corrosion inhibitors, or sealants are identified in the service procedure. Some replacement components may come with these coatings already applied. Do not use these coatings on components unless specified. These coatings can affect the final torque, which may affect the operation of the component. Use the correct torque specification when installing components in order to avoid damage. - Use care when handling the coolant sensor. Damage to the coolant sensor will affect the operation of the fuel control system. Page 1153 Disclaimer Page 506 Control Module References Part 2 Page 10972 For vehicles repaired under warranty, use the table. Disclaimer Page 15954 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Weather Pack Connectors WEATHER PACK CONNECTORS The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. Page 9097 1. Install the engine electrical center bracket assembly to the front fender. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the 4 retaining bolts (1). Tighten Tighten the 4 retaining bolts (1) to 9 N.m (80 lb in). 3. Align the electrical center block (1) stubs in the slots so that the tabs (2) retains it in place. Page 10712 Wheel Bearing: Service and Repair With Full Floating 10.5" or 11.5" Ring Gear Rear Axle Hub, Bearing, Cup, and/or Seal Replacement ^ Tools Required J 8092 Universal Driver Handle - 3/4 inch - 10 - J 2222-C Wheel Bearing Nut Wrench - J 24426 Wheel Bearing Race Installer - Outer - J 24427 Wheel Bearing Race Installer - Inner - J 44419 Hub Outer Bearing Race Installer - J 44420 Differential Bearing and Hub Seal Installer Removal Procedure 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Remove the tire and wheel assembly. 3. Remove the brake caliper. 4. Remove the axle shaft. 5. Remove the axle nut retaining ring. 6. Remove the key. 7. Remove the adjusting nut using the J 2222-C. Page 6774 43. Install the right inner axle shaft housing assembly to the differential carrier assembly. 44. Install the inner axle shaft housing bolts. Tighten Tighten the inner axle shaft housing bolts to 40 N.m (30 lb ft). 45. Install the inner axle shaft housing washers and nuts to the bracket. Tighten Tighten the inner axle shaft housing nuts to 100 N.m (75 lb ft). 46. Connect the wheel drive shaft inboard flange to the inner axle shaft. 47. Install the wheel drive shaft inboard flange to the inner axle shaft bolts. Tighten Tighten the wheel drive shaft inboard flange to the inner axle shaft bolts to 79 N.m (58 lb ft). 48. Connect the wire harness to the inner axle shaft housing and differential carrier. 49. Connect the electrical connector to the front axle actuator. 50. Fill the differential carrier assembly with axle lubricant. Use the proper fluid. Refer to Lubricant Replacement - Front Drive Axle in the Front Axle sub-section of the Service Manual. 51. Install the front engine protection shield. Refer to Engine Protection Shield Replacement in the Frame and Underbody sub-section of the service manual. 52. Lower the vehicle. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Page 3502 Disclaimer Page 9045 Junction Block - Rear Lamps - C1 Part 1 Page 10014 Front Steering Knuckle: Service and Repair Front Steering Knuckle Replacement (4WD) ^ Tools Required ^ J 43631 Ball Joint Remover ^ J 45851 Ball Joint Separator Protector Adapters Removal Procedure 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Remove the tire and wheel. 3. Remove the wheel hub and bearing assembly. Refer to Wheel Hub, Bearing, and Seal Replacement (RWD) Wheel Hub, Bearing, and Seal Replacement (4WD). 4. Support the lower control arm with a suitable jack. 5. Disconnect the outer tie rod to the steering knuckle. Refer to Tie Rod Replacement in Steering Linkage (Non- Rack and Pinion). 6. Remove the brake hose bracket retaining bolt from the steering knuckle. 7. Remove the upper control arm retaining nut and separate the upper ball joint from the steering knuckle using the J 43631 and J 45851. 8. Remove the lower control arm retaining nut. Separate the lower ball joint from the steering knuckle using the J 43631 and J 45851. Service Precautions Jump Starting: Service Precautions CAUTION: Batteries produce explosive gases. Batteries contain corrosive acid. Batteries supply levels of electrical current high enough to cause burns. Therefore, in order to reduce the risk of personal injury while working near a battery, observe the following guidelines: - Always shield your eyes. - Avoid leaning over the battery whenever possible. - Do not expose the battery to open flames or sparks. - Do not allow battery acid to contact the eyes or the skin. - Flush any contacted areas with water immediately and thoroughly. - Get medical help. Service and Repair Oil Pressure Sensor: Service and Repair Engine Oil Pressure Sensor and/or Switch Replacement ^ Tools Required J 41712 Oil Pressure Switch Socket Removal Procedure 1. If necessary, remove the engine sight shield. 2. Disconnect the oil pressure sensor electrical connector (1). 3. Using J 41712 or equivalent, remove the oil pressure sensor. Installation Procedure A/T - Harsh Light Throttle 1-2 Shift Valve Body: All Technical Service Bulletins A/T - Harsh Light Throttle 1-2 Shift TECHNICAL Bulletin No.: 09-07-30-017A Date: May 20, 2010 Subject: Harsh 1-2 Shift at Light Throttle (Install New 1-2 Accumulator Valve Kit) Models: 2003-2007 Cadillac Escalade 2003-2007 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2003-2007 GMC Sierra, Yukon, Yukon XL All Equipped with 4.8L or 5.3L Engine (RPOs LR4, LM7, L59, LM4, LH6, L33) and 4L60E Automatic Transmission (RPO M30) Please Refer to GMVIS Supercede: This bulletin is being revised to update the Warranty Information. Please discard Corporate Bulletin Number 09-07-30-017 (Section 07 - Transmission/Transaxle). Condition Some customers may comment about a harsh 1-2 shift at light throttle. Cause This condition may be caused by the 2-4 band apply time extending through the 1-2 accumulator stroke. Correction 1. Verify the customer's concern. 2. Remove the valve body. Refer to Valve Body and Pressure Switch Removal in SI. 3. Remove the coiled spring pin (360). 4. Remove the 1-2 accumulator valve sleeve (372). 5. Remove the 1-2 accumulator valve (371) and the 1-2 accumulator valve spring (370). 6. Install the new 1-2 accumulator valve kit, GM P/N 24255821. 7. Install the valve body. Refer to Valve Body and Pressure Switch Installation in SI. Parts Information Warranty Information For vehicles repaired under warranty, use the table above. Page 3977 Fuel Tank Pressure (FTP) Sensor Page 11172 Heater Hose: Service and Repair Heater Hose Replacement - Inlet (With RPO Code HP2 Rear) HEATER HOSE REPLACEMENT - INLET (W/ HP2 REAR) TOOLS REQUIRED J 43181 Quick Connect Connector Removal Tool REMOVAL PROCEDURE 1. Drain the cooling system. Refer to Draining and Filling Cooling System (with HP2)Draining and Filling Cooling System (without HP2) in Cooling System. 2. Using the J 43181 disconnect the heater hose from the heater core inlet. 2.1. Install the J 43181 to the heater core pipe. 2.2. Close the tool around the heater core pipe. 2.3. Firmly pull the tool into the quick connect end of the heater hose. 2.4. Firmly grasp the heater hose. Pull the heater hose forward in order to disengage the hose from the heater core. 3. Reposition the inlet heater hose clamp (2) from the auxiliary water pump (1). 4. Remove the inlet heater hose (3) from the auxiliary water pump (1). INSTALLATION PROCEDURE Page 12954 Speaker - LF - Tweeter - With RPO Code UQ7 Page 11332 Control Module HVAC: Diagrams HVAC System - Automatic HVAC Control Module - C1 Part 1 Page 2773 Relay Box: Service and Repair I/P Electrical Center or Junction Block Replacement - Right INSTRUMENT PANEL ELECTRICAL CENTER OR JUNCTION BLOCK REPLACEMENT - RIGHT REMOVAL PROCEDURE 1. Remove the right side end panel. 2. Push in the tabs in order to remove the fuse block. 3. Pull out the fuse block out of the I/P in order to remove the retaining bolt. 4. Loosen the bolt. 5. Insert a screw driver between the wire harness block and fuse block in order to separate. 6. Separate the fuse block from the I/P harness block. 7. Remove the I/P wiring harness block from the vehicle. INSTALLATION PROCEDURE 1. Install the fuse block to the I/P wire harness block. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the retaining bolt. Tighten Tighten the bolt to 6 N.m (53 lb in) 3. Install the fuse block to the I/P until it clicks in place. Page 11082 HVAC Control Module - C1 Part 2 Page 11389 Low Pressure Sensor / Switch: Service and Repair AIR CONDITIONING (A/C) LOW PRESSURE SWITCH REPLACEMENT REMOVAL PROCEDURE 1. Disconnect the electrical connector from the A/C low pressure switch. 2. Remove the A/C low pressure switch from the accumulator. 3. Remove the O-ring and discard. INSTALLATION PROCEDURE 1. Lightly coat the NEW O-ring seal with mineral base 525 viscosity refrigerant oil. 2. Install the NEW O-ring seal to the switch. NOTE: Refer to Fastener Notice in Service Precautions. 3. Install the A/C low pressure switch to the accumulator. Tighten Tighten the switch to 6 N.m (53 lb in). 4. Connect the electrical connector to the A/C low pressure switch. 5. Leak test the fittings of the components using the J 39400-A. Page 14358 When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage TESTING FOR A SHORT TO VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity TESTING FOR CONTINUITY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents TESTING FOR ELECTRICAL INTERMITTENTS Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground - Testing for Continuity - Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 msRECORD and emits an audible tone (beep). EVAP System Hoses/Pipes Replacement Cab/Chassis) Evaporative Emissions Hose: Service and Repair EVAP System Hoses/Pipes Replacement Cab/Chassis) EVAPORATIVE EMISSION (EVAP) SYSTEM HOSES/PIPES REPLACEMENT (PICKUP AND CAB/CHASSIS) REMOVAL PROCEDURE IMPORTANT: Clean the evaporative emission (EVAP) pipe connections and surrounding area prior to disconnecting the fittings in order to avoid possible fuel system contamination. 1. Remove the fuel tank. 2. Disconnect and remove the EVAP purge line (2) from the sending unit and retaining clips. 3. Disconnect and remove the EVAP fuel level vent valve (FLVV) line (3) from the sending unit and retaining clips. 4. Cap the fuel feed and EVAP openings in order to prevent possible fuel/EVAP system contamination. INSTALLATION PROCEDURE 1. Remove the caps from the fuel feed and EVAP lines. 2. Install and connect the EVAP FLVV line (3) line to the sending unit and retaining clips. 3. Install and connect the EVAP purge line (2) to the sending unit and retaining clips. 4. Install the fuel tank. Page 5113 1. Relieve the fuel system pressure. Refer to the Fuel Pressure Relief Procedure. 2. Disconnect the fuel feed and return pipes (1) at the fuel rail. 3. Disconnect the evaporative emission (EVAP) canister purge tube (3). 4. Cap the fuel rail and EVAP pipes. 5. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 6. Remove the fuel pipe bracket nut (2). 7. Remove the fuel pipe bracket from the bellhousing stud. 8. Remove the heated oxygen sensor (HO2S) sensor connector from the bracket. 9. Remove the fuel hose/pipe clip from the bracket on the automatic transmission. 10. If equipped with 4-wheel drive (4WD), remove the fuel hose/pipe clip from the bracket on the transfer case. 11. Remove the clip from the bracket on the frame. 12. Remove the transfer case harness from the clip bracket. 13. Remove the EVAP canister. IMPORTANT: The area around the electro-hydraulic control unit (EHCU) MUST be free from loose dirt to prevent contamination of disassembled anti-lock brake components (ABS) components. Interior - Erratic Memory Seat Operation Memory Positioning Module: All Technical Service Bulletins Interior - Erratic Memory Seat Operation Bulletin No.: 04-08-50-016C Date: August 12, 2005 TECHNICAL Subject: Memory Seat May Not Return to Requested Position (Reprogram Driver Seat Module) Models: 2003-2005 Cadillac Escalade, Escalade ESV, Escalade EXT 2003-2005 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2003-2005 GMC Sierra, Yukon, Yukon XL, Yukon Denali All with Seat FRT, Individual (Non BKT) (RPO AN3) 2003-2005 HUMMER H2 with Seat, Front Bucket Deluxe (RPO AR9) Supercede: This bulletin is being revised to update the correction information. Please discard Corporate Bulletin Number 04-08-50-016B (Section 08 - Body and Accessories). Condition Some customers may comment that with repeated cycling of the memory seat between the "exit" and one of the "presets", the position of the seat may "creep" forward or rearward out of expected adjustment. Cause There is a coding deficiency in the software for the memory seat module. Correction Technicians are to reprogram the driver seat module with an updated software calibration. The previous bulletin stated to use a service calibration that was released with TIS satellite data update version 4.5. Feedback has proved that calibration to be ineffective in eliminating the memory seat creep condition. An updated service calibration was released with TIS satellite data update version 6.5 available June 13, 2005. This new calibration has additional memory seat creep protection. As always, make sure your Tech 2(R) is updated with the latest software version. Important: After programming is complete, move the seat all the way rearward and down, then bump the seat slightly forward and up. This position will be just off the end of travel hard stops. Reset both memory seat exit positions at this position. Having the seat set at just off the hard stops will aid in reducing the creep condition. Warranty Information Page 9718 C151 I/P Harness To ATC Harness (With RPO Codes NP1/NP8) Page 4006 1. Apply sealant GM P/N 12346004, (Canadian P/N 10953480), or equivalent, to the threads of the oil pressure sensor. Notice: Refer to Fastener Notice in Service Precautions. 2. Using J 41712 or equivalent, install the oil pressure sensor. ^ Tighten the oil pressure sensor to 30 Nm (22 ft. lbs.). 3. Connect the oil pressure sensor electrical connector (1). 4. If necessary, install the engine sight shield. Page 4571 2. Connect the MAP sensor electrical connector (1). 3. Install the engine sight shield. Page 3009 hot particles embed themselves in the chrome layer and create a small pit. If the material is allowed to sit on the wheel while it is exposed to moisture or salt, it will corrode the wheel beneath the chrome leaving a pit or small blister in the chrome. Heavy brake dust build-up should be removed from wheels by using GM Chrome Cleaner and Polish, P/N 1050173 (in Canada use 10953013). For moderate cleaning, light brake dust build-up or water spots use GM Swirl Remover Polish, P/N 12377965 (in Canada, use Meguiars Plast-X(TM) Clear Plastic Cleaner and Polish #G12310C**). After cleaning, the wheel should be waxed using GM Cleaner Wax, P/N 12377966 (in Canada, use Meguiars Cleaner Wax #M0616C**), which will help protect the wheel from brake dust and reduce adhesion of any brake dust that gets on the wheel surface. For general maintenance cleaning, PEEK Metal Polish† may be used. It will clean and shine the chrome and leave behind a wax coating that may help protect the finish. Warranty of Stardust Corroded Chrome Wheels Wheels returned with pitting or spotting as a result of neglect and brake dust build-up may be replaced one time. Important Notify the customer that this is a one time replacement. Please stress to the customer the vital importance of keeping the wheels clean and free of prolonged exposure to brake dust build-up. "GM of Canada" dealers require prior approval by the District Manager - Customer Care and Service Process (DM-CCSP). Customer Assistance and Instructions GM has looked for ways customers may improve the appearance of wheels damaged by acidic cleaners. The following product and procedure has been found to dramatically improve the appearance of stained wheels. For wheels that have milky stains caused by acidic cleaners try the following: Notice THE 3M CHROME AND METAL POLISH REQUIRED FOR THIS PROCEDURE IS AN EXTREMELY AGGRESSIVE POLISH/CLEANER. THE WHEELS MUST BE CLEANED BEFORE APPLICATION TO AVOID SCRATCHING THE WHEEL SURFACE. THIS PRODUCT WILL REDUCE THE THICKNESS OF THE CHROME PLATING ON THE WHEEL AND IF USED INCORRECTLY OR EXCESSIVELY MAY REMOVE THE CHROME PLATING ALL TOGETHER, EXPOSING A LESS BRIGHT AND BRASSY COLORED SUB-LAYER. FOLLOW INSTRUCTIONS EXACTLY. 1. Wash the wheels with vigorously with soap and water. This step will clean and may reduce wheel staining. Flood all areas of the wheel with water to rinse. 2. Dry the wheels completely. Notice Begin with a small section of the wheel and with light pressure buff off polish and examine results. ONLY apply and rub with sufficient force and time to remove enough staining that you are satisfied with the results. Some wheels may be stained to the extent that you may only achieve a 50% improvement while others may be able to be restored to the original lustre. IN ALL CASES, only apply until the results are satisfactory. 3. Apply 3M Chrome and Metal Polish #39527* with a clean terry cloth towel. As you apply the polish, the staining will be diminished. 4. When dry, buff off the polish with a clean portion of the towel. 5. Repeat application of the 3M Chrome and Metal Polish until satisfied with the results. If continued applications fail to improve the appearance further discontinue use. This procedure will improve the appearance of the wheels and may, with repeated applications, restore the finish dramatically. For wheels that exhibit spotting from road chemicals the above procedure may marginally improve the condition but will not restore the finish or remove the pitting. In this type of staining the wheel finish has actually been removed in spots and no manner of cleaning will restore the finish. †*We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Parts Information Page 4039 For vehicles repaired under warranty, use the table. Disclaimer Page 9043 Junction Block - I/P - C7 Page 1540 Intake Air Temperature (IAT)/Mass Air Flow (MAF) Sensor Page 16103 Control Module References Part 4 Page 15155 When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage TESTING FOR A SHORT TO VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity TESTING FOR CONTINUITY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents TESTING FOR ELECTRICAL INTERMITTENTS Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground - Testing for Continuity - Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 msRECORD and emits an audible tone (beep). Specifications Fuel Pressure: Specifications Fuel Pressure (Key ON Engine OFF) .............................................................................................................................................. 385-425 kPa (55-62 psi) Page 9625 Fuse Block - Underhood - Secondary Wire Entry (With RPO Code HP2) Part 2 Page 12861 Important: The optic cable must not be bent with a radius less than 25 mm (1 in). 12.5. Cars with brackets for e.g. an amplifier: Fit the cable tie (11 900 515) to the wiring harness approx. 100 mm (4 in) from H2-9, fit the cable tie (H) to the bracket. Gather the optic cable in a gentle loop (I) and then place the loop behind the bracket. Important: The optic cable must not be bent with a radius less than 25 mm (1 in). 12.6. Cars without brackets for e.g. an amplifier: Gather the optic cable in a gentle loop (J) and secure with cable tie. 13. CV: Fit the left-hand, rear side hatch trim in accordance with WIS - 8. Body - Interior equipment - Adjustment/Replacement. 14. Fit the ground cable to the battery's negative terminal. 15. Carry out procedures after disconnecting the battery, see WIS - 3. Electrical System - Charging system - Adjustment/Replacement. Important: Follow Tech 2(R) on-screen instructions. 16. Add ECU ICM, choose without OnStar(R). See WIS-General-Tech 2(R) - Description and Operation - Add/Remove. 2000-2004 Saab 9-5 2000-2004 Saab 9-5 Page 12459 4.1. Unplug the SRS control module's connector (A). 4.2. Cut off the cable tie (B), detach the connector's rear end face (C), and pull out the connecting rail (D). 4.3. Extract pin 15, cut off the cable terminal and insulate the end with tape (E). Fold back the cable and secure it with tape (F). 4.4. Fit the connecting rail and end face. 4.5. Plug in the connector (A) and secure the cables with cable ties (B). 5. Remove the parcel shelf trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6. M03: Replace the optic cable on the right-hand side Page 15429 Engine Oil Pressure (EOP) Sensor Page 4175 1. Install the CKP sensor. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the CKP sensor bolt. Tighten Tighten the bolt to 25 N.m (18 lb ft). 3. Connect the CKP sensor electrical connector. 4. Install the starter. 5. Perform the CKP system variation learn procedure. See: Testing and Inspection/Programming and Relearning Page 10837 4. Remove the mode actuator mounting screws from the HVAC module. 5. Remove the mode actuator as an assembly with the actuator cam. INSTALLATION PROCEDURE 1. Install the mode actuator as an assembly with the actuator cam. - Line up the heater/defroster lever with the mode actuator cam slot. - Line up the A/C lever with the mode actuator cam. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the mode actuator mounting screws to the HVAC module. Tighten Tighten the screws to 1.6 N.m (14 lb in). Page 4897 Vehicle Speed Sensor: Service and Repair Manual Transmission - NV 4500 Vehicle Speed Sensor (VSS) Replacement Removal Procedure 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. Disconnect the vehicle speed sensor (VSS) electrical connector (3). 3. Remove the VSS and seal. Installation Procedure 1. Coat the NEW O-ring seal with a thin film of transmission fluid, use GM P/N 12346190 (Canadian P/N 10953477), or equivalent. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the VSS. ^ Tighten the VSS to 16 Nm (12 ft. lbs.). Page 12351 IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. Splicing Twisted or Shielded Cable SPLICING TWISTED OR SHIELDED CABLE Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. - Rewrap the conductors with the mylar tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with mylar tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Control Module References Page 8541 1. Lubricate the input speed sensor seal with automatic transmission fluid. 2. Install the input speed sensor (1). Notice: Refer to Fastener Notice in Service Precautions. 3. Install the input speed sensor bolt. ^ Tighten the bolt to 11 Nm (96 inch lbs.). 4. Connect the input speed sensor electrical connector (1). 5. Lower the vehicle. Page 9793 Junction Block - I/P Wire Entry Part 4 Page 14397 Driver Door Module (DDM) - C5 (With RPO Code AN3) Part 2 Page 8903 IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. Splicing Twisted or Shielded Cable SPLICING TWISTED OR SHIELDED CABLE Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. - Rewrap the conductors with the mylar tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with mylar tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Control Module References Page 14406 Door Module: Electrical Diagrams Door Control Module Diagram 1 Page 13844 4. Align the outboard air inlet grille panel clips and press down in order to install. 5. Install the wiper arms. Page 993 Fuel Pump (FP) Relay-Secondary (w/Dual Tanks) Page 12472 9. Erase the diagnostic trouble codes. 10. Set the date and time, see WIS - 3. Electrical system - Information display (SID) - Technical description. Page 4146 Mass Air Flow (MAF) Sensor: Service and Repair MASS AIR FLOW (MAF)/INTAKE AIR TEMPERATURE (IAT) SENSOR REPLACEMENT REMOVAL PROCEDURE IMPORTANT: Use care when handling the mass air flow/intake air temperature (MAF/IAT) sensor. Do not dent, puncture, or otherwise damage the honeycell located at the air inlet end of the MAF/IAT. Do not touch the sensing elements or allow anything including cleaning solvents and lubricants to come in contact with them. Use a small amount of a non-silicone based lubricant, on the air duct only, to aid in installation. 1. Remove the air cleaner outlet duct. 2. Pull out the gray connector position assurance (CPA) retainer. 3. Push down on the black clip in order to disconnect the MAF/IAT sensor electrical connector (4). 4. Loosen the MAF/IAT clamp. 5. Remove the MAF/IAT sensor from the air cleaner assembly. INSTALLATION PROCEDURE IMPORTANT: The embossed arrow on the MAF/IAT sensor indicates the proper air flow direction. The arrow must point toward the engine. Page 1130 Seat Recliner Motor Position Sensor - Driver (With RPO Code AN3) Page 9565 Fuse Block - Underhood C7 Page 5406 Fuel Filler Hose: Service and Repair Filler Tube Replacement - 2 FILLER TUBE REPLACEMENT REMOVAL PROCEDURE 1. Remove the fuel tank filler housing to body TORX(R) screws (1) and pushpin retainer (2). 2. Remove the fuel tank filler housing to fuel tank fill pipe bolt. 3. Remove the fuel tank filler housing. 4. Raise and suitably support the vehicle half way. Refer to Vehicle Lifting. 5. Open the axle vent hose clip on the fuel fill pipe bracket. 6. Remove the rear axle vent hose from the clip. Page 10899 TOOLS REQUIRED J 34142-B 12 V Unpowered Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. When testing for voltage: 1. Attach 1 lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach 1 lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Using Connector Test Adapters USING CONNECTOR TEST ADAPTERS NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-B Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires USING FUSED JUMPER WIRES TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Connector Position Assurance Locks CONNECTOR POSITION ASSURANCE LOCKS The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Terminal Position Assurance Locks TERMINAL POSITION ASSURANCE LOCKS The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Push to Seat Connectors PUSH TO SEAT CONNECTORS TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Page 3253 Steps 1 - 11 The number(s) below refer to the step(s) in the diagnostic table. 2. This test is to verify that the vibration is present during diagnosing. Other vehicle components may cause a similar symptom such as the exhaust system, or the drivetrain. 3. This test is to verify that the drive belt(s) or accessory drive components may be causing the vibration. Remove the drive belt(s) and operate the engine for a few seconds, this will verify if the vibration is related to the drive belt(s) or not. With the drive belt(s) removed the water pump will not operate and the engine may overheat. Also diagnostic trouble codes (DTCs) may set when the engine is operated with the drive belt(s) removed. 4. The drive belt(s) may cause a vibration. While the drive belt(s) is removed this is the best time to inspect the condition of the drive belt(s). 6. Inspection of the fasteners can eliminate the possibility that a incorrect bolt, nut, spacer, or washer was installed. 8. This step should only be performed if the fan is driven by the drive belt. Inspect the engine cooling fan for bent, twisted, loose, or cracked blades. Page 6931 8. Pack the tripot seal (4) and the tripot housing (1) with the grease supplied in the kit. The amount of grease supplied in this kit has been pre-measured for this application. Page 4884 10. Connect the PNP switch electrical connector (2). 11. If equipped with 4WD, install the front propeller shaft. 12. Lower the vehicle. 13. Check the PNP switch for proper operation. The engine must start in the park (P) or neutral (N) positions only. If proper operation of the switch can not be obtained, replace the switch. Park Lock Pawl and Actuator Replacement Park Lock Pawl and Actuator Replacement Removal Procedure 1. Remove the transmission filter. 2. Remove the park/neutral position (PNP) switch. 3. Remove the manual shaft nut and pin. 4. Remove the detent lever and actuator. 5. Remove the parking pawl bracket bolts. 6. Remove the parking pawl return spring. OnStar(R) - Re-establishing OnStar(R) Communications Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Re-establishing OnStar(R) Communications Bulletin No.: 00-08-46-004C Date: January 17, 2008 INFORMATION Subject: Re-establishing Communications with OnStar(R) Center After Battery Disconnect Models: 2000-2008 GM Passenger Cars and Trucks (Including Saturn and Saab) with Digital OnStar(R) (RPO UE1) Supercede: This bulletin is being revised to add models and model years. Please discard Corporate Bulletin Number 00-08-46-004B (Section 08 - Body and Accessories). When servicing any of the above models and a battery cable is disconnected or power to the OnStar(R) Vehicle Communication Interface Module (VCIM) is interrupted for any reason the following procedure must be performed to verify proper Global Positioning System (GPS) function. Never swap OnStar(R) Vehicle Communication Interface Modules (VCIM) from other vehicles. Transfer of OnStar(R) modules from other vehicles should not be done. Each OnStar(R) module has a unique identification number. The VCIM has a specific Station Identification (STID). This identification number is used by the National Cellular Telephone Network and OnStar(R) systems and is stored in General Motors Vehicle History files by VIN. After completing ALL repairs to the vehicle you must perform the following procedure: Move the vehicle into an open area of the service lot. Sit in the vehicle with the engine running and the radio turned on for five minutes. Press the OnStar(R) button in the vehicle. When the OnStar(R) advisor answers ask the advisor to verify the current location of the vehicle. If the vehicle location is different than the location the OnStar(R) advisor gives contact GM Technical Assistance (TAC) and choose the OnStar(R) prompt. GM OnStar(R) TAC will assist in the diagnosis of a failed VCIM and, if appropriate, order a replacement part. Replacement parts are usually shipped out within 24 hours, and a pre-paid return package label will be included for returning the faulty part. By returning the faulty part, you will avoid a non-return core charge. Disclaimer Page 8426 Important: The spring clip kits mentioned in this bulletin do not address any parking brake concerns. Refer to the Parking Brakes sub-section of the Service Manual for any diagnostic information. Parts Information Parts are currently available from GMSPO. Warranty Information When removal of the rear brake rotors results in damage to the spring clips on vehicles under warranty, use the labor operation shown in conjunction with one of the kit part numbers listed above. Page 1404 The values in the table are approximate values based on information obtained from properly operating vehicles. Actual results may vary slightly. Page 8397 6. Remove the rear cable mounting bracket bolt. 7. Remove the cable from the lever. 8. Remove the cable (2) from the rear brake cable mounting bracket (3) by depressing the locking tabs (1) on the brake cable. 9. Remove the cable from the guides and the body mounts. Installation Procedure Page 13405 Refer to the table as a guide in selecting the correct test adapter for frontprobing connectors: Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure SCAN TOOL SNAPSHOT PROCEDURE Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: - Snapshot - taken from the Snapshot menu choice - Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information Page 2030 5. Install the front door trim panel. 6. If equipped with camper mirrors program the door module. Refer to Service Programming System (SPS) in Programming. Page 10809 ^ Reinstall the fuse and fuse panel cover. ^ Press the "Enter" button to perform the "Refresh" function. ^ "Test in Progress" will be displayed and the right front passenger door lock will cycle once. ^ The screen will display "Procedure Completed". ^ Press the "Exit" button as necessary to return to the main menu screen. 3. Using the switches in the right front passenger door, verify that the power window and power door lock located in that door function properly. Important: The calibrations required for performing SPS reprogram in the next step are based on the type of exterior rearview mirror the vehicle has. To determine the correct calibration, check the Service Parts Identification Label on the vehicle for the RPO code for exterior mirrors. 4. Follow normal Service Programming System (SPS) to reprogram the passenger door module with the current calibration available in TIS 2000. 5. After reprogramming is complete, using the switches in the right front passenger door, verify that the power window and power door lock located in that door function properly. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 9189 C149 Engine Harness To Coil Jumper Harness Page 9186 C125 Snowplow Harness To Forward Lamp Harness (With RPO Code VYU) Page 8628 Use clean, new power steering fluid only. 12. Fill the pump reservoir with fluid to the FULL COLD level. 13. Attach J 43485, Power Steering Bleeder Adapter, to J 35555, Metal Mityvac, or equivalent. 14. Place J 43485 on or in the pump reservoir filler neck. 15. Apply a vacuum of 68 kpa (20 in Hg) maximum. 16. Wait 1 minute. 17. Remove 1 J43485 and J 35555. 18. Reinstall the pump reservoir cap. 19. Start the engine. Allow the engine to idle. 20. Turn the steering wheel 180-360 degrees in both directions 5 times. 21. Switch the ignition off 22. Verify the fluid level. 23. Release the park brake and unblock the wheels. Page 10212 3. The adjuster plug (4) 11. Turn the adjuster plug (1) clockwise onto the rack and pinion gear assembly until the adjuster plug (1) bottoms in the rack and pinion gear assembly, then turn the adjuster plug (1) back 50 degrees to 70 degrees. 12. Check the rotational torque on the pinion. The maximum pinion preload torque is 1.8 Nm (16 inch lbs.). 13. Install the adjuster plug lock nut (5) to the adjuster plug (4).Finger tighten the adjuster plug lock nut (5) while holding the adjuster plug (4) stationary. ^ Tighten the nut to 68 Nm (50 ft. lbs.). 14. Install the steering gear into the vehicle, 15. Flush and bleed power the steering system (hoses, reservoir and cooler lines) with power steering fluid GM P/N 1050017 (Canadian P/N 992646) (or equivalent meeting GM Specification number 9985010). Important: Refer to Bleeding the Power Steering System. Page 10252 - Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-D in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-D if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Brakes/Wheels - Excessive Debris Build Up Wheels: Customer Interest Brakes/Wheels - Excessive Debris Build Up Bulletin No.: 04-05-23-005 Date: June 22, 2004 INFORMATION Subject: Availability of Rear Wheel Mud Flaps to Reduce Debris Build-up on Rear Brake Calipers and/or Rear Wheels Models: 1999-2004 Chevrolet Silverado Pickup Models 1999-2004 GMC Sierra Pickup Models This bulletin is to inform dealers of the release of rear wheel mud flaps. The above models that are exposed to extensive off-paved roads may benefit from the mud flaps. The mud flaps have been developed to minimize the amount of stones and/or mud that can impact and collect on the rear caliper and/or wheel rim. Please advise customers that the installation of these mud flaps and following the recommended off-road driving information provided in their Owner's Manual should greatly reduce the possibility of accelerated rear brake component wear and/or rim damage. Install the mud flap forward of each rear wheel using the following procedure. Important: Always work from outboard to inboard, drilling one hole at a time and securing with a fastener. Follow the sequence of the procedure. This will prevent distortion of the mud flap. 1. Raise the vehicle. Support the vehicle. 2. Locate the pickup box side panel rear brace. 3. Remove the existing outboard upper fastener on the brace. 4. Install the mud flap through the "V" of the brace. Install the previously removed fastener in the hole (2) of the mud flap to the brace. Do not tighten the fastener at this time. 5. Using the mud flap as a template, locate and mark the location of the hole (1) in the pickup box wheel house. Page 6258 14. Important: It is not necessary to remove the selector cable from the bracket. Remove the transmission range selector cable bracket (2) bolts and bracket from the transmission. Reposition the bracket with cable. 15. Remove the oil pan bolts. 16. Important: The transmission oil pan gasket is reusable. Inspect the gasket and replace as needed. Remove the oil pan and gasket. 17. Remove the magnet from the bottom of the pan, if necessary. 18. Remove the oil filter. 19. Remove the filter neck seal. 20. Clean the transmission case and the oil pan gasket surfaces with solvent. Installation Procedure Page 569 Disclaimer Page 14366 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Weather Pack Connectors WEATHER PACK CONNECTORS The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. Page 11190 Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 9980 Steering Column Position Sensor: Service and Repair Steering Wheel Position Sensor Centering Steering Wheel Position Sensor Centering Removal Procedure 1. Important: Identify the type of steering wheel position sensor from the illustrations shown BEFORE removing the sensor from the steering column. Once you have identified the steering wheel position sensor, follow the instructions listed in the removal procedure. Verify the type of steering wheel position sensor. 2. From the technicians point of view, the FRONT of the sensor (1) connector will be on the right. 3. Important: If reusing the existing sensor, you do not have to align the sensor before removal. Centering is not required when it is time to reinstall. Remove the connector from the sensor. 4. Remove the sensor (1) from the adapter and bearing assembly. 5. To install the sensor, proceed to step 1 in the installation section. 6. From the technicians point of view, the FRONT of the sensor will have: ^ A foam ring (2) ^ A pin hole (1) for centering the pin. Note the location of the pin hole. ^ A flush rotor flange cuff (4) 7. Important: If reusing the existing sensor, you must make an alignment mark on the rotor flange cuff (3) before removing the sensor. Failure to do so will cause misalignment when installing the sensor. A new sensor will be required if misaligned. Make an alignment mark on the flush rotor flange cuff (3). 8. Remove the connector from the sensor. 9. Remove the sensor from the adapter and bearing assembly. 10. To install the sensor, proceed to step 5 in the installation procedure. Page 3449 9. Use the J 38606 in order to compress the valve spring. 10. Remove the valve stem keys (2). 11. Carefully release the valve spring tension. 12. Remove the J 38606. 13. Remove the valve spring cap (3). 14. Remove the valve spring (4). 15. Remove the valve stem oil seal and shim (1, 5). Installation Procedure 1. Clean the cylinder head valve spring seat and/or shim area. 2. Lubricate the valve guide and valve stem oil seal with clean engine oil. 3. Install the valve stem oil seal and shim (1, 5). 4. Install the valve spring (4). 5. Install the valve spring cap (3). Page 13222 Vehicles Built with Upgradeable OnStar(R) System Analog Modules Note: Page 9590 Relay Block - I/P C1 Part 1 Page 12579 Claim Information - GM, Saturn Canada and Saab Canada Only Claim Information - Saturn US Only Customer Reimbursement Claims - Special Attention Required Customer reimbursement claims must have entered into the "technician comments" field the CSO # (if repair was completed at a Saturn Retail Facility) date, mileage, customer name, and any deductibles and taxes paid by the customer. Claim Information - Saab US Only Page 527 Front Passenger Door Module (FPDM) - C4 (With RPO Code YE9) Part 2 Front Passenger Door Module (FPDM) - C5 (With RPO Code AN3) Part 1 Page 456 Remove all rust from the ground terminal, the cylinder head and the retaining nut or bolt. Position the main engine wiring harness ground terminal and install the nut or bolt. Tighten: Tighten the retaining nut or bolt to 16 N.m (12 lb ft). Apply some type of electrical moisture sealant to protect the harness terminal from further corrosion. Disclaimer Page 3389 Intake Manifold: Specifications Intake Manifold Bolts - First Pass in Sequence ....................................................................................................................................... 5 Nm (44 inch lbs.) Intake Manifold Bolts - Final Pass in Sequence .................................................................................................................................... 10 Nm (89 inch lbs.) Throttle Body Nuts ....................................................................................................................... ......................................................... 10 Nm (89 inch lbs.) Throttle Body Studs .................................. .............................................................................................................................................. 6 Nm (53 inch lbs.) Page 11422 Repairs and Inspections Required After a Collision: Service and Repair Seat Belt System REPAIRS AND INSPECTIONS REQUIRED AFTER A COLLISION CAUTION: Restraint systems can be damaged in a collision. To help avoid injury and ensure that all parts in need of replacement are replaced: - Replace any seat belt system that was in use during the collision serious enough to deploy any automatic restraint device such as air bags and seat belt pretensioners. This not only includes seat belt systems in use by people of adult size, but seat belt systems used to secure child restraints, infant carriers and booster seats, including LATCH system and top tether anchorages. - Replace any seat belt system that has torn, worn, or damaged components. This not only includes adult seat belt systems, but built-in child restraints and LATCH system components, if any. - Replace any seat belt system if you observe the words "REPLACE" or "CAUTION", or if a yellow tag is visible. Do not replace a seat belt if only the child seat caution label is visible. - Replace any seat belt system if you are doubtful about its condition. This not only includes adult seat belt systems, but built-in child restraints, LATCH system components, and any restraint system used to secure infant carriers, child restraints, and booster seats. Do NOT replace single seat belt system components in vehicles that have been in a collision as described above. Always replace the entire seat belt system with the buckle, guide and retractor assembly, which includes the latch and webbing material. After a minor collision where no automatic restraint device was deployed, seat belt system replacement may not be necessary, unless some of the parts are torn, worn, or damaged. Page 14311 WA9260/74 - WA926L/59 Page 8410 1. Install the cable support bracket. 2. Notice: Refer to Fastener Notice in Service Precautions. Install the cable support bracket nuts. ^ Tighten the support bracket nuts to 85 Nm (64 ft. lbs.). 3. Install the rear cables to the mounting bracket by inserting the cable till all the retaining tabs snap into place. 4. Connect the rear cables to the equalizer. 5. Tighten the nut to the intermediate cable at the equalizer. ^ Tighten the nut to 3.5 Nm (31 inch lbs.). 6. Remove the safety stands. 7. Lower the vehicle. Park Brake Cable Equalizer Replacement Park Brake Cable Equalizer Replacement Removal Procedure 1. Release the park brake. 2. Raise and support the vehicle. Refer Vehicle Lifting 3. For the 15 series vehicles, remove the nut from the threaded end of the intermediate cable. 4. Disconnect the equalizer from the rear park brake cables. Page 2316 2. Install the evaporator tube nut to the condenser. Tighten Tighten the nut to 16 N.m (12 lb ft). 3. Install the grille to the vehicle. 4. Install the right park/turn signal lamp. 5. Install the evaporator tube to the evaporator. 6. Install the evaporator tube nut to the evaporator. Tighten Tighten the nut to 16 N.m (12 lb ft). 7. Evacuate and recharge the A/C system. Refer to Refrigerant Recovery and Recharging. 8. Leak test the fittings of the components using the J 39400-A. Page 12699 Page 1310 Ambient Temperature Sensor / Switch HVAC: Service and Repair AMBIENT AIR TEMPERATURE SENSOR REPLACEMENT REMOVAL PROCEDURE 1. Remove the Park/Turn Signal. 2. Disconnect the electrical connector from the ambient air temperature sensor (3). 3. Remove the ambient air temperature sensor (3). INSTALLATION PROCEDURE 1. Install the ambient air temperature sensor (3). 2. Connect the electrical connector to the ambient air temperature sensor (3). 3. Install the Park/Turn Signal. Page 11262 A/C Low Pressure Switch And A/C Accumulator Service and Repair Cowl Moulding / Trim: Service and Repair Air Inlet Grille Panel Replacement Removal Procedure 1. Remove the wiper arms. 2. Pull up in order to release the outboard air inlet grille panel clips. 3. Remove the attaching clips running along the edges of the center air inlet grille panel. 4. Remove the sheet metal screws on each end of the air inlet grille panel. 5. Disconnect the windshield washer hose from the nozzle underneath the center air inlet grille panel. 6. Remove the air inlet grille panel. Installation Procedure 1. Connect the windshield washer hose to the nozzle under the center air inlet grille panel. 2. Position the air inlet grille panel to the vehicle and attach the clips to the edges of the center air inlet grille panel. Notice: Refer to Fastener Notice in Service Precautions. 3. Install the sheet metal screws on each end of the air inlet grille panel. Tighten the sheet metal screws to 2 N.m (18 lb in). Page 7249 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-8 (12085115) crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-8 (12085115) until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes SPLICING INLINE HARNESS DIODES Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate Service Data wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. 9. Tape the diode to the harness or connector using electrical tape. Page 13043 7.3. If equipped, connect the rear seat heater's connector and install the switch. 8. Install the floor console: 8.1. Install the floor console's retaining bolts (C) and retaining nuts (F). 8.2. Align the rear cover; make sure that the air duct connects firmly to the air nozzle. Screw in the cover (E). 8.3. Install the ashtray/cover (D). 8.4. Install the ignition switch cover (B). 8.5. Plug in the immobilizer unit (A) connector. Install the unit, bayonet fitting. 9. Remove the OnStar(R) control modules and secure the wiring: 9.1. Remove the right-hand rear luggage compartment trim in accordance with WIS - 8. Body - Interior equipment - Adjustment/Replacement. 9.2. Unplug the connectors (A) from the OnStar(R) control modules. 9.3. Remove the console (B) together with the OnStar(R) control modules. Page 10287 7. From inside the vehicle remove the upper bolt from the upper intermediate steering shaft (1) to the steering column connection. 8. Remove the upper intermediate steering shaft assembly. 1. From inside the vehicle slide the shaft down and off the steering column. 2. From inside the vehicle slide the upper intermediate shaft through the dash boot seal and remove the shaft from the vehicle. 9. Replace the upper intermediate shaft. 10. Install the upper intermediate steering shaft through the dash boot seal and slide the lower end into the steering gear coupling shaft. 11. Raise the upper end of the intermediate steering shaft and install into the steering column shaft. 12. Install the upper bolt and nut. Tighten Tighten the bolt to 47 N.m (35 lb ft). 13. Install the lower bolt and nut. Tighten Tighten the bolt to 50 N.m (37 lb ft). 14. For vehicles equipped with adjustable foot pedals perform the following steps: 1. Reposition the accelerator pedals into position on the bulkhead. 2. Install the two retaining nuts. Tighten Tighten the nuts to 20 N.m (15 lb ft). 3. Reposition the carpet into place. Parts Information Warranty Information For vehicles repaired under warranty use, the table. Page 1746 1. Install the CKP sensor. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the CKP sensor bolt. Tighten Tighten the bolt to 25 N.m (18 lb ft). 3. Connect the CKP sensor electrical connector. 4. Install the starter. 5. Perform the CKP system variation learn procedure. See: Testing and Inspection/Programming and Relearning Page 11462 Air Bag Deactivation Switch: Service and Repair INFLATABLE RESTRAINT INSTRUMENT PANEL (I/P) MODULE DISABLE SWITCH REPLACEMENT REMOVAL PROCEDURE CAUTION: Refer to SIR Caution in Service Precautions. 1. Remove the instrument panel trim bezel. 2. Remove the I/P module switch from the lower right opening of the switch plate panel. 3. Disconnect the I/P module switch electrical connector. INSTALLATION PROCEDURE 1. Connect the I/P module switch electrical connector. 2. Install the I/P module switch into the lower right opening of the switch plate panel. 3. Install the instrument panel trim bezel. Page 5384 4. Connect the quick connect fittings to the EVAP canister. 5. Install the EVAP line to the clips (2) on the fuel tank. 6. Remove the caps from the fuel and EVAP lines. 7. Connect the fuel and EVAP quick connect fittings. 8. If equipped with 4WD, install the fuel line clip to the bracket on the transfer case. 9. Install the fuel line clips to the brackets on the transmission. Page 12326 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors USING CONNECTOR TEST ADAPTERS IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-B Connector Test Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Page 12536 DTC B2483: Global Positioning System (GPS) Antenna Malfunction Short to Ground DTC B2484: Global Positioning System (GPS) Antenna Malfunction Open Circuit Conditions for Running the DTCs The ignition is in RUN or ACC position System voltage is between 9.5 - 15.5 volts. The above conditions are met for more than 1 second. Conditions for Setting the DTCs B2462 02: The CIM detects a short to ground on the navigation antenna signal circuit. B2462 04: The CIM detects an open/high resistance on the navigation antenna signal circuit. B2483: The CIM detects a short to ground on the navigation antenna signal circuit. B2484: The CIM detects an open/high resistance on the navigation antenna signal circuit. Action Taken When the DTCs Set The OnStar(R) status LED turns red. The OnStar(R) Call Center cannot locate the vehicle. Conditions for Clearing the DTCs The condition responsible for setting the DTC no longer exists. A history DTC will clear once 50 consecutive malfunction-free ignition cycles have occurred. Circuit/System Testing Turn OFF the ignition. 1. Disconnect the navigation antenna coax cable from the VCIM. 2. Ignition ON, test for 4.5-5.5 volts between the VCIM coax cable center conductor terminal at the VCIM and ground. ^ If not within the specified range, replace the VCIM. Refer to the appropriate vehicle in SI. 3. Reconnect the coax cable to the VCIM. 4. Disconnect the coax cable from the navigation antenna. 5. Test for 4.55.5 volts between the coax cable center conductor and the outer shield. ^ If not within the specified range, replace the coax cable. 6. If all circuits test normal, replace the navigation antenna. Refer to the appropriate vehicle in SI. DTC B2470 DTC Descriptor DTC B2470 04: Cellular Phone Antenna Circuit Malfunction Open Circuit Circuit/System Description The cellular antenna is connected to the vehicle communication interface module (VCIM) with an RG-58 coax cable. The VCIM collects the data from the cellular antenna once every second. Page 15189 ADDITIONAL WARNINGS The following warnings have an associated instrument panel cluster (IPC) indicator or driver information center (DIC) indicator: - Engine Overheated Stop Engine The chime producer activates the audible warning as requested by the IPC. The IPC sends a class 2 message to the chime producer indicating the chime frequency and duration, continuous. - Ice Possible The chime producer activates the audible warning as requested by the IPC. The IPC sends a class 2 message to the chime producer indicating the chime frequency and duration. - Liftgate Ajar/Rear Access Open The chime producer activates the audible warning as requested by the IPC. The IPC sends a class 2 message to the chime producer indicating the chime frequency and duration, 4 pulses. - Low Fuel The chime producer activates the audible warning as requested by the IPC. The IPC sends a class 2 message to the chime producer indicating the chime frequency, medium rate, and duration, 4 pulses. - Oil Pressure Low Stop Engine The chime producer activates the audible warning as requested by the IPC. The IPC sends a class 2 message to the chime producer indicating the chime frequency and duration, continuous. - Overspeed/Vehicle Overspeed The chime producer activates the audible warning as requested by the IPC. The IPC sends a class 2 message to the chime producer indicating the chime frequency and duration, continuous. - Reduced Engine Power The chime producer activates the audible warning as requested by the IPC. The IPC sends a class 2 message to the chime producer indicating the chime frequency and duration. - Service Stability System The chime producer activates the audible warning as requested by the IPC. The IPC sends a class 2 message to the chime producer indicating the chime frequency and duration. - Stability System Disabled The chime producer activates the audible warning as requested by the IPC. The IPC sends a class 2 message to the chime producer indicating the chime frequency and duration. - Trans Hot Idle Engine The chime producer activates the audible warning as requested by the IPC. The IPC sends a class 2 message to the chime producer indicating the chime frequency and duration, continuous. Refer to Indicator/Warning Message Description and Operation. Page 4603 3. If equipped with a 6.0L engine, connect the HO2S electrical connector (1). 4. If equipped with a 4.8L or 5.3L engine, connect the HO2S electrical connector (1). 5. Install the HO2S electrical connector to the fuel line clip. 6. Disconnect the CPA retainer. 7. If necessary, bolt the front propeller shaft to the front differential. Refer to Propeller Shaft Replacement - Front in Propeller Shaft. 8. Lower the vehicle. Page 14611 Seat Front Vertical Motor - Front Passenger Page 5108 2. Disconnect the EVAP tube from the EVAP canister purge solenoid (1). 2.1. Push the large side white retainer portion in. 2.2. Push down, while pulling up slightly in order to disengage the tube. 3. Disconnect the EVAP tube from the chassis EVAP pipe (2). 3.1. Push the large side white retainer portion in. 3.2. Push down, while pulling up slightly in order to disengage the tube. 4. Remove the EVAP tube. 5. Cap the EVAP canister purge solenoid and EVAP chassis pipe in order to prevent possible EVAP system contamination. INSTALLATION PROCEDURE 1. Remove the caps from the EVAP canister purge solenoid and EVAP chassis pipe. 2. Install the EVAP tube. 3. Connect the EVAP tube to the EVAP chassis pipe (2). 4. Connect the EVAP tube to the EVAP purge solenoid (1). 5. Install the engine sight shield. Evaporative Emission (EVAP) Hoses/Pipes Replacement - Chassis 1 EVAPORATIVE EMISSION (EVAP) HOSES/PIPES REPLACEMENT - CHASSIS (PICKUP) REMOVAL PROCEDURE IMPORTANT: Clean the fuel and evaporative emission (EVAP) connections and surrounding areas prior to disconnecting the lines in order to avoid possible system contamination. 1. Relieve the fuel system pressure. Refer to Fuel Pressure Relief Procedure. 2. Disconnect the fuel feed line (1) at the engine. 3. Disconnect the EVAP canister purge tube line (2). 4. Cap the fuel rail in order to avoid possible system contamination. 5. Raise and suitably support the vehicle. Refer to Vehicle Lifting. Page 10378 Stabilizer Link: Service and Repair Rear Suspension Stabilizer Shaft Link Replacement (15/25 Series) Removal Procedure 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Remove the stabilizer shaft link nut and bolt from the frame bracket. 3. Remove the stabilizer shaft link nut from the ball stud. 4. Remove the stabilizer shaft link. Installation Procedure 1. Install the stabilizer shaft link. 2. Install the stabilizer shaft link nut to the ball stud. Important: When tightening the lower link nut verify that the inner jam nut bottoms out on the ball stud. Page 4281 Body Control Module (BCM) Page 10694 ACCESSORY WHEEL AND TIRE INFORMATION FORM You have just modified your vehicle by installing an "Accessory Package" which includes Wheels and Tires. This form contains important information about your accessory installation. In an effort to provide superior service to you, our customer, we ask that you please present this form to your Servicing Dealer when removing or installing wheels and tires on your vehicle. This form contains important information necessary to service your vehicle. Disclaimer Page 6453 1. Place the steering column shift lever back into the park (P) position. 2. Raise the vehicle. 3. Ensure that the transmission manual shaft lever is in the park (P) position. 4. Pull the white cover (1) back to expose the natural colored lock (2). Under the lock (2), insert a flat bladed screwdriver under the lock ramp located at the top of the lock. The lock will pop up, and the transmission end will move slightly away from the shifter end. 5. Push the end of the transmission end (3) inside the shifter end (1) until the blue spring (2) on the transmission end (3) is fully compressed, this will engage the inner wire and lock both wires together. Recall 04V240000: Incorrect Spare Tire on Vehicle Spare Tire: Recalls Recall 04V240000: Incorrect Spare Tire on Vehicle Make / Models : Model/Build Years: GMC / 1500 2004 Regency / Chevrolet 1500 2004 MANUFACTURER: General Motors Corp. NHTSA CAMPAIGN ID Number : 04V240000 Recall Date : MAY 14, 2004 COMPONENT: Tires: Temporary/Emergency Spare Tire Potential Number Of Units Affected : 285 SUMMARY: The spare tire and wheel assembly that was provided on certain conversion vehicles will not fit on the front wheel hub due to offset of the wheel. However, it will fit on the rear wheels. CONSEQUENCE: If someone has a flat tire on the front wheel, they will not be able to install the provided spare tire. REMEDY: Dealers will install a spare wheel with the correct offset. Owner notification began on June 11, 2004. Owners should contact Regency at 1-800-989-4727. NOTES: Customers can also contact The National Highway Traffic Safety Administration's Auto Safety Hotline at 1-888-DASH-2-DOT (1-888-327-4236). Page 13272 Important: The optic cable must not be bent with a radius less than 25 mm (1 in). 6.17. Fold back the wiring harness and tape over the connectors (G). Fold back the wiring harness once more and secure with cable ties (H). 6.18. Secure the new optic cable on the parcel shelf along the existing wiring harness by the ordinary securing points and by the speaker (I). 6.19. Thread the optic cable down next to the old cable from the parcel shelf to the left-hand wheel housing, next to REC. The cable is secured in the existing clips. 6.20. Fit the right-hand C-pillar trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.21. Fit the parcel shelf trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.22. Fit the passenger seat in accordance with WIS - 8. Body - Seats - Adjustment/Replacement. 6.23. Fit the right-hand side bolster in accordance with WIS - 8. Body - Seats Adjustment/Replacement. 6.24. Fold up the rear seat backrest. 6.25. Fit the right-hand B-pillar trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.26. Fit the A-pillar's lower side piece. 7. M04-05, 4D: Removing the OnStar® control modules and securing the wiring: Ignition System - New Spark Plugs & Gapping Info. Spark Plug: Technical Service Bulletins Ignition System - New Spark Plugs & Gapping Info. INFORMATION Bulletin No.: 03-06-04-060B Date: July 30 2008 Subject: Information on New Spark Plugs and Gapping Models Attention: Please disregard the Set Gap Per Vehicle Specification statement on the side of an ACOelco(R) Iridium Spark Plug Box. The statement will be removed from the boxes in the future. Supercede: This bulletin is being revised to add the Chevrolet SSR and the 2005 Pontiac GTO. Please discard Corporate Bulletin Number 03-06-04-060A (Section 06 - Engine/Propulsion System). ^ A new spark plug has been released for use in the above vehicles. The new spark plug has an Iridium tip instead of the current Platinum tip. Due to the different tip design the gap of the spark plug has also changed. ^ The new spark plug P/N 12571164 with AC Delco P/N 41-985 is gapped to 1.01 mm (0.040 in) when the spark plug is made. Notice: The spark plug gap is set during manufacturing and should not be changed or damage to the spark plug may result. Any new spark plug found to not be properly gapped should not be used. Disclaimer Interior - Heated Seats Intermittently Inoperative Seat Heater: All Technical Service Bulletins Interior - Heated Seats Intermittently Inoperative Bulletin No.: 05-08-05-008 Date: August 18, 2005 TECHNICAL Subject: Intermittent Heated Seats Inoperative, DTC B3941 Set (Reprogram Driver Seat Module) Models: 2003-2005 Cadillac Escalade, Escalade ESV, Escalade EXT 2003-2005 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2003-2005 GMC Sierra, Yukon, Yukon XL, Yukon Denali All with Seat FRT, Individual (Non BKT) (RPO AN3) 2003-2005 HUMMER H2 with Seat, Front Bucket Deluxe (RPO AR9) Condition Some customers may comment that occasionally the seat heater will not operate when activated. If the ignition key is cycled OFF and back ON again, the heated seat will operate correctly. Also, on some LB7 diesel engine vehicles, the seat heater may turn itself off during the first 10 minutes of operation. This occurs only with the first activation for the day and works correctly with subsequent activations immediately after the event. These conditions are intermiffent and DTC B3941 may be set. Correction Technicians are to reprogram the driver seat module with an updated software calibration. This new service calibration was released with TIS satellite data update version 6.5 available June 13, 2005. As always, make sure your Tech 2(R) is updated with the latest software version. Warranty Information Disclaimer Page 5377 6. Remove the fuel pipe bracket nut. 7. Remove the fuel pipe bracket from the bellhousing stud. 8. Remove the heated oxygen (HO2S) sensor connector from the bracket. 9. Remove the fuel line clip(s) from the bracket(s) on the transmission. 10. Remove the fuel line clip from the bracket on the transfer case, if equipped with 4 wheel drive (4WD). 11. Remove the clip from the bracket on the frame. 12. Remove the transfer case harness from the clip bracket. IMPORTANT: The area around the electro-hydraulic control unit (EHCU) MUST be free from loose dirt to prevent contamination of disassembled anti-lock brake (ABS) components. 13. Thoroughly wash all contaminants from around the EHCU. 14. Disconnect the chassis electrical harness connectors from the electronic brake control module (EBCM). 15. Disconnect the brake lines from the brake pressure modulator valve (BPMV). Propeller Shaft Replacement - One Piece Drive/Propeller Shaft: Service and Repair Propeller Shaft Replacement - One Piece Propeller Shaft Replacement - One Piece Removal Procedure 1. Important: Observe and accurately reference mark all driveline components relative to the propeller shaft and axles before disassembly. These components include the propeller shafts, the drive axles, the pinion flanges, the output shafts, etc. All components must be reassembled in the exact relationship to each other as they were when removed. In addition, published specifications and torque values, as well as any measurements made prior to disassembly must be followed. Raise the vehicle. Refer to Vehicle Lifting. 2. Reference mark the propeller shaft to the rear axle pinion yoke. 3. Reference mark the propeller shaft to the transmission or transfer case. 4. Remove the bolts (1) and the yoke retainers (2) from the rear axle pinion yoke (3). 5. Slide the propeller shaft forward in order to disconnect the propeller shaft from the rear axle pinion yoke. Notice: When removing the propeller shaft, do not attempt to remove the shaft by pounding on the yoke ears or using a tool between the yoke and the universal joint. If the propeller shaft is removed by using such means, the injection joints may fracture and lead to premature failure of the joint. 6. Slide the propeller shaft rearward in order to disconnect the propeller shaft from the transmission or transfer case. 7. Remove the propeller shaft from the vehicle. Page 8456 visible in the clear adapter tube). If fluid is seen coming out of the inlet port adapter up to 65 Nm (48 lb-ft) maximum torque, the hydro-boost booster assembly is "OK", Proceed to Step 19. A. If NO fluid is seen exiting from the inlet port adapter, complete Steps 19-27 and then repeat Steps 1-18. B. If no fluid is visible from the second evaluation, replace the hydro-boost unit. Proceed to the appropriate procedure found in this bulletin. 19. Loosen the clamp bolt, remove the clamp containment bolt, and remove the accumulator pressure clamp. Remove the inlet port adapter from the supply port of the booster. Wipe the excess power steering fluid off of the adapter with a clean, lint-free shop cloth. Store the adapter in a clean location, such as a plastic bag. 20. Reinstall the supply hose/tube to the booster. Tighten Tighten to 28 N.m (21 lb-ft). 21. Clean any spilled fluid from the outside of the booster. 22. For Express/Savana only: ^ Connect the reservoir outlet hose to the booster unit. Keeping the hose end higher than reservoir, reposition the reservoir onto the mounting studs. A. Install the remote power steering reservoir mounting nuts. Tighten Tighten to 7 Nm (58 lb in). 23. Start the engine and run at idle. Depress the brake pedal 5 times. Turn the steering wheel to the "steering lock" position. Hold for 1-2 seconds. Check to see if there is any leakage from the ports/fittings. 24. Turn the engine off. 25. If leaks were observed, re-check that the fittings are at the recommended torque values. Repeat Steps 17 and 18. 26. Check the power steering reservoir fluid level, add fluid if necessary. 27. Close the hood. Hydro-Boost(R) Replacement - Avalanche, Express, Savana, Silverado, Sierra, Suburban, Yukon XL Tools Required ^ J 35555 Metal Mityvac ^ J 43485 Power Steering Bleeder Adapter Removal 1. Apply the park brake and block the wheels. Page 6561 8. Connect the PNP switch electrical connector (2). 9. If equipped with 4WD, install the front propeller shaft. 10. Lower the vehicle. 11. Check the switch for proper operation. The engine must start in the park (P) or neutral (N) positions only. If proper operation of the switch can not be obtained, replace the switch. Page 6073 6. Install the J 29714-A. 7. Compress the servo cover with J 29714-A. Important: Flat-faced servo cover retaining rings that have been removed when servicing a transmission for any reason should not be re-used. 8. Remove the servo cover retaining ring. 9. Install the new round wire servo cover ring, P/N 24232065. 10. Remove J 29714-A. 11. Clean the servo cover area with Brake Clean and shop air. 12. Lower the vehicle. 13. Fill the transmission to the proper level with DEXRON(R)III transmission fluid. Refer to the appropriate SI Document. Parts Information Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use the table. Page 8359 1. Remove all traces of the original adhesive patch. 2. Clean the threads of the bolt with brake parts cleaner or the equivalent and allow to dry. 3. Apply Threadlocker GM P/N 12345493 (Canadian P/N 10953488) to the threads of the bolt. 3. Notice: Refer to Fastener Notice in Service Precautions. Install the backing plate bolts. ^ Tighten the backing plate bolts to 135 Nm (100 ft. lbs.). 4. Install the park brake shoe. 5. Install the axle shaft. 6. Adjust the park brake shoe. 7. Install the rotor. 8. For vehicles without RPO NYS, install the park brake cable to the mounting bracket until the locking tabs snap into place. 9. For vehicles with RPO NYS, install the rear park brake bracket bolt. ^ Tighten the bolt to 61 Nm (45 ft. lbs.). 10. Install the rear park brake cable to the park brake actuator lever. 11. Install the rear cables to the equalizer by pulling down on the intermediate cable and install the rear cables to the equalizer bar. 12. Install the tire and wheel assembly. 13. Remove the safety stands. 14. Lower vehicle. 15. Adjust park brake cable. Campaign - ECM Software Upgrade PROM - Programmable Read Only Memory: All Technical Service Bulletins Campaign - ECM Software Upgrade Bulletin No.: 06535 Date: August 09, 2006 SYSTEM SOFTWARE UPGRADE Subject: 06535-ON-BOARD DIAGNOSTIC (OBD) SYSTEM SOFTWARE UPGRADE - OBD SYSTEM IMPROVEMENTS (REPROGRAM POWERTRAIN CONTROL MODULE {PCM}) Models: 2004-05 CHEVROLET SILVERADO CHASSIS CAB, SUBURBAN, AVALANCHE 2004-05 GMC SIERRA CHASSIS CAB, YUKON XL EQUIPPED WITH DUAL FUEL TANKS Purpose This bulletin provides information about installing new Powertrain Control Module (PCM) software and calibration on certain involved 2004-05 Chevrolet Silverado chassis cab, Suburban, Avalanche; GMC Sierra chassis cab and Yukon XL model trucks, equipped with dual fuel tanks. The revised calibration includes OBD system improvements that affect the fuel level sender diagnostics that should be installed as soon as practical. Install the new calibration on all affected vehicles identified in this bulletin, including vehicles in new dealer inventory and any vehicles that return for service, for any reason, during the applicable 8 year / 80,000 mile (130,000 km) emission controller warranty coverage period. To verify if an updated calibration is required, refer to the following procedure in this bulletin. Parts Information Do not attempt to order the calibration number from GMSPO. The calibration numbers are programmed into Control Modules via a Techline Tech 2 scan tool and the Techline Information System (TIS) 2000 terminal with the calibration update. Use data version 8.0 for 2006 or later, broadcast to dealers on August 6, 2006 or TIS 2 Web version 8.0 for 2006 (website version of TIS); and on TIS DVD version 8.0 / 2006 or later, mailed to dealers beginning August 23, 2006. If you cannot access the calibration, call the Techline Customer Support Center and it will be provided. Service Procedure The "Required Field Actions" section of the GM Vehicle Inquiry System (GMVIS) must be checked to determine if a specific vehicle requires this action. If GMVIS indicates that System Software Upgrade 06535 remains 'open' and PCM reprogramming has not taken place otherwise after the TIS Broadcast or DVD availability dates identified in this bulletin, reprogram the PCM using a Tech 2 scan tool with the calibration update from Techline Information System (TIS) 2000. Tech 2(R) Remote Programming Method for PCM Note: Before reprogramming, please check the battery condition to prevent a reprogramming error of any of the modules due to battery discharge. Battery voltage must be between 12 and 16 volts during reprogramming. If the vehicle battery is not fully charged, use jumper cables from an additional battery. Be sure to turn off or disable any system that may put a load on the battery, such as automatic head lamps, daytime running lights, interior lights, heating, ventilation, and air conditioning (HVAC) system, radio, engine cooling fan, etc. A programming failure or control module damage may occur if battery voltage guidelines are not observed. The ignition switch must be in the proper position. The Tech 2(R) prompts you to turn ON the ignition, with the engine OFF. DO NOT change the position of the ignition switch during the programming procedure, unless instructed to do so. Make certain all tool connections are secure, including the following components and circuits: ^ The RS-232 communication cable port ^ The connection at the data link connector (DLC) ^ The voltage supply circuits DO NOT disturb the tool harnesses while programming. If an interruption occurs during the programming procedure, programming failure or control module damage may occur. DO NOT turn OFF the ignition if the programming procedure is interrupted or unsuccessful. Ensure that all control module and DLC connections Page 16017 Electrical Symbols Part 13 Page 1964 1. Notice: Refer to Fastener Notice in Service Precautions. Install the left rear speed sensor. ^ Tighten the speed sensor to 15 Nm (11 ft. lbs.). 2. Connect the left rear speed sensor electrical connector (4) 3. Lower the vehicle. Transfer Case Speed Sensor Replacement - Right Rear Transfer Case Speed Sensor Replacement - Right Rear Removal Procedure 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. Disconnect the right rear speed sensor electrical connector (3). Page 1082 Passlock Sensor Specifications Piston Ring: Specifications Piston Ring End Gap - First Compression Ring - Measured in Cylinder Bore - Production ............................................. 0.23-0.44 mm (0.009-0.017 inch) Piston Ring End Gap - First Compression Ring - Measured in Cylinder Bore - Service .................................................. 0.23-0.5 mm (0.009-0.0196 inch) Piston Ring End Gap - Second Compression Ring - Measured in Cylinder Bore - Production .......................................... 0.44-0.7 mm (0.017-0.027 inch) Piston Ring End Gap - Second Compression Ring - Measured in Cylinder Bore - Service ............................................. 0.44-0.76 mm (0. 0173-0.03 inch) Piston Ring End Gap - Oil Control Ring - Measured in Cylinder Bore - Production ........................................................ 0.18-0.75 mm (0.007-0.029 inch) Piston Ring End Gap - Oil Control Ring - Measured in Cylinder Bore - Se ..................................................................... 0.18-0.81 mm (0.007-0.032 inch) Piston Ring to Groove Clearance - First Compression Ring - Production ............................................................. 0.04-0.085 mm (0. 00157-0.00335 inch) Piston Ring to Groove Clearance - First Compression Ring - Service ................................................................... 0.04-0.085 mm (0. 00157-0.00335 inch) Piston Ring to Groove Clearance - Second Compression Ring - Production ............................................................ 0.04-0.078 mm (0.00157-0.0031 inch) Piston Ring to Groove Clearance - Second Compression Ring - Service .................................................................. 0.04-0.078 mm (0.00157-0.0031 inch) Piston Ring to Groove Clearance - Oil Control Ring Production ............................................................................... 0.012-0.2 mm (0.0005-0.0078 inch) Piston Ring to Groove Clearance - Oil Control Ring - Service ..................................................................................... 0.012-0.2 mm (0.0005-0.0078 inch) Page 12975 Speaker Replacement Reference Page 15891 Upper Steering Column Page 10803 The new calibrations have been updated to compensate for the actuator overtravel condition, the actuator hunting and the ticking/clicking noises. The new calibrations effectively eliminate the codes listed above, the default position of the doors associated with the DTCs and opens up the feedback position value. The new calibrations should not be used unless the vehicle has one or more of the customer concerns listed above or a DTC listed above has been set. The new calibrations will not correct any other DTC or NC system performance concern. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 15915 3. Prepare the surface of the used defroster tab (not required for new tabs on new-style full-size utility models) and the defroster buss bar with fine grain (500 grit) sandpaper or Emery cloth. It is not necessary to remove all of the original solder, but it should be scuffed sufficiently so that no oxidation is present. The photo above shows a close up of a properly prepared surface. Tip You may want to mask the glass around the contact area with tape. This is easy to do and will allow you to safely prepare the contact surface without the risk of scratching the glass or the black painted shading. Important Most rear glass has a black painted masking around the edge of the glass. When cleaning up the connection surface, be very careful not to damage the surface of the black shading or the surface of the glass. 4. Wipe the newly prepared contact area with Kent Automotive* Acrysol(TM) (or equivalent) to remove any residual oil or dirt. Important Page 3138 1. Lubricate the valve rocker arms and pushrods with clean engine oil. 2. Lubricate the flange of the valve rocker arm bolts with clean engine oil.Lubricate the flange or washer surface of the bolt that will contact the valve rocker arm. 3. Install the valve rocker arm pivot support. 4. Important: Make sure that the pushrods seat properly to the valve lifter sockets. Install the pushrods. 5. Important: Make sure that the pushrods seat properly to the ends of the rocker arms. DO NOT tighten the rocker arm bolts at this time. Install the rocker arms and bolts. Page 4481 Electrical Symbols Part 3 Page 12669 2007 Model Year Vehicles and Newer all have Digital OnStar(R) Modules. Part 1 OnStar(R) Description and Operation This OnStar(R) digital system consists of the following components: ^ Vehicle Communication Interface Module (VCIM) ^ OnStar(R) button assembly ^ Microphone ^ Cellular antenna ^ Navigation antenna Note This system also interfaces with the factory installed vehicle audio system. Vehicle Communication Interface Module (VCIM) The vehicle communication interface module (VCIM) is a cellular device that allows the user to communicate data and voice signals over the national cellular network. Power is provided by a dedicated, fused B+ circuit. Ground is provided through the vehicle wiring harness attached to the module. The ignition state is determined by the VCIM through serial data messaging. Dedicated circuits are used to connect the VCIM to a microphone, the button assembly, and to command the status LED. The VCIM communicates with the rest of the vehicle modules using the serial data bus. The module houses 2 technology systems, one to process GPS data, and another for cellular information. The cellular system connects the OnStar(R) system to the cellular carrier's communication system by interacting with the national cellular infrastructure. The module sends and receives all cellular communications over the cellular antenna and cellular antenna coax. GPS satellites orbiting earth are constantly transmitting signals of their current location. The OnStar(R) system uses the GPS signals to provide location on demand. The module also has the capability of activating the horn, initiating door lock/unlock, or activating the exterior lamps using the serial data circuits. These functions can be commanded by the OnStar(R) Call Center per: a customer request. OnStar(R) Button Assembly The OnStar(R) button assembly may be part of the rearview mirror, or a separate, stand alone unit. The button assembly is comprised of 3 buttons and a status LED. The buttons are defined as follows: ^ The answer/end call button, which is black with a white phone icon, allows the user to answer and end calls or initiate speech recognition. ^ The blue OnStar(R) call center button, which displays the OnStar(R) logo, allows the user to connect to the OnStar(R) call center. ^ The emergency button, which displays a white cross with a red background, sends a high priority emergency call to the OnStar(R) call center when pressed. The VCIM supplies 10 volts to the OnStar(R) button assembly on the keypad supply voltage circuit. When pressed, each button completes a circuit across a resistor allowing a specific voltage to be returned to the VCIM on the keypad signal circuit. Depending upon the voltage range returned the VCIM is able to identify which button has been pressed. The OnStar(R) status LED is located with the button assembly. The LED is green when the system is ON and operating normally. When the status LED is green and flashing, it is an indication that a call is in progress. When the LED is red, this indicates a system malfunction is present. In the event there is a system malfunction and the OnStar(R) system is still able to make a call, the LED will flash red during the call. If the LED does not illuminate, this may indicate that the customers OnStar(R) subscription is not active or has expired. Push the blue OnStar button to connect to an advisor who can then verify the account status. Each LED is controlled by the VCIM over dedicated LED signal circuits. Ground for the LED is provided by the wiring harness attached to the button assembly. Page 6544 Steps 1-9 Test Description The numbers below refer to the step numbers on the diagnostic table. 2. This step tests for a faulty tow/haul switch. 3. This step tests for voltage input from the BCM to the tow/haul switch. 6. This step tests for ground integrity. TPMS System - Service And Re-Learning Sensor IDs Tire Pressure Module: Technical Service Bulletins TPMS System - Service And Re-Learning Sensor IDs INFORMATION Bulletin No.: 10-03-16-001 Date: July 19, 2010 Subject: TPMS System Service and Re-Learning Sensor IDs Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks 2010 and Prior HUMMER H2 2009 and Prior HUMMER H3 2010 and Prior Saturn Models 2009 and Prior Saab 9-7X with Wheel-Mounted Tire Pressure Sensors In the event that the spare tire, which is normally not equipped with a tire pressure monitor (TPM) sensor, is installed in place of one of the road tires and the vehicle is driven above 40 km/h (25 mph) for 20 minutes or more, the TPM indicator icon on the instrument panel cluster (IPC) will flash for approximately one minute and then remain on steady each time the ignition is turned ON, indicating a diagnostic trouble code (DTC) has been set. The driver information center (DIC), if equipped, will also display a SERVICE TIRE MONITOR type message. When the road tire is repaired and reinstalled in the original location, the TPM indicator icon illumination and DIC message may remain displayed until the DTC is cleared. To ensure that the TPM indicator and the DIC message are cleared after service, it is necessary to clear any TPM DTCs using a scan tool. If a scan tool is unavailable, performing the TPM relearn procedure using a TPM diagnostic tool will provide the same results. It is advised to perform the relearn procedure away from other vehicles to prevent picking up a stray sensor signal. If one or more of the TPM sensors are missing or damaged and have been replaced, then the relearn procedure must be performed. Disclaimer Page 12199 Page 8810 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves SPLICING COPPER WIRE USING SPLICE SLEEVES TOOLS REQUIRED J 38125-D Terminal Repair Kit IMPORTANT: Use only GM splice sleeves, other splice sleeves may not protect the splice from moisture or a provide good electrical connection. Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. Page 7275 3. This step tests for open cruise fuse. 4. This step tests the battery positive circuit for battery voltage. 5. This step tests the battery positive circuit for an open. 6. This step tests the PTO relay output circuit for an open. 7. This step tests the PTO ON signal circuit for battery voltage. 8. This step tests the PTO ON signal circuit for an open. 9. This step tests the cruise control set/coast switch signal circuit for battery voltage. 10. This step tests the PTO status circuit for an open. 11. This step tests the PTO switch and PTO unit ground circuits for an open. 12. This step tests the battery positive and PTO relay output circuits for a short to ground. 13. This step tests the ignition 3 circuit for a short to ground. 14. This step tests the cruise control ON switch signal, cruise control set/coast signal, PTO status, and PTO ON signal circuits for a short to ground. 15. This step tests the control side of the PTO relay for proper operation. Power Take-Off (PTO) Indicator Inoperative POWER TAKE-OFF (PTO) INDICATOR INOPERATIVE CIRCUIT DESCRIPTION This symptom chart will aid in diagnosing a failed Power Take-Off (PTO) indicator. This diagnostic assumes that the PTO solenoid is functional and only the indicator is failing to come on. When the ignition switch is in RUN, voltage should be present on the Ignition 3 Voltage circuit. When the PTO switch is turned to ON, the LED will illuminate. The indicator has its own ground circuit. The LED and PTO solenoid have different ground circuits. Therefore, the LED may be illuminated when the PTO solenoid is disengaged. TEST DESCRIPTION Page 5640 - Worn ignition wires - Incorrect spark plug gap - Excessive idling or slow speeds under light loads can keep spark plug temperatures so low that normal combustion deposits may not burn off. - Deposit fouling - Oil, coolant, or additives that include substances such as silicone, very white coating, reduces the spark plug intensity. Most powdery deposits will not affect spark plug intensity unless they form into a glazing over the electrode. Page 9371 Disclaimer Page 6921 18. Pinch the new swage ring (2) slightly by hand to distort it into an oval shape. 19. Slide the distorted swage ring (2) over the large diameter of the boot (1). 20. Slide the CV joint (4) onto the halfshaft bar (3). The retaining snap ring inside of the inner race engages in the halfshaft bar groove with a click when the CV joint (4) is in the proper position. Pull on the CV joint (4) to verify engagement. Important: Be sure that the retaining ring side of the CV joint inner race faces the halfshaft bar (3) before installation. 21. Slide the large diameter of the CV joint boot (1), with the large swage ring (2) in place, over the outside edge of the CV joint outer race (4). 22. Clamp the CV joint boot (2) tightly to the CV joint outer race (1) with the large swage ring (4), using the following procedure: 23. Mount the base of J 36652 in a vise. 24. Position the CV joint end (outboard end) of the halfshaft assembly in the bottom half of J 36652. Page 5228 8. Install the new fuel cap, P/N 15225005, tether strap in the elongated hole in the fuel filler housing. 9. Install the fuel fill cap on the filler pipe and tighten until the cap clicks. Parts Information Warranty Information For vehicles repaired under warranty, use the table Disclaimer Page 16066 Electrical Symbols Part 9 Page 13978 Carpet: Technical Service Bulletins Interior - Elimination Of Unwanted Odors INFORMATION Bulletin No.: 00-00-89-027E Date: September 29, 2008 Subject: Eliminating Unwanted Odors in Vehicles Models: 2009 and Prior GM Passenger Cars and Trucks (including Saturn) 2009 and Prior HUMMER H2, H3 Vehicles 2009 and Prior Saab 9-7X Supercede: This bulletin is being revised to add model years and refine the instructions. Please discard Corporate Bulletin Number 00-00-89-027D (Section 00 - General Information). Vehicle Odor Elimination General Motors offers a product that may control or eliminate odors in the interior and luggage compartment areas of GM vehicles. GM Vehicle Care Odor Eliminator is a non-toxic, biodegradable odor remover. This odorless product has been shown to greatly reduce or remove objectionable smells of mold and mildew resulting from vehicle water leaks (as well as customer created odors, i.e. smoke). You may use GM Vehicle Care Odor Eliminator on fabrics, vinyl, leather, carpet and sound deadening materials. It may also be induced into HVAC modules and instrument panel ducts (for the control of non-bacterial related odors). Important: This product leaves no residual scent and should not be sold as or considered an air freshener. Product action may result in the permanent elimination of an odor and may be preferable to customers with allergies who are sensitive to perfumes. How to Use This Product GM Vehicle Care Odor Eliminator may be sprayed on in a ready-to-use formula or used in steam cleaners as an additive with carpet shampoo. This water-based, odorless product is safe for all vehicle interiors. Do not wet or soak any interior surface that plain water would cause to deteriorate, as this product will have the same effect. Also avoid letting this product come into contact with vinegar or any acidic substance. Acid-based products will hamper the effectiveness of, or render GM Vehicle Care Odor Eliminator inert. Note: Complete eight page treatment sheets are enclosed within each case of GM Vehicle Care Odor Eliminator. These treatment instructions range from simple vehicle odor elimination to full step by step procedures for odor removal from water leaks. If lost, contact 800-977-4145 to get a replacement set faxed or e-mailed to your dealership. Instructions and cautions are printed on the bottle, but additional help is available. If you encounter a difficult to eliminate or reoccurring odor, you may call 1-800-955-8591 (in Canada, 1-800-977-4145) to obtain additional information and usage suggestions. Important: This product may effectively remove odors when directly contacting the odor source. It should be used in conjunction with diagnostic procedures (in cases such as a water leak) to first eliminate the root cause of the odor, and then the residual odor to permanently correct the vehicle condition. Vehicle Waterleak Odor Elimination STEP ONE: Confirm that all water leaks have been repaired. Determine what areas of the vehicle were water soaked or wet. Components with visible mold/mildew staining should be replaced. Isolate the odor source inside the vehicle. Often an odor can be isolated to an area or component of the vehicle interior by careful evaluation. Odor evaluation may need to be performed by multiple persons. Another method of isolating an odor source is to remove and segregate interior trim and components. Plastic sheeting or drop cloths can be used to confine seats, headliners, etc. to assist in evaluation and diagnoses. If appropriate the vehicle and interior trim should be evaluated separately to determine if the odor stays with the vehicle or the interior components. Odors that stay with the vehicle may be isolated to insulating and sound deadening materials (i.e. water leak at the windshield or standing water in the front foot well area caused mold/mildew to form on the bulkhead or kick panel sound deadening pads. If the interior is removed the floor pan and primed/painted surfaces should be treated with bleach/soap solution, rinsed with clean water and dried. Interior surfaces should then be treated with GM Vehicle Care Odor Eliminator product before reinstalling carpet or reassembling. Page 13282 9. Erase the diagnostic trouble codes. 10. Set the date and time, see WIS - 3. Electrical system - Information display (SID) - Technical description. Page 5356 18. Remove the torsion bar bracket, if equipped with 4WD. 19. Remove the EVAP canister. 20. Disconnect the fuel line at the tank. 21. Cap the fuel and EVAP lines in order to avoid possible system contamination. 22. Remove the fuel/EVAP bundle clip nuts. 23. Remove the fuel/EVAP bundle. INSTALLATION PROCEDURE 1. Install the fuel/EVAP bundle. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the fuel/EVAP bundle clip nuts. Tighten Tighten the nuts to 12 N.m (106 lb in). 3. Remove the caps from the fuel and EVAP lines. 4. Connect the fuel line at the tank. 5. Install the EVAP canister. 6. Install the torsion bar bracket, if equipped with 4WD. Page 816 Junction Block - I/P Wire Entry Part 4 Page 1550 Camshaft Position Sensor: Description and Operation CAMSHAFT POSITION (CMP) SENSOR The CMP sensor is also a magneto resistive sensor, with the same type of circuits as the CKP sensor. The CMP sensor signal is a digital ON/OFF pulse, output once per revolution of the camshaft. The CMP sensor information is used by the PCM to determine the position of the valve train relative to the CKP. Page 12555 Page 914 Body Control Module (BCM) - C2 Part 1 Drivetrain - Excessive Effort When Shift 2HI to 4HI Case: All Technical Service Bulletins Drivetrain - Excessive Effort When Shift 2HI to 4HI TECHNICAL Bulletin No.: 09-04-19-002A Date: February 17, 2011 Subject: 4WD System Shift Performance in Cold Ambient Temperatures (Use Synthetic Fluid in Light Duty Front Axles with 8.5" Ring Gears) Models: 1999-2011 Chevrolet Silverado 1500 Series Models 1999-2011 GMC Sierra 1500 Series Models Equipped with 4WD and 8.25" Front Axle Ring Gears (Transfer Case RPOs NP2, NQG) Attention: It is important to determine the RPO for the transfer case in GWM/IVH prior to applying this bulletin. This bulletin applies ONLY to vehicles equipped with 8.25" front axle ring gears, used in conjunction with a manual transfer case (RPOs NP2, NQG). Supercede: This bulletin is being revised to add the 2011 model year. Please discard Corporate Bulletin Number 09-04-19-002 (Section 04 - Driveline/Axle). Condition Some customers may comment about the effort required to shift from 2HI to 4HI in cold ambient temperatures at -6°C (20°F) or below. Cause This condition may be caused by the standard front axle being equipped with conventional mineral oil axle fluid. In cold ambient temperatures, prior to complete warm up, the fluid viscosity is thick. This may affect transfer case shift performance prior to full warm up. Correction Drain the front axle fluid and refill with GM SAE 75W-90 Synthetic Axle Fluid, P/N 89021677 (in Canada, 89021678). Refer to Front Axle Lubricant Replacement in SI. It is important to use synthetic fluid in this 8.25" axle to improve the performance of the 4WD system in cold ambient temperatures. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 13407 IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections TESTING FOR INTERMITTENT AND POOR CONNECTIONS TOOLS REQUIRED - J 35616-C GM-Approved Terminal Test Kit - J 38125-D Terminal Repair Kit - J 42675 Flat-Wire Probe Adapter Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector. - Poor terminal to wire connection - Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. - Wire insulation which is rubbed through - This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. - Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. Testing For Proper Terminal Contact It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-D or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-D, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. Page 3391 7. Remove the positive crankcase ventilation (PCV) hose. 8. Remove the MAP sensor (1) from the intake manifold. Page 4506 Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. 1. Disconnect the connector from the component. 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. Page 8642 1. Install the gasket to the booster. 2. Install the vacuum booster. 3. Notice: Refer to Fastener Notice in Service Precautions. Install the 4 vacuum booster mounting nuts. ^ Tighten the nuts to 33 Nm (24 ft. lbs.). 4. Install the pushrod (3) and the stop lamp switch (2) to the brake pedal stud (1). 5. Install the pushrod retaining clip (4) to the brake pedal stud (1). 6. Install the vacuum hose to the brake booster check valve. 7. Install the master cylinder. 8. Release the park brake and unblock the wheels. Page 4534 Information Bus: Description and Operation DATA LINK COMMUNICATIONS DESCRIPTION AND OPERATION CIRCUIT DESCRIPTION The serial data communication among the control modules is performed through multiple serial data communication links. The class 2 serial data line is always present. The high speed GMLAN or controller area network (CAN) may be present for different vehicle options. The data link connector (DLC) allows a scan tool to communicate with the modules on class 2 or high speed GMLAN serial data lines. In order for the scan tool to communicate with the modules on high speed GMLAN link, a CANdi module is needed. The CANdi module behaves as an interface between the scan tool and the high speed GMLAN data link. The CAN is used for functional communication only, among the modules connected to it. DATA LINK CONNECTOR (DLC) The data link connector (DLC) is a standardized 16 cavity connector. Connector design and location is dictated by an industry wide standard, and is required to provide the following: Scan tool power battery positive voltage at terminal 16 - Scan tool power ground at terminal 4 - Common signal ground at terminal 5 - Class 2 signal at terminal 2 - High speed GMLAN serial data bus (+) at terminal 6 - High speed GMLAN serial data bus (-) at terminal 14 CLASS 2 SERIAL DATA LINE lass 2 serial data is transmitted on a single wire at an average of 10.4 kbps. This value is an average, class 2 uses a variable pulse width modulation to carry data and depending on the message it may operate faster or slower. The bus will float at a nominal 7.0 volts during normal operation. Each module can pull this lower during the transmission. The bus is not at battery positive voltage or ground potential during normal operation. When the ignition switch is in RUN, each module communicating on the class 2 serial data line sends a state of health (SOH) message every 2 seconds to ensure that the module is operating properly. When a module stops communicating on the class 2 serial data line, for example if the module loses power or ground, the SOH message it normally sends on the data line every 2 seconds disappears. Other modules on the class 2 serial data line, which expect to receive that SOH message, detect its absence; those modules in turn set an internal DTC associated with the loss of SOH of the non-communicating module. The DTC is unique to the module which is not communicating, for example, when the inflatable restraint sensing and diagnostic module (SDM) SOH message disappears, several modules set DTC U1088. Note that a loss of serial data DTC does not normally represent a failure of the module that set it. The class 2 serial data line on this vehicle is a star configuration. The powertrain control module (PCM) has an additional class 2 serial data circuit to body control module (BCM). If one of the class 2 serial data circuits to the PCM opens, communication will not be interrupted. The following modules communicate on the class 2 serial data line: The audio amplifier (early production)- Refer to Radio/Audio System Description and Operation in Radio, Stereo and Compact Disc for more information. - The body control module (BCM) - The digital radio receiver (DRR) - The driver door module (DDM) - The driver seat module (DSM) - The electronic brake control module (EBCM) - The front passenger door control module (FPDM) - The HVAC control module - The hybrid control module (HCM), for PHT - The inflatable restraint sensing and diagnostic module (SDM) - The instrument panel cluster (IPC) - The powertrain control module (PCM) - The radio - The rear seat audio (RSA) controller - The rear seat entertainment (RSE) assembly, w/U42 - The rear wheel steering control module (RWSCM) - The remote playback device. CD player (CDX), w/U1S - The transfer case shift control module (TCSCM), w/4WD - The transmission control module (TCM), w/Allison Transmission - The vehicle communication interface module (VCIM), w/UE1 The class 2 serial data line allows a scan tool to communicate with these modules for testing purposes, checking for DTCs, and to activate/enable/disable functions. These class 2 serial data circuits are bussed together via two splice packs: SP205.Located behind the I/P near the headlamp switch connector. - SP207.Located in the I/P harness. Refer to Data Link Communications Component Views. CONTROLLER AREA NETWORK (CAN) SERIAL DATA LINE W/6.6L ENGINE Page 2356 8. Important: Align the arrow at the throttle body end of the duct with the throttle body attaching stud. Install the air cleaner outlet duct. 9. Install the radiator inlet hose clip to the outlet duct. 10. Tighten the air cleaner outlet duct clamps at the following locations: ^ Throttle body ^ MAF/IAT sensor Tighten the air cleaner outlet duct clamp screws to 7 Nm (62 inch lbs.). 11. Fill the cooling system. Page 280 networks, and will not require an upgrade in connection with the cellular industry's transition to the digital network. In order to verify the type of OnStar(R) Hardware in a vehicle, type the VIN into the VIN look-up tool, which is available at the OnStar(R) Online Enrollment website within GM GlobalConnect (for U.S. dealers) or InfoNet (for Canadian dealers). Disclaimer Page 9154 For vehicles repaired under warranty, use the table. Disclaimer Page 6550 Transmission Mount: Service and Repair Automatic Transmission - 4L80-E/4L85-E Transmission Mount Replacement Removal Procedure 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Support the transmission with a transmission jack. 3. Remove the transmission mount to the transmission support retaining nut or nuts. 4. Raise the transmission to take the weight off of the mount. 5. Remove the transmission mount to the transmission or transfer case adapter mounting bolts (1). 6. Raise the transmission just enough to remove the transmission mount. 7. Remove the transmission mount from the vehicle. Installation Procedure 1. Install the transmission mount to the vehicle. 2. Notice: Refer to Fastener Notice in Service Precautions. Install the transmission mount to the transmission or transfer case adapter mounting bolts (1). ^ Tighten the bolts to 50 Nm (37 ft. lbs.). Connector Views License Plate Lamp: Connector Views License Lamp - Left Page 15819 Horn Switch: Service and Repair Horn Switch Replacement Removal Procedure 1. Caution: Refer to Servicing the SIR System Caution in Cautions and Notices. Disable the SIR system. 2. Remove the inflatable restraint steering wheel module. 3. Remove the horn plunger from the steering column by pressing inward to the stop and rotating the horn plunger 90 degrees. 4. Disconnect the captured screws (1,4) to the horn contact plate (2) from the steering wheel (3). 5. Remove the horn switch (2) from the steering wheel (3). Installation Procedure 1. Install the horn switch (2) to the steering wheel (3). 2. Notice: Refer to Fastener Notice in Service Precautions. Connect the captured screws (1,4) from the horn contact plate (2) to the steering wheel (3). ^ Tighten the screws to 5.5 Nm (50 inch lbs.). Page 7692 Parts Information Warranty Information (excluding Saab U.S. Models) Warranty Information (Saab U.S. Models) Page 8495 Yukon XL vehicles built within the VIN breakpoints shown. Important: Dealers should confirm vehicle eligibility through GMVIS (GM Vehicle Inquiry System) before beginning recall repairs. [Not all vehicles within the above breakpoints may be involved.] For US For dealers with involved vehicles, a Campaign Initiation Detail Report containing the complete Vehicle Identification Number, customer name and address data has been prepared and will be loaded to the GM DealerWorld, Recall Information website. Dealers that have no involved vehicles currently assigned will not have a report available in GM DealerWorld. For Canada For dealers with involved vehicles, a Campaign Initiation Detail Report containing the complete Vehicle Identification Number, customer name and address data has been prepared and is being furnished to involved dealers. Dealers that have no involved vehicles currently assigned will not receive a report with the recall bulletin. For Export For dealers with involved vehicles, a Campaign Initiation Detail Report containing the complete Vehicle Identification Number, customer name and address data has been prepared and is being furnished to involved dealers. Dealers that have no involved vehicles currently assigned will not receive a report with the recall bulletin. The Campaign Initiation Detail Report may contain customer names and addresses obtained from Motor Vehicle Registration Records. The use of such motor vehicle registration data for any other purpose other than follow-up necessary to complete this recall is a violation of law in several states/provinces/countries. Accordingly, you are urged to limit the use of this report to the follow-up necessary to complete this program. Parts Information A very small number of vehicles (less than 90 world-wide) will require the replacement of the hydraulic brake booster. Do not order boosters for shelf stock. When a replacement is required, order the appropriate booster from GMSPO. All replaced boosters (excluding Export) must be returned to the Warranty Parts Center. Hold the booster until you receive the request for return. Special Tool Beginning February 18, 2005, each dealer was shipped a Hydro-Boost Checking Tool, CH 47950, for use in this recall. This tool is being furnished at no charge. Additional tools, if required, may be purchased by contacting SPX Kent-Moore at 1-800-468-6657. Courtesy Transportation The General Motors Courtesy Transportation program is intended to minimize customer inconvenience when a vehicle requires a repair that is covered by the New Vehicle Limited Warranty. The availability of courtesy transportation to customers whose vehicles are within the warranty coverage period and involved in a product recall is very important in maintaining customer satisfaction. Dealers are to ensure that these customers understand that shuttle service or some other form of courtesy transportation is available and will be provided at no charge. Dealers should refer to the General Motors Service Policies and Procedures Manual for Courtesy Transportation guidelines. Page 8479 13. Using a clean shop towel, clean up any fluid that may have leaked out of the hydraulic brake booster when removing the original valve. 14. Position the master cylinder (and brake combination valve mounting bracket on full size pickups and utilities) on the mounting bolts on the hydraulic brake booster. 15. With the master cylinder mounted flush to the booster, install the nuts. Tighten Tighten the nuts to 33 N.m (24 lb ft). 16. On van models, install the diagonal brace with the water deflector attached to it between the left fender and the radiator. Install the two bolts. Tighten Tighten bolts to 25 N.m (18 lb ft). 17. Start the engine and verify the hydraulic brake booster operation. 18. Turn the engine OFF and check the power steering fluid reservoir. Add fluid if necessary. 19. Close the hood. Page 11579 Service Procedure 1. Note the position of the rear seats. 2. Position the seats to gain access to the lower seat belt anchor stud for the rear center seat. 3. Remove any cover necessary to gain access to the lower seat belt anchor point for the rear center seat. 4. Remove the nut (1) retaining the rear center seat's lower seat belt anchor (seat back shown in the up position). 5. Remove the belt anchor point from the stud. 6. Remove the belt from the seat loop on the front of the seat back cushion. 7. Route the belt outside of the seat loop and install it on the lower anchor stud. Be sure that the belt is not twisted. 8. Install the retaining nut to the anchor stud. Tighten Tighten the retaining nut to 53 Nm (39 lb ft). 9. Using an appropriate color of locally obtained upholstery thread and needle (size 16 recommended), sew the retaining loop closed in the center. 10. Reposition the seats to the customer's original position as noted in Step 1 Courtesy Transportation -- for US and Canada The General Motors Courtesy Transportation Program is intended to minimize customer inconvenience when a vehicle requires a repair that is covered by the New Vehicle Limited Warranty. The availability of courtesy transportation to customers whose vehicles are within the warranty coverage period and involved in a product recall is very important in maintaining customer satisfaction. Dealers are to ensure that these customers understand that shuttle service or some other form of courtesy transportation is available and will be provided at no charge. Dealers should refer to the General Motors Service Page 7595 Page 15498 1. Install the park brake warning lamp switch. 2. Notice: Refer to Fastener Notice in Service Precautions. Install the park brake warning lamp switch mounting bolt. ^ Tighten the bolt to 3 Nm (25 inch lbs.). 3. Connect the park brake warning lamp switch electrical connector. 4. Install the MID-bussed electrical center to the bracket. 5. Connect the negative battery cable. Page 2655 Fuse Block - Underhood C4 Part 2 Page 15059 The illustrations shown are typical examples of the types of fractures/damage that may occur. Parts Information Warranty Information Page 13079 monitor the Tech2(R) for the current time and date. REMINDER - Keep in mind that the time displayed on the Tech2(R) is in Greenwich Mean Time (GMT) and the offset is based on the time zones relationship to GMT. If replacement of the VIU/VCIM is necessary, you MUST reconfigure the OnStar® system. Failure to reconfigure the system will result in an additional customer visit for repair. OnStar® VIU, Generations 2 and 3, will require the technician to press the blue OnStar® button to reconfigure the vehicle with an OnStar® advisor. OnStar(R) VCIM, Generations 4-7 will require the technician to reconfigure the vehicle with the use of the TIS2WEB and SPS applications (pass thru only), along with the Tech2(R). The configuration and set-up procedure is a two-step process that must be completed step-by-step without interruption or delay in between each step. This procedure enables an automated activation without a button press by the technician to the OnStar(R) Call Center. Following this procedure, it may take up to 24 hours for all OnStar(R) services to be fully activated. How to Order Parts If the OnStar(R) GPS date/time stamp is non-recoverable and the unit needs to be replaced, dealers in the U.S. should contact Autocraft Electronics select the catalog item that contains this bulletin number. Canadian dealers should contact MASS Electronics. Dealers DO NOT need to call the GM Technical Assistance Center (TAC) for replacement approval. Autocraft Electronics and MASS Electronics will be responsible for verifying that the subject vehicle is a candidate for a replacement VIU/VCIM. Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use the table. Warranty Information (Saab U.S. Models) Interior - Seat Memory Feature Appears Inoperative Memory Positioning Module: All Technical Service Bulletins Interior - Seat Memory Feature Appears Inoperative Bulletin No.: 04-08-50-003 Date: February 26, 2004 INFORMATION Subject: Enabling Memory Seat Feature via DIC If Feature Appears Inoperative Models: 2003-2004 Cadillac Escalade, Escalade ESV, Escalade EXT 2003-2004 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2003-2004 GMC Sierra, Yukon, Yukon Denali, Yukon Denali XL 2003-2004 HUMMER H2 with Steering Wheel Controls (RPO UK3) (standard on H2) If the memory seat feature appears inoperative, check the Driver Information Center (DIC). Many of the memory seat modules that were returned through the Warranty Parts Center for a condition of inoperative have shown No Trouble Found. The Driver Information Center (DIC), programmed for Seat Entry and Exit, is set to the default "Off" mode at the assembly plant. DO NOT REPLACE THE MEMORY SEAT MODULE. Perform the following procedure. Important: The following procedure will need to be completed for each Remote/Key selection. Using the DIC menu, do the following steps: 1. Set the "Seat Recall" to either "At Key In" or "On Remote" based on the customer's preference. 2. Set the "Exit Seat" to "On". 3. Adjust the following items: Memory Seat: 3.1. Driver's Seat (including the seat back, recliner, lumbar, and side wings) 3.2. Throttle and Brake Pedals (not available on H2 or Silverado and Sierra Trucks) 3.3. Outside Mirrors 3.4. Radio Station Presets 3.5. Last Chosen Climate Control System Settings (not available on Silverado or Sierra Trucks) 3.6. Press and hold the "1" or "2" (for driver 1 or 2) button of the memory control for three seconds. A double chime will sound to let you know that the position has been stored. Easy Exit Seat: 3.1. Press and release the 1 or 2 button or press the unlock button on the desired remote keyless entry transmitter. The seat will move to the stored memory position. 3.2. Adjust the seat to the desired exit position. 3.3. Press and hold the exit button of the memory control (located on the door) for three seconds. A double chime will sound to let you know that the position has been stored for the identified driver (1 or 2). Page 11976 Page 9216 C222 I/P Harness To Body Harness Page 1087 Pedal Positioning Switch: Service and Repair Brake Pedal Position Sensor Replacement Removal Procedure 1. Important: Once the Brake Pedal Position Sensor bolt is removed for any reason, a new 4 mm bolt, with fresh LOCTITETM will need to be installed. Remove the brake pedal position sensor bolt (1). 2. Remove the brake pedal position sensor (2) from the mounting bracket. 3. Disconnect the brake pedal position sensor electrical connector (1). 4. Remove the brake pedal position sensor (2) from the vehicle Installation Procedure Page 9553 Fuse Block - Underhood C2 Part 2 Page 13420 Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses CIRCUIT PROTECTION - FUSES The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the Page 16297 Wiper Blade: Service and Repair Blade Element Cleaning BLADE ELEMENT CLEANING 1. Lift the wiper blade assemblies off of the windshield glass. 2. Clean the wiper blade element with a clean cloth saturated with full strength washer solution. 3. Rinse the wiper blade assemblies with water. 4. Place the wiper blade assemblies back onto the windshield glass. Heated Oxygen Sensor (HO2S) Bank 1 Sensor 1 Heated Oxygen Sensor (HO2S) Bank 1 Sensor 1 Page 12673 Check - Vehicle. The Diagnostic System Check will provide the following information: ^ The identification of the control modules which command the system ^ The ability of the control modules to communicate through the serial data circuit ^ The identification of any stored diagnostic trouble codes (DTCs) and their status The use of the Diagnostic System Check will identify the correct procedure for diagnosing the system and where the procedure is located. Visual/Physical Inspection Perform the following visual inspections; ^ Inspect for aftermarket devices which could affect the operation of the Radio/Audio System. Refer to Checking Aftermarket Accessories in SI. ^ Inspect the easily accessible and visible system components for obvious damage or conditions which could cause the symptom. Intermittent Conditions Faulty electrical connections or wiring may be the cause of intermittent conditions. Refer to Testing for Intermittent Conditions and Poor Connections in SI. Symptom List Page 1887 10. Connect the PNP switch electrical connector (2). 11. If equipped with 4WD, install the front propeller shaft. 12. Lower the vehicle. 13. Check the PNP switch for proper operation. The engine must start in the park (P) or neutral (N) positions only. If proper operation of the switch can not be obtained, replace the switch. Park Lock Pawl and Actuator Replacement Park Lock Pawl and Actuator Replacement Removal Procedure 1. Remove the transmission filter. 2. Remove the park/neutral position (PNP) switch. 3. Remove the manual shaft nut and pin. 4. Remove the detent lever and actuator. 5. Remove the parking pawl bracket bolts. 6. Remove the parking pawl return spring. Page 13069 Important: This bulletin does NOT apply to 2006 vehicles built AFTER the VIN breakpoints listed above. Refer to applicable diagnostics in SI for those vehicles that exhibit this condition. Remove the OnStar(R) fuse from the fuse box, wait five minutes and reinstall the fuse. (For Saturn VUE vehicles, remove the "INT LTS" fuse from the I/P fuse block for five minutes, then reinstall the fuse.) If the OnStar(R) system DOES NOT return to normal functionality, then follow the diagnostics in SI for this condition. If the OnStar(R) system DOES return to normal functionality, perform the following steps: 1. Install the Tech 2(R) and determine what generation hardware and software ID is in the vehicle. 2. If the vehicle is equipped with Generation 5 hardware and a software version 146, the VCIM should have the B1000 reprogramming performed as described in Corporate Bulletin Number 04-08-46-004A. The system should be tested and if the concern returns, the VCIM should be replaced. 3. If Gen 5 with a software version OTHER than 146 or Gen 6 and above, the VCIM needs to be replaced and the system reconfigured. Refer to the current version of Corporate Bulletin 03-08-46-004 for details on how to order a new VCIM. Important: As with any OnStar(R) VCIM replacement, the OnStar(R) system must be reconfigured after replacement. Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use the table. Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table. Disclaimer Locks - Key Code Security Rules and Information Key: Technical Service Bulletins Locks - Key Code Security Rules and Information INFORMATION Bulletin No.: 10-00-89-010 Date: May 27, 2010 Subject: Key Code Security Rules and Information on GM KeyCode Look-Up Application (Canada Only) Models: 2011 and Prior GM Passenger Cars and Trucks 2010 and Prior HUMMER H2, H3 2009 and Prior Saturn and Saab 2002 and Prior Isuzu Attention: This bulletin has been created to address potential issues and questions regarding KeyCode security. This bulletin should be read by all parties involved in KeyCode activity, including dealer operator, partner security coordinator, sales, service and parts departments. A copy of this bulletin should be printed and maintained in the parts department for use as a reference. Important U.S. dealers should refer to Corporate Bulletin Number 10-00-89-009. Where Are Key Codes Located? General Motors provides access to KeyCodes through three sources when a vehicle is delivered to a dealer. Vehicle KeyCodes are located on the original vehicle invoice to the dealership. There is a small white bar coded tag sent with most new vehicles that also has the key code printed on it. Dealerships should make a practice of comparing the tag's keycode numbers to the keycode listed on the invoice. Any discrepancy should be reported immediately to the GM of Canada Key Code Inquiry Desk. Remember to remove the key tag prior to showing vehicles to potential customers. The third source for Key codes is through the GM KeyCode Look-Up feature within the OEConnection D2DLink application. KeyCode Look-Up currently goes back 17 previous model years from the current model year. When a vehicle is received by the dealership, care should be taken to safeguard the original vehicle invoice and KeyCode tag provided with the vehicle. Potential customers should not have access to the invoice or this KeyCode tag prior to the sale being completed. After a sale has been completed, the KeyCode information belongs to the customer and General Motors. Tip Only the original invoice contains key code information, a re-printed invoice does not. GM KeyCode Look-Up Application for GM of Canada Dealers All dealers should review the General Motors of Canada KeyCode Look-Up Policies and Procedures (Service Policy & Procedures Manual Section 3.1.6 "Replacement of VIN plates & keys"). Please note that the KeyCode Access site is restricted. Only authorized users should be using this application. Please see your Parts Manager for site authorized users. KeyCode Look-Up currently goes back 17 years from current model year. Important notes about security: - Users may not access the system from multiple computers simultaneously. - Users may only request one KeyCode at a time. - KeyCode information will only be available on the screen for 2 minutes. - Each user is personally responsible for maintaining and protecting their password. - Never share your password with others. - User Id's are suspended after 6 consecutive failed attempts. - User Id's are disabled if not used for 90 days. - Processes must be in place for regular dealership reviews. - The Parts Manager (or assigned management) must have processes in place for employee termination or life change events. Upon termination individuals access must be turned off immediately and access should be re-evaluated upon any position changes within the dealership. - If you think your password or ID security has been breached, contact Dealer Systems Support at 1-800-265-0573. Page 9412 Electrical Symbols Part 11 Page 350 Page 11141 1. Install the evaporator core (1) to the HVAC module assembly (2). 2. Install the upper HVAC module assembly (2) from the lower HVAC module assembly. 3. Install the evaporator cowl gasket to the evaporator. Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for the application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems. 4. Install the screws to the HVAC module assembly. Tighten Page 11593 Page 3286 Engine Oil Pressure: Testing and Inspection Oil Pressure Diagnosis and Testing ^ Tools Required J 21867 Pressure Gage - J 42907 Oil Pressure Testing Tool 1. With the vehicle on a level surface, run the vehicle for a few minutes. Allow adequate drain down time, 2-3 minutes, and measure the oil level. 2. If required, add the recommended grade engine oil and fill the crankcase until the oil level measures full on the oil level indicator. 3. Run the engine briefly, 10-15 seconds, and verify low or no oil pressure on the vehicle gage or light. 4. Listen for a noisy valve train or a knocking noise. 5. Inspect for the following conditions: ^ Oil diluted by water or glycol anti freeze ^ Foamy oil 6. Remove the oil filter and install the J 42907. 7. Install J 21867 or equivalent to the J 42907. 8. Run the engine and measure the engine oil pressure. 9. Compare the readings to Specifications. 10. If the engine oil pressure is below specifications, inspect the engine for one or more of the following conditions: ^ Oil pump worn or dirty ^ Oil pump-to-engine block bolts loose ^ Oil pump screen loose, plugged, or damaged ^ Oil pump screen O-ring seal missing or damaged ^ Malfunctioning oil pump pressure regulator valve ^ Excessive bearing clearance ^ Cracked, porous, or restricted oil galleries ^ Oil gallery plugs missing or incorrectly installed ^ Broken valve lifters. Repair as necessary. 11. If the oil pressure reading on the J 21867 or equivalent is within specifications, inspect for the following conditions: ^ Plugged or incorrect oil filter and/or malfunctioning oil bypass valve ^ Malfunctioning oil pressure gage or sensor. Repair as necessary. Service and Repair Hood Weatherstrip: Service and Repair Seal Replacement - Hood Rear Removal Procedure Pull up on the rear hood seal and remove from the cowl pinch-weld flange. Installation Procedure Align the slot in the rear hood seal with the cowl pinch-weld flange and press into place. Page 15428 Rear of the Engine Page 8812 IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. Splicing Twisted or Shielded Cable SPLICING TWISTED OR SHIELDED CABLE Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. - Rewrap the conductors with the mylar tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with mylar tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Control Module References Engine - GM dexos 1 and dexos 2(R) Oil Specifications Engine Oil: Technical Service Bulletins Engine - GM dexos 1 and dexos 2(R) Oil Specifications INFORMATION Bulletin No.: 11-00-90-001 Date: March 14, 2011 Subject: Global Information for GM dexos1(TM) and GM dexos2(TM) Engine Oil Specifications for Spark Ignited and Diesel Engines, Available Licensed Brands, and Service Fill for Adding or Complete Oil Change Models: 2012 and Prior GM Passenger Cars and Trucks Excluding All Vehicles Equipped with Duramax(TM) Diesel Engines GM dexos 1(TM) Information Center Website Refer to the following General Motors website for dexos 1(TM) information about the different licensed brands that are currently available: http://www.gmdexos.com GM dexos 1(TM) Engine Oil Trademark and Icons The dexos(TM) specification and trademarks are exclusive to General Motors, LLC. Only those oils displaying the dexos‹›(TM) trademark and icon on the front label meet the demanding performance requirements and stringent quality standards set forth in the dexos‹›(TM) specification. Look on the front label for any of the logos shown above to identify an authorized, licensed dexos 1(TM) engine oil. GM dexos 1(TM) Engine Oil Specification Important General Motors dexos 1(TM) engine oil specification replaces the previous General Motors specifications GM6094M, GM4718M and GM-LL-A-025 for most GM gasoline engines. The oil specified for use in GM passenger cars and trucks, PRIOR to the 2011 model year remains acceptable for those previous vehicles. However, dexos 1(TM) is backward compatible and can be used in those older vehicles. In North America, starting with the 2011 model year, GM introduced dexos 1(TM) certified engine oil as a factory fill and service fill for gasoline engines. The reasons for the new engine oil specification are as follows: - To meet environmental goals such as increasing fuel efficiency and reducing engine emissions. - To promote long engine life. - To minimize the number of engine oil changes in order to help meet the goal of lessening the industry's overall dependence on crude oil. dexos 1(TM) is a GM-developed engine oil specification that has been designed to provide the following benefits: - Further improve fuel economy, to meet future corporate average fuel economy (CAFE) requirements and fuel economy retention by allowing the oil to maintain its fuel economy benefits throughout the life of the oil. - More robust formulations for added engine protection and aeration performance. Page 4979 Canister Purge Solenoid: Service and Repair EVAPORATIVE EMISSION (EVAP) CANISTER PURGE SOLENOID VALVE REPLACEMENT REMOVAL PROCEDURE 1. Remove the engine sight shield. 2. Remove the evaporative emission (EVAP) line from the canister purge solenoid, perform the following: - Push the large size white retainer portion in. - Push down, while pulling up slightly in order the disengage the tube. 3. Disconnect the EVAP canister purge solenoid electrical connector (1). Page 12349 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves SPLICING COPPER WIRE USING SPLICE SLEEVES TOOLS REQUIRED J 38125-D Terminal Repair Kit IMPORTANT: Use only GM splice sleeves, other splice sleeves may not protect the splice from moisture or a provide good electrical connection. Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. Page 11140 3. If equipped remove the screws from the HVAC module assembly. 4. Remove the evaporator cowl gasket from the evaporator. 5. Separate the upper HVAC module assembly (2) from the lower HVAC module assembly (1). 6. Remove the evaporator core (1) from the upper HVAC module assembly. Installation Procedure Important: If replacing the evaporator core, add the refrigerant oil the evaporator core. Page 9077 Application Table Part 4 Page 4108 7. Remove the transmission control lever from the manual shaft. 8. Remove the PNP switch bolts. 9. Remove the PNP switch from the manual shaft. If the PNP switch did not slide off the manual shaft, file the outer edge of the manual shaft in order to remove any burrs. Installation Procedure 1. Install the PNP switch to the transmission manual shaft by aligning the switch hub flats with the manual shaft flats. 2. Slide the PNP switch onto the transmission manual shaft until the switch mounting bracket contacts the mounting bosses on the transmission. 3. Important: If a NEW PNP switch is being installed, the switch will come with a positive assurance bracket. The positive assurance bracket aligns the new switch in its proper position for installation and the use of the park neutral switch aligner will not be necessary. Install the PNP switch bolts finger tight. 4. Install J 41364-A onto the PNP switch. Ensure that the two slots on the switch where the manual shaft is inserted are lined up with the lower two tabs on the tool. 5. Notice: Refer to Fastener Notice in Service Precautions. Rotate the tool until the upper locator pin on the tool is lined up with the slot on the top of the switch. ^ Tighten the bolts to 25 Nm (18 ft. lbs.). 6. Remove the J 41364-A from the switch. If installing a new switch, remove the positive assurance bracket at this time. 7. Install the transmission control lever to the manual shaft with the nut. ^ Tighten the nut to 25 Nm (18 ft. lbs.). Rear Front Steering Knuckle: Service and Repair Rear Steering Knuckle Replacement ^ Tools required J 24319-B Universal Steering Linkage Puller Removal Procedure 1. Notice: Refer vehicle Lifting. Raise the vehicle. Refer to Vehicle Lifting. 2. Remove the tire and wheel. 3. Remove the wheel hub and bearing. 4. Remove the upper ball joint. 5. Remove the lower ball joint. 6. Remove the outer tie rod retaining nut and bracket (2). 7. Disconnect the outer tie rod from the steering knuckle using the J 24319-B (1). 8. Remove the park brake cable retaining bolt (3) from the steering knuckle. OnStar(R) - Incorrect GPS Position Reported During Call Emergency Contact Module: Customer Interest OnStar(R) - Incorrect GPS Position Reported During Call Bulletin No.: 02-08-46-006C Date: January 08, 2008 INFORMATION Subject: Incorrect OnStar(R) Global Positioning System (GPS) Location Reported During OnStar(R) Call Models: 2000-2008 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2008 HUMMER H2 2006-2008 HUMMER H3 2005-2008 Saab 9-7X with OnStar(R) Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 02-08-46-006B (Section 08 - Body and Accessories). A small number of the above-mentioned vehicles may exhibit a condition in which the vehicle reports an inaccurate location to the OnStar(R) Call Center. This condition can only be identified via a button press to the OnStar(R) Call Center by the customer. Call Center personnel will be able to identify this inaccurate location condition. Customers will then be notified through the mail by OnStar(R) if their vehicle exhibits this condition. Once this condition has been identified OnStar(R) will instruct the customer to return to the dealership to have this condition corrected. It is not necessary to reconfigure the vehicle after the following procedure. In order to correct this condition you must cycle power to the OnStar(R) system. This can be done by either removing the fuses powering the OnStar(R) system or disconnecting the OnStar(R) module (VCIM) from the vehicle. As a last resort you can disconnect the vehicle's battery. The power needs to be removed from the system for approximately 15 minutes. After completing this procedure the vehicle should be taken to an area with an unobstructed view of the sky. The vehicle should be kept running for approximately 10 minutes to allow the vehicle to reacquire the global positioning system (GPS). Then contact the OnStar(R) Call Center via the blue OnStar(R) button and ask the advisor to verify the GPS position. If the OnStar(R) advisor still has an inaccurate GPS location refer to the Navigation Systems and Cellular Communications sub-sections in the Service Manual in order to diagnose and repair the concern. If the normal diagnostics lead to module replacement you will need to contact Technical Assistance (TAC) and choose the OnStar(R) prompt. GM OnStar(R) TAC will assist in the diagnosis and if appropriate order a replacement part. Replacement parts are usually shipped out within 24 hours and a pre-paid return package label will be included for returning the faulty part. By returning the faulty part you will avoid a significant non-return core charge. Warranty Information (excluding Saab US Models) For vehicles repaired under warranty, use the table. Warranty Information (Saab US Models) Page 15976 Control Module References Part 7 Page 10218 Electrical Symbols Part 2 OnStar(R) - No Power/Inoperative/No LED Emergency Contact Module: Customer Interest OnStar(R) - No Power/Inoperative/No LED TECHNICAL Bulletin No.: 05-08-46-001D Date: May 02, 2008 Subject: OnStar(R) Generation 5 or 6 (Digital) System Inoperative/Has No Power, LED Light Not On (Remove/Reinstall OnStar(R) Fuse and Replace VCIM or Follow SI Diagnostics) Models Supercede: This bulletin is being revised to update the information on VCIM ordering instructions in step 3 of the Correction statement. Please discard Corporate Bulletin Number 05-08-46-001C (Section 08 - Body & Accessories). Condition Some customers may comment any or all of the following conditions: ^ The OnStar(R) system may be inoperative. ^ The OnStar(R) system may have no power. ^ The OnStar(R) LED light may not be on. The technician may also not be able to communicate with the OnStar(R) Vehicle Communication Interface Module (VCIM) with a Tech 2(R). Correction Notice: On 2006 Chevrolet Impala and Monte Carlo models, make sure the ignition is OFF and the vehicle has "RAP"ed out prior to removing the OnStar(R) fuse. Disconnecting power to the OnStar(R) module while the ignition is ON may discharge and permanently damage the OnStar(R) back-up battery. Page 11154 Flushing Procedures using DEX-COOL(R) Important: The following procedure recommends refilling the system with DEX-COOL(R), P/N 12346290 (in Canada, use P/N 10953464), GM specification 6277M. This coolant is orange in color and has a service interval of 5 years or 240,000 km (150,000 mi). However, when used on vehicles built prior to the introduction of DEX-COOL(R), maintenance intervals will remain the same as specified in the Owner's Manual. ^ If available, use the approved cooling system flush and fill machine (available through the GM Dealer Equipment Program) following the manufacturer's operating instructions. ^ If approved cooling system flush and fill machine is not available, drain the coolant and dispose of properly following the draining procedures in the appropriate Service Manual. Refill the system using clear, drinkable water and run the vehicle until the thermostat opens. Repeat and run the vehicle three (3) times to totally remove the old coolant or until the drained coolant is almost clear. Once the system is completely flushed, refill the cooling system to a 50%-60% concentration with DEX‐COOL(R), P/N 12346290 (in Canada, use P/N 10953464), GM specification 6277M, following the refill procedures in the appropriate Service Manual. If a Service Manual is not available, fill half the capacity of the system with 100% DEX-COOL(R), P/N 12346290 (in Canada, use P/N 10953464), GM specification 6277M. Then slowly add clear, drinkable water (preferably distilled) to the system until the level of the coolant mixture has reached the base of the radiator neck. Wait two (2) minutes and reverify the coolant level. If necessary, add clean water to restore the coolant to the appropriate level. Once the system is refilled, reverify the coolant concentration using a Refractometer J 23688 (Fahrenheit scale) or J 26568 (centigrade scale) coolant tester, or equivalent. The concentration levels should be between 50% and 65%. Flushing Procedures using Conventional Silicated (Green Colored) Coolant Important: 2004-2005 Chevrolet Aveo (Pontiac Wave, Canada Only) does not use DEX‐COOL(R). The Aveo and Wave are filled with conventional, silicated engine coolant that is blue in color. Silicated coolants are typically green in color and are required to be drained, flushed and refilled every 30,000 miles (48,000 km). The Aveo and Wave are to be serviced with conventional, silicated coolant. Use P/N 12378560 (1 gal) (in Canada, use P/N 88862159 (1 L). Refer to the Owner's Manual or Service Information (SI) for further information on OEM coolant. Important: Do not mix the OEM orange colored DEX-COOL(R) coolant with green colored coolant when adding coolant to the system or when servicing the vehicle's cooling system. Mixing the orange and green colored coolants will produce a brown coolant which may be a customer dissatisfier and will not extend the service interval to that of DEX-COOL(R). Conventional silicated coolants offered by GM Service and Parts Operations are green in color. ^ If available, use the approved cooling system flush and fill machine (available through the GM Dealer Equipment Program) following the manufacturer's operating instructions. ^ If approved cooling systems flush and fill machine is not available, drain coolant and dispose of properly following the draining procedures in appropriate Service Manual. Refill the system using clear, drinkable water and run vehicle until thermostat opens. Repeat and run vehicle three (3) times to totally remove old coolant or until drained coolant is almost clear. Once the system is completely flushed, refill the cooling system to a 50%-60% concentration with a good quality ethylene glycol base engine coolant, P/N 12378560, 1 gal (in Canada, use P/N 88862159 1 L), conforming to GM specification 1825M, or recycled coolant conforming to GM specification 1825M, following the refill procedures in the appropriate Service Manual. If a Service Manual is not available, fill half the capacity of the system with 100% good quality ethylene glycol base (green colored) engine coolant, P/N 12378560 1 gal., (in Canada, use P/N 88862159 1 L) conforming to GM specification 1825M. Then slowly add clear, drinkable water (preferably distilled) to system until the level of the coolant mixture has reached the base of the radiator neck. Wait two (2) minutes and recheck coolant level. If necessary, add clean water to restore coolant to the appropriate level. Once the system is refilled, recheck the coolant concentration using a Refractometer J 23688 (Fahrenheit scale) or J 26568 (centigrade scale) coolant tester, or equivalent. Concentration levels should be between 50% and 65%. Parts Information Warranty Information Page 15948 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground TESTING FOR SHORT TO GROUND NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting With A Digital Multimeter TROUBLESHOOTING WITH A DIGITAL MULTIMETER NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TROUBLESHOOTING WITH A TEST LAMP Page 14070 Electrical Symbols Part 10 Page 5185 1. Locate the air flow direction arrow (2) on the MAF/IAT sensor. 2. Install the MAF/IAT sensor to the air cleaner assembly. NOTE: Refer to Fastener Notice in Service Precautions. 3. Tighten the MAF/IAT clamp. Tighten Tighten the clamp to 7 N.m (62 lb in). 4. Connect the MAF/IAT sensor electrical connector (4). 5. Push in the gray CPA retainer. 6. Install the air cleaner outlet duct. Page 6526 Q: Why didn't the machine come with the adapters to hook up to the car? A: The J 45096 was designed to use the previously released essential cooler line adapters for the J 35944-A. All adapters are listed on page 17 of the Operation Manual and can be ordered from Kent-Moore at 1-800-345-2233. Q: How do I connect the J 45096 to a Catera, Prizm or a Vibe? A: These vehicles, along with many other models, only require barbed fittings to connect to the rubber cooler hose. These fittings are commercially available and already found in many shops. Q: Why didn't I receive an Operation Manual with the machine? A: The Operation Manual was packaged in the upper portion of the shipping carton. If the shipping carton was lifted off the base without opening the top of the carton, the Operation Manual could have been discarded with the carton. Replacement Operation Manual packages can be obtained from Kent-Moore Customer Service at 1-800-345-2233. Q: Why can't I re-use the transmission fluid I use for flushing? A: The very fine metal and clutch material debris from the transmission failure in the ATF causes failures with the hall effect speed sensors that are used to measure the flow rate. To avoid costly repairs, expensive filters, regular maintenance and problems caused by a partially restricted filter, the filter was not included. Q: What do I do if I need service on my machine? A: Call Kent-Moore Customer Service at 1-800-345-2233. The J 45096 has a one-year warranty. Q: Can I flush and flow engine oil coolers? A: The engine oil cooler flow rates, the appropriate adapters and an acceptable procedure are currently under development. Disclaimer Vehicle Speed Sensor (VSS) Vehicle Speed Sensor: Diagrams Vehicle Speed Sensor (VSS) Page 4252 Accelerator Pedal Position Sensor: Service and Repair ACCELERATOR PEDAL POSITION (APP) SENSOR REPLACEMENT REMOVAL PROCEDURE NOTE: Handle the electronic throttle control components carefully. Use cleanliness in order to prevent damage. Do not drop the electronic throttle control components. Do not roughly handle the electronic throttle control components. Do not immerse the electronic throttle control components in cleaning solvents of any type. 1. Remove the connector position assurance (CPA) retainer. 2. Disconnect the accelerator pedal position (APP) sensor electrical connector. 3. Reposition the carpet to access the lower nut. 4. Remove the accelerator pedal nuts. 5. Remove the accelerator pedal assembly. INSTALLATION PROCEDURE Initial Inspection and Diagnostic Overview Accessory Delay Module: Initial Inspection and Diagnostic Overview Diagnostic Starting Point DIAGNOSTIC STARTING POINT Begin the system diagnosis with the Diagnostic System Check - Accessory Delay Module. The diagnostic system check will provide the following information: - The identification of the control modules which command the system - The ability of the control modules to communicate through the serial data circuit - The identification of any stored diagnostic trouble codes DTCs and their status The use of the Diagnostic System Check will identify the correct procedure for diagnosing the system and where the procedure is located. Diagnostic System Check DIAGNOSTIC SYSTEM CHECK TEST DESCRIPTION Page 15282 Feature Programming Refer to Personalization Description and Operation in Personalization. Driver Warnings For the list of Driver Warnings, refer to Indicator/Warning Message Description and Operation. Campaign - Deactivation Of Analog OnStar(R) Technical Service Bulletin # 08089C Date: 081118 Campaign - Deactivation Of Analog OnStar(R) # 08089C: Special Coverage Adjustment - Analog OnStar Deactivation (Nov 18, 2008) Subject: 08089C -- SPECIAL COVERAGE ADJUSTMENT - ANALOG ONSTAR(R) DEACTIVATION Page 1839 Steering Column Position Sensor: Service and Repair Inflatable Restraint Steering Wheel Module Coil Centering Inflatable Restraint Steering Wheel Module Coil Centering 1. Notice: The new SIR coil assembly will be centered. Improper alignment of the SIR coil assembly may damage the unit, causing an inflatable restraint malfunction. Important: If double wire harness strap is installed onto the wire harness assembly and column, you must reuse the holder for the wire straps during installation. Remove the wire harness strap(s) where necessary. Verify the following conditions before centering the SIR coil: ^ The wheels on the vehicle are straight ahead. ^ The block tooth (1) of the steering shaft assembly is in the 12 o'clock position. ^ The ignition switch is in the LOCK position. 2. If the front (5) of the SIR coil has a centering window (4), and the back side (2) includes a spring service lock (1), perform the following steps: 1. Hold the SIR coil with the face up. 2. While depressing the spring service lock, rotate the coil hub clockwise until the coil ribbon stops. 3. Rotate the coil hub slowly, counterclockwise, until the centering window appears yellow and both arrows (3) line up. 4. Release spring service lock between the locking tab. The SIR coil is now centered. 5. Align the centered SIR coil with the horn tower and slide onto the steering shaft assembly. 3. If the front (4) of the SIR coil has a centering window (3), and the back side (1) includes NO spring service lock, perform the following steps: 0. Hold the SIR coil with the face up. 1. Rotate the coil hub clockwise until the coil ribbon stops. Page 14343 Electrical Symbols Part 3 Page 5476 Disclaimer Page 15992 Steps 11-15 Temperature Displays SC or OC - Mirrors MIRRORS - TEMPERATURE DISPLAYS SC OR OC Page 10463 8. Remove the wheel hub and the 15-series bearing mounting bolts (4). 9. Remove the wheel hub and bearing (4) mounting bolts, 25/35 series. 10. Remove the wheel hub and bearing and splash shield from the vehicle. 11. Remove the O-ring seal from the steering knuckle bore, 25/35 series. 12. Remove the wheel speed sensor mounting bolt (5). 13. Clean and inspect the O-ring seal, 25/35 series. 14. Replace the seal if the following conditions exist: ^ Nicks ^ Cuts ^ Dry or brittle ^ Compression set Installation Procedure 1. Clean all corrosion or contaminates from the steering knuckle bore and the hub and bearing assembly. 2. Lubricate the steering knuckle bore with wheel bearing grease or the equivalent. 3. Install the O-ring (7) to the steering knuckle, the 25/35 series. 4. Notice: Refer to Fastener Notice in Service Precautions. Install the wheel speed sensor mounting bolt to the wheel hub and bearing. ^ Tighten the sensor mounting bolt to 18 Nm (13 ft. lbs.). 5. Install the wheel hub and bearing and splash shield to the vehicle, 25/35 series. Page 14995 Notice: It is recommended that a support be placed under the open tailgate in the next step to prevent the tailgate from being damaged in the event that it drops when disconnecting, inspecting, and replacing the support cables. Support Cable Inspection - Escalade EXT, Avalanche, New Style Silverado and Sierra, Kodiak, TopKick 1. Open the rear tailgate and support it as necessary. 2. Release (unhook) the right side tailgate support cable from the pickup box. Important: In the above illustration, the clear sealant (1) is shown as black in color. This was done for illustration purposes only. If sealant is present on the support cables it will be clear or hazy (cloudy) in appearance. 3. Inspect the end (eyelet) of the support cable that attaches to the tailgate for sealant covering the end of the cable strands. - If there IS a clear type sealant (1) over the end of the cable strands, the support cable needs to be replaced. Reconnect the support cable to the pickup box and perform this same inspection on the left support cable. After inspecting both cables, proceed to the section titled "Hinge Inspection". - If there IS NOT a clear type sealant (2) over the end of the cable strands, that support cable does NOT need to be replaced. Reconnect the support cable to the pickup box and perform this same inspection on the left support cable. After inspecting both cables, proceed to the section titled "Hinge Inspection". Hinge Inspection - Escalade EXT, Avalanche, New Style Silverado and Sierra, Kodiak, TopKick 1. Release (unhook) the RIGHT side tailgate support cable from the pickup box aga1n. Page 5253 Fuel Filler Cap: Description and Operation FUEL FILLER CAP The fuel fill pipe has a tethered fuel filler cap. A torque-limiting device prevents the cap from being over tightened. To install the cap, turn the cap clockwise until you hear clicks. This indicates that the cap is correctly torqued and fully seated. A built-in device indicates that the fuel filler cap is fully seated. A fuel filler cap that is not fully seated may cause a malfunction in the emission system. Page 10196 ^ A foam ring (3) ^ An alignment tab (2) for installing into the adapter and bearing assembly ^ A view of the inside of the connector 7. Important: If reusing the existing sensor, you must align the marks on the flush rotor flange cuff before installation. The alignment mark must stay aligned until the sensor is seated into the adapter and bearing assembly. If installing a new sensor, it will come with a pin installed in the sensor. Do not remove the pin until the sensor is seated. If the new sensor did not come with a pin installed, you must reorder a new sensor. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install into the adapter and bearing assembly. 8. Install the connector to the sensor. 9. From the technicians point of view, the FRONT of the sensor will have: ^ A pin hole (3) for the centering pin. Note location of the pin hole. ^ A raised rotor flange cuff (5) ^ An alignment mark (4) for installation 10. From the technicians point of view, the BACK of the sensor will have: ^ Double D flats (1) ^ An alignment tab (2) for installing into the adapter and bearing assembly 11. Important: If reusing the existing sensor, you must align the marks on the raised rotor flange cuff before installation. The alignment mark must stay aligned until the sensor is seated into the adapter and bearing assembly. If installing a new sensor, it will come with a pin installed in the sensor. Do not remove the pin until the sensor is seated. If the new sensor did not come with a pin installed, you must reorder a new sensor. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install into the adapter and bearing assembly. 12. Install the connector to the sensor. 13. From the technicians point of view, the FRONT of the sensor will have: ^ A pin hole (2) for the centering pin. Note the location of the pin hole. ^ A raised rotor flange cuff (4) ^ An alignment mark (3) for installation 14. From the technicians point of view, the BACK of the sensor will have an alignment tab (1) for installation. This sensor does not have double D flats. 15. Important: If reusing the existing sensor, you must align the marks on the raised rotor flange cuff before installation. The alignment mark must stay aligned Page 1416 5. Connect the fuel pump electrical connector. 6. Install the sending unit. Page 6461 9. Important: Avoid unnecessary twisting/bending of the range selector cable when removing the cable from the support. Remove the range selector cable from the support. 10. Remove the cable grommet from the floor panel. 11. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 12. Remove the clips on the cable from the floor panel reinforcement. 13. Ensure the transmission manual shaft is positioned in mechanical park. 14. Remove the retainer that secures the cable to the bracket. Page 2502 7. If the level is low, add lubricant until the level is between 17-21 mm (0.6-0.8 inch) below the fill plug opening. Use the proper fluid. 8. Notice: Refer to Fastener Notice in Service Precautions. Install the rear axle fill plug and gasket. ^ Tighten the rear axle fill plug to 33 Nm (24 ft. lbs.). 9. Lower the vehicle. 8.6 Inch Axle Lubricant Replacement - Rear Drive Axle (8.6 Inch Axle) Removal Procedure 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Remove the rear axle fill plug. 3. Remove the rear axle housing cover bolts (1). Discard the rear axle housing cover bolts. 4. Carefully remove the rear axle housing cover (2) and drain the lubricant into a suitable container. 5. Remove any gasket material from the rear axle housing and/or the rear axle housing cover. 6. Inspect the bottom of the rear axle housing for excessive metal particle accumulation. This accumulation is an indication of extreme wear. Installation Procedure Page 14078 Refer to the table as a guide in selecting the correct test adapter for frontprobing connectors: Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure SCAN TOOL SNAPSHOT PROCEDURE Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: - Snapshot - taken from the Snapshot menu choice - Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information Page 13793 Disclaimer Page 3354 22. Remove the following from the positive battery cable clip: ^ Engine wiring harness clip ^ Positive battery cable clip 23. Remove the engine oil cooler lines from the positive battery cable clip. 24. Remove the positive battery cable clip bolt and clip. 25. Remove the oil pan bolts. 26. Remove the oil pan. Page 14317 WA9566/13 - WA964L/29 Page 14997 2. Remove the tailgate from the vehicle. 3. Remove the two bolts attaching the right side hinge to the tailgate. Important: On Chevrolet Silverado and GMC Sierra models, the NEW hinge being installed must be primed and painted in the body color prior to installation. New hinges for the Chevrolet Avalanche and Cadillac Escalade EXT come pre-painted in a glossy back primer, these hinges must still be painted black. 4. Install a NEW hinge to the tailgate and install the two bolts. Tighten Tighten the bolts to 25 Nm (18 lb-ft). 5. Reinstall the tailgate on the vehicle. If one or both tailgate support cables require replacement, proceed to the section titled "Support Cable Replacement". If neither support cables require replacement, no further action is required. Support Cable Replacement - Escalade EXT, Avalanche, New Style Silverado and Sierra, Kodiak, TopKick The following procedure should only be performed if sealant was found in one or both support cables in the earlier inspection. Important: If the support cable (2) has NOT been replaced previously, there will be a toothed nut (1) located between the latch (4) and the tailgate that will prevent the bolt (3) from being removed in the next step. The nut is an assembly aid used in the assembly plant. The nut does NOT need to be reinstalled or replaced when installing a new support cable in this recall. Page 520 Driver Door Module (DDM) - C5 (With RPO Code AN3) Part 2 Instruments - Service Tire Monitor Message is Displayed Low Tire Pressure Indicator: Customer Interest Instruments - Service Tire Monitor Message is Displayed Bulletin No.: 05-08-49-018A Date: May 11, 2006 ADVANCE SERVICE INFORMATION RESOLUTION Subject: EI 05065 - Service Tire Monitor Message Displayed (Pull/Reinstall IPC Fuse or Verify Correct Passenger Door Module (PDM) and Tires) Models: 2004 Chevrolet Silverado 2004 GMC Sierra Supercede: This bulletin is being revised to provide correction action. Please discard Corporate Bulletin Number 05-08-49-018 (Section 08 - Body and Accessories). Condition Some customers may comment that the "SERVICE TIRE MONITOR" message is being displayed on the DIC. Correction DO NOT REPLACE THE INSTRUMENT PANEL CLUSTER. If the DIC is displaying the SERVICE TIRE MONITOR message: 1. Verify if the vehicle has an electronic aftermarket module spliced into the ALDL Class 2 data line (purple wire). 2. If the vehicle HAS an aftermarket module spliced into the Class 2 line, pull the IPC fuse (located underhood) for 25 seconds. Important: Due to the electronic aftermarket module, the SERVICE TIRE MONITOR message may reoccur. 3. Reinstall the IPC fuse. This will clear the SERVICE TIRE MONITOR message from the display. 4. If the vehicle DOES NOT have an aftermarket module spliced into the Class 2 line, verify the vehicle is equipped with the correct PDM (Passenger Door Module) and tires. Warrant Information This repair is not covered under the vehicle warranty due to the installation of an aftermarket module. Disclaimer Page 5303 Fuel Pressure Regulator: Service and Repair FUEL PRESSURE REGULATOR REPLACEMENT REMOVAL PROCEDURE IMPORTANT: The fuel pressure regulator retaining clip is specific to the fuel rail-regulator design and cannot be interchanged. 1. Relieve the fuel system pressure. Refer to Fuel Pressure Relief Procedure. 2. Remove the fuel pressure regulator vacuum hose. 3. Clean any dirt from the fuel pressure regulator retainer and surrounding area. 4. Remove the fuel pressure regulator retainer (8). 5. Remove the fuel pressure regulator (9). 6. Ensure none of the following parts are still in the fuel rail. - Backup ring (10) - Regulator seal O-ring (11) - Regulator filter (12) - Regulator seal O-ring (13) INSTALLATION PROCEDURE 1. Ensure that the NEW fuel pressure regulator retainer is the correct one. 2. The tab (1) is used on the E85-straight vacuum port retainer (3). Page 8542 Transmission Speed Sensor: Service and Repair Output Shaft Speed Sensor Replacement Output Shaft Speed Sensor Replacement Removal Procedure Important: This procedure is for 2-wheel drive (2WD) vehicles only. If the vehicle is equipped with 4-wheel drive (4WD), the output speed sensor is located on the transfer case. 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. Disconnect the output speed sensor (2) electrical connector. 3. Remove the output speed sensor bolt. 4. Remove the output speed sensor (2). 5. Inspect the output speed sensor (2) for any evidence of damage. Installation Procedure Automatic Transmission - 4L60-E/4L65-E Transmission Position Switch/Sensor: Adjustments Automatic Transmission - 4L60-E/4L65-E Park/Neutral Position Switch Adjustment Important: ^ The following procedure is for vehicles that have not had the park/neutral position (PNP) switch removed or replaced. If the PNP switch has been removed or replaced, refer to Park/Neutral Position Switch Replacement for the proper adjustment procedure. ^ Apply the park brake. ^ The engine must start in the park (P) or neutral (N) positions only. ^ Check the PNP switch for proper operation. If adjustment is required, proceed as follows: 1. Place the transmission range selector in the neutral (N) position. 2. With an assistant in the drivers seat, raise and suitably support the vehicle. Refer to Vehicle Lifting. 3. Loosen the park/neutral position (PNP) switch bolts. 4. With the vehicle in the neutral (N) position, rotate the switch while the assistant attempts to start the engine. 5. Following a successful start, turn the engine off. 6. Notice: Refer to Fastener Notice in Service Precautions. ^ Tighten the PNP switch bolts. ^ Tighten the bolts to 25 Nm (18 ft. lbs.). 7. Lower the vehicle. 8. Check the PNP switch for proper operation. The engine must start in the park (P) or neutral (N) positions only. 9. Replace the PNP switch if proper operation can not be achieved. Body - Polypropylene Energy Absorber Replacement Front Bumper Reinforcement: Technical Service Bulletins Body - Polypropylene Energy Absorber Replacement Bulletin No.: 07-08-63-001 Date: April 17, 2007 INFORMATION Subject: Information on Repair of Polypropylene Energy Absorbers Models: 2007 and Prior GM Passenger Cars and Trucks (including Saturn) 2007 and Prior HUMMER H2, H3 2005-2007 Saab 9-7X Supercede: This bulletin is being revised to change the repair information. Please discard Corporate Bulletin Number 63-20-02 (Section 8 - Body and Accessories). Because the energy absorbers are relatively low in cost to replace, it is now more cost efficient to replace the energy absorbers whenever they are damaged. Disclaimer Page 5571 6. If equipped with RPO HP2, remove the starter/generator control module (SGCM) cover bolts, and cover. 7. Remove the 3-phase cable nuts to the SGCM. 8. Remove the 3-phase cable from the SGCM. 9. If equipped with RPO HP2, remove the 3-phase cable bracket nuts. 10. Remove the 3-phase cable bracket from the studs, and reposition the cable and bracket out of the way. 11. Remove the ignition coil bolts. Page 13438 Steering Wheel Driver Information Center (DIC) Controls - Right (With RPO Code YE9) Page 6441 Page 9329 Relay Box: Service and Repair I/P Electrical Center or Junction Block Replacement - Left INSTRUMENT PANEL ELECTRICAL CENTER OR JUNCTION BLOCK REPLACEMENT - LEFT REMOVAL PROCEDURE 1. Remove the left side end panel. 2. Remove the knee bolster. 3. Disconnect all the wiring connectors from the fuse block. 4. Remove all the fuses. 5. Remove the turn signal relay from the back of the fuse block. 6. From behind the fuse block, remove the retaining bolt. 7. Insert a screw driver between the fuse block and the wire harness block to separate. 8. Push on the retainers in order to remove the fuse block. 9. Remove the fuse block from the vehicle. INSTALLATION PROCEDURE 1. Install the fuse block onto the I/P assembly until it clicks in place. 2. Install the wire harness block to the back of the fuse block. NOTE: Refer to Fastener Notice in Service Precautions. 3. Install the bolt. Tighten Tighten the bolt to 6 N.m (53 lb in). 4. Install the turn signal relay to the back of the fuse block. 5. Using the wiring diagram on the cover of the fuse panel, install the fuses. 6. Install the electrical connectors. 7. Install the knee bolster. Page 7839 1. Install the locating pins to the NEW encoder motor. 2. Position a NEW actuator insulator gasket to the transfer case. 3. Install the encoder motor. Notice: Refer to Fastener Notice in Service Precautions. 4. Install encoder motor bolts. ^ Tighten the bolts, in the sequence shown, to 20 Nm (15 ft. lbs.). 5. Connect the encoder motor electrical connector. Ensure that the retention clips activate. 6. Install the front propeller shaft. 7. Install the transfer case shield, if equipped. Locations Crankshaft Position (CKP) Sensor Location Specifications Fuel Pressure: Specifications Fuel Pressure (Key ON Engine OFF) .............................................................................................................................................. 385-425 kPa (55-62 psi) Page 3900 Location View The Fuel Pump Relay is located in the Underhood Fuse Block. The Underhood Fuse Block is located in the left side of the engine compartment to the rear of the battery. Page 5427 The values in the table are approximate values based on information obtained from properly operating vehicles. Actual results may vary slightly. Page 4699 1. Slide the BCM onto the bracket. 2. Connect all the connectors (1) except the brown connector. 3. Connect the brown connector. 4. Install the knee bolster. 5. Connect the negative battery cable(s). 6. Reprogram the BCM. Refer to Body Control Module (BCM) Programming/RPO Configuration. 7. Perform the Passlock Learn Procedure. See: Testing and Inspection/Programming and Relearning Body - Replacement Fender Hood Hinge Hole Too Large Hood Hinge: Customer Interest Body - Replacement Fender Hood Hinge Hole Too Large INFORMATION Bulletin No.: 08-08-63-003 Date: November 26, 2008 Subject: Hood Hinge Pivot Hole Too Large On Some Replacement Fenders Models: 1999-2007 Chevrolet Silverado Classic 2001-2006 Chevrolet Avalanche, Suburban, Tahoe 1999-2007 GMC Sierra Classic 2001-2006 GMC Yukon Models Technicians installing GMSPO service replacement fenders may find that the fender side hood hinge pivot bolt attachment hole is too large (12 mm). The hood hinge pivot bolt attachment hole on some service fenders may be too large (12 mm), causing improper retention of the pivot bolt. To correct this condition, add a M8 X 32 mm O.D. X 2 mm thick washer between the hinge halves on the inboard side of the fender side hood hinge. This will provide the proper surface for the shoulder of the pivot bolt to contact as it is tightened. Refer to the illustration above. Parts Information Disclaimer A/T - DEXRON(R)-VI Fluid Information Fluid - A/T: Technical Service Bulletins A/T - DEXRON(R)-VI Fluid Information INFORMATION Bulletin No.: 04-07-30-037E Date: April 07, 2011 Subject: Release of DEXRON(R)-VI Automatic Transmission Fluid (ATF) Models: 2008 and Prior GM Passenger Cars and Light Duty Trucks 2003-2008 HUMMER H2 2006-2008 HUMMER H3 2005-2007 Saturn Relay 2005 and Prior Saturn L-Series 2005-2007 Saturn ION 2005-2008 Saturn VUE with 4T45-E 2005-2008 Saab 9-7X Except 2008 and Prior Chevrolet Aveo, Equinox Except 2006 and Prior Chevrolet Epica Except 2007 and Prior Chevrolet Optra Except 2008 and Prior Pontiac Torrent, Vibe, Wave Except 2003-2005 Saturn ION with CVT or AF23 Only Except 1991-2002 Saturn S-Series Except 2008 and Prior Saturn VUE with CVT, AF33 or 5AT (MJ7/MJ8) Transmission Only Except 2008 Saturn Astra Attention: DEXRON(R)-VI Automatic Transmission Fluid (ATF) is the only approved fluid for warranty repairs for General Motors transmissions/transaxles requiring DEXRON(R)-III and/or prior DEXRON(R) transmission fluids. Supercede: This bulletin is being revised to update information. Please discard Corporate Bulletin Number 04-07-30-037D (Section 07 - Transmission/Transaxle). MANUAL TRANSMISSIONS / TRANSFER CASES and POWER STEERING The content of this bulletin does not apply to manual transmissions or transfer cases. Any vehicle that previously required DEXRON(R)-III for a manual transmission or transfer case should now use P/N 88861800. This fluid is labeled Manual Transmission and Transfer Case Fluid. Some manual transmissions and transfer cases require a different fluid. Appropriate references should be checked when servicing any of these components. Power Steering Systems should now use P/N 9985010 labeled Power Steering Fluid. Consult the Parts Catalog, Owner's Manual, or Service Information (SI) for fluid recommendations. Some of our customers and/or General Motors dealerships/Saturn Retailers may have some concerns with DEXRON(R)-VI and DEXRON(R)-III Automatic Transmission Fluid (ATF) and transmission warranty claims. DEXRON(R)-VI is the only approved fluid for warranty repairs for General Motors transmissions/transaxles requiring DEXRON(R)-III and/or prior DEXRON(R) transmission fluids (except as noted above). Please remember that the clean oil reservoirs of the J-45096 - Flushing and Flow Tester machine should be purged of DEXRON(R)-III and filled with DEXRON(R)-VI for testing, flushing or filling General Motors transmissions/transaxles (except as noted above). DEXRON(R)-VI can be used in any proportion in past model vehicles equipped with an automatic transmission/transaxle in place of DEXRON(R)-III (i.e. topping off the fluid in the event of a repair or fluid change). DEXRON(R)-VI is also compatible with any former version of DEXRON(R) for use in automatic transmissions/transaxles. DEXRON(R)-VI ATF General Motors Powertrain has upgraded to DEXRON(R)-VI ATF with the start of 2006 vehicle production. Current and prior automatic transmission models that had used DEXRON(R)-III must now only use DEXRON(R)-VI. Locations Page 6521 each repair. With the ATF in a tightly sealed container, place the container in a tub of hot water for a period of time. Then pour the ATF into the reservoir. This method works best with a low fluid level in the reservoir. Place the Transflow(R) machine in the direct sunlight with the cabinet door open to expose the reservoir to the rays of the warm sun. Flush / Flow Test Procedure Important All labor operations that include removal of the transmission from the vehicle and require the transmission oil pan or transmission side cover to be removed include labor time to flush the transmission oil cooler system. Refer to SI for Automatic Transmission Oil Cooler Flushing and Flow Test J 45096 for the appropriate procedure. Important The J 45096 can be used to flush the transmission oil cooler system on an Allison equipped vehicle, but the flow meter should not be utilized. Refer to SI for Automatic Transmission Oil Cooler Flushing and Flow Test J 45096 for the appropriate flow check procedure. Machine Displays After completion of the flush and flow test, the following information is to be recorded on the repair order. This information is displayed on the Transmission Cooling System Service Tool, J 45096, Transflow(R) machine when the dial is in the code position. - Tested flow rate (displayed in Gallons Per Minute (GPM) - Temperature (displayed is degrees Fahrenheit) - Cycle number (a number) - Seven digit Alpha/Numeric flow code (i.e. A10DFB2) Warranty Information Important All labor operations that include removal of the transmission from the vehicle include labor time to flush the transmission oil cooler system. Performing a transmission oil cooling system flush and flow test will use between 4.7-7.5 L (5-8 qts) of DEXRON(R)VI transmission fluid. The amount Description and Operation Pedal Positioning Switch: Description and Operation Brake Pedal Position Sensor Calibration Description and Operation Calibration Criteria The brake pedal position (BPP) sensor receives a low reference signal and a 5-volt reference signal from the electro-hydraulic power steering (EHPS). Whenever the brake pedal is applied, the brake pedal position sensor applies a variable voltage signal to the EHPS through the BPP sensor signal circuit. Brake pedal position sensor calibration must be performed after the brake pedal position sensor or EHPS system have been serviced. The calibration procedure will set brake pedal position sensor home value. This value is used by the EHPS to determine the brake pedal position and the brake pedal rate. These two outputs are provided to the hybrid control module (HCM) via GMLAN. Calibration Procedure 1. Install a scan tool. 2. Turn ON the ignition, with the engine OFF. 3. Important: Make sure the brake pedal is not depressed before sending BPP sensor calibration command. Navigate to the Special Functions screen on the scan tool and select BPP Sensor Calibration in order to perform the brake pedal position sensor calibration. Page 9769 C322 Seat Motor Jumper Harness To Seat Jumper Harness (With RPO Code AN3) Part 2 Page 7176 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. Remove the rear propeller shaft. 3. Using the J 8614-01 to hold the transmission yoke, remove and discard the yoke nut. 4. Remove the yoke. 5. Using J 6125-1B (1) and J 23129 (2), remove the rear oil seal. Installation Procedure Important: The J 44732 will set the oil seal to the proper depth. Failure to use the J 44732 will cause improper installation of the oil seal. 1. Using J 44732 install the rear oil seal. Page 2541 Refrigerant: Technical Service Bulletins A/C - Contaminated R134A Refrigerant Bulletin No.: 06-01-39-007 Date: July 25, 2006 INFORMATION Subject: Contaminated R134a Refrigerant Found on Market for Automotive Air-Conditioning Systems Models: 2007 and Prior GM Passenger Cars and Trucks (including Saturn) 2007 and Prior HUMMER H2, H3 2007 and Prior Saab 9-7X Attention: This bulletin should be directed to the Service Manager as well as the Parts Manager. Commercially Available Contaminated R134a Refrigerant Impurities have been found in new commercially available containers of R134a. High levels of contaminates may cause decreased performance, and be detrimental to some air-conditioning components. Accompanying these contaminates has been high levels of moisture. Tip: Excessive moisture may cause system concerns such as orifice tube freeze-up and reduced performance. Industry Reaction: New Industry Purity Standards Due to the potential availability of these lower quality refrigerants, the Society of Automotive Engineers (SAE), and the Air Conditioning and Refrigeration Industry (ARI) are in the process of instituting reliable standards that will be carried on the labels of future R134a refrigerant containers. This identifying symbol will be your assurance of a product that conforms to the minimum standard for OEM Automotive Air-Conditioning use. How Can You Protect Yourself Today? It is recommended to use GM or ACDelco(R) sourced refrigerants for all A/C repair work. These refrigerants meet General Motors own internal standards for quality and purity, insuring that your completed repairs are as good as the way it left the factory. Parts Information The part numbers shown are available through GMSPO or ACDelco(R). The nearest ACDelco(R) distributor in your area can be found by calling 1-800-223-3526 (U.S. Only). Page 881 Refer to the table as a guide in selecting the correct test adapter for frontprobing connectors: Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure SCAN TOOL SNAPSHOT PROCEDURE Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: - Snapshot - taken from the Snapshot menu choice - Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information Page 3797 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the cover up until the dress cover releases. Repeat this procedure for the other locking tab. 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. 5. If the connector has a nose piece, use a small flat-blade tool to remove the nose piece by inserting the blade into the slot on the front of the connector and prying up on the nose piece. IMPORTANT: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 6. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. IMPORTANT: Be careful not to angle or rock the J 38125-13A tool when inserting it into the connector or the tool may break. Page 1676 7. Remove the control lever to the manual shaft nut. 8. Remove the control lever from the manual shaft. 9. Remove the PNP switch bolts. 10. Remove the PNP switch from the manual shaft. If the PNP switch does not slide off the manual shaft, file the outer edge of the manual shaft in order to remove any burrs. Installation Procedure 1. Install the PNP switch to the manual shaft by aligning the switch hub flats with the manual shaft flats. 2. Slide the PNP switch onto the manual shaft until the switch mounting bracket contacts the mounting bosses on the transmission. 3. Important: If a new PNP switch is being installed, the switch will come with a positive assurance bracket. The positive assurance bracket aligns the new switch in its proper position for installation and the use of the park neutral switch aligner will not be necessary. Install the PNP switch bolts finger tight. Page 3239 Steps 14 - 15 The number(s) below refer to the step(s) in the diagnostic table. 2. The chirping noise may not be engine related. This step is to verify that the engine is making the noise. If the engine is not making the noise do not proceed any further in this table. 3. The noise may be an internal engine noise. Remove the drive belt(s) and operate the engine for a few seconds, this will verify if the chirping noise is related to the drive belt(s) or not. With the drive belt(s) removed the water pump will not operate and the engine may overheat. Also diagnostic trouble codes (DTCs) may set when the engine is operated with the drive belt(s) removed. 4. Inspect the drive belt(s) for signs of pilling. Pilling is the small balls, pills, or strings in the drive belt grooves caused by the accumulation of rubber dust. 6. Misalignment of the accessory drive pulley(s) may be caused from improper mounting or incorrect installation of an accessory drive component, or the pulley may be bent inward or outward from a previous repair. Test for a misaligned accessory drive pulley using a straight edge in the pulley grooves across two or three pulleys. If a misaligned pulley is found, refer to that accessory drive component for the proper removal and installation procedure for that pulley. 10. Inspection of the fasteners can eliminate the possibility that a incorrect bolt, nut, spacer, or washer was installed. 12. Inspection of the accessory drive pulley(s) should include inspecting for bends, dents, or other damage to the pulley(s) that would prevent the drive belt(s) from seating properly in the pulley grooves or on the smooth surface of the pulley when the back side of the drive belt is used to drive the pulley. 14. Replacing the drive belt(s) when it is not damaged or there is not excessive pilling will only be a temporary repair. Page 8197 JC3/JH1: Brake Vac/Hydraulic Power Disc, 6,400 lbs JC4: Brake Vac Power. Disc, 7,200 lbs JH2: Brake Hydraulic Power, Disc, 7,200 lbs JH6: Brake Hydraulic Power, 4-Wheel Disc, 9,900 lbs JH7: Brake Hydraulic Power, 4-Wheel Disc, 12,300 lbs Page 2145 Drive Belt: Testing and Inspection Drive Belt Rumbling Drive Belt Rumbling Diagnosis Diagnostic Aids Vibration from the engine operating may cause a body component or another part of the vehicle to make rumbling noise. The drive belt(s) may have a condition that can not be seen or felt. Sometimes replacing the drive belt(s) may be the only repair for the symptom. If after replacing the drive belt(s) and completing the diagnostic table, the rumbling is only heard with the drive belt(s) installed, there might be an accessory drive component failure. Varying the load on the accessory drive component(s) may aid in identifying which component is causing the rumbling noise. Test Description Steps 1 - 8 The number(s) below refer to the step(s) in the diagnostic table. 2. This test is to verify that the symptom is present during diagnosing. Other vehicle components may cause a similar symptom. 3. This test is to verify that the drive belt(s) is causing the rumbling. Rumbling may be confused with an internal engine noise due to the similarity in Page 8183 TOOL INFORMATION CORRECTION PLATE PART INFORMATION Refer to TSB 01-05-23-001 for the Brake Align(R) application chart. For vehicles repaired under warranty, Brake Align(R) Run-Out Correction Plates should be submitted in the Net Amount at cost plus 40%. Brake Align(R) Run-Out Correction Plates are available through the following suppliers: - Dealer Equipment and Services - Brake Align(R) LLC (U.S. Dealers Only) * We believe this source and their products to be reliable. There may be additional manufacturers of such products. General Motors does not endorse, indicate any preference for or assume any responsibility for the products from this firm or for any such items, which may be available from other sources. Locations Fuel Composition Sensor Page 751 HVAC Control Module - C1 Part 2 Page 1476 Door Switch: Diagrams Door Latch Assembly (Door Jamb Switch) - RR C2 (Crew Cab Only) Door Latch Assembly (Door Jamb Switch) - RR C2 (Crew Cab Only) Page 13347 - HVAC Actuator - Inflatable Restraint Sensing and Diagnostic Module (SDM) - Any AIR BAG module - Seatbelt Lap Anchor Pretensioner - Seatbelt Retractor Pretensioner - An SIR system connection or connector condition resulting in the following DTCs being set: B0015, B0016, B0019, B0020, B0022, or B0023 - Powertrain Control Module (PCM) - Remote Control Door Lock Receiver (RCDLR) - Transmission Control Module (TCM) Correction Important DO NOT replace the control module, wiring or component for the following conditions: - The condition is intermittent and cannot be duplicated. - The condition is present and by disconnecting and reconnecting the connector the condition can no longer be duplicated. Use the following procedure to correct the conditions listed above. 1. Install a scan tool and perform the Diagnostic System Check - Vehicle. Retrieve and record any existing history or current DTCs from all of the control modules (refer to SI). ‹› If any DTC(s) are set, refer to Diagnostic Trouble Code (DTC) List - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). ‹› If DTCs are not set, refer to Symptoms - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). 2. When identified, use the appropriate DTC Diagnostics, Symptoms, Schematics, Component Connector End Views and Component Locator documents to locate and disconnect the affected harness connector(s) which are causing the condition. Note Fretting corrosion looks like little dark smudges on electrical terminals and appear where the actual electrical contact is being made. In less severe cases it may be unable to be seen or identified without the use of a magnifying glass. Important DO NOT apply an excessive amount of dielectric lubricant to the connectors as shown, as hydrolock may result when attempting to mate the connectors. Use ONLY a clean nylon brush that is dedicated to the repair of the conditions in this bulletin. 3. With a one-inch nylon bristle brush, apply dielectric lubricant to both the module/component side and the harness side of the affected connector(s). 4. Reconnect the affected connector(s) and wipe away any excess lubricant that may be present. 5. Attempt to duplicate the condition by using the following information: - DTC Diagnostic Procedure - Circuit/System Description - Conditions for Running the DTC - Conditions for Setting the DTC - Diagnostic Aids - Circuit/System Verification ‹› If the condition cannot be duplicated, the repair is complete. ‹› If the condition can be duplicated, then follow the appropriate DTC, Symptom or Circuit/System Testing procedure (refer to SI). Repair Order Documentation Page 9019 Fuse Block - Underhood C3 Part 2 Page 4662 Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses CIRCUIT PROTECTION - FUSES The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the Page 11438 ^ C222 (4 Cavities) (w/HP2) - Behind the left side I/P access panel ^ Refer to the Master Electrical Component List for additional location information. 1. Remove the appropriate side door sill plate. 2. Remove the appropriate side hinge pillar panel. 3. Locate the IP harness to inflatable restraint module yellow 4-way connector C221 or C222. 4. Inspect the IP harness to inflatable restraint module connector C221 or C222 for proper connection. 5. Disconnect and reconnect the IP harness to inflatable restraint module connector C221 or C222 THREE times. 6. Clear the DTC and road test the vehicle. ^ If DTCs B0013, B0014, B0017, B0018, B0024, B0026, B0043, B0044 DOES NOT reset, no additional repairs are necessary. Continue with step 10. ^ If DTCs B0013, B0014, B0017, B0018, B0024, B0026, B0043, B0044 DOES reset, the most likely cause is high resistance in the IP harness to inflatable restraint module connector C221 or C222. Continue with the next step. 7. Replace the appropriate connector C221 and/or C222, P/N's 15306186 and 88987998. Refer to SIR/SRS Wiring Repairs (SI Document ID #325229). 8. Road test the vehicle and confirm that the repair is complete. 9. Install the driver's side hinge pillar panel. 10. Install the driver's side door sill plate. Parts Information Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Page 10291 6. Remove the accelerator pedal position sensor. 7. Slide the upper intermediate shaft towards the instrument panel, out of the lower intermediate shaft, and remove the shaft from the vehicle. Installation Procedure 1. Important: If you are installing the same shaft, align the marks and the relationship of the bolt and clamp made during the removal procedure. Install the lower end of the upper intermediate shaft through the bulkhead, into the lower shaft. 2. Install the upper end of the upper intermediate shaft (2) to the steering column. 3. Notice: Refer to Fastener Notice in Service Precautions. Install the bolt and nut (1) at the connection of the upper intermediate shaft to the steering column. ^ Tighten the nut to 62 Nm (46 ft. lbs.). 4. Install the accelerator pedal position sensor. 5. Install the bolt and nut at the connection of the upper intermediate shaft to the lower intermediate shaft. ^ Tighten the nut to 47 Nm (35 ft. lbs.). 6. Remove the J 42640 from the steering column lower access hole. Page 16140 High Temperature Conditions Tools Required J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency MEASURING FREQUENCY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage MEASURING VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop MEASURING VOLTAGE DROP NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Page 5922 are secure and the TIS terminal operating software is up to date. 1. Verify the battery charge of 12 to 16 volts. The battery must be able to maintain the charge during programming. Use an additional jump battery if necessary. 2. Use the normal "request method" through "Service Programming System" to request information from the vehicle. 3. At the Techline Terminal, enter TIS SPS programming system. 4. Select Tech 2(R) from the "Select Diagnostic Tool" window. 5. Select Reprogram ECU from the Select Programming Process window. 6. Select Vehicle from the "Select ECU Location" window. 7. Select Next to go to the "Preparing for Communication" instruction screen. 8. Select Next to view the Validate Vehicle ID Number screen. If the vehicle ID number does not appear on the screen, manually insert the VIN into the VIN window of the Validate Vehicle ID Number screen. 9. Select Next to view the "Supported Controllers" screen. 10. Select PCM/VCM Powertrain/Vehicle Control Module from "Supported Controllers" window. 11. Select Next to view the "Select Programming Type" window. 12. Select Normal from the Select Programming Type window. 13. Select Next to view the "Service Programming System Calibration Selection" screen. 14. Select Next to view Summary screen. 15. Verify that current and selected calibration information is displayed on the Summary screen. 16. Select Next to download the calibration to the Tech 2(R). 17. Back at the vehicle, enter "Service Programming Systems". 18. Select Program ECU and follow the on-screen instructions. 19. When programming is complete, do the following: 19.1. Turn the Tech 2(R) OFF. 19.2. Turn the ignition switch OFF. 20. Wait 30 seconds. 21. Turn the ignition switch to ON with the engine OFF. 22. Go into Diagnostics and check for DTC codes. 23. Clear all codes. Claim Information Page 1886 4. Position the J 41364-A onto the PNP switch. Ensure that the two slots on the switch where the manual shaft is inserted are lined up with the lower two tabs on the tool. 5. Notice: Refer to Fastener Notice in Service Precautions. Rotate J 41364-A until the upper locator pin on the tool is lined up with the slot on the top of the switch. ^ Tighten the bolts to 25 Nm (18 ft. lbs.). 6. Remove J 41364-A from the PNP switch. If installing a new switch, remove the positive assurance bracket at this time. 7. Install the control lever to the manual shaft with the nut. 8. Install the manual shaft nut. ^ Tighten the nut to 25 Nm (18 ft. lbs.). 9. Install the range selector cable end (2) to the range selector lever ball stud (1). Page 2240 Oil Filter: Service and Repair Engine Oil and Oil Filter Replacement Removal Procedure Important: In order to completely drain the oil from the oil pan internal baffling, the bottom of the oil pan must be level during the oil drain procedure. 1. Open the hood. 2. Remove the oil fill cap. 3. Raise and suitably support the vehicle. 4. Place a oil drain pan under the oil pan drain plug. 5. Remove the oil pan drain plug. 6. Drain the engine oil. 7. Wipe the excess oil from the drain plug hole and plug. 8. Remove the oil filter from the engine block. Important: Check the old oil filter to ensure that the filter seal is not left on the engine block. 9. Wipe the excess oil from the oil filter mounting. Installation Procedure 1. Lubricate the oil filter seal with clean engine oil. Page 13080 For vehicles repaired under warranty, use the table. Disclaimer OnStar(R) - Analog/Digital System Information Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Analog/Digital System Information INFORMATION Bulletin No.: 06-08-46-008C Date: September 18, 2008 Subject: Information on OnStar(R) Dual-Mode (Analog/Digital) Systems Models Supercede: This bulletin is being revised to correct the model year range for the Chevrolet Impala and Monte Carlo and update the reference to GM Dealerworld. Please discard Corporate Bulletin Number 06-08-46-008B (Section 08 - Body and Accessories). All 2000-2003 model year vehicles equipped with OnStar® from the list above were built with Analog/Digital-Ready OnStar(R) Hardware. Some of these vehicles may have been upgraded to Dual-Mode (Analog/Digital). Certain 2004-2005 model year vehicles equipped with OnStar(R) from the list above may have been either: ^ Originally built at the factory with Dual-Mode (Analog/Digital) OnStar(R) Hardware with Dual-Mode (Analog/Digital) OnStar(R) Hardware OR ^ Upgraded to Dual-Mode (Analog/Digital) Hardware All 2006 model year and newer vehicles equipped with OnStar(R) were built at the factory with Dual-Mode (Analog/Digital) OnStar(R) Hardware. If a vehicle has Dual-Mode (Analog/Digital) OnStar(R) Hardware, then the system is capable of operating on both the analog and digital cellular Page 11916 Important: The optic cable must not be bent with a radius less than 25 mm (1 in). 6.12. Place the optic cable in the wiring harness channels on the right-hand side. Thread through the existing cable ties (C) if possible, otherwise, secure with a cable tie to the existing one. Close the cover on the channels. Ensure the catches lock. 6.13. Secure the optic cable along the right-hand rear wheel housing, next to the ordinary wiring harness securing points and by the SRS unit (D). 6.14. Thread the optic cable up next to the safety belt by the old optic cable and place on the parcel shelf. 6.15. Unplug the connectors (E) from the OnStar(R) control modules. 6.16. Remove the console (F) together with the OnStar(R) control modules. Page 862 Body Control Module (BCM) Page 8343 3. Install the master cylinder to the vehicle. 4. Notice: Refer to Fastener Notice in Service Precautions. Install the master cylinder mounting nuts. ^ Tighten the nuts to 33 Nm (24 ft. lbs.). 5. Remove the rubber cap or plug from the exposed brake pipe fitting ends. 6. Connect the brake pipes. ^ Tighten the fittings to 25 Nm (18 ft. lbs.). 7. Connect the electrical connector to the brake fluid level sensor. 8. Bleed the hydraulic brake system. 9. Release the park brake and unblock the wheels. Master Cylinder Replacement (Hydraulic Boost) Master Cylinder Replacement (Hydraulic Boost) Removal Procedure Caution: Refer to Brake Fluid Irritant Caution in Service Precautions. Notice: Refer to Brake Fluid Effects on Paint and Electrical Components Notice in Service Precautions. 1. Apply the park brake and block the wheels. 2. Disconnect the electrical connector from the brake fluid level sensor. Page 4300 Refer to the table as a guide in selecting the correct test adapter for frontprobing connectors: Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure SCAN TOOL SNAPSHOT PROCEDURE Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: - Snapshot - taken from the Snapshot menu choice - Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information Page 4303 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground TESTING FOR SHORT TO GROUND NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting With A Digital Multimeter TROUBLESHOOTING WITH A DIGITAL MULTIMETER NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TROUBLESHOOTING WITH A TEST LAMP Page 7316 1. If a NEW control module is being installed, program the new module. 2. Install the shift control module to the bracket. 3. Connect the shift control module electrical connectors. 4. Start the engine and test the automatic transfer case system for proper shift operation. Page 7646 1. Install the J 43484 (2) to the J 8092 (1). 2. Install a NEW seal onto J 43484. 3. Using J 43484 (2), and J 8092 (1), install the seal. 4. Install the front propeller shaft. 5. Check the fluid level. Add fluid, if necessary. 6. Install the transfer case shield, if equipped. Transfer Case Output Shaft Seal Replacement - Rear Transfer Case Output Shaft Seal Replacement - Rear ^ Tools Required J 37668-A Output Shaft Seal Installer - J 45380 Transfer Case Rear Bushing Remover and Installer Removal Procedure 1. Remove the transfer case shield, if equipped. 2. Remove the rear propeller shaft. 3. Pry out the rear output shaft seal, using a flat-tipped screwdriver. Page 5120 16. Remove the bolts (4) attaching the EHCU bracket to the frame (5). 17. Remove the EHCU (1). 18. Remove the torsion bar bracket, if equipped with 4WD. 19. Remove the EVAP canister. 20. Disconnect the fuel line at the tank. 21. Cap the fuel and EVAP lines in order to avoid possible system contamination. 22. Remove the fuel/EVAP bundle clip nuts. 23. Remove the fuel/EVAP bundle. INSTALLATION PROCEDURE 1. Install the fuel/EVAP bundle. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the fuel/EVAP bundle clip nuts. Tighten Tighten the nuts to 12 N.m (106 lb in). 3. Remove the caps from the fuel and EVAP lines. 4. Connect the fuel line at the tank. 5. Install the EVAP canister. 6. Install the torsion bar bracket, if equipped with 4WD. Tire/Wheel - Spare Tire Is Non-Matching To Other Tires Spare Tire: All Technical Service Bulletins Tire/Wheel - Spare Tire Is Non-Matching To Other Tires INFORMATION Bulletin No.: 02-03-10-001E Date: November 01, 2010 Subject: Spare Tire is a Different Size than Other Tires Models: 2002-2011 Cadillac Escalade Models 1999-2007 Chevrolet Silverado (Classic) 2000-2011 Chevrolet Suburban, Tahoe 2002-2011 Chevrolet Avalanche 1999-2007 GMC Sierra (Classic) 2001 GMC Sierra C3 2001-2011 GMC Yukon Models 2002-2011 GMC Sierra Denali Supercede: This bulletin is being revised to update the model years. Please discard Corporate Bulletin Number 02-03-10-001D (Section 03 - Suspension). This bulletin is being issued to supply additional information concerning the spare tire on the above vehicles. You or your customers may have noticed that the spare tire has a 16-inch diameter steel wheel or 17-inch diameter aluminum wheel while the road tires have a 17-inch, 18-inch, 20-inch or 22-inch diameter aluminum wheel. Although the spare tire has a different wheel diameter and may be a different brand, the rolling circumference is nearly identical to the road tires. The size difference will not cause a concern because the spare and the other tires will travel the same distance in one revolution. This combination of non-matching tires is used most often on full-size trucks. These vehicles use a road tire and wheel combination that may be too large to conveniently fit the storage compartment space of the vehicle. The customer may not be able to easily remove the spare tire/wheel from the storage area because of its size and/or weight. A steel spare wheel, rather than an aluminum one, may be used since the spare is stowed under the vehicle where it is exposed to road and weather elements. A steel wheel is less likely to incur cosmetic damage while in the stowed position for long periods of time. Please provide this information to your customers. Also, remind your customers of the importance of following the tire maintenance schedule as listed in their Owner Manual. Additional tire care information can be found by visiting www.gmtiresafety.com or contacting GM toll-free. Disclaimer Page 9536 Junction Block - I/P Wire Entry Part 3 Page 5439 5. Connect the fuel pump electrical connector. 6. Install the sending unit. Page 5334 8. Install the PCV hose. 9. Perform the following steps in order to connect the fuel injector electrical connectors. 9.1. Install the connectors to their corresponding injectors to ensure correct reassembly. 9.2. Connect the fuel injector electrical connector. 9.3. Push the CPA retainer (2) in the connector in 1 click. 9.4. Repeat the steps for each injector electrical connector. 10. Position the engine wire harness. 11. Connect the following electrical connectors to both sides of the engine: - Main coil (2) - Fuel injectors Page 12816 Diagnostic Tips Review # 1 - Delphi Super Nav and Black Tie Nav Electrical - Information For Electrical Ground Repair Wiring Harness: All Technical Service Bulletins Electrical - Information For Electrical Ground Repair INFORMATION Bulletin No.: 10-08-45-001B Date: October 25, 2010 Subject: Information for Electrical Ground Repair - Use New Replacement Fasteners with Conductive Finish Models: 2011 and Prior GM Passenger Cars and Trucks (including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X Supercede: This bulletin is being revised to add the 2011 model year and update the Warranty Information. Please discard Corporate Bulletin Number 10-08-45-001A (Section 08 - Body and Accessories). Electrical Ground Repair Overview Proper electrical system function relies on secure, stable and corrosion-free electrical ground connections. Loose, stripped, or corroded connections increase the possibility of improper system function and loss of module communication. These conditions may also lead to unnecessary repairs and component replacement. In general, electrical ground connections are accomplished using one, or a combination of the following attachment methods: - Welded M6 stud and nut - Welded M6 nut and bolt - Welded M8 nut and bolt Determine which attachment method is used and perform the appropriate or alternative repair as described in this bulletin. M6 Weld Stud Replacement Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. Select a location adjacent the damaged or missing M6 ground stud having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the M6 conductive rivet stud flange. 2. Using GM approved residue-free solvent or equivalent, remove any grease from the repair site and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 3. Drill a 10 mm (0.40 in) diameter hole through the panel. 4. Remove paint and primer from the area surrounding the 10 mm (0.40 in) hole until bare metal is visible. Page 4391 Electronic Throttle Actuator: Diagrams Throttle Actuator Control (TAC) Module C1 Part 1 Instruments - Trip Odometer Apparently Inoperative Odometer: Customer Interest Instruments - Trip Odometer Apparently Inoperative Bulletin No.: 04-08-49-007 Date: February 26, 2004 INFORMATION Subject: Personal Trip/Business Trip Feature - Must be On for Trip Odometer to Accumulate Models: 2003-2004 Cadillac Escalade, Escalade ESV, Escalade EXT 2003-2004 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2003-2004 GMC Sierra, Sierra Denali, Yukon, Yukon XL, Yukon Denali The purpose of this bulletin is to prevent the inadvertent replacement of the instrument cluster if a customer comes in to your dealership stating that the trip odometer is inoperative or does not accumulate. For vehicles with steering wheel controls, the Personal Trip (or Business Trip) feature must be turned On in order for the trip odometer to accumulate. When the display reads Personal Trip: On (or Business Trip: On), the trip odometer shall accumulate. The Personal Trip and Business Trip features can be turned on or off by pressing the select button. Refer to Driver Information Center (DIC) in the Owner's Manual for additional information. Page 1005 Step 24 Navigation System - Replacement Navigation Discs Navigation System: All Technical Service Bulletins Navigation System - Replacement Navigation Discs Bulletin No.: 07-08-44-007 Date: April 17, 2007 INFORMATION Subject: Information on Obtaining Replacement Navigation Discs When Radios are Exchanged Order Replacement Navigation Disc Through Navigation Disc Center Models: 2007 and Prior GM Passenger Cars and Trucks (Including Saturn) 2007 and Prior HUMMER H2, H3 2007 and Prior Saab 9-7X with a Navigation Radio Attention: The purpose of this bulletin is to inform dealership personnel of a new procedure for obtaining a replacement navigation disc for radios that are sent to an ESC for exchange. This bulletin applies to U.S. and Canadian dealers only and is not intended for use by export dealers. When a navigation radio warranty exchange is performed, the customer must have a navigation disc to operate the new radio. If the customer's navigation disc was damaged or is stuck in the failed radio, the customer would have to wait for an excessive period of time for the disc to be returned or replaced. The Electronic Service Centers (ESC) are not authorized to remove stuck navigation discs from cores, as the cores must be returned to the supplier for analysis prior to any disassembly. The time it would take for the supplier to return the navigation disc would significantly delay the completion of the repair at the dealership. If the customer's navigation disc is damaged or cannot be removed from the radio, the dealership is to obtain an exchange radio through an ESC and a new navigation disc through the GM Navigation Disc Center. Both items can be shipped overnight to the dealership upon request. GM Navigation Disc Center Contact Information Via the web through gmnavdisc.com The GM Navigation Disc Center is also the center of expertise for navigation system questions. Warranty Information Include the part number and cost of the new navigation disc on the warranty claim for the navigation radio exchange. Disclaimer Page 5142 Steps 4 - 6 Service and Repair Cowl Moulding / Trim: Service and Repair Air Inlet Grille Panel Replacement Removal Procedure 1. Remove the wiper arms. 2. Pull up in order to release the outboard air inlet grille panel clips. 3. Remove the attaching clips running along the edges of the center air inlet grille panel. 4. Remove the sheet metal screws on each end of the air inlet grille panel. 5. Disconnect the windshield washer hose from the nozzle underneath the center air inlet grille panel. 6. Remove the air inlet grille panel. Installation Procedure 1. Connect the windshield washer hose to the nozzle under the center air inlet grille panel. 2. Position the air inlet grille panel to the vehicle and attach the clips to the edges of the center air inlet grille panel. Notice: Refer to Fastener Notice in Service Precautions. 3. Install the sheet metal screws on each end of the air inlet grille panel. Tighten the sheet metal screws to 2 N.m (18 lb in). Page 7875 Pay particular attention to the terminal connections at the module. Spread or open terminal connections may create an intermittent contact. Do a pin drag test. Refer to the terminal testing information in the table shown. ^ After repairs are complete, ALWAYS clear DTCs from the module prior to a system function test. If codes are not cleared first, the system will not function after repair. The technician may erroneously think that the system is still down and that further repairs are needed. Warranty Dealers who unnecessarily replace the TCCM that are found to have No Trouble Found (NTF) at the WPC will be returned to the AVM (Area Service Manager), or the DSM (District Service Manager) in Canada, through the Regional Feedback Process and may be charged back for the repair through the WINS system. Disclaimer Page 5280 Step 6 Page 13553 Control Module References Part 2 Page 15292 13. If necessary, lower the vehicle. 14. Using a scan tool, clear the DTCs. 15. Start the vehicle and inspect for leaks. Important: Advise the customer that a similar condition may occur if the vehicle is fueled with the engine running AND the rear tank is fueled first. The engine must be shut off (as required by law) during vehicle refueling. Parts Information Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 14963 This information has been added within SI. If you are using a paper version of this Service Manual, please make a reference to this bulletin. Disclaimer Page 3639 INSTALLATION PROCEDURE 1. Install the heater core (1) to the HVAC module assembly (2). 2. Install the heater core cowl gasket (1) to the HVAC module assembly (2). 3. Install the heater core cover (1) to the HVAC module assembly (2). NOTE: Refer to Fastener Notice in Service Precautions. 4. Install the screws to the heater core cover (1). Tighten Automatic Transmission - 4L60-E/4L65-E Accumulator: Service and Repair Automatic Transmission - 4L60-E/4L65-E Accumulator Assembly, Spacer Plate, and Gaskets ^ Tools Required J 25025-B Pump and Valve Body Alignment Pin Set - J 36850 Transjel Lubricant Removal Procedure 1. Remove the transmission filter. 2. Important: The 1-2 accumulator can be removed without removing the valve body. Remove the valve body. 3. Remove the accumulator cover bolts. 4. Remove the 1-2 accumulator cover. 5. Important: regular production option (RPO) M33 transmissions do not use a 1-2 accumulator spring inner (104). Remove the 1-2 accumulator cover (57) and pin. 6. Disassemble the 1-2 accumulator assembly (54, 56, 57, 104). 7. Inspect the 1-2 accumulator springs for cracks. Front End Sensors Impact Sensor: Description and Operation Front End Sensors INFLATABLE RESTRAINT FRONT END SENSORS The front end sensors are equipped on vehicles to supplement the SIR system performance. The front end sensors are electronic and are not part of the deployment loops, but instead provide inputs to the sensing and diagnostic module (SDM). The front end sensors can assist in determining the severity of some frontal collisions. The SDM uses the input from the front end sensors to assist in determining the severity of a frontal collision further supporting air bag deployment. If the SDM determines a deployment is warranted, the SDM will cause current to flow through the deployment loops deploying the frontal air bags. Page 7326 Park Neutral Position (PNP) Switch C175 Page 8339 Brake Master Cylinder: Service and Repair Master Cylinder Bench Bleeding Master Cylinder Bench Bleeding Caution: Refer to Brake Fluid Irritant Caution in Service Precautions. Notice: When adding fluid to the brake master cylinder reservoir, use only Delco Supreme 11, GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. The use of any type of fluid other than the recommended type of brake fluid, may cause contamination which could result in damage to the internal rubber seals and/or rubber linings of hydraulic brake system components. 1. Secure the mounting flange of the brake master cylinder in a bench vise so that the rear of the primary piston is accessible. 2. Remove the master cylinder reservoir cap and diaphragm. 3. Install suitable fittings to the master cylinder ports that match the type of flare seat required and also provide for hose attachment. 4. Install transparent hoses to the fittings installed to the master cylinder ports, then route the hoses into the master cylinder reservoir. 5. Fill the master cylinder reservoir to at least the half-way point with Delco Supreme 11® (GM P/N 12377967) or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. 6. Ensure that the ends of the transparent hoses running into the master cylinder reservoir are fully submerged in the brake fluid. 7. Using a smooth, round-ended tool, depress and release the primary piston as far as it will travel, a depth of about 25 mm (1 inch), several times. Observe the flow of fluid coming from the ports.As air is bled from the primary and secondary pistons, the effort required to depress the primary piston will increase and the amount of travel will decrease. 8. Continue to depress and release the primary piston until fluid flows freely from the ports with no evidence of air bubbles. 9. Remove the transparent hoses from the master cylinder reservoir. 10. Install the master cylinder reservoir cap and diaphragm. 11. Remove the fittings with the transparent hoses from the master cylinder ports. Wrap the master cylinder with a clean shop cloth to prevent brake fluid spills. 12. Remove the master cylinder from the vise. Page 2119 - Inspect the insulator (2) for cracks. All or part of the electrical charge may arc through the crack instead of the electrodes (3, 4). - Inspect for evidence of improper arcing. Measure the gap between the center electrode (4) and the side electrode (3). Refer to Ignition System Specifications. An excessively wide electrode gap can prevent correct spark plug operation. - Inspect for the correct spark plug torque. Refer to Ignition System Specifications. Insufficient torque can prevent correct spark plug operation. An over torqued spark plug, causes the insulator (2) to crack. - Inspect for signs of tracking that occurred near the insulator tip instead of the center electrode (4). - Inspect for a broken or worn side electrode (3). - Inspect for a broken, worn, or loose center electrode (4) by shaking the spark plug. A rattling sound indicates internal damage. - A loose center electrode (4) reduces the spark intensity. - Inspect for bridged electrodes (3, 4). Deposits on the electrodes (3, 4) reduce or eliminates the gap. - Inspect for worn or missing platinum pads on the electrodes (3, 4), if equipped. - Inspect for excessive fouling. - Inspect the spark plug recess area of the cylinder head for debris. Dirty or damaged threads can cause the spark plug not to seat correctly during installation. VISUAL INSPECTION - Normal operation - Brown to grayish-tan with small amounts of white powdery deposits are normal combustion by-products from fuels with additives. - Carbon fouled - Dry, fluffy black carbon, or soot caused by the following conditions: Rich fuel mixtures Leaking fuel injectors - Excessive fuel pressure - Restricted air filter element - Incorrect combustion - Reduced ignition system voltage output Weak ignition coils Page 7312 Page 13146 Important: Secure the wiring harness so that there is no risk of chafing or rattling. 6.1. Remove the passenger seat in accordance with WIS 8. Body - Seats Adjustment/Replacement. 6.2. Remove the right-hand B-pillar trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.3. Remove the right-hand C pillar trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.4. Fold the rear seat backrest forward. 6.5. Remove the right-hand side bolster in accordance with WIS - 8. Body - Seats Adjustment/Replacement. 6.6. Remove the A-pillar's lower side piece. 6.7. Open the cover on the right-hand wiring harness channels. 6.8. Loosen the locking strip (A) on the 2-pin connector (H2-11) for the optic cable, located by the right-hand A-pillar. 6.9. Loosen the catch (B) and remove the optic cable that runs backward in the car. 6.10. Dismantle the end cap from the new optic cable (12 783 577) and connect it to the connector H2-11. Push in the optic cable and make sure the catch (B) locks and refit the locking strip (A). 6.11. Secure the connector and the old optic cable using the cable tie for the existing wiring harness (C). Component Locations Transmission Temperature Sensor/Switch: Component Locations Automatic Transmission - 4L60-E/4L65-E Automatic Transmission Electronic Component Views (M30/M32) Electronic Components Service and Repair Cowl Moulding / Trim: Service and Repair Air Inlet Grille Panel Replacement Removal Procedure 1. Remove the wiper arms. 2. Pull up in order to release the outboard air inlet grille panel clips. 3. Remove the attaching clips running along the edges of the center air inlet grille panel. 4. Remove the sheet metal screws on each end of the air inlet grille panel. 5. Disconnect the windshield washer hose from the nozzle underneath the center air inlet grille panel. 6. Remove the air inlet grille panel. Installation Procedure 1. Connect the windshield washer hose to the nozzle under the center air inlet grille panel. 2. Position the air inlet grille panel to the vehicle and attach the clips to the edges of the center air inlet grille panel. Notice: Refer to Fastener Notice in Service Precautions. 3. Install the sheet metal screws on each end of the air inlet grille panel. Tighten the sheet metal screws to 2 N.m (18 lb in). Page 1461 Upper Steering Column Page 11696 Right Side Impact Sensor (With RPO Code HP2) Page 9726 Multiple Junction Connector: Diagrams C201 - C277 C201 Steering Column Harness To I/P Harness Part 1 Page 7610 For vehicles repaired under warranty, use the table. Disclaimer Page 12595 Important: The optic cable must not be bent with a radius less than 25 mm (1 in). 12.5. Cars with brackets for e.g. an amplifier: Fit the cable tie (11 900 515) to the wiring harness approx. 100 mm (4 in) from H2-9, fit the cable tie (H) to the bracket. Gather the optic cable in a gentle loop (I) and then place the loop behind the bracket. Important: The optic cable must not be bent with a radius less than 25 mm (1 in). 12.6. Cars without brackets for e.g. an amplifier: Gather the optic cable in a gentle loop (J) and secure with cable tie. 13. CV: Fit the left-hand, rear side hatch trim in accordance with WIS - 8. Body - Interior equipment - Adjustment/Replacement. 14. Fit the ground cable to the battery's negative terminal. 15. Carry out procedures after disconnecting the battery, see WIS - 3. Electrical System - Charging system - Adjustment/Replacement. Important: Follow Tech 2(R) on-screen instructions. 16. Add ECU ICM, choose without OnStar(R). See WIS-General-Tech 2(R) - Description and Operation - Add/Remove. 2000-2004 Saab 9-5 2000-2004 Saab 9-5 Page 8533 Park Neutral Position (PNP) Switch C175 Page 7260 Power Take Off (PTO) Switch - Part 2 Page 514 Driver Door Module (DDM) - C2 (With RPO Code YE9) Part 2 Page 7584 Parts Information Parts are currently available from GMSPO. Warranty Information Page 7826 Locations Manifold Pressure/Vacuum Sensor: Locations Full Engine View Left Side Page 1630 Disclaimer Page 9099 Fuse Block: Service and Repair I/P Electrical Center or Junction Block Replacement - Left INSTRUMENT PANEL ELECTRICAL CENTER OR JUNCTION BLOCK REPLACEMENT - LEFT REMOVAL PROCEDURE 1. Remove the left side end panel. 2. Remove the knee bolster. 3. Disconnect all the wiring connectors from the fuse block. 4. Remove all the fuses. 5. Remove the turn signal relay from the back of the fuse block. 6. From behind the fuse block, remove the retaining bolt. 7. Insert a screw driver between the fuse block and the wire harness block to separate. 8. Push on the retainers in order to remove the fuse block. 9. Remove the fuse block from the vehicle. INSTALLATION PROCEDURE 1. Install the fuse block onto the I/P assembly until it clicks in place. 2. Install the wire harness block to the back of the fuse block. NOTE: Refer to Fastener Notice in Service Precautions. 3. Install the bolt. Tighten Tighten the bolt to 6 N.m (53 lb in). 4. Install the turn signal relay to the back of the fuse block. 5. Using the wiring diagram on the cover of the fuse panel, install the fuses. 6. Install the electrical connectors. 7. Install the knee bolster. Page 4190 Step 3 Page 10105 11. Calibrate the brake pedal position sensor. Page 9413 Electrical Symbols Part 12 Page 9763 C310 Body Harness To Left Rear Door Harness (Crew Cab) Part 2 Drivetrain - Transfer Case Control Module Replacement Control Module: All Technical Service Bulletins Drivetrain - Transfer Case Control Module Replacement Bulletin No.: 05-04-21-002 Date: March 10, 2005 INFORMATION Subject: Guidelines for Replacement of Transfer Case Control Module (TCCM) Models: 2005 and Prior Light Duty Trucks with New Venture Gear (NVG) Transfer Case (RPOs NP1, NP4, NP8) Dealers are replacing the TCCM unnecessarily. Dealers are replacing the TCCM with codes stored in HISTORY only. The TCCM does not have a current fault condition when tested. Parts reviewed at the Warranty Parts Center (WPC) have a 75% No Trouble Found (NTF) rate. The only two legitimate reasons to replace the TCCM are: ^ Diagnostic Trouble Code (DTC) C0550 ^ NO Communication with a scan tool. DTC C0550 This DTC indicates that the module has an internal fault and should be replaced. No Communication ^ The no communication conditions referenced here are also caused by a module internal fault to a point where the module physically will not talk. A technician cannot pull DTCs from the module because it will not communicate. The module is electrically dead. ^ No communication is not to be confused with a U1026 code. This code tells the technician that the module may still be functioning but is temporarily off line. This code may be set by the Instrument Panel (IP) or the Powertrain Control Module (PCM) against the TCCM. The technician needs to figure out why the module went off line. These are typically caused by connection concerns. There is no need to replace a TCCM for a U1026 DTC. Diagnostic Aids ^ When diagnosing a transfer case electrical control system, ALWAYS check power and ground wiring first. ^ Test the connections for intermittent or poor connections, complete plug insertion, bent pins, pushed out terminals and water contamination. Page 11194 6. Install the discharge hose (1) to the A/C compressor using new sealing washers. 7. Install the discharge hose mounting bolt. Tighten Tighten the bolt to 16 N.m (12 lb ft). 8. Evacuate and recharge the A/C system. Refer to Refrigerant Recovery and Recharging. 9. Leak test the fittings of the component using the J 39400-A. Page 746 - Proof of ownership at time of repair. - Original paid receipt confirming the amount of unreimbursed repair expense(s) (including Service Contract deductibles), a description of the repair, and the person or entity performing the repair. If the work was done by someone other than a GM dealership, the amount of reimbursement will be limited to the amount that the repair would have cost GM to have it completed by a GM dealership. Courtesy Transportation The General Motors Courtesy Transportation program is intended to minimize customer inconvenience when a vehicle requires a repair that is covered by the New Vehicle Limited Warranties. The availability of courtesy transportation to customers whose vehicles are within the warranty coverage period and involved in a product program is very important in maintaining customer satisfaction. Dealers are to ensure that these customers understand that shuttle service or some other form of courtesy transportation is available and will be provided at no charge. Dealers should refer to the General Motors Service Policies and Procedures Manual for Courtesy Transportation guidelines. Warranty Transaction Information Submit a transaction using the table below. * The amount identified in "Net Item" should represent the dollar amount reimbursed to the customer. Disclaimer Specifications Idle Speed: Specifications Information not supplied by manufacturer. Memory Seat Calibration Procedure Memory Positioning Module: Service and Repair Memory Seat Calibration Procedure MEMORY SEAT CALIBRATION PROCEDURE The memory seat module uses position sensor inputs to establish soft stop locations for the adjuster motors several millimeters ahead of the physical limits of the adjuster assembly. After replacing a memory seat module or adjuster components, it may be necessary to reset the adjuster motor soft stop locations. When the repair procedure has been completed, operate the seat adjuster switch in every direction until the seat adjuster reaches its mechanical hard stop by repeatedly pressing and releasing the switch as necessary. Page 8564 Page 13188 Important: This bulletin does NOT apply to 2006 vehicles built AFTER the VIN breakpoints listed above. Refer to applicable diagnostics in SI for those vehicles that exhibit this condition. Remove the OnStar(R) fuse from the fuse box, wait five minutes and reinstall the fuse. (For Saturn VUE vehicles, remove the "INT LTS" fuse from the I/P fuse block for five minutes, then reinstall the fuse.) If the OnStar(R) system DOES NOT return to normal functionality, then follow the diagnostics in SI for this condition. If the OnStar(R) system DOES return to normal functionality, perform the following steps: 1. Install the Tech 2(R) and determine what generation hardware and software ID is in the vehicle. 2. If the vehicle is equipped with Generation 5 hardware and a software version 146, the VCIM should have the B1000 reprogramming performed as described in Corporate Bulletin Number 04-08-46-004A. The system should be tested and if the concern returns, the VCIM should be replaced. 3. If Gen 5 with a software version OTHER than 146 or Gen 6 and above, the VCIM needs to be replaced and the system reconfigured. Refer to the current version of Corporate Bulletin 03-08-46-004 for details on how to order a new VCIM. Important: As with any OnStar(R) VCIM replacement, the OnStar(R) system must be reconfigured after replacement. Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use the table. Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table. Disclaimer Page 1773 Impact Sensor: Description and Operation Side Impact Sensor (SIS) (Right) With RPO HP2 INFLATABLE RESTRAINT SIDE IMPACT SENSOR (SIS) (RIGHT) WITH RPO HP2 The right side impact sensor (SIS) contains a sensing device which monitors vehicle acceleration and velocity changes to detect side collisions that are severe enough to warrant disabling the 42-volt system. The SIS is not part of the deployment loop, but instead provides an input to the sensing and diagnostic module (SDM). When the SDM receives a signal from the SIS that a collision has occurred, the SDM communicates this over the vehicles communication bus. The module responsible for the 42-volt system receives this message and disables the 42-volt system. Page 9891 5. Remove paint and primer from the area surrounding the 10 mm (0.40 in) until bare metal is visible. Important The M6 conductive rivet stud as shown, can accommodate a panel thickness range of 0.7-4.2 mm (0.03-0.17 in). If there are layers of sheet metal, they should be touching without any air gaps to ensure a good ground. 6. Select a M6 conductive rivet stud. Refer to the Parts Information section of this bulletin. Note Use the GE-50317 rivet stud tool kit. 7. Place the M6 conductive rivet stud (1) in the 10 mm (0.40 in) hole. Assemble the rivet stud tool (2) with the groove and flare side facing the rivet stud, then the washer and the M6 nut (3). 8. Using a wrench on the rivet stud tool, and a socket on the M6 nut, secure the M6 conductive rivet stud. 9. Ensure the new rivet stud is securely fastened, WITHOUT ANY detectable movement. 10. Completely wrap the threads of the rivet stud with painters tape or equivalent. Service and Repair Thermostat: Service and Repair Thermostat Housing Replacement (4.8L, 5.3L, and 6.0L Engines) Removal Procedure Important: The thermostat is not serviceable separately. The water pump inlet and thermostat must be replaced as an assembly. 1. Remove the radiator outlet hose. 2. Remove the water pump inlet bolts. 3. Remove the water pump inlet and thermostat from the water pump. Installation Procedure 1. Install the thermostat and thermostat housing to the water pump. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the thermostat housing bolts. Tighten the bolts to 15 Nm (11 ft. lbs.). 3. Install the radiator outlet hose. Page 14988 and involved in a product recall is very important in maintaining customer satisfaction. Dealers are to ensure that these customers understand that shuttle service or some other form of courtesy transportation is available and will be provided at no charge. Dealers should refer to the General Motors Service Policies and Procedures Manual for Courtesy Transportation guidelines. Claim Information Page 4316 circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links CIRCUIT PROTECTION - FUSIBLE LINKS Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Flat Wire Repairs FLAT WIRE REPAIRS NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Heated Oxygen Sensor (HO2S) Wiring Repairs HEATED OXYGEN SENSOR (HO2S) WIRING REPAIRS TOOLS REQUIRED J 38125-D Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: - Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-D. Repairing Damaged Wire Insulation REPAIRING DAMAGED WIRE INSULATION Page 8222 10. Remove the 2 brake caliper bracket mounting bolts. 11. Mark the relationship of the rotor to the hub. 12. Notice: Support the brake caliper with heavy mechanic's wire, or equivalent, whenever it is separated from its mount and the hydraulic flexible brake hose is still connected. Failure to support the caliper in this manner will cause the flexible brake hose to bear the weight of the caliper, which may cause damage to the brake hose and in turn may cause a brake fluid leak. Remove the brake caliper and brake caliper mounting bracket as an assembly and support with heavy mechanic's wire or equivalent. DO NOT disconnect the hydraulic brake flexible hose from the caliper. 13. Remove the rotor retaining push nuts from the wheel studs, if applicable. 14. It may be necessary to strike the end of the hub or the rotor with a dead blow hammer to separate the rotor from the hub. 15. Remove the rotor by slowly turning the rotor while pulling the rotor away from the axle. Installation Procedure 1. Important: Whenever the brake rotor has been separated from the hub/axle flange, any rust or contaminants should be cleaned from the hub/axle flange and the brake rotor mating surfaces. Failure to do this may result in excessive assembled lateral runout (LRO) of the brake rotor, which could lead to brake pulsation. Use the J 42450-A to clean all rust and contaminants from the mating surface of the hub flange. 2. Use the J 41013 to clean all rust and contaminants from the inside diameter of the hat section of the brake rotor to prevent any foreign material from getting between the brake rotor and the hub flange. 3. Inspect the mating surfaces of the hub/axle flange and the rotor to ensure that there are no foreign particles or debris remaining. 4. Align the rotor to its original position on the hub, if applicable. Page 12456 5.2 Cut off the cable tie (B), detach the connector's rear end face (C) and pull out the connecting rail (D). 5.3. Remove pin 39, cut off the cable terminal and insulate the end with tape (E). Fold back the cable and secure it with tape (F). 5.4. Fit the connecting rail and end face. 5.5. Plug in the connector (A) and secure the cables with cable ties (B). 6. Install the floor console over the handbrake. Do not press the console down into place, but instead allow it to fit loosely. 7. Install the switch: 7.1. Install the switch for the roof lighting (B) and plug in its connector. 7.2. Guide the connectors for the window lift module and rear seat heater, if equipped, through the hole for each respective unit. Plug in the window lift module's connector and install the module (A). Page 15196 Electrical Symbols Part 3 Page 13256 Page 11477 Inflatable Restraint Side Impact Sensor (SIS) - Right (With RPO Code HP2) Page 11090 Control Module HVAC: Description and Operation HVAC System - Automatic HVAC CONTROL MODULE The HVAC control module is a class 2 device that interfaces between the operator and the HVAC system to maintain air temperature and distribution settings. The battery positive voltage circuit provides power that the control module uses for keep alive memory (KAM). If the battery positive voltage circuit loses power, all HVAC DTCs and settings will be erased from KAM. The body control module (BCM), which is the vehicle mode master, provides a device on signal. The control module supports the above features. HVAC CONTROL MODULE The HVAC control module is a class 2 device that interfaces between the operator and the HVAC system to maintain air temperature and distribution settings. The battery positive voltage circuit provides power that the control module uses for keep alive memory (KAM). If the battery positive voltage circuit loses power, all HVAC DTCs and settings will be erased from KAM. The body control module (BCM), which is the vehicle mode master, provides a device on signal. The control module supports the above features. Page 8155 13. Remove the caliper guide pin bolts. 14. Remove the brake caliper from the vehicle. 15. Inspect the caliper assembly. Refer to Brake Caliper Inspection. Installation Procedure 1. Important: Use denatured alcohol to clean the outside surface of caliper boot before installing new brake pads. If you are installing new brake pads, use a C-clamp in order to compress the piston to the bottom of the caliper bore. Use the old brake pad, a metal plate or a wooden block across the face of the piston in order to protect the piston and the caliper boot. 2. Important: Use a small flat-bladed tool and lift the inner edge caliper boot next to the piston to release any trapped air. Ensure that the piston boot is below the level of the piston face. 3. Install the caliper to the caliper mounting bracket. 4. Perform the following procedure before installing the caliper guide pin bolts (15 Series pickups only). 1. Remove all traces of the original adhesive patch. 2. Clean the threads of the bolt with brake parts cleaner or the equivalent and allow to dry. 3. Apply Threadlocker GM P/N 12345493 (Canadian P/N 10953488) to the threads of the bolt. Page 4308 7. Insert the J 38125-13A (GM P/N 12031876-1) tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the Terminal Repair Kit to ensure that the correct release tool is used. 8. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. REPAIR PROCEDURE Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. Page 4034 Important The M6 conductive rivet stud as shown, can accommodate a panel thickness range of 0.7-4.2 mm (0.03-0.17 in). If there are layers of sheet metal, they should be touching without any air gaps to ensure a good ground. 5. Select a M6 conductive rivet stud. Refer to the Parts Information section of this bulletin. Note Use the GE-50317 rivet stud tool kit. 6. Place the M6 conductive rivet stud (1) in the 10 mm (0.40 in) hole. Assemble the rivet stud tool (2) with the groove and flare side facing the rivet stud, then the washer and the M6 nut (3). 7. Using a wrench on the rivet stud tool, and a socket on the M6 nut, secure the M6 conductive rivet stud. 8. Ensure the rivet stud is securely fastened, WITHOUT ANY detectable movement. 9. Completely wrap the threads of the rivet stud with painters tape or equivalent. Note The rivet stud and surrounding panel area MUST BE properly refinished PRIOR to the installation of the ground wire terminal and conductive nut to maintain a secure, stable and corrosion-free electrical ground. 10. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 11. Allow the refinished repair area to cure sufficiently before removing the protective material applied to the rivet stud threads. 12. Remove the painters tape or equivalent from the rivet stud threads. 13. Using GM approved residue-free solvent or equivalent, thoroughly clean the rivet stud threads to remove any adhesive and allow to dry. 14. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive rivet stud. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. Page 15203 Electrical Symbols Part 11 Page 12222 8.2. Remove the console (A) together with the OnStar(R) control modules. 8.3. Remove the connectors (B). Important: The optic cable must not be bent with a radius less than 25 mm (1 in). Important: Secure the wiring harness so that there is no risk of chafing and rattling. 8.4. Fold back the wiring harness and tape over the connectors (C). Fold back the wiring harness once more and secure with cable ties (D). Page 6360 Seals and Gaskets: By Symptom Technical Service Bulletin # 01-07-30-032E Date: 080929 A/T - 4T65E Fluid Leaking From A/T Vent TECHNICAL Bulletin No.: 01-07-30-032E Date: September 29, 2008 Subject: Transmission Oil Leaking From Transmission Vent (Replace Transmission Case Cover (Channel Plate) Gasket) Models: 1997-2009 GM Passenger Cars and Light Duty Trucks (including Saturn) with Hydra-Matic 4T65-E Automatic Transmission (RPOs MN3, MN7, M15, M76) Supercede: This bulletin is being revised to add the 2008 and 2009 model years. Please discard Corporate Bulletin Number 01-07-30-032D (Section 07 - Transmission/Transaxle). Condition Some customers may comment on a transmission oil leak. Cause This condition may be caused by an improperly torqued channel plate gasket. Correction To correct this condition, replace the case cover (channel plate) gaskets (429 and 430). Refer to Unit Repair publication in SI of the appropriate vehicle being serviced. Visual inspection of the upper gasket (1) will reveal damage at the referenced area. Parts Information Warranty Information Drivetrain - Excessive Effort When Shift 2HI to 4HI Differential Fluid - Transfer Case: All Technical Service Bulletins Drivetrain - Excessive Effort When Shift 2HI to 4HI TECHNICAL Bulletin No.: 09-04-19-002A Date: February 17, 2011 Subject: 4WD System Shift Performance in Cold Ambient Temperatures (Use Synthetic Fluid in Light Duty Front Axles with 8.5" Ring Gears) Models: 1999-2011 Chevrolet Silverado 1500 Series Models 1999-2011 GMC Sierra 1500 Series Models Equipped with 4WD and 8.25" Front Axle Ring Gears (Transfer Case RPOs NP2, NQG) Attention: It is important to determine the RPO for the transfer case in GWM/IVH prior to applying this bulletin. This bulletin applies ONLY to vehicles equipped with 8.25" front axle ring gears, used in conjunction with a manual transfer case (RPOs NP2, NQG). Supercede: This bulletin is being revised to add the 2011 model year. Please discard Corporate Bulletin Number 09-04-19-002 (Section 04 - Driveline/Axle). Condition Some customers may comment about the effort required to shift from 2HI to 4HI in cold ambient temperatures at -6°C (20°F) or below. Cause This condition may be caused by the standard front axle being equipped with conventional mineral oil axle fluid. In cold ambient temperatures, prior to complete warm up, the fluid viscosity is thick. This may affect transfer case shift performance prior to full warm up. Correction Drain the front axle fluid and refill with GM SAE 75W-90 Synthetic Axle Fluid, P/N 89021677 (in Canada, 89021678). Refer to Front Axle Lubricant Replacement in SI. It is important to use synthetic fluid in this 8.25" axle to improve the performance of the 4WD system in cold ambient temperatures. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 7378 Page 4431 Page 3738 5. If vehicle is a regular cab pick-up truck, install the exhaust front heat shield (1) and/or the exhaust heat shield (2) to the studs. 6. Install the exhaust heat shield nuts. Tighten the exhaust heat shield nuts to 9 Nm (80 inch lbs.). 7. Install the exhaust front heat shield to the studs. 8. Install the exhaust front heat shield nuts. Tighten the exhaust heat shield nuts to 9 Nm (80 inch lbs.). 9. Install the catalytic converter, if necessary. 10. Install the exhaust manifold pipe, if necessary. Page 329 The control module ID number list above provides a method for determining which module is not communicating. A module with a class 2 serial data circuit malfunction or which loses power during the current ignition cycle will have a Loss of Communication DTC set by other modules that depend on information from that failed module. The modules that can communicate will set a DTC indicating the module that cannot communicate. Diagnostic Order When more than one Loss of Communication DTC is set in either one module or in several modules, diagnose the DTCs in the following order: 1. Current DTCs before history DTCs unless told otherwise in the diagnostic table. 2. The DTC which is reported the most times. 3. From the lowest number DTC to the highest number DTC. Conditions for Running the DTC The following DTCs do not have a current status: ^ B1327 ^ B1328 ^ U1300 ^ U1301 ^ U1305 AND ^ The vehicle power mode requires serial data communication to occur. Conditions for Setting the DTC A node alive message has not been received from a module with a learned identification number within the last 5 seconds. Action Taken When the DTC Sets Page 3814 IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. Splicing Twisted or Shielded Cable SPLICING TWISTED OR SHIELDED CABLE Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. - Rewrap the conductors with the mylar tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with mylar tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Control Module References Page 830 Junction Block - I/P Wire Entry Part 4 Page 11170 7. Reposition the inlet heater hose clamp (4) from the auxiliary water pump (1). 8. Remove the inlet heater hose (6) from the auxiliary water pump (1). INSTALLATION PROCEDURE 1. Install the inlet heater hose (6) to the auxiliary water pump (1). 2. Position the inlet heater hose clamp (4) to the auxiliary water pump (1). 3. Install the inlet heater hose to the engine. 4. Position the inlet heater hose clamp to the engine. IMPORTANT: Align the arrow at the throttle body end of the duct with the throttle body attaching stud. Locations Passenger Presence Components - Under Front Passenger Seat OnStar(R) - Analog/Digital System Information Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Analog/Digital System Information INFORMATION Bulletin No.: 06-08-46-008C Date: September 18, 2008 Subject: Information on OnStar(R) Dual-Mode (Analog/Digital) Systems Models Supercede: This bulletin is being revised to correct the model year range for the Chevrolet Impala and Monte Carlo and update the reference to GM Dealerworld. Please discard Corporate Bulletin Number 06-08-46-008B (Section 08 - Body and Accessories). All 2000-2003 model year vehicles equipped with OnStar® from the list above were built with Analog/Digital-Ready OnStar(R) Hardware. Some of these vehicles may have been upgraded to Dual-Mode (Analog/Digital). Certain 2004-2005 model year vehicles equipped with OnStar(R) from the list above may have been either: ^ Originally built at the factory with Dual-Mode (Analog/Digital) OnStar(R) Hardware with Dual-Mode (Analog/Digital) OnStar(R) Hardware OR ^ Upgraded to Dual-Mode (Analog/Digital) Hardware All 2006 model year and newer vehicles equipped with OnStar(R) were built at the factory with Dual-Mode (Analog/Digital) OnStar(R) Hardware. If a vehicle has Dual-Mode (Analog/Digital) OnStar(R) Hardware, then the system is capable of operating on both the analog and digital cellular Page 4483 Electrical Symbols Part 5 Page 6995 6. Important: Do not reuse the nut. A new nut must be used when installing the wheel drive shaft. Remove the wheel driveshaft assembly retaining nut (2) and washer (3) from the wheel driveshaft. 7. Disengage the wheel drive shaft from the wheel hub and bearing using J 45859 or equivalent. Page 15159 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly, Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Pull to Seat Connectors PULL TO SEAT CONNECTORS TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Page 14854 Power Door Lock Switch: Removal and Replacement Switch Replacement - Door Lock and Side Window - Driver Switch Replacement - Door Lock and Side Window - Driver Removal Procedure 1. Remove the front door trim panel. 2. Disconnect the electrical connectors. 3. Remove the screw that retains the switch panel bezel (1) from the front door panel. 4. Remove the switch panel bezel from the door panel using a flat-bladed tool. 5. Using a wide plastic flat-bladed tool, release the retaining clips on both sides of the door module. 6. Remove the door module from the switch panel bezel. Page 14832 3. Take one of the adhesive sachets and carefully cut the flag tip off the notched end spout in line with the notch. 4. While holding the sachet vertical, slowly dribble the adhesive into the edge of the bolt hole as shown, ensuring that the adhesive flows into the joint between the seat rail and the zinc block. DO NOT pour the adhesive down the center of the hole. The object is to let the adhesive "wick" between the zinc block and the seat rail in order to bond the two pieces together. Important: If the bolt thread strips or the proper torque cannot be achieved, then the entire seat adjuster mechanism must be replaced. 5. Replace the previous bolt with a new M8 bolt (1) (included) and install using a "click torque wrench" preset to 9 N.m (79 lb in). 6. Remove the second M8 mounting bolt from the rail and discard. 7. Repeat steps 2 through 5 for the second bolt. 8. Repeat steps 2 through 6 for the opposite mounting rail. 9. Before installing the seat into the vehicle, verify that the seat will function correctly and does not make any unusual noises during forward and rearward travel motion. 10. Install the seat. Refer to the applicable Seats sub-section of SI. 11. While sitting in the seat, verify seat function and listen for any unusual noises. Campaign - HVAC Blower Not Functional Runs Continuously Control Module HVAC: All Technical Service Bulletins Campaign - HVAC Blower Not Functional Runs Continuously SPECIAL COVERAGE Bulletin No.: 11046 Date: April 07, 2011 Subject: 11046 - Special Coverage Adjustment - Heating, Ventilation, and Air Conditioning Blower Not Fully Functional on All Blower Speeds, Inoperative, or Runs Continuously with the Ignition Off Models: 2003-2006 Chevrolet Avalanche, Suburban, Tahoe 2003-2007 Chevrolet Silverado 2003-2006 GMC Yukon, Yukon XL 2003-2007 GMC Sierra Equipped with Manual HVAC (CJ3) or Heavy Duty Heater (C42) Due to part availability, owner letters will be released in phases starting with older model year first. Owners for model year vehicles not included in first phase owner mailing will receive an owner advisory letter. The letter will inform the customer that parts are not yet available and that another letter will be sent to them when parts become available. A copy of this letter will be attached to the dealer message announcing this bulletin. In the meantime, if a customer brings their vehicle to the dealership with the condition described in this bulletin, repair the vehicle using the parts called out in this bulletin. Condition On some 2003-2006 model year Chevrolet Avalanche, Suburban, Tahoe; GMC Yukon, Yukon XL; and 2003-2007 model year Chevrolet Silverado and GMC Sierra vehicles equipped with a manual heating, ventilation, and air conditioning (HVAC) system (CJ3) or heavy duty heater (C42), the interface between the electrical terminals of the relay resistor module and the wiring connector that powers the module may be incapable of conducting higher current levels for sustained periods of blower motor operation. In addition, moisture and other contaminants may enter the fresh air intake plenum and contact the internal circuit of the module or corrode the terminals. Either of the above may cause the relay resistor module or wiring connector to overheat, resulting in one or more of the following symptoms: - The HVAC blower may not function on certain or all blower speed settings - A burning plastic smell or smoke may be present in the vehicle - The HVAC blower may run continually with the ignition in the OFF position In very rare events, if the above symptoms are ignored, a fire could occur. Special Coverage Adjustment This special coverage covers the condition described above for a period of 10 years or 240,000 km, whichever occurs first, from the date the vehicle was originally placed in service, regardless of ownership. Dealers are to install a new blower motor resistor and resistor module connector. The repairs will be made at no charge to the customer. For vehicles covered by Vehicle Service Contracts, all eligible claims with repair orders on or after April 8, 2011 are covered by this special coverage and must be submitted using the labor operation codes provided with this bulletin. Claims with repair orders prior to April 8, 2011 must be submitted to the Service Contract provider. Vehicles Involved Involved are certain 2003-2006 model year Chevrolet Avalanche, Suburban, Tahoe; GMC Yukon, Yukon XL; and 2003-2007 model year Chevrolet Silverado and GMC Sierra vehicles equipped with a manual HVAC (CJ3) or heavy duty heater (C42). Important Dealers are to confirm vehicle eligibility prior to beginning repairs by using the Applicable Warranties section in the Global Warranty Management system. Parts Information Page 304 For vehicles repaired under warranty, use the table. Disclaimer Page 317 Vehicles Built with Upgradeable OnStar(R) System Analog Modules Note: Page 14289 WA722J/25 - WA800J/98 Page 489 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Weather Pack Connectors WEATHER PACK CONNECTORS The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. OnStar(R) - Negative Impact of Cloth/Vinyl Roofs Navigation System: All Technical Service Bulletins OnStar(R) - Negative Impact of Cloth/Vinyl Roofs INFORMATION Bulletin No.: 02-08-44-007D Date: May 12, 2009 Subject: Negative Impact of Dealer-Installed Cloth/Vinyl Roofs on XM Radio and/or OnStar(R) Systems Models: 2002-2009 Passenger Cars and Trucks (Including Saturn) 2003-2009 HUMMER H2 2006-2009 HUMMER H3 2005-2009 Saab 9-7X with XM Radio (RPO U2K) and/or OnStar(R) (RPO UE1) .............................................................................................................................................................. .................................................................................. Supercede: This bulletin is being revised to include the 2009 model year. Please discard Corporate Bulletin Number 02-08-44-007C (Section 08 - Body and Accessories). .............................................................................................................................................................. .................................................................................. Dealers should not install a cloth or vinyl roof on vehicles that have been ordered with the XM radio option (RPO U2K) and/or OnStar(R) (RPO UE1). The performance of these systems may be negatively impacted by the installation of the cloth/vinyl roof. Additionally, water leaks may result from installing a cloth or vinyl roof on vehicles with roof-mounted antenna systems. Relocating the antenna to another spot on the vehicle exterior, in order to install a cloth or vinyl roof, is not advised either. The performance of the OnStar(R) and XM Radio antennas has been optimized for their current locations. Relocating the antennas may result in a performance degradation. Disclaimer Page 15030 1. Install the linkage rod to the endgate handle assembly. 2. Engage the linkage rod (1) to the latch assembly. 3. Install the endgate latch assembly. 4. Raise the endgate. 5. Install the endgate handle bezel. Pressing into place until fully seated. Notice: Refer to Fastener Notice in Service Precautions. 6. Tighten the endgate handle bolts. Tighten the handle bolts to 25 N.m (18 lb ft). Page 2658 Fuse Block - Underhood C7 Page 9753 C277 Steering Wheel Module Coil To Steering Wheel Harness (With RPO Code UK3) Locations Turn Signal Switch: Locations Upper Steering Column Page 13837 4. Remove the emblem/nameplate from the door surface using a plastic, flat-bladed tool. 5. Remove all adhesive from the door panel surface and the back of the emblem/nameplate using 3M(TM) scotch brite molding adhesive remover disk 3M(TM) P/N 07501 or equivalent. 6. Clean the door surface using varnish makers and painters (VMP) naptha. Installation Procedure 1. If the location of the emblem/nameplate has not been marked apply tape. 2. Warm the door surface with a heat gun J 25070 152 mm (6.0 in) from the surface to a minimum of 21°C (70°F). Important: Do not touch the adhesive backing of the emblem/nameplate. 3. Remove the backing from the front end of the emblem/nameplate. 4. Press the emblem/nameplate to the door panel surface while continuing to remove the backing. 5. Hand roll the emblem/nameplate to the door panel to ensure proper adhesion. 6. Inspect the emblem/nameplate for bonding. 7. Remove the tape from the area around the door emblem. Emblem/Nameplate Replacement - Endgate (W/O SS) Emblem/Nameplate Replacement - Endgate (W/O SS) Tools Required J 25070 Heat Gun Removal Procedure Important: Use the tape for protection and alignment marks for alignment of the new emblem. 1. Apply tape to the area around the endgate emblem. 2. Heat the emblem/nameplate, using a heat gun J 25070 152 mm (6.0 in) from the surface. 3. Apply the heat using a circular motion for about 30 seconds. Notice: Refer to Exterior Trim Emblem Removal Notice in Service Precautions. 4. Remove the emblem/nameplate from the endgate surface using a plastic, flat-bladed tool. Page 10996 6. Remove the blower motor. INSTALLATION PROCEDURE 1. Install the blower motor. 2. Install the blower motor to the heater/ventilation module. Turn the blower assembly clockwise until the retaining tab locks into place. 3. Install the blower motor insulating cover. 4. Connect the electrical connector to the blower motor. NOTE: Refer to Fastener Notice in Service Precautions. 5. Install the blower motor insulating cover screws. Page 12971 Speaker - Subwoofer With RPO Code UQ7 Page 12179 Page 12700 Page 12128 Labor Time Information Page 15182 Control Module References Part 4 Page 12239 ^ On 2002 Sevilles and DeVilles, the GPS jumper cable MUST be unclipped from the back seat cross brace, or unplugged from the VCIM first. DO NOT pull back on the mounting bracket until the GPS antenna jumper cable is unclipped from the back seat cross brace or unplugged from the VCIM. The short length of jumper cable does not allow the VCIM mounting bracket to be pulled back very far, and could lead to a break at the VCIM connector. ^ On 2000-2002 Bonnevilles and LeSabres and 2001-2002 Auroras you will need to follow these steps: 1. Remove the 4 nuts that secure the VCU/VIU bracket assembly to the rear seat back brace. Note: Save these nuts for later use. 2. Remove and discard the plastic VCU/VIU bracket assembly from the vehicle. 3. Remove the upper right stud (1) from the rear seat back brace and re-install in the middle lower slot (2) on the brace. Tighten the fastener to 4 Nm (36 lb in). 4. Position the new VCIM in the vehicle over the studs on the rear seat back brace. 5. Install two of the nuts saved from step (1). Tighten the nuts to 4 Nm (36 lb in). 6. Connect the new OnStar jumper harness supplied in the kit to the VCIM (two white connectors) and the body wiring harness (C345 connector). 7. Connect the small coaxial jumper cable supplied in the kit, to the VCIM, with the end that has a blue plastic housing connector. Plug the other end of this coaxial jumper cable to the OnStar Global Positioning Satellite (GPS) antenna coaxial cable at the right angle connector. Note: The GPS cable in the new OnStar jumper harness is not utilized. 8. Connect the cellular coaxial cable to the OnStar VCIM. On 2001 Impala and Monte Carlos you will need to follow these steps: 9. Remove the Vehicle Communications Unit (VCU) and Vehicle Interface Unit (VIU) following the procedures listed in SI. Save the bracket nuts for later use. Locations Air Induction Components Page 8719 8. Remove the wheel speed sensor (WSS) mounting bolt. 9. NOTICE: Carefully remove the sensor by pulling it straight out of the bore. DO NOT use a screwdriver, or other device to pry the sensor out of the bore. Prying will cause the sensor body to break off in the bore. Remove the wheel speed sensor (5) from the hub/bearing assembly (4) shown on the 2500/3500 series. Installation Procedure 1. Plug the WSS bore to prevent debris from falling into the hub. 2. Using a wire brush or equivalent, clean the WSS mounting surface on the hub to remove any rust or corrosion. 3. Apply a thin layer of wheel bearing lubricant, GM P/N 01051344 to the hub surface and the sensor O-ring prior to sensor installation. 4. Install the WSS (5) into the hub/bearing assembly (4) shown on the 2500/3500 series. Ensure that the sensor is seated flat against the hub. Service and Repair Tailgate Striker: Service and Repair Lock Striker Replacement - Endgate Removal Procedure 1. Open the endgate. 2. Remove the tail/turn signal lamp. 3. Remove the striker bolt. Installation Procedure Notice: Refer to Fastener Notice in Service Precautions. 1. Install the striker bolt. Tighten the bolt to 50 N.m (37 lb ft). 2. Install the tail/turn signal lamp. 3. Close the endgate. Page 14387 Control Module References Part 6 Page 3784 Electrical Symbols Part 12 Page 1846 7. Lower the vehicle. 8. Perform a four wheel alignment. Page 3307 13. If equipped with a 8.1L engine, perform the following: 1. Remove the oil cooler hose bracket bolt. 2. Disconnect the quick connect fittings (1) at the engine. 3. Remove the oil cooler hose assembly. Discard the gasket. 4. Inspect the fittings, connectors and cooler hoses for damage or distortion. Installation Procedure 1. Important: A distinct snap should be heard when assembling the tube ends of the hose assembly to quick connectors. To ensure the tube is fully inserted into the connector, check by giving the tube a forceful pull. If equipped with a 8.1L engine, perform the following: 1. Remove the oil cooler hose assembly. 2. Connect the quick connect fittings (1) at the engine. 3. Notice: Refer to Fastener Notice in Service Precautions. Install the oil cooler hose bracket bolt. Tighten the bolt to 50 Nm (37 ft. lbs.). 2. If equipped with a 6.0L engine, perform the following: 1. Install the oil cooler hose assembly and a new gasket. 2. Install the oil cooler hose adapter bolts (2). Tighten the bolts to 12 Nm (106 inch lbs.). 3. Install the oil cooler hose bracket bolt (1). Tighten the bolt to 25 Nm (18 ft. lbs.). Page 3311 Oil Cooler: Service and Repair Engine Oil Cooler Pipe/Hose Quick Connect Fitting Engine Oil Cooler Pipe/Hose Quick Connect Fitting Removal Procedure 1. Disengage the plastic caps from the quick connect fittings. Pull the caps back along the pipe. 2. Using a bent-tip screwdriver or equivalent, pull on one of the open ends of the retaining ring in order to rotate the retaining ring. 3. Rotate the retaining ring around the quick connector until the retaining ring is out of position and can be completely removed.Discard the retaining rings. 4. Remove the engine oil cooler line from the quick connector fitting at the radiator.Pull the lines straight out from the connectors. 5. Clean all of the components in a suitable solvent, and dry them with compressed air. 6. Inspect the fittings, the connectors, the cooler lines, and the cooler for damage, distortion, or restriction. Replace parts as necessary. Installation Procedure 1. Important: When performing the following procedure, do not reuse the old retaining rings. Replace the old retaining rings with new ones. Do not install the new retaining ring onto the fitting by pushing the retaining ring down over the fitting. Install a new retaining ring into each quick connector fitting. Page 9804 Junction Block - I/P Wire Entry Part 1 Page 4848 Disclaimer Page 9052 Relay Block - I/P C1 Part 3 Page 16131 Electrical Symbols Part 6 Page 641 Electronic Brake Control Module (ECBCM) - C2 (10/20 Series w/o HP2 Page 14005 Drink Holders: Service and Repair Cupholder Replacement (Rear) Cupholder Replacement (Rear) Removal Procedure 1. Lower the cupholder. 2. Insert a flat bladed tool between the cupholder hinge and the end panel. 3. Pry off the cupholder from the console. Installation Procedure 1. Install one of the hinge in the opening in the panel. 2. Swing the cupholder assembly so that the other hinge can be installed in the other opening. 3. Inspect for correct operation. Page 14763 Seat Heater: Diagrams Heated Seat Element - Driver Cushion Page 4515 Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips SPLICING COPPER WIRE USING SPLICE CLIPS IMPORTANT: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. TOOLS REQUIRED J 38125-D Terminal Repair Kit 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-D in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. Page 8157 ^ Replace all the components included in the repair kits used to service this brake caliper. ^ Lubricate the rubber parts with clean brake fluid to make assembly easier. ^ The torque values specified are for dry, non lubricated fasteners. ^ Perform the service operations on a clean bench free from all mineral oil materials. 1. Remove the brake caliper from the vehicle. 2. Caution: Do not place your fingers in front of the piston in order to catch or protect the piston while applying compressed air. This could result in serious injury. Place a thin piece wood in front of the piston in order to prevent damage. Remove the piston by directing compressed air into the brake hose inlet fitting port of the brake caliper housing. 3. Remove the piston boot. 4. Remove the piston seal. 5. Remove the brake caliper bleed screw cap. 6. Remove the brake caliper bleed screw. 7. Inspect the brake caliper bore and the piston seal groove for scoring and corrosion. If you find excessive scoring or corrosion around the piston seal area, replace the brake caliper housing. 8. Inspect the brake caliper mounting bracket guide surfaces for corrosion and wear. Remove and replace the brake caliper mounting bracket if needed. 9. Clean all of the residue from the brake pad guiding surfaces on the brake caliper housing and the brake caliper mounting bracket. 10. Clean all of the parts not included in the repair kit with denatured alcohol. 11. Dry all the parts with non lubricated filtered compressed air. 12. Blow out all passages in the brake caliper housing and the brake caliper bleeder valve. Page 9831 Location View Page 14636 For vehicles repaired under warranty, use the table. Disclaimer Page 8778 Electrical Symbols Part 8 Page 11985 A current DTC clears when the condition for setting the DTC is no longer present. A history DTC clears after 50 malfunction-free ignition cycles. Circuit/System Testing Without RPO UAV 1. Turn OFF the ignition and all electrical components, including the scan tool. 2. Disconnect the harness connector at the cellular microphone. 3. Test for less than 5 Ohms between the low reference circuit terminal A and ground. ^ If greater than the specified range, test the low reference circuit for an open/high resistance. If the circuit tests normal, replace the VCIM. 4. Ignition ON, test for 9 - 11 volts between the signal circuit terminal B and ground. ^ If greater than the specified range, test the signal circuit for a short to voltage. If the circuit tests normal, replace the VCIM. ^ If less than the specified range, test the signal circuit for a short to ground or an open/high resistance. If the circuit tests normal, replace the VCIM. Refer to the appropriate vehicle in SI. 5. If all circuits test normal, test or replace the cellular microphone. Circuit/System Testing With RPO UAV 1. Turn OFF the ignition and all electrical components, including the scan tool. 2. Disconnect the X4 harness connector at the navigation radio and the harness connector at the cellular microphone. 3. Test for less than 5 Ohms between the low reference circuit terminal A and ground. ^ If greater than the specified range, test the low reference circuit for an open/high resistance. If the circuit tests normal, replace the VCIM. Refer to the appropriate vehicle in SI. 4. Ignition ON, test for 9 - 11 volts between the signal circuit terminal B and ground. ^ If greater than the specified range, test the signal circuit for a short to voltage. If the circuit tests normal, replace the VCIM. ^ If less than the specified range, test the signal circuit for a short to ground or an open/high resistance. If the circuit tests normal, replace the VCIM. 5. If all circuits test normal, test or replace the cellular microphone. 6. Connect the X4 harness connector at the navigation radio. 7. With a scan tool, verify that DTC B2455 is not set as current in the navigation radio. ^ If DTC B2455 is set as current, replace the navigation radio. Refer to the appropriate vehicle in SI. DTC B2462, B2483, or B2484 Circuit/System Description The vehicle communication interface module (VCIM) receives information from a specific navigation antenna located on the outside of the vehicle. The navigation antenna is connected to the VCIM via a shielded coaxial cable. The antenna cable also provides a path for DC current for powering the antenna. DTC Descriptors DTC B2462 02: Global Positioning System (GPS) Antenna Malfunction Short to Ground DTC B2462 04: Global Positioning System (GPS) Antenna Malfunction Open Circuit Locations Ambient Light Sensor Page 2005 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. REPLACEMENT PROCEDURE After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Insure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the Terminal Removal Procedure. Repairing Connector Terminals REPAIRING CONNECTOR TERMINALS TOOLS REQUIRED J 38125-D Terminal Repair Kit Use the following repair procedures in order to repair the following: - Push to Seat terminals - Pull to Seat terminals - Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-D contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100 World terminals. Soldering Micro-Pack 100 World terminals may damage the terminal. Circuit Protection - Circuit Breakers CIRCUIT PROTECTION - CIRCUIT BREAKERS A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Page 11338 Control Module HVAC: Description and Operation HVAC System - Automatic HVAC CONTROL MODULE The HVAC control module is a class 2 device that interfaces between the operator and the HVAC system to maintain air temperature and distribution settings. The battery positive voltage circuit provides power that the control module uses for keep alive memory (KAM). If the battery positive voltage circuit loses power, all HVAC DTCs and settings will be erased from KAM. The body control module (BCM), which is the vehicle mode master, provides a device on signal. The control module supports the above features. HVAC CONTROL MODULE The HVAC control module is a class 2 device that interfaces between the operator and the HVAC system to maintain air temperature and distribution settings. The battery positive voltage circuit provides power that the control module uses for keep alive memory (KAM). If the battery positive voltage circuit loses power, all HVAC DTCs and settings will be erased from KAM. The body control module (BCM), which is the vehicle mode master, provides a device on signal. The control module supports the above features. Page 3930 Air Induction Components Page 11520 14. Separate the right carrier case half from the left carrier case half. 15. Remove the differential case assembly from the carrier. 16. Place the differential case in a vise. 17. Remove the differential side bearings using the J 22888-20A. 18. Remove the differential case from the vise. Important: The ring gear bolts have left-hand threads. 19. Remove the ring gear bolts. 20. Remove the ring gear from the differential case. Drive the ring gear off with a brass drift if necessary. 21. Remove the pinion shaft pin. Use a hammer and a drift pin in order to drive out the pin. 22. Remove the pinion shaft. 23. Roll the differential pinion gears out of the case with the pinion gear thrust washers. 24. Remove the differential side gears and the side gear thrust washers. Mark the pinion gears and thrust washers top and bottom and the differential side gears and thrust washers left and right. 25. Lubricate the pinion and side gears using axle lubricant. Use the proper fluid. Refer to the Maintenance and Lubrication subsection. 26. Install the differential side gear thrust washers to the differential side gears. 27. Install the differential side gears and thrust washers into the new differential case. 28. Install the differential pinion gears and thrust washers by performing the following steps: 28.1. Position one pinion gear between the differential side gears. 28.2. Position the second pinion gear between the differential side gear directly opposite of the first gear. 28.3. Rotate the differential side gears until the pinion gears are directly opposite the opening in the differential case. 28.4. Install the thrust washers. Rotate the pinion gears toward the differential case opening in order to permit the sliding in of the thrust washers. 29. Install the pinion gear shaft. 30. Install the pinion gear shaft lock pin using a hammer and a brass drift. Important: The mating surface of the ring gear and the differential case must be clean and free of burrs before installing the ring gear. Diagrams Cruise Control Module: Diagrams Cruise Control Module (CCM) Part 1 Page 1348 Low Pressure Sensor / Switch: Service and Repair AIR CONDITIONING (A/C) LOW PRESSURE SWITCH REPLACEMENT REMOVAL PROCEDURE 1. Disconnect the electrical connector from the A/C low pressure switch. 2. Remove the A/C low pressure switch from the accumulator. 3. Remove the O-ring and discard. INSTALLATION PROCEDURE 1. Lightly coat the NEW O-ring seal with mineral base 525 viscosity refrigerant oil. 2. Install the NEW O-ring seal to the switch. NOTE: Refer to Fastener Notice in Service Precautions. 3. Install the A/C low pressure switch to the accumulator. Tighten Tighten the switch to 6 N.m (53 lb in). 4. Connect the electrical connector to the A/C low pressure switch. 5. Leak test the fittings of the components using the J 39400-A. Page 15587 Clearance Lamp - LR (With RPO Code NYS Or E63) Page 8247 Brake Bleeding: Service and Repair Hydraulic Brake System Bleeding (Pressure) Hydraulic Brake System Bleeding (Pressure) ^ Tools Required J 29532 Diaphragm Type Brake Pressure Bleeder, or equivalent - J 35589-A Brake Pressure Bleeder Adapter Caution: Refer to Brake Fluid Irritant Caution in Service Precautions. Notice: Refer to Brake Fluid Effects on Paint and Electrical Components Notice in Service Precautions. Notice: When adding fluid to the brake master cylinder reservoir, use only Delco Supreme 11®, GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. The use of any type of fluid other than the recommended type of brake fluid, may cause contamination which could result in damage to the internal rubber seals and/or rubber linings of hydraulic brake system components. 1. Place a clean shop cloth beneath the brake master cylinder to prevent brake fluid spills. 2. With the ignition OFF and the brakes cool, apply the brakes 3-5 times, or until the brake pedal effort increases significantly, in order to deplete the brake booster power reserve. 3. If you have performed a brake master cylinder bench bleeding on this vehicle, or if you disconnected the brake pipes from the master cylinder, you must perform the following steps: 1. Ensure that the brake master cylinder reservoir is full to the maximum-fill level. If necessary add Delco Supreme 11®, GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container.If removal of the reservoir cap and diaphragm is necessary, clean the outside of the reservoir on and around the cap prior to removal. 2. With the rear brake pipe installed securely to the master cylinder, loosen and separate the front brake pipe from the front port of the brake master cylinder. 3. Allow a small amount of brake fluid to gravity bleed from the open port of the master cylinder. 4. Reconnect the brake pipe to the master cylinder port and tighten securely. 5. Have an assistant slowly depress the brake pedal fully and maintain steady pressure on the pedal. 6. Loosen the same brake pipe to purge air from the open port of the master cylinder. 7. Tighten the brake pipe, then have the assistant slowly release the brake pedal. 8. Wait 15 seconds, then repeat steps 3.3-3.7 until all air is purged from the same port of the master cylinder. 9. With the front brake pipe installed securely to the master cylinder - after all air has been purged from the front port of the master cylinder loosen and separate the rear brake pipe from the master cylinder, then repeat steps 3.3-3.8. 10. After completing the final master cylinder port bleeding procedure, ensure that both of the brake pipe-to-master cylinder fittings are properly tightened. 4. Fill the brake master cylinder reservoir to the maximum-fill level with Delco Supreme 11®, GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container.Clean the outside of the reservoir on and around the reservoir cap prior to removing the cap and diaphragm. 5. Install the J 35589-A to the brake master cylinder reservoir. 6. Check the brake fluid level in the J 29532 , or equivalent. Add Delco Supreme 11®, GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container as necessary to bring the level to approximately the half-full point. 7. Connect the J 29532 , or equivalent, to the J 35589-A. 8. Charge the J 29532 , or equivalent, air tank to 175-205 kPa (25-30 psi). 9. Open the J 29532 , or equivalent, fluid tank valve to allow pressurized brake fluid to enter the brake system. 10. Wait approximately 30 seconds, then inspect the entire hydraulic brake system in order to ensure that there are no existing external brake fluid leaks. Any brake fluid leaks identified require repair prior to completing this procedure. 11. Install a proper box-end wrench onto the RIGHT REAR wheel hydraulic circuit bleeder valve. 12. Install a transparent hose over the end of the bleeder valve. 13. Submerge the open end of the transparent hose into a transparent container partially filled with Delco Supreme 11®, GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. 14. Loosen the bleeder valve to purge air from the wheel hydraulic circuit. Allow fluid to flow until air bubbles stop flowing from the bleeder, then tighten the bleeder valve. 15. With the right rear wheel hydraulic circuit bleeder valve tightened securely - after all air has been purged from the right rear hydraulic circuit install a proper box-end wrench onto the LEFT REAR wheel hydraulic circuit bleeder valve. 16. Install a transparent hose over the end of the bleeder valve, then repeat steps 13-14. 17. With the left rear wheel hydraulic circuit bleeder valve tightened securely - after all air has been purged from the left rear hydraulic circuit - install a proper box-end wrench onto the RIGHT FRONT wheel hydraulic circuit bleeder valve. 18. Install a transparent hose over the end of the bleeder valve, then repeat steps 13-14. 19. With the right front wheel hydraulic circuit bleeder valve tightened securely - after all air has been purged from the right front hydraulic circuit install a proper box-end wrench onto the LEFT FRONT wheel hydraulic circuit bleeder valve. 20. Install a transparent hose over the end of the bleeder valve, then repeat steps 13-14. 21. After completing the final wheel hydraulic circuit bleeding procedure, ensure that each of the 4 wheel hydraulic circuit bleeder valves are properly tightened. 22. Close the J 29532 , or equivalent, fluid tank valve, then disconnect the J 29532 , or equivalent, from the J 35589-A. 23. Remove the J 35589-A from the brake master cylinder reservoir. Page 16214 7. With the aid of an assistant, remove the window from the opening. Installation Procedure 1. Install a stationary window into the opening. 2. Install the window lower garnish molding. 3. Install both rear seat headrests (extended cab). 4. Raise the rear seat back. 5. Remove the double layer of masking tape around the perimeter of the painted surfaces and interior trim. Page 12341 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. REPLACEMENT PROCEDURE After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Insure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the Terminal Removal Procedure. Repairing Connector Terminals REPAIRING CONNECTOR TERMINALS TOOLS REQUIRED J 38125-D Terminal Repair Kit Use the following repair procedures in order to repair the following: - Push to Seat terminals - Pull to Seat terminals - Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-D contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100 World terminals. Soldering Micro-Pack 100 World terminals may damage the terminal. Circuit Protection - Circuit Breakers CIRCUIT PROTECTION - CIRCUIT BREAKERS A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Page 7916 8. Connect the PNP switch electrical connector (2). 9. If equipped with 4WD, install the front propeller shaft. 10. Lower the vehicle. 11. Check the switch for proper operation. The engine must start in the park (P) or neutral (N) positions only. If proper operation of the switch can not be obtained, replace the switch. Page 7906 Steps 1-9 Test Description The numbers below refer to the step numbers on the diagnostic table. 2. This step tests for a faulty tow/haul switch. 3. This step tests for voltage input from the BCM to the tow/haul switch. 6. This step tests for ground integrity. Page 2748 Application Table A/C - Blower Motor Runs After Vehicle Is Shut OFF Blower Motor Relay: All Technical Service Bulletins A/C - Blower Motor Runs After Vehicle Is Shut OFF TECHNICAL Bulletin No.: 03-01-38-015A Date: October 27, 2008 Subject: HVAC Blower Motor May Run Continuously After Vehicle is Turned Off (Replace Blower Resistor Relay) Models: 2004 Chevrolet Avalanche, Silverado, Suburban, Tahoe, TrailBlazer, TrailBlazer EXT 2004 GMC Envoy, Envoy XL, Sierra, Yukon, Yukon XL with Manual Control HVAC (RPO CJ3) Built Prior to August, 2003 Supercede: This bulletin is being revised to update the parts information. Please discard Corporate Bulletin Number 03-01-38-015 (Section 01 - HVAC). Condition Some customers may comment on the HVAC blower motor running after the vehicle has been turned off. The blower may run for just a few minutes or continuously until the battery is discharged. Cause A new style HVAC blower relay/resistor may stick in the "on" position. When the HVAC fan blower relay has been energized, the contacts may "micro-weld" together. After this occurrence, the HVAC blower may not respond to the HVAC controller commands. Correction Replace the HVAC blower resistor/relay with the type used previous to the 2004 model year. The appropriate part numbers are listed in the table below. For specific repair procedures, refer to the 2004 Service Information (SI) under Blower Motor Resistor Assembly Replacement (SI Document ID # 526350 (C/K) or # 729996 (S/T). Parts Information Warranty Information Disclaimer Specifications Brake Bleeding: Specifications HYDRAULIC BRAKE SYSTEM Delco Supreme II Brake Fluid or equivalent DOT-3 brake fluid. Page 4551 Information Bus: Scan Tool Testing and Procedures DATA LINK REFERENCES IMPORTANT: There are modules in this vehicle that communicate on a controller area network (CAN) serial data link. This CAN serial data link is not connected to the data link connector (DLC), and the scan tool cannot communicate on this link. Communication DTCs for this CAN Serial data link may be set by the module acting as an interface to the other serial data links. Refer to Data Link Connector (DLC) Schematics for CAN serial data circuits. The following DTCs may be set when the interface module detects a loss of communication with a module on the CAN serial data link. Diagnose these DTCs as directed in the DTC Table: CAN Serial Data - Powertrain Control Module (PCM) and Transmission Control Module (TCM) DTC U0100, U0101, U0105 or U0106-Refer to DTC U0100-U0299 (Diesel Engine)DTC U0100-U0299 (HP2) See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures - DTC U1800, U2105 or U2106-Refer to DTC U1800, U2105, U2106, or U2108 See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/U Code Charts/U1800 See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/U Code Charts/U2105 See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/U Code Charts/U2106 See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/U Code Charts/U2108 For any other U codes or communication problems, refer to the table below for the correct procedure. Page 5133 1. Install the hose as necessary. 2. Install the vent hose to the throttle body and the valve rocker arm cover. 3. Install the PCV hose to the intake manifold and valve rocker arm cover. 4. Install the engine sight shield. Specifications Brake Master Cylinder: Specifications Master Cylinder Brake Lines to BPMV .................................................................................................................................................... 25 Nm (18 ft. lbs.) Page 3477 Timing Cover: Service and Repair Engine Front Cover Replacement ^ Tools Required J 41476 Front and Rear Cover Alignment Tool Removal Procedure 1. Remove the water pump. 2. Remove the crankshaft balancer. 3. Remove the oil pan-to-front cover bolts. 4. Remove the front cover bolts. 5. Remove the front cover and gasket. 6. Discard the front cover gasket. 7. If required, clean and inspect the engine front cover. Installation Procedure Important: ^ Do not reuse the crankshaft oil seal or front cover gasket. ^ Do not apply any type of sealant to the front cover gasket (unless specified). ^ The special tool in this procedure is used to properly center the front crankshaft front oil seal. ^ All gasket surfaces should be free of oil or other foreign material during assembly. ^ The crankshaft front oil seal MUST be centered in relation to the crankshaft. ^ An improperly aligned front cover may cause premature front oil seal wear and/or engine oil leaks. Page 10147 Do not apply force to the steering wheel position sensor and the adapter and bearing assembly in a sideways direction. Seat the adapter and bearing assembly into the steering column jacket. 5. Connect the steering wheel position sensor connector. 6. Notice: Refer to Fastener Notice in Service Precautions. Align the marks on the upper intermediate shaft and the steering column shafts, where they connect, that you made during the removal procedure. 7. Install the intermediate shaft to the steering column pinch bolt. ^ Tighten the nut to 62 Nm (46 ft. lbs.). 8. Connect the negative battery cable. 9. Enable the SIR system. Page 10827 Mode Actuator Drivetrain - Service 4WD Light/DTC C0374 Set Speed Sensor: Customer Interest Drivetrain - Service 4WD Light/DTC C0374 Set TECHNICAL Bulletin No.: 05-04-21-003C Date: April 15, 2008 Subject: Service 4WD Light Illuminated, DTC C0374 Set (Inspect Wiring Harness to Transfer Case Speed Sensors,, Replace Wiring Harness) Models: 2004-2007 Buick Rainier 2003-2006 Chevrolet Avalanche, Suburban, Tahoe 2003-2007 Chevrolet Silverado Classic, TrailBlazer, TrailBlazer EXT 2003-2006 GMC Yukon, Yukon XL 2003-2007 GMC Envoy, Envoy XL, Sierra Classic 2003-2004 Oldsmobile Bravada 2005-2007 Saab 9-7X With Four Wheel Drive or All-Wheel Drive and Active All-Wheel Drive (RPO NP4) or Active Two-Speed (RPO NP8) Transfer Case Supercede: This bulletin is being revised to update the Model and Warranty Information. Please discard Corporate Bulletin Number 05-04-21-003B (Section 04 - Driveline/Axle). Condition Some customers may comment on intermittent illumination of the Service 4WD light. Upon investigation, the technician may find DTC C0374 set. The customer may also comment on intermittent erratic operation of the 4WD or AWD system after driving through rain/snow or simply going through a car wash. Cause The speed sensor signal may have become corrupted. Possible openings in the speed sensor wire insulation (twisted pairs) can allow water intrusion. Also wire connections contaminated by water may result in short circuits and erroneous speed sensor readings. This most often occurs on the rear speed sensor circuit. Correction Inspect the wiring harness to the transfer case speed sensors. On Rainier, TrailBlazer, Envoy and 9-7X models, fabricate a replacement speed sensor harness between the C101 connector and the speed sensors. Completely inspect and test all wiring. Refer to Speed Signal Front Axle Actuator and Indicators schematic in SI. Replace the affected twisted pairs. Do not over-twist the two wires in the replacement harness. Wires should be twisted at a rate of 9 revolutions per foot. Use service connector pack, P/N 88987993 at the speed sensor end and terminal, P/N 15326267, at C101. Terminal testing tools and service terminals can be found in Terminal Repair Kit J 38125. Terminals are available from SPX/Kent-Moore. The smaller transfer case harness splices into the larger chassis harness a few inches in front of the crossmember. The chassis harness routes along the left side of the frame under the driver door area. Use nylon tie straps to secure the fabricated harness to the main chassis harness between the transfer case and C101. On the full-size pickup and full-size utility models, replace the 2.2 m (88 in) pigtail harness that runs from the C151 connector under the hood to the transfer case. Use either harness P/N 15832722 or 15224663 depending on vehicle equipment. Refer to Propshaft Speed Sensors Front Axle Actuator and Transfer Case Shift Control Switch schematic in SI. Important: Technicians should verify the integrity of the splice joints after the repair. All splice joints and connections should seal properly against water or a repeat condition can occur. Specifications Oil Pan: Specifications Oil Pan Baffle Bolts .............................................................................................................................. .................................................... 12 Nm (106 lb in) Oil Pan Closeout Cover Bolt - Left Side ................................................................................................................................................... 12 Nm (106 lb in) Oil Pan Closeout Cover Bolt - Right Side ................................................................................................................................................. 12 Nm (106 lb in) Oil Pan Cover Bolts ............................................................................................................ ....................................................................... 12 Nm (106 lb in) Oil Pan Drain Plug .......................... ............................................................................................................................................................. 25 Nm (18 lb ft) Oil Pan M8 Bolts, Oil Pan-to-Rngine Block and Oil Pan-to-Front Cover ................................................................................................................................. 25 Nm (18 lb ft) Oil Pan M6 Bolts - Oil Pan-to-Rear Cover ................................................................................................................................................ 12 Nm (106 lb in) Oil Pan Skid Plate Bolt ....................................................................................................... ........................................................................ 20 Nm ( 15 lb ft) Automatic Transmission - 4L60-E/4L65-E Transmission Position Switch/Sensor: Adjustments Automatic Transmission - 4L60-E/4L65-E Park/Neutral Position Switch Adjustment Important: ^ The following procedure is for vehicles that have not had the park/neutral position (PNP) switch removed or replaced. If the PNP switch has been removed or replaced, refer to Park/Neutral Position Switch Replacement for the proper adjustment procedure. ^ Apply the park brake. ^ The engine must start in the park (P) or neutral (N) positions only. ^ Check the PNP switch for proper operation. If adjustment is required, proceed as follows: 1. Place the transmission range selector in the neutral (N) position. 2. With an assistant in the drivers seat, raise and suitably support the vehicle. Refer to Vehicle Lifting. 3. Loosen the park/neutral position (PNP) switch bolts. 4. With the vehicle in the neutral (N) position, rotate the switch while the assistant attempts to start the engine. 5. Following a successful start, turn the engine off. 6. Notice: Refer to Fastener Notice in Service Precautions. ^ Tighten the PNP switch bolts. ^ Tighten the bolts to 25 Nm (18 ft. lbs.). 7. Lower the vehicle. 8. Check the PNP switch for proper operation. The engine must start in the park (P) or neutral (N) positions only. 9. Replace the PNP switch if proper operation can not be achieved. Page 392 Parts Information Page 13324 ^ Reinstall the fuse and fuse panel cover. ^ Press the "Enter" button to perform the "Refresh" function. ^ "Test in Progress" will be displayed and the right front passenger door lock will cycle once. ^ The screen will display "Procedure Completed". ^ Press the "Exit" button as necessary to return to the main menu screen. 3. Using the switches in the right front passenger door, verify that the power window and power door lock located in that door function properly. Important: The calibrations required for performing SPS reprogram in the next step are based on the type of exterior rearview mirror the vehicle has. To determine the correct calibration, check the Service Parts Identification Label on the vehicle for the RPO code for exterior mirrors. 4. Follow normal Service Programming System (SPS) to reprogram the passenger door module with the current calibration available in TIS 2000. 5. After reprogramming is complete, using the switches in the right front passenger door, verify that the power window and power door lock located in that door function properly. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 14909 4. Press the button a second time, 2 light bars will glow indicating the MEDIUM temperature setting for the entire seat. 5. Press the button a third time, 1 light bar will glow indicating the LOW temperature setting for the entire seat. 6. Press the button a fourth time to turn the entire heated seat OFF. 7. To heat ONLY the seat back, press the vertical (LH) button one time. ^ An ON/OFF indicator light over the heated seat back symbol will glow to designate that ONLY the seat back is being heated. ^ All 3 light bars over the horizontal (RH) button will glow indicating the HIGH temperature setting for ONLY the seat back. 8. Press the button a second time, 2 light bars will glow indicating the MEDIUM temperature setting for ONLY the seat back. 9. Press the button a third time, 1 light bar will glow indicating the LOW temperature setting for ONLY the seat back. 10. Press the button a fourth time to turn the heated seat back OFF. Switch Diagnostics Important: In order to eliminate unnecessary part replacement and comeback repairs, it is essential that the appropriate diagnostic tables and aids found in the applicable manuals are followed. 1. Verify the condition prior to making any repairs. Refer to Seats and Seat Controls in the applicable Owners Manual or this bulletin for proper heated seat switch operation information. 2. If an improperly operating front heated seat condition exists, refer to the Diagnostic Information and Procedures in the Seats sub-section of the applicable Service Manual in order to diagnose the system accurately. 3. When measuring the resistance of the seat heater elements, ensure the values are within the updated range of 1.5-5.5 ohms. Refer to DTC B2425 or B2430-Clearing the DTC in the Diagnostic Information and Procedures in the Seats sub-section of the applicable Service Manual. Customer Information Some heated seat components from the above listed vehicles have been returned to the Warranty Parts Center (WPC) for heat function not operating properly. Analyses of these parts show 'no out of specification condition' or No Trouble Found (NTF). 1. Provide customers with the knowledge that if bumped, either one of the heated seat switches can be activated/deactivated accidentally. 2. Ensure customers have a thorough understanding of how the heated seat switches function. Disclaimer Page 15244 Cigarette Lighter: Electrical Diagrams Cigar Lighter/Auxiliary Outlets Diagram 1 Description and Operation Door/Trunk Ajar Indicator/Lamp: Description and Operation DOOR AJAR INDICATOR DESCRIPTION AND OPERATION DOOR AJAR INDICATOR SYSTEM COMPONENTS The door ajar indicator system consists of the following components: The driver door module (DDM) - The passenger front door module (PDM) - The body control module (BCM) - The instrument panel cluster (IPC) - The driver information center (DIC) - The driver door ajar switch - The passenger door ajar switch - The left rear door ajar switch - The right rear door ajar switch - The liftgate ajar switch DRIVER DOOR AJAR AND PASSENGER DOOR AJAR The DDM and PDM receive a discrete input from the respective door ajar switch to indicate the status of the door. The DDM or PDM then communicates this status to the IPC via class 2 message. The IPC, upon receipt of this class 2 message, will illuminate the appropriate door ajar message in the DIC and also send a class 2 message to the radio to activate the door ajar audible warning when the following conditions are met: The transmission is removed from PARK - The vehicle speed is greater then 8.05 km/h (5 mph) LEFT REAR DOOR AJAR AND RIGHT REAR DOOR AJAR The BCM receives a discrete inputs from both the left and right rear door and liftgate ajar switches to indicate the status of the doors and liftgate. The BCM then communicates this status to the IPC via class 2 message. The IPC, upon receipt of this class 2 message, will illuminate the appropriate door ajar message in the DIC and also send a class 2 message to the radio to activate the door ajar audible warning when the following conditions are met: The transmission is removed from PARK - The vehicle speed is greater then 8.05 km/h (5 mph) Power Window Switch Replacement - Rear Door Power Window Switch: Service and Repair Power Window Switch Replacement - Rear Door POWER WINDOW SWITCH REPLACEMENT - REAR DOOR REMOVAL PROCEDURE 1. Use a small flat-bladed tool in order to carefully pry the door power window switch from the door trim panel. 2. Disconnect the electrical connector from the switch. INSTALLATION PROCEDURE 1. Connect the electrical connector to the switch. 2. Install the switch to the door trim panel by pressing the switch into place until fully seated. Page 5020 Disclaimer Page 13220 Page 3956 Crankshaft Position (CKP) Sensor Page 4740 Page 13822 Page 3576 5. Remove the gaskets from the coolant air bleed pipe and covers. 6. Discard the gaskets. 7. Remove the coolant air bleed hose (1) from the pipe (2). Installation Procedure Page 6602 Disclaimer Page 13105 ^ Audio amplifier ^ Driver door module (DDM) ^ Driver door switch assembly (DDSA) ^ Front passenger door module (FPDM) ^ Left rear door module (LRDM) ^ Memory seat module (MSM) ^ Radio antenna module (listed as remote function actuation in scan tool display) ^ Rear integration module (RIM) ^ Right rear door module (RRDM) ^ Theft deterrent module (TDM) ^ TV antenna module ^ Vehicle communication interface module (VCIM) The star has 4 splice packs: ^ SP200 located in the left side of the instrument panel, near the steering column , taped to the instrument panel harness ^ SP201 located in the center of the instrument panel, near the radio ^ SP300 located in the left side middle of the passenger compartment, taped to the body harness, near the carpet seam ^ SP303 located in the right rear of the passenger compartment, taped to the body harness, approximately 24 cm (9.5 in) from the fuse block - right rear. Refer to Data Communication Schematics in SI. The following modules, components, and splice packs are connected to the ring portion of the class 2 serial data circuit: ^ Dash integration module (DIM) ^ Electronic brake control module (EBCM) ^ Engine control module (ECM) ^ Inflatable restraint sensing and diagnostic module (SDM) ^ Instrument panel cluster (IPC) ^ HVAC control module ^ Radio ^ Rear integration module (RIM) ^ Vehicle communication interface module (VCIM) OR ^ Communication interface module (CIM) ^ SP200 ^ SP201 ^ SP300 Page 8560 3. Remove the master cylinder nuts. Do not remove the pipes from the master cylinder. Position the master cylinder away from the booster head. Secure the master cylinder in an upright position. 4. Disconnect the power brake booster inlet hose, the steering gear inlet hose, and the power brake booster outlet hose from the booster assembly. 5. Remove the booster pump rod retainer from the lever. 6. Remove the stop lamp switch from the lever. 7. Remove the booster pump rod from the lever. 8. Remove the nuts at the booster. 9. Remove the booster assembly. Installation 1. Install the booster assembly to the vehicle. 2. Install the nuts at the booster. Page 8815 Control Module References Part 3 Page 13125 Models The service procedure in this bulletin has been revised. Step 11 in the procedure for the 2004-2005 Saab 9-3 (9440) Convertible has been revised. Discard all copies of bulletin 08089B, issued September 2008. Condition In November 2002, the U.S. Federal Commissions (FCC) ruled that wireless carriers would no longer be required to support the analog wireless network beginning in 2008. As a result, On Star(R) is unable to continue analog service. OnStar(R) has deactivated most of the systems operating in the analog mode; however, there are some vehicles that OnStar(R) could not deactivate. Although the analog OnStar(R) hardware in these vehicles can no longer communicate with OnStar(R), the hardware in the vehicle is still active. If the OnStar(R) emergency button is pressed, or in the case of an airbag deployment, or near deployment, the customer may hear a recording that OnStar(R) is being contacted. However, since analog service is no longer available, the call will not connect to OnStar(R). To end the call, the customer must press the white phone or white dot button. If the call is not ended, the system will continue to try to connect to OnStar(R) until the vehicle battery is drained. Special Policy Adjustment At the customer's request, dealers/retailers are to deactivate the OnStar(R) system. The service will be made at no charge to the customer. This special coverage covers the condition described above until December 31, 2008 for all non-Saab vehicles; April 30, 2009 for all Saab vehicles. Vehicles Involved Page 13054 Important: The optic cable must not be bent with a radius less than 25 mm (1 in). 12.5. Cars with brackets for e.g. an amplifier: Fit the cable tie (11 900 515) to the wiring harness approx. 100 mm (4 in) from H2-9, fit the cable tie (H) to the bracket. Gather the optic cable in a gentle loop (I) and then place the loop behind the bracket. Important: The optic cable must not be bent with a radius less than 25 mm (1 in). 12.6. Cars without brackets for e.g. an amplifier: Gather the optic cable in a gentle loop (J) and secure with cable tie. 13. CV: Fit the left-hand, rear side hatch trim in accordance with WIS - 8. Body - Interior equipment - Adjustment/Replacement. 14. Fit the ground cable to the battery's negative terminal. 15. Carry out procedures after disconnecting the battery, see WIS - 3. Electrical System - Charging system - Adjustment/Replacement. Important: Follow Tech 2(R) on-screen instructions. 16. Add ECU ICM, choose without OnStar(R). See WIS-General-Tech 2(R) - Description and Operation - Add/Remove. 2000-2004 Saab 9-5 2000-2004 Saab 9-5 Page 9199 Multiple Junction Connector: Diagrams C201 - C277 C201 Steering Column Harness To I/P Harness Part 1 Page 9929 Important When performing adjustments to vehicles requiring a 4-wheel alignment, set the rear wheel alignment angles first in order to obtain proper front wheel alignment angles. Perform the following steps in order to measure the front and rear alignment angles: 1. Install the alignment equipment according to the manufacturer's instructions. 2. Jounce the front and the rear bumpers 3 times prior to checking the wheel alignment. 3. Measure the alignment angles and record the readings. If necessary, adjust the wheel alignment to vehicle specification and record the before and after measurements. Refer to Wheel Alignment Specifications in SI. Important Technicians must refer to SI for the correct wheel alignment specifications. SI is the only source of GM wheel alignment specifications that is kept up-to-date throughout the year. Test drive vehicle to ensure proper repair. Page 4611 5. If equipped with a 6.0L engine, disconnect the HO2S electrical connector. 6. Remove the HO2S. INSTALLATION PROCEDURE IMPORTANT: A special anti-seize compound is used on the HO2S threads. The compound consists of liquid graphite and glass beads. The graphite tends to burn away, but the glass beads remain, making the sensor easier to remove. New, or service replacement sensors already have the compound applied to the threads. If the sensor is removed from an exhaust component and if for any reason the sensor is to be reinstalled, the threads must have anti-seize compound applied before the reinstallation. 1. If reinstalling the old sensor, coat the threads with anti-seize compound GM P/N 12377953, or equivalent. NOTE: Refer to Component Fastener Tightening Notice in Service Precautions. 2. Install the HO2S. Tighten Tighten the sensor to 42 N.m (31 lb ft). Page 549 ^ Reinstall the fuse and fuse panel cover. ^ Press the "Enter" button to perform the "Refresh" function. ^ "Test in Progress" will be displayed and the right front passenger door lock will cycle once. ^ The screen will display "Procedure Completed". ^ Press the "Exit" button as necessary to return to the main menu screen. 3. Using the switches in the right front passenger door, verify that the power window and power door lock located in that door function properly. Important: The calibrations required for performing SPS reprogram in the next step are based on the type of exterior rearview mirror the vehicle has. To determine the correct calibration, check the Service Parts Identification Label on the vehicle for the RPO code for exterior mirrors. 4. Follow normal Service Programming System (SPS) to reprogram the passenger door module with the current calibration available in TIS 2000. 5. After reprogramming is complete, using the switches in the right front passenger door, verify that the power window and power door lock located in that door function properly. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 3213 15. If equipped with RPO HP2, remove the 3-phase cable bracket nuts (2). 16. Remove the 3-phase cable bracket (1) from the studs, and reposition the cable and bracket out of the way. 17. Remove the ignition coil bracket studs. 18. Remove the ignition coil bracket. Page 7368 1. Lubricate the output speed sensor seal with automatic transmission fluid. 2. Install the output speed sensor (2). Notice: Refer to Fastener Notice in Service Precautions. 3. Install the output speed sensor bolt. ^ Tighten the bolt to 11 Nm (96 inch lbs.). 4. Connect the output speed sensor (2) electrical connector. 5. Lower the vehicle. Campaign - Deactivation Of Analog OnStar(R) Technical Service Bulletin # 08089C Date: 081118 Campaign - Deactivation Of Analog OnStar(R) # 08089C: Special Coverage Adjustment - Analog OnStar Deactivation (Nov 18, 2008) Subject: 08089C -- SPECIAL COVERAGE ADJUSTMENT - ANALOG ONSTAR(R) DEACTIVATION Page 15020 Notice: It is recommended that a support be placed under the open tailgate in the next step to prevent the tailgate from being damaged in the event that it drops when disconnecting, inspecting, and replacing the support cables. Support Cable Inspection - Escalade EXT, Avalanche, New Style Silverado and Sierra, Kodiak, TopKick 1. Open the rear tailgate and support it as necessary. 2. Release (unhook) the right side tailgate support cable from the pickup box. Important: In the above illustration, the clear sealant (1) is shown as black in color. This was done for illustration purposes only. If sealant is present on the support cables it will be clear or hazy (cloudy) in appearance. 3. Inspect the end (eyelet) of the support cable that attaches to the tailgate for sealant covering the end of the cable strands. - If there IS a clear type sealant (1) over the end of the cable strands, the support cable needs to be replaced. Reconnect the support cable to the pickup box and perform this same inspection on the left support cable. After inspecting both cables, proceed to the section titled "Hinge Inspection". - If there IS NOT a clear type sealant (2) over the end of the cable strands, that support cable does NOT need to be replaced. Reconnect the support cable to the pickup box and perform this same inspection on the left support cable. After inspecting both cables, proceed to the section titled "Hinge Inspection". Hinge Inspection - Escalade EXT, Avalanche, New Style Silverado and Sierra, Kodiak, TopKick 1. Release (unhook) the RIGHT side tailgate support cable from the pickup box aga1n. Page 12689 DTC B2476 04: Cellular Phone Select Service Switch Open Circuit DTC B2476 59: Cellular Phone Select Service Switch Stuck Button DTC B2482 00: Cellular Phone Select Service Switch Range/Performance Circuit Short to Ground Open / High Resistance Short to Voltage Signal Performance Circuit/System Description The OnStar(R) button assembly consists of 3 buttons, Call/Answer, OnStar(R) Call Center, and OnStar(R) Emergency. The vehicle communication interface module (VCIM) supplies the OnStar(R) button assembly with 10 volts via the keypad supply voltage circuit. Each of the buttons, when pressed, completes the circuit across a resistor allowing a specific voltage to be returned to the VCIM over the keypad signal circuit. Depending upon the voltage range returned, the VCIM is able to identify which button has been activated. Conditions for Running the DTCs The ignition is ON. System voltage is between 9 - 16 volts. Conditions for Setting the DTCs B2476 04: The VCIM detects an open/high resistance on the keypad supply voltage circuit. B2482 and B2476 59: The VCIM detects a valid signal on the keypad signal circuit for more than 15 seconds. If one of the OnStar(R) buttons is held or stuck for 15 seconds or more, the VCIM will set these DTCs. Action Taken When the DTCs Set The OnStar(R) status LED turns red. No calls can be placed. The VCIM will ignore all inputs from the OnStar® button assembly. Conditions for Clearing the DTCs The condition responsible for setting the DTC no longer exists. A history DTC will clear once 100 consecutive malfunction-free ignition cycles have occurred. Description and Operation Knee Diverter: Description and Operation DRIVER AND PASSENGER KNEE BOLSTERS The knee bolsters are designed to help restrain the lower torsos of front seat occupants by absorbing energy through the front seat occupants' upper legs. In a frontal collision, the front seat occupants' legs may come in contact with the knee bolsters. The knee bolsters are designed to crush or deform, absorbing some of the impact, which helps to reduce bodily injuries. The driver and passenger knee bolsters are located in the lower part of the I/P and must be inspected for damage after a collision. Page 6626 Inspection Procedure Using the exploded views in this bulletin, inspect each bore for freedom of valve(s) movement and evidence of debris. Pay particular attention to those valves related to the customer's concern. Verify movement of the valves in their normal installed position. Valves may become restricted during removal or installation. This is normal due to small tolerances between the valves and bores. If a valve is restricted and cannot be corrected by cleaning the valve and bore, then replace the valve body. Describe the restricted valve on the repair order. Page 9723 C160 Chassis Harness To Brake/Clutch Harness (With RPO Codes 5X7/5Y0) Page 526 Front Passenger Door Module (FPDM) - C4 (With RPO Code YE9) Part 1 Locations Page 11085 HVAC Control Module - C1 Part 2 Page 8501 1. Install the gasket. 2. Install the booster assembly. 3. Install the 4 booster to bulkhead nuts. Tighten Tighten the nuts to 36 N.m (26 lb-ft). 4. Snap the stop lamp switch onto the pushrod to the power brake booster. 5. Install the stop lamp switch with the pushrod on the brake pedal pin. 6. Install the brake switch retainer. 7. Connect the electrical connector to the stop lamp switch. 8. Install the master cylinder to the booster. 9. Install the master cylinder mounting nuts. Tighten Tighten the nuts to 36 N.m (27 lb-ft). 10. Connect the power brake booster outlet hose, the steering gear inlet hose, and the power brake booster inlet hose. Tighten ^ Tighten the power brake booster inlet hose to 28 N.m (20 lb-ft). ^ Tighten the steering gear inlet hose to 28 N.m (20 lb-ft). Important: Maintain the fluid level throughout the bleed procedure. 11. Remove the pump reservoir cap. Important: Page 6445 2. Install the 2-3 shift solenoid (367A) and the 2-3 shift solenoid retainer (395). 3. Install the 1-2 shift solenoid (267A) and the 1-2 shift solenoid retainer (395). 4. Important: When installing the pressure control solenoid, the electrical connector (2) must be in the position shown. Install the pressure control solenoid (377). 5. Notice: Refer to Fastener Notice in Service Precautions. Install the pressure control solenoid retainer (378) and retainer bolt (364A). ^ Tighten the bolt to 11 Nm (97 inch lbs.). OnStar(R) - Re-establishing OnStar(R) Communications Navigation System: All Technical Service Bulletins OnStar(R) - Re-establishing OnStar(R) Communications Bulletin No.: 00-08-46-004C Date: January 17, 2008 INFORMATION Subject: Re-establishing Communications with OnStar(R) Center After Battery Disconnect Models: 2000-2008 GM Passenger Cars and Trucks (Including Saturn and Saab) with Digital OnStar(R) (RPO UE1) Supercede: This bulletin is being revised to add models and model years. Please discard Corporate Bulletin Number 00-08-46-004B (Section 08 - Body and Accessories). When servicing any of the above models and a battery cable is disconnected or power to the OnStar(R) Vehicle Communication Interface Module (VCIM) is interrupted for any reason the following procedure must be performed to verify proper Global Positioning System (GPS) function. Never swap OnStar(R) Vehicle Communication Interface Modules (VCIM) from other vehicles. Transfer of OnStar(R) modules from other vehicles should not be done. Each OnStar(R) module has a unique identification number. The VCIM has a specific Station Identification (STID). This identification number is used by the National Cellular Telephone Network and OnStar(R) systems and is stored in General Motors Vehicle History files by VIN. After completing ALL repairs to the vehicle you must perform the following procedure: Move the vehicle into an open area of the service lot. Sit in the vehicle with the engine running and the radio turned on for five minutes. Press the OnStar(R) button in the vehicle. When the OnStar(R) advisor answers ask the advisor to verify the current location of the vehicle. If the vehicle location is different than the location the OnStar(R) advisor gives contact GM Technical Assistance (TAC) and choose the OnStar(R) prompt. GM OnStar(R) TAC will assist in the diagnosis of a failed VCIM and, if appropriate, order a replacement part. Replacement parts are usually shipped out within 24 hours, and a pre-paid return package label will be included for returning the faulty part. By returning the faulty part, you will avoid a non-return core charge. Disclaimer Page 3241 Drive Belt: Testing and Inspection Drive Belt Falls Off Drive Belt Falls Off Diagnosis Diagnostic Aids If the drive belt(s) repeatedly falls off the accessory drive pulley(s), this may be caused by a pulley misalignment. An extra load that is quickly applied or released by an accessory drive component may also cause the drive belt(s) to fall off. Verify that the accessory drive component(s) are operating properly. If the drive belt(s) is the incorrect length, the drive belt tensioner may not maintain the proper tension on the drive belt(s). Test Description Steps 1 - 12 The number(s) below refer to the step(s) in the diagnostic table. 2. This inspection is to verify the condition of the drive belt(s). Damage may have occurred to the drive belt(s) when the drive belt(s) fell off the pulley. Inspect the drive belt(s) for cuts, tears, sections of ribs missing, or damaged belt plys. Page 9102 4. Connect the wiring connectors to the fuse block. Refer to Electrical Center Identification Views to ensure the right connections are made. 5. Install the right side end panel. Page 3971 5. Remove the fuel level sensor retaining clip. 6. Remove the fuel level sensor. INSTALLATION PROCEDURE 1. Install the fuel level sensor. Page 9837 Junction Block - Rear Lamps - C3 Capacity Specifications Fluid - M/T: Capacity Specifications Transmission Fluid NV3500 ................................................................................................................ ............................................................................................. 2.3L (2.4 Qt) NV4500 ............................ .............................................................................................................................................................. ................... 3.8L (4.0 Qt) 6 Speed (ZF) (RPO ML6) ........................................................................... ...................................................................................................... 6.0L (6.3 Qt) Page 4340 Body Control Module (BCM) - C5 Page 1125 Power Seat Motor Position Sensor: Diagrams Seat Bolster Motor/Position Sensor - Driver (With RPO Code AN3) Page 9556 Fuse Block - Underhood C2 Part 5 OnStar(R) - System Inoperative/No LED Lamp ON Fuse: All Technical Service Bulletins OnStar(R) - System Inoperative/No LED Lamp ON Bulletin No.: 04-08-46-005 Date: December 21, 2004 TECHNICAL Subject: OnStar(R) Generation 6 (Digital) System Inoperative/Has No Power, LED Light Not On (Remove/Reinstall OnStar(R) Fuse and Replace VCIM or Follow SI Diagnostics) Models: 2004-2005 Buick Rainier, Rendezvous 2005 Buick Allure (Canada), LaCrosse, LeSabre, Terrazza 2004-2005 Cadillac Escalade, Escalade ESV, Escalade EXT 2005 Cadillac CTS, DeVille 2004-2005 Chevrolet Avalanche, Silverado, Suburban, Tahoe, TrailBlazer, TrailBlazer EXT 2005 Chevrolet Colorado, Express, Impala, Monte Carlo, Uplander 2004-2005 GMC Denali, Denali XL, Envoy, Envoy XL, Envoy XUV, Sierra, Yukon, Yukon XL 2005 GMC Canyon, Savana 2004-2005 Pontiac Aztek 2005 Pontiac Bonneville, Grand Prix, Montana SV6, Vibe with Digital Gen 6 OnStar(R) (RPO UE1) Condition Some customers may comment any or all of the following conditions: ^ The OnStar(R) system may be inoperative. ^ The OnStar(R) system may have no power. ^ The OnStar(R) LED light may not be on. The technician may also not be able to communicate with the OnStar(R) Vehicle Communication Interface Module VCIM) with a Tech 2(R). Correction Remove the OnStar(R) fuse from the fuse box, wait five minutes and reinstall the fuse. If the OnStar(R) system DOES NOT return to normal functionality, then follow the diagnostics in SI for this condition. If the OnStar(R) system DOES return to normal functionality, you will need to replace the VCIM. If the VCIM is not replaced, there is the possibility that the customer will return to the dealership with the same conditions at a later date. Please contact the GM Technical Assistance Center (TAC), to obtain a new VCIM. The TAC consultant will verify your diagnosis and, if appropriate, order a replacement part. Replacement parts are usually shipped out within 24 hours, and a pre-paid return package label will be included for returning the faulty part. By returning the faulty part, you will avoid a significant non-return core charge. After the VCIM has been replaced, press the blue OnStar(R) button and request a full reconfiguration. When contacting TAC regarding this concern, the availability of certain information from the vehicle will streamline the process for the dealership technician as well as minimize the time necessary for TAC to provide the correct diagnosis. Please refer to Corporate Bulletin Number 01-00-89-011B for further information concerning the information necessary before contacting TAC. Dealers in Canada should refer to GM Service Policies & Procedures Section 5.3.1 "DEALER REQUIREMENTS FOR ASSISTANCE". Warranty Information Page 14067 Electrical Symbols Part 6 Entertainment System - DVD Monitor Display Inoperative Television / Monitor: All Technical Service Bulletins Entertainment System - DVD Monitor Display Inoperative Bulletin No.: 07-08-44-016A Date: August 28, 2007 TECHNICAL Subject: GM Accessories Headrest DVD System Display Monitor Inoperative (Install Cable Connector Clamps) Models Supercede: This bulletin is being revised to update the models affected list. Please discard Corporate Bulletin Number 07-08-44-016 (Section 08 - Body & Accessories). Condition Some customers may comment on an inoperative display monitor or monitors in the GM Accessories Headrest DVD System. Cause This condition may be caused by a loose connection at the display monitor cable connectors. These connectors are located at the lower rear part of both front seats. Two cables are routed to the display monitor in each seat. Correction A number of headrest monitors have been replaced under warranty and in many cases, no trouble was found by the supplier when these units were Electrical - Instrument Panel & General Wiring Repair Wiring Harness: All Technical Service Bulletins Electrical - Instrument Panel & General Wiring Repair Bulletin No.: 06-08-45-004 Date: May 02, 2006 INFORMATION Subject: Instrument Panel (I/P), Body and General Wiring Harness Repair Models: 2007 and Prior GM Cars and Trucks 2003-2007 HUMMER H2 2006-2007 HUMMER H3 Important: A part restriction has been implemented on all Body and I/P harnesses and is being administered by the PQC. If a body or I/P harness replacement is required, it can take 12-28 weeks for a harness to be built and delivered to a dealer. The dealer technician is expected to repair any harness damage as the first and best choice before replacing a harness. In an effort to standardize repair practices, General Motors is requiring that all wiring harnesses be repaired instead of replaced. If there is a question concerning which connector and/or terminal you are working on, refer to the information in the appropriate Connector End Views in SI. The Instruction Manual J 38125-620, which is sent with each new update of the J 38125 Terminal Repair Kit, also has terminal crimping and terminal remove information. Important: There are some parts in the J 38125 Terminal Repair Kit (i.e. SIR connector CPAs and heat shrink tube (used in high heat area pigtail replacement) and some TPAs that are not available from GMSPO. It is vitally important that each update to the J 38125 Terminal Repair Kit be done as soon as it arrives at the dealer. Utilize the Terminal Repair Kit (J 38125) to achieve an effective wiring repair. The Terminal Repair Kit has been an essential tool for all GM Dealers since 1987. Replacement terminals and tools for this kit are available through SPX/Kent Moore. Refer to Corporate Bulletin Number 06-08-45-001 for more information. The Instruction Manual J 38125-620, which is sent with each new update to the J 38125 Terminal Repair Kit, also has terminal crimping and terminal removal information. U.S. Dealers Only - Training courses (including Tech Assists, Emerging Issues, Web, IDL and Hands-on) are available through the GM Training website. Refer to Resources and then Training Materials for a complete list of available courses. Canadian Dealers Only - Refer to the Training section of GM infoNet for a complete list of available courses and a copy of the J 38125 Terminal Repair Kit Instruction Manual. Wiring repair information is also available in Service Information (SI). The Wiring Repair section contains information for the following types of wiring repairs: - Testing for intermittent conditions and poor conditions - Flat wire repairs - GMLAN wiring repairs - High temperature wiring repairs - Splicing copper wire using splice clips - Splicing copper wire using splice sleeves - Splicing twisted or shielded cable - Splicing inline harness diodes Brakes - Wheel Cylinder Inspection Guidelines Wheel Cylinder: Technical Service Bulletins Brakes - Wheel Cylinder Inspection Guidelines Bulletin No.: 03-05-24-001A Date: March 21, 2005 INFORMATION Subject: Service Information Regarding Rear Brake Drum Wheel Cylinder Inspections Models: 2005 and Prior GM Passenger Cars and Trucks 2005 and Prior Saturn Vehicles with Rear Drum Brakes Supercede: This bulletin is being revised add model years and include all GM vehicles. Please discard Corporate Bulletin Number 03-05-24-001 (Section 03 - Suspension). This bulletin provides information on proper inspection of rear drum brake wheel cylinders. Important: It is not recommended that dust boots be removed during inspection processes as dirt and debris could contaminate the wheel cylinder bore causing premature wear of the wheel cylinder. In addition, most bores should look damp and some lubricant may drip out from under the boot as a result of lubricant being present. All rear drum brake wheel cylinders are assembled with a lubricant to aid in assembly, provide an anti-corrosion coating to the cylinder bore, and lubricate internal rubber components. As a result of this lubrication process, it is not uncommon for some amount of lubricant to accumulate at the ends of the cylinder under the dust boot. Over time, the lubricant may work its way to the outside of the boot and cause an area of the boot to look damp. Evidence of a damp area on the boot does not indicate a leak in the cylinder. However, if there is excessive wetness (i.e. drips) coming from the boot area of the wheel cylinder, it could indicate a brake hydraulic fluid leak requiring wheel cylinder replacement. (Refer to the Wheel Cylinder Replacement procedures in the appropriate Service Manual.) Disclaimer Page 12406 Disclaimer Page 3037 ACCESSORY WHEEL AND TIRE INFORMATION FORM You have just modified your vehicle by installing an "Accessory Package" which includes Wheels and Tires. This form contains important information about your accessory installation. In an effort to provide superior service to you, our customer, we ask that you please present this form to your Servicing Dealer when removing or installing wheels and tires on your vehicle. This form contains important information necessary to service your vehicle. Disclaimer Service and Repair Resonator: Service and Repair AIR CLEANER RESONATOR OUTLET DUCT REPLACEMENT REMOVAL PROCEDURE 1. Loosen the clamp and separate the air cleaner outlet duct at the mass air flow/intake air temperature (MAF/IAT) sensor. 2. Loosen the clamp and separate the air cleaner outlet duct from the throttle body. 3. Remove the radiator inlet hose clamp from the outlet duct. 4. Remove the air cleaner outlet duct. INSTALLATION PROCEDURE 1. Install the air cleaner outlet duct. 2. Install the air cleaner outlet duct to the throttle body. 3. Install the air cleaner outlet duct to MAF/IAT sensor. 4. Install the radiator inlet hose clamp to the outlet duct. NOTE: Refer to Fastener Notice in Service Precautions. 5. Tighten the air cleaner outlet duct clamps. Tighten Tighten the clamps to 7 N.m (62 lb in). Page 15386 Disclaimer Page 9601 Relay Block - I/P C5 Part 2 Page 9101 Fuse Block: Service and Repair I/P Electrical Center or Junction Block Replacement - Right INSTRUMENT PANEL ELECTRICAL CENTER OR JUNCTION BLOCK REPLACEMENT - RIGHT REMOVAL PROCEDURE 1. Remove the right side end panel. 2. Push in the tabs in order to remove the fuse block. 3. Pull out the fuse block out of the I/P in order to remove the retaining bolt. 4. Loosen the bolt. 5. Insert a screw driver between the wire harness block and fuse block in order to separate. 6. Separate the fuse block from the I/P harness block. 7. Remove the I/P wiring harness block from the vehicle. INSTALLATION PROCEDURE 1. Install the fuse block to the I/P wire harness block. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the retaining bolt. Tighten Tighten the bolt to 6 N.m (53 lb in) 3. Install the fuse block to the I/P until it clicks in place. Page 8910 Control Module References Part 7 Body - Vehicle Glass Distortion Information Back Window Glass: All Technical Service Bulletins Body - Vehicle Glass Distortion Information INFORMATION Bulletin No.: 00-08-48-005D Date: September 10, 2010 Subject: Distortion in Outer Surface of Vehicle Glass Models: 2011 and Prior GM Passenger Cars and Trucks 2009 and Prior HUMMER H2 2010 and Prior HUMMER H3 2005-2009 Saab 9-7X 2010 and Prior Saturn Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 00-08-48-005C (Section 08 - Body and Accessories). Distortion in the outer surface of the windshield glass, door glass or backlite glass may appear after the vehicle has: - Accumulated some mileage. - Been frequently washed in automatic car washes, particularly "touchless" car washes. This distortion may look like a subtle orange peel pattern, or may look like a drip or sag etched into the surface of the glass. Some car wash solutions contain a buffered solution of hydrofluoric acid which is used to clean the glass. This should not cause a problem if used in the correct concentration. However, if not used correctly, hydrofluoric acid will attack the glass, and over time, will cause visual distortion in the outer surface of the glass which cannot be removed by scraping or polishing. If this condition is suspected, look at the area of the windshield under the wipers or below the belt seal on the side glass. The area of the glass below the wipers or belt seal will not be affected and what looks like a drip or sag may be apparent at the edge of the wiper or belt seal. You may also see a line on the glass where the wiper blade or the belt seal contacts the glass. Important The repair will require replacing the affected glass and is not a result of a defect in material or workmanship. Therefore, is not covered by New Vehicle Warranty. Disclaimer Page 2361 3. Ensure the 3 retaining ring ears can be seen from the inside of the connector and the retaining ring can move freely in the slots. 4. Install the radiator outlet hose (2) onto the radiator quick connector fitting until a click is heard or felt.Pull back on the radiator outlet hose (2) to ensure a proper connection. Interior - Heated Seats Intermittently Inoperative Seat Heater Control Module: Customer Interest Interior - Heated Seats Intermittently Inoperative Bulletin No.: 05-08-05-008 Date: August 18, 2005 TECHNICAL Subject: Intermittent Heated Seats Inoperative, DTC B3941 Set (Reprogram Driver Seat Module) Models: 2003-2005 Cadillac Escalade, Escalade ESV, Escalade EXT 2003-2005 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2003-2005 GMC Sierra, Yukon, Yukon XL, Yukon Denali All with Seat FRT, Individual (Non BKT) (RPO AN3) 2003-2005 HUMMER H2 with Seat, Front Bucket Deluxe (RPO AR9) Condition Some customers may comment that occasionally the seat heater will not operate when activated. If the ignition key is cycled OFF and back ON again, the heated seat will operate correctly. Also, on some LB7 diesel engine vehicles, the seat heater may turn itself off during the first 10 minutes of operation. This occurs only with the first activation for the day and works correctly with subsequent activations immediately after the event. These conditions are intermiffent and DTC B3941 may be set. Correction Technicians are to reprogram the driver seat module with an updated software calibration. This new service calibration was released with TIS satellite data update version 6.5 available June 13, 2005. As always, make sure your Tech 2(R) is updated with the latest software version. Warranty Information Disclaimer Page 6509 Locations Engine Oil Pressure (EOP) Sensor And CMP Sensor Page 13437 Steering Mounted Controls Transmitter: Connector Views Steering Wheel Driver Information Center (DIC) Controls - Left (With RPO Code YE9) Service and Repair Steering Angle Sensor: Service and Repair Rear Position Sensor Replacement Removal Procedure 1. Notice: Refer vehicle Lifting. Raise the vehicle. Refer to Vehicle Lifting. 2. Remove the steering gear protection shield (1) retaining bolts (3). 3. Disconnect the electrical connector (1). 4. Notice: When removing the rear position cover from the steering gear be careful not to damage to the rear position sensor. Remove the rear wheel position sensor cover (4) from the steering gear by prying on the cover using the slot. 5. Remove the rear wheel position sensor retaining bolts (3). 6. Important: Check the inner tie rod boot for wear or damage. If the boots are damaged replace the steering gear actuator. 7. Important: Page 6896 Installation Procedure 1. Important: Carefully insert the axle shaft in order to not damage the seal. Install the axle shaft (1) into the rear axle housing (5). 2. Slide the axle shaft (1) into place allowing the splines to engage the differential side gear. 3. On axles without a locking differential, place the lock (4) on the button end of the axle shaft (1). 4. On axles with a locking differential, keep the pinion shaft partially withdrawn. 5. On axles with a locking differential, place the C-lock (1) on the axle shaft (3) so that the ends are flush with the thrust block (2). 6. Pull the shaft flange outward in order to seat the lock in the differential gear. Page 13421 circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links CIRCUIT PROTECTION - FUSIBLE LINKS Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Flat Wire Repairs FLAT WIRE REPAIRS NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Heated Oxygen Sensor (HO2S) Wiring Repairs HEATED OXYGEN SENSOR (HO2S) WIRING REPAIRS TOOLS REQUIRED J 38125-D Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: - Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-D. Repairing Damaged Wire Insulation REPAIRING DAMAGED WIRE INSULATION Page 7174 Seals and Gaskets: Service and Repair ZF S6-650 Transmission Input Shaft Seal Replacement Transmission Input Shaft Seal Replacement ^ Tools Required J 23907 Slide Hammer - J 44748 Seal Remover - J 44731 Input Shaft Oil Seal Installer Removal Procedure 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. Remove the rear propeller shaft. 3. Remove the transmission. Important: The clutch actuator hose can remain connected to the clutch actuator. Disconnecting the hose from the clutch actuator will allow the hydraulic fluid to drain from the hydraulic system. 4. Remove the clutch actuator cylinder bolts. Do not disconnect the hose from the actuator. 5. Remove the clutch actuator cylinder. 6. Remove the front oil seal using J 23907 (2) and J 44748 (1). Installation Procedure Page 6929 5. Install the convolute retainer tool over the inboard joint seal, being sure to capture the following convolutions: ^ 2-5 for the 1500 model (except 1500 HD) ^ 2-4 for the 1500 HD, 2500, 3500, and Hummer H2 models. Important: Assemble the tripot joint with the convolute retainer in the correct position, as illustrated. Page 9748 C249 Console Harness To Bezel Harness (With RPO Code Y91) Page 11144 5. Remove the evaporator cowl gasket (1) from the evaporator (2). 6. Remove the evaporator core (1) from the HVAC module assembly (2). Installation Procedure Important: If replacing the condenser, add the refrigerant oil to the evaporator core. OnStar(R) - Incorrect GPS Position Reported During Call Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Incorrect GPS Position Reported During Call Bulletin No.: 02-08-46-006C Date: January 08, 2008 INFORMATION Subject: Incorrect OnStar(R) Global Positioning System (GPS) Location Reported During OnStar(R) Call Models: 2000-2008 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2008 HUMMER H2 2006-2008 HUMMER H3 2005-2008 Saab 9-7X with OnStar(R) Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 02-08-46-006B (Section 08 - Body and Accessories). A small number of the above-mentioned vehicles may exhibit a condition in which the vehicle reports an inaccurate location to the OnStar(R) Call Center. This condition can only be identified via a button press to the OnStar(R) Call Center by the customer. Call Center personnel will be able to identify this inaccurate location condition. Customers will then be notified through the mail by OnStar(R) if their vehicle exhibits this condition. Once this condition has been identified OnStar(R) will instruct the customer to return to the dealership to have this condition corrected. It is not necessary to reconfigure the vehicle after the following procedure. In order to correct this condition you must cycle power to the OnStar(R) system. This can be done by either removing the fuses powering the OnStar(R) system or disconnecting the OnStar(R) module (VCIM) from the vehicle. As a last resort you can disconnect the vehicle's battery. The power needs to be removed from the system for approximately 15 minutes. After completing this procedure the vehicle should be taken to an area with an unobstructed view of the sky. The vehicle should be kept running for approximately 10 minutes to allow the vehicle to reacquire the global positioning system (GPS). Then contact the OnStar(R) Call Center via the blue OnStar(R) button and ask the advisor to verify the GPS position. If the OnStar(R) advisor still has an inaccurate GPS location refer to the Navigation Systems and Cellular Communications sub-sections in the Service Manual in order to diagnose and repair the concern. If the normal diagnostics lead to module replacement you will need to contact Technical Assistance (TAC) and choose the OnStar(R) prompt. GM OnStar(R) TAC will assist in the diagnosis and if appropriate order a replacement part. Replacement parts are usually shipped out within 24 hours and a pre-paid return package label will be included for returning the faulty part. By returning the faulty part you will avoid a significant non-return core charge. Warranty Information (excluding Saab US Models) For vehicles repaired under warranty, use the table. Warranty Information (Saab US Models) Page 9222 C250 Brake/Clutch Harness To Brake Clutch Jumper Harness (With RPO Code ZX3) Page 16151 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Weather Pack Connectors WEATHER PACK CONNECTORS The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. Page 16259 7. Reinstall the window reveal molding. 1. Start from the loose area and hand-press the reveal molding into place over the edge of the window. 2. Run warm water over the reveal molding in order to speed the setup time of the urethane adhesive. 3. Tape should be applied in order to retain the reveal molding to the window. This will maintain a flush fit with the body. 4. The tape is to be removed after 6 hours. Page 1651 7. Remove the HO2S. INSTALLATION PROCEDURE IMPORTANT: A special anti-seize compound is used on the HO2S threads. The compound consists of liquid graphite and glass beads. The graphite tends to burn away, but the glass beads remain, making the sensor easier to remove. New, or service replacement sensors already have the compound applied to the threads. If the sensor is removed from an exhaust component and if for any reason the sensor is to be reinstalled, the threads must have anti-seize compound applied before the reinstallation. 1. If reinstalling the old sensor, coat the threads with anti-seize compound GM P/N 12377953, or equivalent. NOTE: Refer to Component Fastener Tightening Notice in Service Precautions. 2. Install the HO2S. Tighten Tighten the sensor to 42 N.m (31 lb ft). Instruments - Service Tire Monitor Message is Displayed Low Tire Pressure Indicator: Customer Interest Instruments - Service Tire Monitor Message is Displayed Bulletin No.: 05-08-49-018A Date: May 11, 2006 ADVANCE SERVICE INFORMATION RESOLUTION Subject: EI 05065 - Service Tire Monitor Message Displayed (Pull/Reinstall IPC Fuse or Verify Correct Passenger Door Module (PDM) and Tires) Models: 2004 Chevrolet Silverado 2004 GMC Sierra Supercede: This bulletin is being revised to provide correction action. Please discard Corporate Bulletin Number 05-08-49-018 (Section 08 - Body and Accessories). Condition Some customers may comment that the "SERVICE TIRE MONITOR" message is being displayed on the DIC. Correction DO NOT REPLACE THE INSTRUMENT PANEL CLUSTER. If the DIC is displaying the SERVICE TIRE MONITOR message: 1. Verify if the vehicle has an electronic aftermarket module spliced into the ALDL Class 2 data line (purple wire). 2. If the vehicle HAS an aftermarket module spliced into the Class 2 line, pull the IPC fuse (located underhood) for 25 seconds. Important: Due to the electronic aftermarket module, the SERVICE TIRE MONITOR message may reoccur. 3. Reinstall the IPC fuse. This will clear the SERVICE TIRE MONITOR message from the display. 4. If the vehicle DOES NOT have an aftermarket module spliced into the Class 2 line, verify the vehicle is equipped with the correct PDM (Passenger Door Module) and tires. Warrant Information This repair is not covered under the vehicle warranty due to the installation of an aftermarket module. Disclaimer Page 1361 Door Switch: Diagrams Door Latch Assembly (Door Jamb Switch) - Front Passenger C2 Door Latch Assembly (Door Jamb Switch) - Front Passenger C2 Instruments - Odometer/Hour Meter Programming Procedure Odometer: All Technical Service Bulletins Instruments - Odometer/Hour Meter Programming Procedure INFORMATION Bulletin No.: 07-08-49-015D Date: May 04, 2010 Subject: Information on Instrument Panel Cluster (IPC) Odometer and Engine Hour Meter Set Up at Dealership After IPC Replacement Models: 2004-2007 Buick Rainier 2003-2006 Cadillac Escalade Models 2002-2009 Chevrolet TrailBlazer 2003-2006 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007 Chevrolet Silverado Classic (12th Digit of VIN 1 or 2) 2002-2009 GMC Envoy 2003-2006 GMC Sierra, Yukon Models 2007 GMC Sierra Classic (12th Digit of VIN 1 or 2) 2002-2004 Oldsmobile Bravada 2003-2007 HUMMER H2 2005-2009 Saab 9-7X Attention: The purpose of this bulletin is to inform dealership personnel that the Instrument Panel Cluster (IPC) odometer and engine hour meter (when applicable) setting will no longer be performed at an Electronic Service Center (ESC). Dealerships will now receive IPCs with the odometer and engine hour meter not programmed. The technician will be required to note the odometer reading and engine hour (when applicable) values of the original IPC, then use the SPS application to program these values into the new IPC. Supercede: This bulletin is being revised to update the text in Steps 1, 2, 3, 4, 5, 6 and 7. Please discard Corporate Bulletin Number 07-08-49-015C (Section 08 - Body and Accessories). Background Information Previous IPC replacement procedures specify that the odometer and engine hour values be communicated to and programmed by the Electronic Service Centers (ESC) into the replacement IPC at the time the replacement is ordered. This required the vehicle to be parked after the replacement IPC is ordered so that no additional mileage can be accumulated on the vehicle while the new IPC is in transit to the dealership. Improvements to the TIS2WEB SPS application will now allow IPC odometer and engine hour programming to be performed as an additional function of the IPC programming event. This new process will allow the vehicle to be returned to the customer, if necessary, and driven while waiting for the replacement IPC to arrive at the dealership. Odometer and engine hour values will no longer be communicated to the ESC for programming purposes but ESCs still need the odometer value for warranty reporting. Dealerships will now receive a replacement IPC with the odometer and engine hour values NOT programmed. The technician will be required to note the odometer and engine hour values of the original IPC, then use the TIS2WEB SPS application to program these values into the replacement IPC. The odometer and engine hour programming will now be included as a normal part of the IPC replacement procedure in SI. Odometer and Engine Hour Programming Procedure Information - If the original IPC odometer value cannot be obtained from the customer's vehicle, follow local and federal regulations regarding unknown odometer mileage situations. - Because the odometer and engine hour values can now be read from the original IPC and programmed into the replacement IPC during the same visit, the customer's vehicle will no longer need to be parked until the replacement IPC is received from an ESC. - Avalanche, Escalade, Sierra, Silverado, H2, Suburban, Tahoe and Yukon vehicles will also require the engine hour data to be recorded for transfer to the replacement IPC. The replacement IPC may already have engine hours showing. This does not affect the IPC Setup procedure. Bravada, Envoy, Rainier and TrailBlazer vehicles do not support the calculation or display of engine hour data. - Ensure that the correct odometer value is entered when prompted. Once programming is complete, the odometer and engine hour values, when applicable cannot be changed. - By default, the application odometer entry will be set to: miles. For metric units, click the button on the left next to: Kilometers. Service Procedure Important The replacement IPC requires IPC Setup procedures and SPS programming to be performed. Legacy Pass-Thru will no longer be Page 12963 Speaker - LR - Except Crew Cab Page 9805 Junction Block - I/P Wire Entry Part 2 Page 7348 Transmission Position Switch/Sensor: Service and Repair Automatic Transmission 4L80-E/4L85-E Park/Neutral Position Switch Replacement Park/Neutral Position Switch Replacement ^ Tools Required J 41364-A Park Neutral Switch Aligner Removal Procedure 1. Apply the park brake. 2. Shift the transmission into neutral. 3. If equipped with 4-wheel drive (4WD), remove the front propeller shaft. 4. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 5. Disconnect the park/neutral position (PNP) switch electrical connector (2). 6. Remove the range selector cable end (2) from the range selector lever ball stud (1). Page 12920 Amplifier: Diagrams Audio Amplifier C2 - With RPO Code UQ7 Without RPO Code Y91 Audio Amplifier C2 - With RPO Code UQ7 Without RPO Code Y91 - Part 1 Page 8587 Page 7337 Steps 1-9 Test Description The numbers below refer to the step numbers on the diagnostic table. 2. This step tests for a faulty tow/haul switch. 3. This step tests for voltage input from the BCM to the tow/haul switch. 6. This step tests for ground integrity. Page 1967 2. Connect the speed sensor electrical connector (4). 3. Lower the vehicle. Page 14312 WA926L/59 - WA929L/15 Page 12414 Memory Positioning Module: Service and Repair Memory Seat Control Module Replacement MEMORY SEAT CONTROL MODULE REPLACEMENT REMOVAL PROCEDURE 1. Remove the seat cushion. 2. Disconnect the upper electrical harness connectors (3). 3. Remove the module (2) retaining screws (1). 4. Slide the module to the right to disengage the lower retainers. 5. Disconnect the lower electrical harness connectors (2). 6. Remove the module from the vehicle. INSTALLATION PROCEDURE Page 5604 Steps 15 - 18 Page 4734 Page 4751 Tighten Tighten the bolts to 8 N.m (71 lb in). 5. Install the PCM cover. 6. If equipped with RPO NYS, install the harness ground clip to the PCM cover. 7. Connect the negative battery cable. 8. If a NEW PCM was installed, program the PCM. Refer to Service Programming System (SPS) in Programming. See: Testing and Inspection/Programming and Relearning 9. Perform the crankshaft position (CKP) system variation learn procedure. Refer to CKP System Variation Learn Procedure. See: Testing and Inspection/Programming and Relearning 10. If necessary, reset the engine oil life monitor. Refer to GM Oil Life System - Resetting in Maintenance and Lubrication. Engine Controls - MIL ON/Misfire/Misfire DTC's Set Ground Strap: All Technical Service Bulletins Engine Controls - MIL ON/Misfire/Misfire DTC's Set Bulletin No.: 06-06-04-046 Date: September 12, 2006 INFORMATION Subject: Information on Engine Misfire MIL/SES Light Illuminated or Flashing DTC P0300, P0301, P0302, P0303, P0304, P0305, P0306, P0307, P0308, P0420 or P0430 Models: 1999-2007 Cadillac, Chevrolet, GMC Full-Size Pickup and/or Utility Trucks with 4.8L, 5.3L, 5.7L, 6.0L or 6.2L VORTEC GEN III, GEN IV, V-8 Engine (VINs V, C, T, Z, B, 3, M, 0, J, R, U, N, Y, K, 8 - RPOs LR4, LY2, LM7, L59, L33, LC9, LH6, LMG, LY5, L31, LQ4, LQ9, L76, LY6, L92) with Active Fuel Management(TM) and E85 Flex Fuel If you encounter vehicles that exhibit the above conditions, refer to SI for the appropriate DTC(s) set. If no trouble is found, the cause may be due to an ECM ground terminal that has corroded with rust over time. Inspect the main engine wiring harness ground terminal (G103) for this condition. The wire terminal (G103) attaches either to the front or to the rear of the right side cylinder head, depending on the model year of the Full Size Pickup and/or Utility Trucks. If the ECM ground terminal has been found to be corroded, then follow the service procedure outlined in this bulletin to correct the corrosion issue. Remove either the nut or bolt securing the main engine wiring harness ground terminal (G103) to the right cylinder head. Refer to the above illustration to determine where the ground is located on the vehicle (1). Page 9557 Fuse Block - Underhood C2 Part 6 Page 16065 Electrical Symbols Part 8 Page 14184 Power Door Lock Actuator: Removal and Replacement Lock Actuator Replacement - Front Door Lock Actuator Replacement - Front Door Removal Procedure 1. Raise the window glass. 2. Remove the door trim panel. 3. Remove the water deflector. 4. Disconnect the inside door lock rod from the handle retainer clip. 5. Disconnect the manual door lock rod from the door retainer clips. 6. Remove the rubber plug in order to disengage the outside handle rod retainer. 7. Disconnect the cylinder lock rod. 8. Remove the bolts which retain the door lock actuator to the door. 9. Remove the door lock actuator and control rods as an assembly. 10. Disconnect the electrical connector from the door lock actuator, if equipped. 11. Remove the control rods as necessary. Page 13688 Front Door Window Regulator: Service and Repair Front Side Door Window Regulator Motor Replacement Window Regulator Motor Replacement - Front Door Removal Procedure 1. Raise the window. If the window motor is inoperable, remove the window to gain access to the window motor retaining screws. Refer to Window Replacement - Front Door. 2. Remove the door trim panel. 3. Remove the water deflector. 4. Remove the door speaker. 5. Support the window. 6. Disconnect the wiring harness from the window regulator motor. 7. Remove the 3 bolts (1) from the window motor. Important: Do not allow the cable gear to come out of the housing. A failure will result with the cable coming off the spool. 8. Separate the motor from the cable housing by wiggling the window motor. Observe the orientation of the window motor. 9. Remove the motor from the door regulator assembly. Installation Procedure 1. Install the motor to the cable housing by wiggling it into place. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the 3 bolts(1) to the window motor. Tighten Tighten the bolts to 5 N.m (44 lb in). 3. Install the window, if removed. 4. Connect the wiring harness to the window regulator motor. 5. Remove the window support. 6. Connect the wire connector to the switch to inspect the operation of the window. After inspection disconnect the wiring harness and continue the installation. 7. Install the speaker. 8. Install the water deflector. 9. Install the door trim panel. Page 2050 What corrected the customer concern and was the repair verified? Please Explain: ............. Disclaimer A/C - New PAG Oil Refrigerant Oil: Technical Service Bulletins A/C - New PAG Oil Bulletin No.: 02-01-39-004B Date: November 16, 2005 INFORMATION Subject: New PAG Oil Released Models: 2006 and Prior GM Passenger Cars and Trucks (Including Saturn) 2003-2006 HUMMER H2 2006 HUMMER H3 2005-2006 Saab 9-7X Built With R-134a Refrigeration System All Air Conditioning Compressor Types (Excluding R4 and A6 Type Compressors) Supercede: This bulletin is being revised to change the PAG oil part number used for R4 and A6 compressors with R-134a refrigerant systems. Please discard Corporate Bulletin Number 02-01-39-004A (Section 01 - HVAC). All General Motors vehicles built with R-134a refrigerant systems shall now be serviced with GM Universal PAG Oil (excluding vehicles equipped with an R4 or A6 compressor). R4 and A6 compressors with R-134a refrigerant systems shall use PAG OIL, GM P/N 12356151 (A/C Delco part number 15-118) (in Canada, use P/N 10953486). Important: The PAG oil referenced in this bulletin is formulated with specific additive packages that meet General Motors specifications and use of another oil may void the A/C systems warranty. Use this new PAG oil when servicing the A/C system on the vehicles listed above. Oil packaged in an 8 oz tube should be installed using A/C Oil Injector, J 45037. Refer to the HVAC Section of Service Information for detailed information on Oil Balancing and Capacities. Disclaimer Page 3544 6. The Melco(R) (1) ignition coil is a square design. 7. The Delphi(R) (2) ignition coil is a round design. 8. The Melco(R) ignition coil bracket (1) is a square design. 9. The Delphi(R) ignition coil bracket (2) is a round design. INSTALLATION PROCEDURE 1. Install the spark plug wire to the ignition coil. 2. Install the spark plug wire to the spark plug. 3. Inspect the spark plug wire for proper installation: 3.1. Push sideways on each boot in order to inspect the seating. Page 387 10. Disconnect and remove the OnStar(R) jumper harness. Note: You will need to remove the short GPS cable from this jumper harness. 11. Untape the cell antenna coax from the body harness in the trunk. This will be necessary to provide adequate length to connect to the new VCIM. 12. Fasten three retainer clips (1) from the kit to the new bracket that is included in the kit, and position the VCIM to the bracket (2). 13. Install the three bolts from the kit. Tighten the bolts to 10 Nm (89 lb in). 14. Connect the new OnStar(R) jumper harness supplied in the kit to the VCIM (two white connectors on module). 15. Connect small GPS coax cable jumper harness supplied in the kit (end with blue plastic housing) to VCIM GPS connector. 16. Position the VCIM / bracket assembly to the studs. 17. Install the bracket nuts saved from the Removal Procedure above to the VCIM / bracket assembly mounting studs. Tighten the nuts to 4 Nm (35 lb in). 18. Connect the new OnStar(R) jumper harness to the body wiring harness (C410 connector). 19. Connect small coax cable jumper from VCIM to the OnStar(R) Global Positioning Satellite (GPS) antenna coaxial cable at the connector previously left in the vehicle (short jumper removed from old harness in step 5.10). 20. Connect the cellular coaxial cable previously left in vehicle to the OnStar(R) VCIM. 21. Verify that all harnesses are properly secured in vehicle. 6. After replacing the VCIM, it is essential to configure the new OnStar(R) system. Failure to configure the system will result in an additional customer visit for repair. DO NOT press and hold the white dot or phone button on the keypad as it will not reset this version of the OnStar(R) system and may result in a DTC being set. Use of the TIS2WEB and SPS applications, along with the Tech2(R), are required in order to perform the VCIM configuration and setup procedure for this vehicle. The configuration and set-up procedure is now a two-step process which enables an automated activation by the OnStar(R) Center, without a button press by the technician to the OnStar(R) Call Center. 1. Connect the Tech2(R) to the vehicle. Page 16176 Window Switch - RR (Crew Cab Only) Part 2 Page 3950 Engine Coolant Temperature (ECT) Sensor Service and Repair Gear: Service and Repair Transfer Case Gear Indicator Switch Replacement Removal Procedure 1. Remove the transfer case shield, if equipped. 2. Disconnect the gear indicator switch electrical connector (2). 3. Remove the gear indicator switch. Installation Procedure 1. Notice: Refer to Fastener Notice in Service Precautions. Install the gear indicator switch. ^ Tighten the switch to 27 Nm (20 ft. lbs.). Page 9310 Junction Block - Rear Lamps - C3 Page 4540 Steps 7 - 10 Page 8496 Claim Information Refer to the General Motors WINS Claims Processing Manual for details on Product Recall Claim Submission. Customer Notification -- For US and Canada General Motors will notify customers of this recall on their vehicle (see copy of customer letter shown in this bulletin). Customer Notification -- For Letters will be sent to known owners of record located within areas covered by the US National Traffic and Motor Vehicle Safety Act. For owners outside these areas, dealers should notify customers using the sample letter. Dealer Recall Responsibility -- For US and Export (US States, Territories and Possessions) The US National Traffic and Motor Vehicle Safety Act provides that each vehicle which is subject to a recall of this type must be adequately repaired within a reasonable time after the customer has tendered it for repair. A failure to repair within sixty days after tender of a vehicle is prima facie evidence Page 2717 Fuse Block - Underhood - Secondary Wire Entry (With RPO Code HP2) Part 1 Page 10316 8. Using the J 44663 (2) , remove the upper ball joint stud from the steering knuckle. 9. Remove the upper ball joint (1) from the vehicle. Installation Procedure 1. Install the upper ball joint (1) to the steering knuckle. 2. Notice: Refer to Fastener Notice in Service Precautions. Install the upper ball joint retaining bolts (2) and stud (1). ^ Tighten the bolts to 110 Nm (81 ft. lbs.). Page 12447 Specifications Engine Oil Pressure: Specifications Oil Pressure - Minimum - Hot 41 kPa (6 psig) at 1,000 engine RPM 124 kPa (18 psig) at 2,000 engine RPM 165 kPa (24 psig) at 4,000 engine RPM Page 1400 Extended Cab Short Box Shown Below, Other Configurations Similar 6. Install the new canister vent valve solenoid to the fuel tank clip or mounting bracket as shown above. The valve port closest to the electrical connector must point towards the canister. 7. Cut bulk 5/8" heater hose to a length of approximately 76 mm (3 in). Install the hose between the solenoid and the canister pipe and secure using clamps. 8. Attach bulk 5/8" heater hose to the vent port and secure using a clamp. Run a length as needed along the frame rail routing to the area above the transmission. 9. Cut the hose to determined length and install the supplied filter box. Secure using a clamp. 10. Remove the transmission support and lower the transmission assembly as necessary to allow for access to the new filter box location. 11. Secure the filter box to the transmission vent hose just forward of the hose tee-section using a tie strap. DO NOT pinch or restrict the transmission vent hose. The filter box opening should be pointing downward. 12. Raise the transmission and reinstall the transmission support. 13. Connect the EVAP canister vent valve electrical connector. 14. Tie strap the hose as needed along the frame rail in order to keep the hose away from pinch-points and heat sources. 15. Lower the vehicle. Correction (2007-2010 New Style Models) After following the published SI diagnostics and determining that the EVAP canister vent valve is the cause of the MIL light, replace the EVAP canister vent valve assembly and relocate the remote filter box. To ensure correct installation, follow the procedures below. Important DO NOT replace the EVAP canister assembly for this concern unless it fails the leak test. Use Service Kit P/N 19207763 1. Raise the vehicle. Suitably support the vehicle. 2. Disconnect the EVAP canister vent valve electrical connector. Page 4492 Information Bus: Diagnostic Aids Basic Knowledge Required BASIC KNOWLEDGE REQUIRED Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the Service Data. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories CHECKING AFTERMARKET ACCESSORIES Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: - Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions INDUCING INTERMITTENT FAULT CONDITIONS In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: - Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. Page 10651 Page 3805 Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses CIRCUIT PROTECTION - FUSES The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the Page 303 monitor the Tech2(R) for the current time and date. REMINDER - Keep in mind that the time displayed on the Tech2(R) is in Greenwich Mean Time (GMT) and the offset is based on the time zones relationship to GMT. If replacement of the VIU/VCIM is necessary, you MUST reconfigure the OnStar® system. Failure to reconfigure the system will result in an additional customer visit for repair. OnStar® VIU, Generations 2 and 3, will require the technician to press the blue OnStar® button to reconfigure the vehicle with an OnStar® advisor. OnStar(R) VCIM, Generations 4-7 will require the technician to reconfigure the vehicle with the use of the TIS2WEB and SPS applications (pass thru only), along with the Tech2(R). The configuration and set-up procedure is a two-step process that must be completed step-by-step without interruption or delay in between each step. This procedure enables an automated activation without a button press by the technician to the OnStar(R) Call Center. Following this procedure, it may take up to 24 hours for all OnStar(R) services to be fully activated. How to Order Parts If the OnStar(R) GPS date/time stamp is non-recoverable and the unit needs to be replaced, dealers in the U.S. should contact Autocraft Electronics select the catalog item that contains this bulletin number. Canadian dealers should contact MASS Electronics. Dealers DO NOT need to call the GM Technical Assistance Center (TAC) for replacement approval. Autocraft Electronics and MASS Electronics will be responsible for verifying that the subject vehicle is a candidate for a replacement VIU/VCIM. Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use the table. Warranty Information (Saab U.S. Models) Description and Operation Cassette Features Page 7150 11. If the vehicle is a 2003 model year Chevrolet Express or GMC Savana van, the vehicle may require a new accumulator. Refer to Corporate Bulletin Number 03-01-38-016 for more information. This bulletin refers to an updated design accumulator that may improve the performance of the A/C system. 12. Install a new serpentine belt tensioner and serpentine belt if they have been damaged due to A/C system slugging or an A/C compressor seizure. The serpentine belt tensioner may have broken stop tabs and/or a missing front cap. 13. Verify proper operation of the A/C system. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Fuel Pump Relay Fuel Pump Relay: Locations Fuel Pump Relay FUEL PUMP RELAY Fuse Block-Underhood Page 7721 Speed Sensor: Service and Repair Transfer Case - NVG 246-NP8 Transfer Case Speed Sensor Replacement - Front Transfer Case Speed Sensor Replacement - Front Removal Procedure 1. Remove the transfer case shield, if equipped. 2. Disconnect the front speed sensor electrical connector (5). 3. Remove the front speed sensor. Installation Procedure 1. Notice: Refer to Fastener Notice in Service Precautions. Install the front speed sensor. ^ Tighten the speed sensor to 15 Nm (11 ft. lbs.). Page 8098 Brake Bleeding: Service and Repair Hydraulic Brake System Bleeding (Manual) Hydraulic Brake System Bleeding (Manual) Caution: Refer to Brake Fluid Irritant Caution in Service Precautions. Notice: Refer to Brake Fluid Effects on Paint and Electrical Components Notice in Service Precautions. Notice: When adding fluid to the brake master cylinder reservoir, use only Delco Supreme 11, GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. The use of any type of fluid other than the recommended type of brake fluid, may cause contamination which could result in damage to the internal rubber seals and/or rubber linings of hydraulic brake system components. 1. Place a clean shop cloth beneath the brake master cylinder to prevent brake fluid spills. 2. With the ignition Off and the brakes cool, apply the brakes 3-5 times, or until the brake pedal effort increases significantly, in order to deplete the brake booster power reserve. 3. If you have performed a brake master cylinder bench bleeding on this vehicle, or if you disconnected the brake pipes from the master cylinder, you must perform the following steps: 1. Ensure that the brake master cylinder reservoir is full to the maximum-fill level. If necessary add Delco Supreme 11, GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container.If removal of the reservoir cap and diaphragm is necessary, clean the outside of the reservoir on and around the cap prior to removal. 2. With the rear brake pipe installed securely to the master cylinder, loosen and separate the front brake pipe from the front port of the brake master cylinder. 3. Allow a small amount of brake fluid to gravity bleed from the open port of the master cylinder. 4. Reconnect the brake pipe to the master cylinder port and tighten securely. 5. Have an assistant slowly depress the brake pedal fully and maintain steady pressure on the pedal. 6. Loosen the same brake pipe to purge air from the open port of the master cylinder. 7. Tighten the brake pipe, then have the assistant slowly release the brake pedal. 8. Wait 15 seconds, then repeat steps 3.3-3.7 until all air is purged from the same port of the master cylinder. 9. With the front brake pipe installed securely to the master cylinder - after all air has been purged from the front port of the master cylinder loosen and separate the rear brake pipe from the master cylinder, then repeat steps 3.3-3.8. 10. After completing the final master cylinder port bleeding procedure, ensure that both of the brake pipe-to-master cylinder fittings are properly tightened. 4. Fill the brake master cylinder reservoir with Delco Supreme 11, GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. Ensure that the brake master cylinder reservoir remains at least half-full during this bleeding procedure. Add fluid as needed to maintain the proper level.Clean the outside of the reservoir on and around the reservoir cap prior to removing the cap and diaphragm. 5. Install a proper box-end wrench onto the RIGHT REAR wheel hydraulic circuit bleeder valve. 6. Install a transparent hose over the end of the bleeder valve. 7. Submerge the open end of the transparent hose into a transparent container partially filled with Delco Supreme 11, GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. 8. Have an assistant slowly depress the brake pedal fully and maintain steady pressure on the pedal. 9. Loosen the bleeder valve to purge air from the wheel hydraulic circuit. 10. Tighten the bleeder valve, then have the assistant slowly release the brake pedal. 11. Wait 15 seconds, then repeat steps 8-10 until all air is purged from the same wheel hydraulic circuit. 12. With the right rear wheel hydraulic circuit bleeder valve tightened securely - after all air has been purged from the right rear hydraulic circuit install a proper box-end wrench onto the LEFT REAR wheel hydraulic circuit bleeder valve. 13. Install a transparent hose over the end of the bleeder valve, then repeat steps 7-11. 14. With the left rear wheel hydraulic circuit bleeder valve tightened securely - after all air has been purged from the left rear hydraulic circuit - install a proper box-end wrench onto the RIGHT FRONT wheel hydraulic circuit bleeder valve. 15. Install a transparent hose over the end of the bleeder valve, then repeat steps 7-11. 16. With the right front wheel hydraulic circuit bleeder valve tightened securely - after all air has been purged from the right front hydraulic circuit install a proper box-end wrench onto the LEFT FRONT wheel hydraulic circuit bleeder valve. 17. Install a transparent hose over the end of the bleeder valve, then repeat steps 7-11. 18. After completing the final wheel hydraulic circuit bleeding procedure, ensure that each of the 4 wheel hydraulic circuit bleeder valves are properly tightened. 19. Fill the brake master cylinder reservoir to the maximum-fill level with Delco Supreme 11, GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. 20. Slowly depress and release the brake pedal. Observe the feel of the brake pedal. 21. If the brake pedal feels spongy, repeat the bleeding procedure again. If the brake pedal still feels spongy after repeating the bleeding procedure, Page 11998 Page 15767 Combination Switch: Diagrams Multifunction Accessory Switch Page 4791 Crankshaft Position Sensor: Description and Operation CRANKSHAFT POSITION (CKP) SENSOR The crankshaft position (CKP) sensor is a three wire sensor based on the magneto resistive principle. A magneto resistive sensor uses two magnetic pickups between a permanent magnet. As an element such as a reluctor wheel passes the magnets the resulting change in the magnetic field is used by the sensor electronics to produce a digital output pulse. The PCM supplies a 12-volt, low reference, and signal circuit to the CKP sensor. The sensor returns a digital ON/OFF pulse 24 times per crankshaft revolution. Cooling System - DEX-COOL(R) Coolant Leak Detection Dye Coolant: Technical Service Bulletins Cooling System - DEX-COOL(R) Coolant Leak Detection Dye Bulletin No.: 05-06-02-002B Date: January 18, 2008 INFORMATION Subject: DEX-COOL(R) Coolant - New Leak Detection Dye J 46366 - Replaces J 29545-6 Models: 1996-2008 GM Passenger Cars and Light/Medium Duty Trucks* (including Saturn) 1997-2008 Isuzu T-Series Medium Duty Tilt Cab Models Built in Janesville and Flint 1999-2008 Isuzu N-Series Medium Duty Commercial Models with 5.7L or 6.0L Gas Engine 2003-2008 HUMMER H2 2006-2008 HUMMER H3 2005-2008 Saab 9-7X *EXCLUDING 2006 and Prior Chevrolet Aveo, Epica, Optra, Vivant and Pontiac Matiz, Wave Supercede: This bulletin is being revised to include additional model years. Please discard Corporate Bulletin Number 05-06-02-002A (Section 06 - Engine/Propulsion System). Leak detection dye P/N 12378563 (J 29545-6) (in Canada P/N 88900915) may cause DEX-COOL(R) coolant to appear green in a black vessel making it appear to be conventional (green) coolant. This may cause a technician to add conventional coolant to a low DEX-COOL(R) system thus contaminating it. The green DEX-COOL(R) appearance is caused by the color of the leak detection dye which alters the color of the DEX-COOL(R) coolant. A new leak detection dye P/N 89022219 (J 46366) (in Canada P/N 89022220) has been released that does not alter the appearance of the DEX-COOL(R) coolant. When adding the new leak detection dye the color of the DEX-COOL(R) coolant will not change. For detecting leaks on any system that uses DEX-COOL(R) leak detection dye P/N 89022219 (in Canada P/N 89022220) should be used. The new leak detection dye can be used with both conventional and DEX-COOL(R) coolant. Disclaimer Page 1330 Discharge Air Temperature Sensor / Switch: Service and Repair Air Temperature Sensor Replacement - Upper Left AIR TEMPERATURE SENSOR REPLACEMENT - UPPER LEFT REMOVAL PROCEDURE 1. Remove the upper left air temperature sensor (2) from the air distributor duct (1). 2. Disconnect the electrical connector (3) from the upper left air temperature sensor (2). INSTALLATION PROCEDURE 1. Install the upper left air temperature sensor (2) to the air distributor duct (1). 2. Connect the electrical connector (3) to the upper left air temperature sensor (2). Page 14993 1. Open the rear tailgate and support it as necessary. 2. Release (unhook) the right side tailgate support cable from the pickup box. Important: If the support cable (2) has NOT been replaced previously, there will be a toothed nut or plastic nut (1) located between the latch (4) and the tailgate that MAY prevent the bolt (3) from being removed in the next step. The nut is an assembly aid used in the assembly plant. Do not reinstall or replace the toothed or plastic nut when installing the new support cable. 3. Loosen the bolt (3) that attaches the opposite end of the support cable to the latch assembly (2). - If the toothed or plastic nut IS present, you will only be able to loosen the bolt partially from the latch. If this condition is encountered, proceed to the next step. - If the toothed or plastic nut is NOT present, proceed to Step 8. Navigation - Report Missing/Inaccurate Nav. Map Info Navigation System: All Technical Service Bulletins Navigation - Report Missing/Inaccurate Nav. Map Info INFORMATION Bulletin No.: 10-08-44-006 Date: October 11, 2010 Subject: Reporting Missing or Inaccurate Navigation Radio Map Disc Information - Complete and Submit Feedback Form at GM Navigation Disc Center Website Models: 2011 and Prior GM Passenger Cars and Trucks Equipped with Navigation Radio Some customers may notice that some navigation radio map discs may have missing or incorrect information. The following list contains some examples: - Missing or incorrect roads, road names or road shapes - Missing or incorrect addresses - Missing or incorrect highway labeling - Missing or incorrect highway exit numbers - Missing or incorrect traffic restrictions - Missing points of interest (POI) or incorrect details, such as location, category or phone number General Motors uses a map database from two different suppliers. The two map suppliers are consistently updating their map database and will gladly accept any input regarding missing or incorrect information on the navigation radio map disc. To report any missing or incorrect information, please access the GM Navigation Disc Center at the following web site: http://www.gmnavdisc.com. At the GM Navigation Disc Center home page, select the tab: Your Feedback. In the Navigation Data Feedback form, fill in the appropriate information as required and then select: Submit, to send the form. Disclaimer Page 7087 Page 12922 Amplifier: Diagrams Audio Amplifier C2 - With RPO Code UQ7,Y91 Audio Amplifier C2 - With RPO Code UQ7,Y91 - Part 1 Page 3739 Heat Shield: Service and Repair Exhaust Heat Shield Replacement Exhaust Heat Shield Replacement Removal Procedure 1. Remove the exhaust muffler. 2. Remove the spare tire hoist. 3. If equipped with a 6 1/2 ft box, remove the exhaust heat shield bolts. 4. Remove the exhaust heat shield. 5. If equipped with a 8 ft box, remove the exhaust heat shield bolts. 6. Remove the exhaust heat shield. Installation Procedure 1. if equipped with a 8 ft box, install the exhaust heat shield. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the exhaust heat shield bolts. Tighten the exhaust heat shield bolts to 9 Nm (80 inch lbs.). Page 15014 Submit a Product Recall claim with the information shown. Customer Notification -- For US and Canada General Motors will notify customers of this recall on their vehicle (see copy of customer letter shown in this bulletin)) Customer Notification -- For IPC Letters will be sent to known owners of record located within areas covered by the US National Traffic and Motor Vehicle Safety Act. For owners outside these areas, dealers should notify customers using the sample letter. Dealer Recall Responsibility - For US and IPC (US States, Territories, and Possessions) The US National Traffic and Motor Vehicle Safety Act provides that each vehicle which is subject to a recall of this type must be adequately repaired within a reasonable time after the customer has tendered it for repair. A failure to repair within sixty days after tender of a vehicle is prima facie evidence of failure to repair within a reasonable time. If the condition is not adequately repaired within a reasonable time, the customer may be entitled to an identical or reasonably equivalent vehicle at no charge or to a refund of the purchase price less a reasonable allowance for depreciation. To avoid having Page 13170 5. Choose the outstanding core you wish to process, by selecting the Virtual Core Button on the far right side of the screen. 6. Enter the information in the required fields and select the submit button. Record the confirmation number. Canadian Dealers 1. Return the removed Analog / Digital-Ready OnStar(R) VCIM to the Parts Manager. 2. The Parts Manager will log onto https://adt.onstar.gm.mass.ca and enter information as prompted. All Dealers If the website indicates that the VCIM needs to be physically returned to the distributor, please use the pre-paid shipping label that was included in the kit to return the removed VCIM. Important: To avoid a $250 core non-return charge, you must do one of the following within 30 days of kit shipment: 1. Submit the necessary VCIM data through the website, as indicated above. 2. Mail the removed core from the customer's vehicle back to the distributor. 3. Return the unused digital upgrade kit back to the distributor using the pre-paid shipping label that is included in the kit box. Returning the Upgraded Vehicle to the Customer Returning the Upgraded Vehicle to the Customer 1. Place the new OnStar Subscriber Information (Owner's Manual kit) in the customer's vehicle where they can review some of the new features of the Digital-Capable system. The continuous digit dialing feature should be highlighted to the customer to avoid a return to the dealership for dialing instructions. Advise the customer to discard any existing OnStar(R) Owner's Manuals that may be in the vehicle. 2. Have the Service Advisor, Service Manager or Sales Consultant review the new OnStar(R) Hands-Free Calling procedure with the customer. The customer is uses to their analog OnStar(R) Hands-Free Calling system, which uses individual digit dial to make a call. The Generation 6 Digital-Capable system uses continuous digit dial, and the customer needs to be made aware of this change. 3. U.S. Dealers Only: Staple the "Tip Sheet - OnStar(R) Generation 6 Digitally-Capable System", that was included in the kit, to the customer's copy of the repair order. This tip sheet will help your customer better understand their new OnStar(R) system. 4. Canadian Dealers Only: Refer the customer to the Hands-Free Calling Quick Review Card from the new OnStar(R) Owner's Manual kit for help with the new dialing procedure. 5. Fill out the form entitled "GM Limited Warranty for Upgraded OnStar(R) Digital Equipment Program Participants" and staple a copy of this to the customer's repair order. You may want to keep a copy for your records. 6. Encourage your customer to press their blue OnStar(R) button the next day. The OnStar(R) Advisor will be able to review some of the new features of their digital OnStar(R) system. Closing the Onstar(R) Upgrade Exchange Closing the OnStar(R) Upgrade Exchange 1. Collect payment from the customer. Your dealership's open account (sales) will be charged for the cost of the chosen subscription plan, any applicable subscription taxes, and the $15 upgrade charge after the vehicle has been configured through the TIS2WEB process. 2. None of the costs associated with the OnStar Digital Upgrade program may be claimed as a GM goodwill event. These costs must be paid by the customer, and may not be included in any goodwill offered to the customer. GM employees or representatives or field personnel are not able to offer goodwill for this program. If the dealership decides to pay for the upgrade for their customer, be aware that your GM or OnStar(R) contact will not be able to reimburse you for this cost. 3. Use labor code Z2096 to submit your claim for the labor time published below plus 0.2 hr Administrative Allowance and an additional $20.00 Net Amount. ^ For all dealer claim submissions (excluding U.S. Saturn), use Complaint Code MH - Technical Bulletin, and Failure Code 93 - Technical Service Bulletin. Page 7545 Fluid - Transfer Case: Service and Repair Transfer Case - NVG 261-NP2 Transfer Case Fluid Replacement Removal Procedure Important: When performing the following service procedures, use only hand tools in order to remove and install the fill or drain plugs. Always start the plugs by hand in order to prevent cross threading. 1. Remove the transfer case shield, if equipped. 2. Remove the fill plug. 3. Remove the drain plug. Installation Procedure Notice: Refer to Fastener Notice in Service Precautions. Important: If the drain or fill plug have to be replaced, use only aluminum replacement drain plugs. Steel plugs will react with the magnesium of the transfer case. 1. Install the drain plug. ^ Tighten the plug to 20 Nm (15 ft. lbs.). 2. Fill the transfer case to the bottom of the fill plug hole with the approved transfer case fluid. Page 2742 Junction Block - I/P Wire Entry Part 1 Page 16078 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground TESTING FOR SHORT TO GROUND NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting With A Digital Multimeter TROUBLESHOOTING WITH A DIGITAL MULTIMETER NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TROUBLESHOOTING WITH A TEST LAMP Page 5678 Page 14290 WA800J/98 - WA805K/62 Page 474 Electrical Symbols Part 12 Page 4346 Door Control Module Diagram 3 Part 1 Page 2660 Fuse Block- I/P C1 Part 1 Page 12104 The number above refers to the step number on the diagnostic table. DTC U0073 or U2100 DTC Descriptors DTC U0073 00: Control Module Communication Bus Off DTC U0073 71: ECU HS Bus Off DTC U0073 72: ECU LS Bus Off DTC U2100 00: Controller Area Network (CAN) Bus Communication DTC U2100 47: Controller Area Network (CAN) Bus Communication Circuit/System Description The serial data circuits are serial data buses used to communicate information between the control modules. The serial data circuits also connect directly to the data link connector (DLC). Conditions for Running the DTCs Supply voltage at the modules are in the normal operating range. The vehicle power mode requires serial data communications. Conditions for Setting the DTC The module setting the DTC has attempted to establish communications on the serial data circuits more than 3 times. Page 10469 8. Install the inner bearing. 9. Important: Each time you replace the wheel hub bearings, install a new oil seal in order to prevent the wheel hub from leaking. Install the new oil seal using the J 44420 (2) and the J 8092 (1). 10. Install the rotor, if necessary. 11. Apply a light coat of high melting point EP bearing lubricant to the axle housing spindle. 12. Install the wheel hub to the axle housing. 13. Install the adjusting nut to the hub using the J 2222-C. 14. Adjust the wheel bearings. 15. Install the axle shaft. 16. Install the brake caliper. 17. Install the tire and wheel assembly. Page 3308 3. If equipped, install the engine shield. 4. Install the engine shield bolts. Tighten the bolts to 20 Nm (15 ft. lbs.). 5. Do not install the new retaining clip onto the fitting by pushing on the clip. 6. Important: Failure to properly install the retaining clip could cause the cooler line to come loose and cause damage to the engine. Install the NEW retaining clip into the quick connect fitting by using your thumb and forefinger. Insert the new retaining clip into one of the three fitting recesses. Ensure that the retaining clip is engaged in all 3 slots. 7. With one end of the retaining clip engaged in the connector fitting slot, use your thumb in order to rotate the retaining clip around the connector fitting, until the retaining clip snaps into place. 8. Ensure that the 3 retaining clip ears are seen from inside the fitting and that the retaining clip moves freely in the fitting slots. 9. Install a new retaining clip into the remaining quick connect fitting. Page 8871 Electrical Symbols Part 10 Page 3847 1. Install the TAC module. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the TAC module nuts. Tighten Tighten the nuts to 9 N.m (80 lb in). 3. Connect the engine wiring harness electrical connector (1). 4. Install the red CPA retainer. 5. Connect the I/P harness electrical connector (2). Page 8792 TOOLS REQUIRED J 34142-B 12 V Unpowered Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. When testing for voltage: 1. Attach 1 lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach 1 lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Using Connector Test Adapters USING CONNECTOR TEST ADAPTERS NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-B Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires USING FUSED JUMPER WIRES TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Connector Position Assurance Locks CONNECTOR POSITION ASSURANCE LOCKS The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Terminal Position Assurance Locks TERMINAL POSITION ASSURANCE LOCKS The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Push to Seat Connectors PUSH TO SEAT CONNECTORS TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Page 4775 Camshaft Position Sensor: Description and Operation CAMSHAFT POSITION (CMP) SENSOR The CMP sensor is also a magneto resistive sensor, with the same type of circuits as the CKP sensor. The CMP sensor signal is a digital ON/OFF pulse, output once per revolution of the camshaft. The CMP sensor information is used by the PCM to determine the position of the valve train relative to the CKP. Page 1718 1. Locate the air flow direction arrow (2) on the MAF/IAT sensor. 2. Install the MAF/IAT sensor to the air cleaner assembly. NOTE: Refer to Fastener Notice in Service Precautions. 3. Tighten the MAF/IAT clamp. Tighten Tighten the clamp to 7 N.m (62 lb in). 4. Connect the MAF/IAT sensor electrical connector (4). 5. Push in the gray CPA retainer. 6. Install the air cleaner outlet duct. Page 471 Electrical Symbols Part 9 Drivetrain - Transfer Case Control Module Replacement Control Module: All Technical Service Bulletins Drivetrain - Transfer Case Control Module Replacement Bulletin No.: 05-04-21-002 Date: March 10, 2005 INFORMATION Subject: Guidelines for Replacement of Transfer Case Control Module (TCCM) Models: 2005 and Prior Light Duty Trucks with New Venture Gear (NVG) Transfer Case (RPOs NP1, NP4, NP8) Dealers are replacing the TCCM unnecessarily. Dealers are replacing the TCCM with codes stored in HISTORY only. The TCCM does not have a current fault condition when tested. Parts reviewed at the Warranty Parts Center (WPC) have a 75% No Trouble Found (NTF) rate. The only two legitimate reasons to replace the TCCM are: ^ Diagnostic Trouble Code (DTC) C0550 ^ NO Communication with a scan tool. DTC C0550 This DTC indicates that the module has an internal fault and should be replaced. No Communication ^ The no communication conditions referenced here are also caused by a module internal fault to a point where the module physically will not talk. A technician cannot pull DTCs from the module because it will not communicate. The module is electrically dead. ^ No communication is not to be confused with a U1026 code. This code tells the technician that the module may still be functioning but is temporarily off line. This code may be set by the Instrument Panel (IP) or the Powertrain Control Module (PCM) against the TCCM. The technician needs to figure out why the module went off line. These are typically caused by connection concerns. There is no need to replace a TCCM for a U1026 DTC. Diagnostic Aids ^ When diagnosing a transfer case electrical control system, ALWAYS check power and ground wiring first. ^ Test the connections for intermittent or poor connections, complete plug insertion, bent pins, pushed out terminals and water contamination. Page 11046 - Proof of ownership at time of repair. - Original paid receipt confirming the amount of unreimbursed repair expense(s) (including Service Contract deductibles), a description of the repair, and the person or entity performing the repair. If the work was done by someone other than a GM dealership, the amount of reimbursement will be limited to the amount that the repair would have cost GM to have it completed by a GM dealership. Courtesy Transportation The General Motors Courtesy Transportation program is intended to minimize customer inconvenience when a vehicle requires a repair that is covered by the New Vehicle Limited Warranties. The availability of courtesy transportation to customers whose vehicles are within the warranty coverage period and involved in a product program is very important in maintaining customer satisfaction. Dealers are to ensure that these customers understand that shuttle service or some other form of courtesy transportation is available and will be provided at no charge. Dealers should refer to the General Motors Service Policies and Procedures Manual for Courtesy Transportation guidelines. Warranty Transaction Information Submit a transaction using the table below. * The amount identified in "Net Item" should represent the dollar amount reimbursed to the customer. Disclaimer Locations Below Driver Seat - Restraint Systems Wiring Page 8320 1. Important: Install 2 new copper brake hose gaskets. Assemble the 2 new copper brake hose gaskets and the brake hose bolt to the brake hose. 2. Notice: Refer to Fastener Notice in Service Precautions. Install the brake hose to caliper bolt and 2 new washers to the brake caliper. ^ Tighten the bolt to 40 Nm (30 ft. lbs.). 3. Important: The hose must not be twisted. Make sure the hose is not in contact with any suspension component. Install the brake hose (1) into the brake hose bracket. 4. Install the brake hose retaining clip (3). 5. Remove the rubber cap or plug from the exposed brake pipe fitting end. 6. Connect the brake pipe fitting nut (2) to the brake hose (1): ^ Use a backup wrench on the hose fitting (1). ^ Do not bend the bracket or the pipe. ^ Tighten the brake pipe fitting end (2) to 25 Nm (18 ft. lbs.). 7. Bleed the hydraulic brake system. 8. Install the tire and wheel assembly. 9. Ensure that the hose does not make contact with any part of the suspension or the wheel. If the hose makes contact remove the hose and correct the condition. 10. Lower the vehicle. OnStar(R) - Number Incorrect/Incorrectly Assigned Emergency Contact Module: Customer Interest OnStar(R) - Number Incorrect/Incorrectly Assigned INFORMATION Bulletin No.: 05-08-46-004C Date: December 23, 2010 Subject: OnStar(R) Phone Number Concerns (Phone Number Incorrect/Assigned to Another Vehicle/Phone) That Occur During Diagnosis of OnStar(R) System Models: 2000-2011 GM Passenger Cars and Trucks Equipped with OnStar(R) (RPO UE1) Supercede: This bulletin is being revised to update model years up to 2011. Please discard Corporate Bulletin Number 05-08-46-004B (Section 08 - Body and Accessories). During diagnosis of an OnStar(R) concern, the technician may be told that the OnStar(R) phone number is incorrect or tied to another vehicle and/or phone of some kind. To resolve these concerns, the Tech 2(R) with software version 22.005 (or higher), has the capability to change the OnStar(R) phone number. Service Procedure 1. With the Tech 2(R), build the vehicle to specifications within the Diagnostics area of the Tech 2(R). 2. For vehicles with physical-based diagnostics - under Body, go to the OnStar(R) section. Then select the Special Functions menu. For vehicles with functional-based diagnostics - under Body and Accessories, go to the Cellular Communication section. Select Module Setup and then Vehicle Communication Interface Module. 3. Locate the Program Phone Number prompt and select it. The original phone number will be displayed on the Tech 2(R) screen. 4. Contact the OnStar(R) team at the GM Technical Assistance Center (TAC) to obtain a new phone number. 5. Highlight the digits of the phone number one at a time and enter the new phone number using the number keys on the Tech 2(R). 6. Press the Soft key at the base of the screen for Done once these numbers have been changed on the screen. 7. Press the Soft key for Done again. The area code or new phone number has now been programmed into the phone. 8. Cycle the ignition to Off and open the driver's door. 9. Press the blue OnStar(R) button to make sure that a normal connection can be made to the OnStar(R) call center. If applicable, make sure the Hands-Free Calling (HFC) works properly by making a phone call. 10. If the system is working properly, fax or voicemail a case closing into the OnStar(R) team at TAC with the results. Dealers in Canada should submit case closing information through the GM infoNET. Please follow this diagnostic process thoroughly and complete each step. If the condition exhibited is resolved WITHOUT completing every step, the remaining steps do not need to be performed. If the procedure above does not resolve the condition, you must contact TAC for further assistance. This diagnostic approach was developed specifically for this condition and should not automatically be used for other vehicles with similar symptoms. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use: Warranty Information (Saab Models) For vehicles repaired under warranty, use the table. Page 5085 Chassis And License Lamp Harnesses Keyless Entry - Inoperative Keyless Entry Module: Customer Interest Keyless Entry - Inoperative Bulletin No.: 04-08-52-005 Date: June 15, 2004 TECHNICAL Subject: Remote Keyless Entry (RKE) System Inoperative (Reprogram Passenger Door Module (PDM)) Models: 2004 Cadillac Escalade, Escalade ESV, Escalade EXT 2004 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2004 GMC Sierra, Yukon, Yukon XL Condition Some customers may comment on any of the following conditions: ^ The RKE key fob does not function. ^ The "Service Tire Pressure Monitoring System" message is displayed, if equipped. ^ The passenger door will not unlock from the passenger's or driver's door switches. ^ The passenger door window is inoperative. Correction Reprogram the PDM with the Tech 2(R). Currently the Tech 2(R) software is not available for the 2004 model year. Engineering is aware of this and are working to release a new service calibration. In the meantime, build the Tech 2(R) as a 2003 model year and perform the reprogram using the procedure listed below. 1. Turn the ignition switch to the ON position. 2. Connect the Tech 2(R) to the vehicle's diagnostic link connector (DLC), power it up and press enter. ^ Select: Diagnostics. ^ Select model year: 2003. ^ Select: Light truck. ^ Select: Body. ^ Select the proper Product line. ^ Select the proper HVAC Type. ^ Select the proper Radio System type. ^ Select: Passenger Door Module. ^ Select: Special Functions. ^ Select: Refresh. Important: You must remove the described fuse in the next step for the "Refresh" program to be performed. If you do not remove the fuse for five seconds, the Tech 2 will continue to display "Test in Progress" and the program will not complete. ^ Remove the PDM fuse for 5 seconds from the fuse center located behind the panel on the left end of the instrument panel. Page 3367 Engine Oil Pressure (EOP) Sensor Page 4152 Flexible Fuel Sensor: Description and Operation FUEL COMPOSITION SENSOR DESCRIPTION The fuel composition sensor (FCS), or flex fuel sensor (service parts term), measures the ethanol-gasoline ratio of the fuel being used in a flexible fuel vehicle. Flexible fuel vehicles can be operated with a blend of ethanol and gasoline, up to 85 percent ethanol. In order to adjust the ignition timing and the fuel quantity to be injected, the engine management system requires information about the percentage of ethanol in the fuel. The FCS uses quick-connect style fuel connections, an incoming fuel connection, and an outgoing fuel connection. The two connections have different diameters, to prevent incorrect attachment of the fuel lines. All fuel passes through the fuel composition sensor before continuing on to the fuel rail. The fuel composition sensor measures two different fuel related parameters, and sends an electrical signal to the powertrain control module (PCM) to indicate ethanol percentage, and fuel temperature. The fuel composition sensor has a three-wire electrical harness connector. The three wires provide a ground circuit, a power source, and a signal output to the PCM. The power source is vehicle system voltage, +12 volts), and the ground circuit connects to chassis ground. The signal circuit carries both the ethanol percentage and fuel temperature within the same signal, on the same wire. The FCS uses a microprocessor inside the sensor to measure the ethanol percentage and fuel temp, and change an output signal accordingly. The electrical characteristic of the FCS signal is a square-wave digital signal. The signal is both variable frequency and variable pulse width. The frequency of the signal indicates the ethanol percentage, and the pulse width indicates the fuel temperature. The PCM provides an internal pull-up to five volts on the signal circuit, and the FCS pulls the 5 volts to ground in pulses. The output frequency is linear to the percentage of ethanol content in the fuel. The normal range of operating frequency is between 50 and 150 Hertz, with 50 Hertz representing 0 percent ethanol, and 150 Hertz representing 100 percent ethanol. The normal pulse width range of the digital pulses is between 1 and 5 milliseconds, with 1 millisecond representing -40°C (-40°F), and 5 milliseconds representing 125°C (257°F). The microprocessor inside the sensor is capable of a certain amount of self-diagnosis. An output frequency of 170 Hertz indicates either that the fuel is contaminated or contains methanol (it should not), or that an internal sensor electrical fault has been detected. Certain substances dissolved in the fuel can cause the fuel to be contaminated, raising the output frequency to be higher than the actual ethanol percentage should indicate. Examples of these substances include water, sodium chloride (salt), and methanol. It should be noted that it is likely that the FCS will indicate a slightly lower ethanol percentage than what is advertised at the fueling station. This is not a fault of the sensor. The reason has to do with government requirements for alcohol-based motor fuels. Government regulations require that alcohol intended for use as motor fuel be DENATURED. This means that 100 percent pure ethanol is first denatured with approximately 41/2 percent gasoline, before being mixed with anything else. When an ethanol gasoline mixture is advertised as E85, the 85 percent ethanol was denatured before being blended with gasoline, meaning an advertised E85 fuel contains only about 81 percent ethanol. The FCS measures the actual percentage of ethanol in the fuel. Page 3128 11. If required, clean and inspect the camshaft and bearings. Installation Procedure Important: If camshaft replacement is required, the valve lifters must also be replaced. 1. Lubricate the camshaft journals and the bearings with clean engine oil. 2. Install three M8-1.25 x 100 mm (M8-1.25 x 4.0 inch) bolts to the bolt holes in the front of the camshaft. Notice: All camshaft journals are the same diameter, so care must be used in removing or installing the camshaft to avoid damage to the camshaft bearings. 3. Using the bolts as a handle, carefully install the camshaft into the engine block. 4. Remove the three bolts from the front of the camshaft. 5. Notice: Refer to Fastener Notice in Service Precautions. Important: Install the retainer plate with the sealing gasket facing the engine block. The gasket surface on the engine block should be clean and free of dirt and/or debris. Install the camshaft retainer and bolts. ^ Tighten the bolts to 25 Nm (18 ft. lbs.). Page 5002 Put unused material on the shelf for future use. Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Page 8629 Page 3731 Remove the nuts securing the muffler to the catalytic converter. On 6.0L and 8.1L equipped vehicles only, loosen the exhaust pipe clamp. Do not use oil base lubricants on the rubber exhaust hangers. Apply a soapy solution to the exhaust pipe hanger rods in order to ease the removal of the exhaust hangers. Pry the exhaust hangers free from the exhaust pipe hanger rods. It is not necessary to remove the muffler from the vehicle to replace the muffler heat shield. Reposition the muffler to gain access to the muffler heat shield. Use extreme caution not to damage the muffler when removing the heat shield from the muffler. Using an air-powered hack saw blade, or equivalent, cut off the existing muffler heat shield just as the heat shield rises off of the muffler. See the illustration above. Remove the heat shield from the muffler. Hammer flush the remaining heat shield to the muffler. The new heat shield should not come in contact with the remaining muffler heat shield. The new heat shield should not come in contact with the horizontal lock seam on the muffler. Interior - Power Seat Switch Knobs Loose/Missing Power Seat Switch: Customer Interest Interior - Power Seat Switch Knobs Loose/Missing Bulletin No.: 05-08-50-017 Date: December 14, 2005 TECHNICAL Subject: Power Front Seat (RPO AN3) Switch Knobs Loose or Missing (Replace Switch Knobs) Models: 2002-2006 Cadillac Escalade, Escalade EXT 2003-2006 Cadillac Escalade ESV 2002-2006 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2002-2006 GMC Sierra, Yukon, Yukon XL with Individual Front Seat Non-Bucket (RPO AN3) and Driver Front Seat Power Adjuster (AG1) and/or Passenger Front Seat Power Adjuster (AG2) Condition Some customers may comment that the power front seat adjuster switch knobs are loose and fall off or are missing. Correction Replace the front seat adjuster switch knob. These knobs were formerly available only as part of the power seat adjuster switch. DO NOT replace the switch if the knob only needs to be replaced. Parts Information Warranty Information Page 5095 1. If necessary, install the CVS to the CVS bracket. 2. Install the CVS to the vehicle. Ensure the locator tab is inserted into the frame hole. 3. Connect the CVS line to the canister. NOTE: Refer to Fastener Notice in Service Precautions. 4. Install the CVS bracket bolt. Tighten Tighten the bolt to 12 N.m (106 lb in). 5. Connect the CVS electrical connector. 6. Lower the vehicle. Page 7395 12. Install the cover. Notice: Refer to Fastener Notice in Service Precautions. 13. Install 2 NEW screws (1) to the casting. ^ Tighten the screws to 2 Nm (18 inch lbs.). 14. Install 2 NEW longer screws (2) to the motor cover. ^ Tighten the screws to 3 Nm (26 inch lbs.). 15. Install the encoder motor. Page 13173 Parts Information Page 10677 Some customers may use penetrating oils, grease or other lubricants on wheel studs to aid in removal or installation. Always use a suitable cleaner/solvent to remove these lubricants prior to installing the wheel and tire assemblies. Lubricants left on the wheel studs may cause improper readings of wheel nut torque. Always install wheels to clean, dry wheel studs ONLY. Notice Lubricants left on the wheel studs or vertical mounting surfaces between the wheel and the rotor or drum may cause the wheel to work itself loose after the vehicle is driven. Always install wheels to clean, dry wheel studs and surfaces ONLY. Beginning with 2011 model year vehicles, put a light coating of grease, GM P/N 1051344 (in Canada, P/N 9930370), on the inner surface of the wheel pilot hole to prevent wheel seizure to the axle or bearing hub. Wheel Stud and Lug Nut Damage Always inspect the wheel studs and lug nuts for signs of damage from crossthreading or abuse. You should never have to force wheel nuts down the stud. Lug nuts that are damaged may not retain properly, yet give the impression of fully tightening. Always inspect and replace any component suspected of damage. Tip Always start wheel nuts by hand! Be certain that all wheel nut threads have been engaged BEFORE tightening the nut. Important If the vehicle has directional tread tires, verify the directional arrow on the outboard side of the tire is pointing in the direction of forward rotation. Wheel Nut Tightening and Torque Improper wheel nut tightening can lead to brake pulsation and rotor damage. In order to avoid additional brake repairs, evenly tighten the wheel nuts to the proper torque specification as shown for each vehicle in SI. Always observe the proper wheel nut tightening sequence as shown below in order to avoid trapping the wheel on the wheel stud threads or clamping the wheel slightly off center resulting in vibration. The Most Important Service You Provide While the above information is well known, and wheel removal so common, technicians run the risk of becoming complacent on this very important Diagram Information and Instructions Garage Door Opener Transmitter: Diagram Information and Instructions Truck Zoning TRUCK ZONING Truck Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that corresponds to where they are located in the vehicle. The table explains the numbering system. Page 4758 Accelerator Pedal Position Sensor: Description and Operation ACCELERATOR PEDAL POSITION (APP) SENSOR The accelerator pedal assembly contains 2 individual APP sensors within the assembly. The APP sensors 1 and 2 are potentiometer type sensors, each with the following circuits: - A 5-volt reference circuit - A low reference circuit - A signal circuit The APP sensors are used to determine the pedal angle. The control module provides each APP sensor a 5-volt reference circuit and a low reference circuit. The APP sensors then provide the control module with signal voltage proportional to pedal movement. Both APP sensor signal voltages are low at rest position and increase as the pedal is applied. Page 10652 Parts Information Warranty Information Wheels All GM Accessories sold and permanently installed on a GM vehicle PRIOR to new vehicle delivery will be covered under the provisions of the New Vehicle Limited Warranty. For the U.S., in the event GM Accessories are installed AFTER the New Vehicle Delivery, or are replaced under the New Vehicle Warranty, they will be covered (parts and labor) for the balance of the vehicle warranty, but in no event less than 12 months/12,000 miles. This coverage is only effective for GM Accessories permanently installed by a GM dealer or a GM approved ADI (Accessory Distributor/Installer). For Canada, in the event GM Accessories are installed AFTER the New Vehicle Delivery, they will be covered (parts and labor) for the balance of the vehicle warranty, or up to 12 months/Unlimited kilometers depending on month installed. For replacement after the new vehicle warranty expires, but within the 12 months/unlimited kilometers coverage, refer to claim type "B" guidelines. GM Accessories sold over-the-counter, or those not requiring installation, will continue to receive the standard GM Dealer Parts Warranty of 12 months from the date of purchase (parts only). Tires Any approved tire installed on a GM Vehicle PRIOR to delivery will be covered under the provisions of the New Vehicle Limited Warranty. Tires are covered against defects in material and workmanship. Tires are warranted for defects "without" prorated charge for tread mileage. Subsequent replacements under this warranty will continue to be covered for the remainder of the New Vehicle Limited Warranty. Any approved tire installed on a GM Vehicle PRIOR to delivery may continue to be warranted on a prorated basis by the tire manufacturer once the New Vehicle Limited Warranty expires. Any approved tire installed AFTER delivery will be covered under the provisions of the tire manufacturer warranty. USA dealers should refer to GM Warranty Administration Bulletin 00-03-10-003I and GM Parts Process / Policy Bulletin IB03-001 for more information. Canadian dealers should refer to GM Warranty Administration Bulletin 01-03-10-003B. GM Warranty Claims Processing Only GM dealerships have the ability to file warranty claims for GM Parts and Accessories. Therefore, any warranty claims filed against such parts must be handled by the servicing GM dealership. This includes those parts purchased from a GM-approved ADI (Accessory Distributor / Installer). A/C - Window Defroster Contact/Tab Repair Information Heated Glass Element: Customer Interest A/C - Window Defroster Contact/Tab Repair Information INFORMATION Bulletin No.: 03-08-48-006H Date: April 11, 2011 Subject: Repair Information for Reconnection of Rear Window Defroster Contact or Tab Models: 2000-2012 GM Passenger Cars and Trucks 2003-2009 HUMMER H2 2006-2010 HUMMER H3 2005-2009 Saab 9-7X 2007-2010 Opel GT 2007-2008 Daewoo G2X Equipped With Electric Rear Window Defroster - RPO C49 Supercede: This bulletin is being revised to add the 2012 model year. Please discard Corporate Bulletin Number 03-08-48-006G (Section 08 - Body and Accessories). Repair Suggestions Soldering Defroster Contact Tabs In many cases the terminal tab will still be in the connector when you examine the vehicle. For Chevrolet Tahoe, Suburban, GMC Yukon, and Cadillac Escalade vehicles (with moveable glass), always replace the defroster tab (GM P/N 25916031) and the defroster electrical power connector (P/N 12034110). For all other vehicles, reconnect the original defroster tab. In most applications it is preferable to create a new solder connection to reattach a separated rear defroster tab. If you take note of the steps below, it is possible to create a new solder joint that is equal to, or stronger than, the original. The generic procedure below is not very time intensive, but does include minor preparation work to create a good bonding surface. Be sure to follow each of the steps, as combined they will produce the strongest bond possible. Please consider the following before attempting the repair: - Soldering introduces significant heat to the glass window of the vehicle. When performing the re-connection of the tab, use only the heat required to do the job. Pre-heat the soldering iron and have the solder in your other hand, ready to go, the moment you have enough heat to melt the solder. - If it is winter, bring the vehicle into the service garage and remove any snow from the back window area. Allow time for the glass to warm to the temperature inside the building. Soldering creates a "hot spot" in the glass. DO NOT solder on cold glass. Caution Heating the glass excessively, or repeatedly without time to cool, may result in glass breakage. ALWAYS wear safety glasses when performing this repair! - You MUST use a silver-bearing solder to make the connection. DO NOT attempt this repair with conventional tin/lead alloy solders. Silver bearing solder will adhere to the electrical buss bar, making a strong and lasting repair. - Protect surfaces under the area to be soldered. It is very easy to drip solder when performing this repair. Placing a shop towel under the soldering area is sufficient protection. Soldering Procedure 1. It is imperative to remove and replace the rear defroster electrical power connector by crimping a new connector to the feed wire. The proper connector P/N 12034110 can be found in the Packard Electrical Assortment, Tray 18, Position 5. - Insert Delphi pick 12094430 to depress the locking tab on the terminal. - Insert Delphi pick 12094429 to release the secondary lock tab. Important DO NOT re-use the existing defroster tab on new-style full-size utility vehicles with moveable glass. 2. Connect the electrical connector to the defroster tab. Fully engage the connector. An improperly seated connector may cause excessive resistance and impede the proper operation of the defroster. Add a small bead of solder to mate the electrical connector tab to the defroster tab. Page 16064 Electrical Symbols Part 6 Page 6086 Disclaimer Page 1507 1. Connect the electrical connectors. 2. Install the headlamp switch by snapping the headlamps switch into place. 3. Install the bezel to the instrument panel. Page 12727 Parts Information Page 7252 Control Module References Part 2 Page 14283 WA408G/44 - WA519F/12 Page 2229 8. Install the transmission support. 9. Install the transmission support side bracket and bolts. 10. Install the transmission support bolts and nuts. ^ Tighten the bolts/nuts to 95 Nm (70 ft. lbs.). 11. Install the transmission mount nuts. ^ Tighten the nuts to 40 Nm (30 ft. lbs.). 12. Remove the transmission jack. 13. Lower the vehicle. 14. Fill the transmission to the proper level with DEXRON® III transmission fluid. Page 4842 Disclaimer Page 10096 Power Steering Pump: Service and Repair Power Steering Pump Replacement Power Steering Pump Replacement (4.8L, 5.3L and 6.0L) Removal Procedure 1. Remove the power steering pulley. Refer to Power Steering Pulley Replacement. 2. Raise the vehicle. Refer to Vehicle Lifting. 3. Remove the oil pan skid plate bolts. 4. Remove the oil pan skid plate from the vehicle, if equipped. 5. Place a drain pan under the vehicle. 6. Remove the power steering pressure hose (2) from the power steering pump from underneath the vehicle. 7. Lower the vehicle. With Full Floating 10.5 Axle Bearing: Service and Repair With Semi Floating 8.6", 9.5", 9.75" Ring Gear Rear Axle Shaft Seal and/or Bearing Replacement ^ Tools Required J 8092 Universal Driver Handle-3/4 in - 10 - J 21128 Axle Pinion Oil Seal Installer (8.6 inch Axle) - J 23690 Axle Shaft Bearing Installer (8.6 inch Axle) - J 2619-01 Slide Hammer - J 29709 Wheel Bearing Installer (9.5 inch Axle) - J 29712 Wheel Bearing Remover (9.5 inch Axle) - J 29713 Axle Seal Installer (9.5 inch Axle) - J 44685 Rear Axle Seal and Bearing Remover (8.6 inch Axle) Removal Procedure 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Remove the tire and wheel assembly. 3. Remove the rear axle housing cover. 4. Remove the axle shaft. 5. Remove the axle shaft seal and the bearing from the axle housing using the J 44685 (8.6 inch axle) (1) and the J 2619-01 (2). 6. Remove the axle shaft seal and the bearing from the axle housing using the J 29712 (9.5 inch axle). Installation Procedure 1. Install the axle shaft bearing using the J 23690 (8.6 inch axle) (1) or the J 29709 (9.5 inch axle) (1) and the J 8092 (2). Page 2530 Engine Oil: Service and Repair Engine Oil and Oil Filter Replacement Removal Procedure Important: In order to completely drain the oil from the oil pan internal baffling, the bottom of the oil pan must be level during the oil drain procedure. 1. Open the hood. 2. Remove the oil fill cap. 3. Raise and suitably support the vehicle. 4. Place a oil drain pan under the oil pan drain plug. 5. Remove the oil pan drain plug. 6. Drain the engine oil. 7. Wipe the excess oil from the drain plug hole and plug. 8. Remove the oil filter from the engine block. Important: Check the old oil filter to ensure that the filter seal is not left on the engine block. 9. Wipe the excess oil from the oil filter mounting. Installation Procedure 1. Lubricate the oil filter seal with clean engine oil. Page 12461 Important: The optic cable must not be bent with a radius less than 25 mm (1 in). 6.12. Place the optic cable in the wiring harness channels on the right-hand side. Thread through the existing cable ties (C) if possible, otherwise, secure with a cable tie to the existing one. Close the cover on the channels. Ensure the catches lock. 6.13. Secure the optic cable along the right-hand rear wheel housing, next to the ordinary wiring harness securing points and by the SRS unit (D). 6.14. Thread the optic cable up next to the safety belt by the old optic cable and place on the parcel shelf. 6.15. Unplug the connectors (E) from the OnStar(R) control modules. 6.16. Remove the console (F) together with the OnStar(R) control modules. Page 5372 14. Thoroughly wash all contaminants from around the EHCU. 15. Disconnect the chassis electrical harness connectors from the electronic brake control module (EBCM). IMPORTANT: Make sure that brake lines are tagged and kept in order for proper reassembly. 16. Disconnect the brake lines from the brake pressure modulator valve (BPMV). 17. Remove the bolts (4) attaching the EHCU bracket to the frame (5). 18. Remove the EHCU (1). 19. If equipped with 4WD, remove the torsion bar bracket. 20. Disconnect the fuel feed and return pipes at the fuel tank. 21. Cap the fuel pipes at the fuel tank. Page 1969 2. Connect the speed sensor electrical connector. 3. Lower the vehicle. Page 7510 Control Module: Locations NVG 263-NP1 Transfer Case Shift Control Module Transfer Case Shift Control Module 1 - I/P Harness 2 - Transfer Case Shift Control Module Connectors 3 - Transfer Case Shift Control Module 4 - Instrument Panel Page 8298 Assembly Procedure 1. Notice: Refer to Fastener Notice in Service Precautions. Install the brake caliper bleed screw. ^ Tighten the brake caliper bleed screw to 12 Nm (106 inch lbs.). 2. Install the brake caliper bleed screw cap. 3. Lubricate the new piston seal and the brake caliper bore seal groove with brake fluid. 4. Install the new seal into the brake caliper bore seal groove. 5. Ensure that the seal is not twisted. 6. Lubricate the brake caliper bore and the piston with brake fluid. 7. Install the boot and piston. 1. Install the boot over the end of the piston so that the fold will face toward the brake caliper housing piston bore opening. 2. Seat the boot into the brake caliper bore groove. Slide the piston into the brake caliper bore. 3. Push down the piston to the bottom of the brake caliper bore. 4. Ensure that the boot is properly seats into the piston groove and into the groove in the brake caliper bore. 8. Install the brake caliper to the vehicle. Brake Caliper Bracket Replacement - Front Brake Caliper Bracket Replacement - Front Caution: Refer to Brake Dust Caution in Service Precautions. Removal Procedure 1. Notice: Support the brake caliper with heavy mechanic's wire, or equivalent, whenever it is separated from its mount and the hydraulic flexible brake hose is still connected. Failure to support the caliper in this manner will cause the flexible brake hose to bear the weight of the caliper, which may cause damage to the brake hose and in turn may cause a brake fluid leak. Remove the caliper from the mounting bracket and support the caliper with heavy mechanic's wire or equivalent. DO NOT disconnect the hydraulic brake flexible hose from the caliper. Refer to Brake Caliper Replacement Front. 2. Remove the brake pads. 3. Remove the anti-rattle clips from the brake caliper bracket. Page 6397 Park Neutral Position (PNP) Switch C175 Page 14403 Front Passenger Door Module (FPDM) - C4 (With RPO Code YE9) Part 1 Fuel Pressure Gage Installation and Removal Fuel Pressure: Testing and Inspection Fuel Pressure Gage Installation and Removal FUEL PRESSURE GAGE INSTALLATION AND REMOVAL INSTALLATION PROCEDURE TOOLS REQUIRED J 34730-1A Fuel Pressure Gage CAUTION: - Refer to Gasoline/Gasoline Vapors Caution in Service Precautions. - Refer to Fuel Gage Leak Caution in Service Precautions. 1. Remove the engine sight shield. 2. Remove the fuel rail pressure fitting cap. 3. Connect the J 34730-1A to the fuel pressure valve. Wrap a shop towel around the fitting while connecting the gage in order to avoid spillage. 4. Install the bleed hose on J 34730-1A into an approved container. REMOVAL PROCEDURE 1. Remove the bleed hose on the J 34730-1A from the approved container. 2. Remove the shop towel from around the fitting and discard into an approved container. 3. Disconnect the J 34730-1A from the fuel pressure valve. 4. Install the fuel rail pressure fitting cap. 5. Install the engine sight shield. Page 10896 When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage TESTING FOR A SHORT TO VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity TESTING FOR CONTINUITY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents TESTING FOR ELECTRICAL INTERMITTENTS Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground - Testing for Continuity - Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 msRECORD and emits an audible tone (beep). Recall 04V225000: Child Seat Anchorage Non-Compliance Child Seat: Recalls Recall 04V225000: Child Seat Anchorage Non-Compliance Make / Models : Model/Build Years: Chevrolet / Express 2003 Chevrolet / Silverado 2003-2004 GMC / Savana 2003 GMC / Sierra 2003-2004 MANUFACTURER: General Motors Corp. NHTSA CAMPAIGN ID Number : 04V225000 Recall Date : MAY 10, 2004 COMPONENT: Seat Belts: Front: Anchorage Potential Number Of Units Affected : 736 SUMMARY: certain extended and regular cab pickup trucks and cargo vans converted to compressed natural gas (CNG) fail to conform to the requirements of Federal Motor Vehicle Safety Standard NO. 225, "Child Restraint Anchorage Systems." These vehicles have one seating position, the center rear seat, equipped with child restraint lower anchorages. CONSEQUENCE: The standard requires child seat lower anchorages in two seating positions for vehicles with three rear seating positions. The standard cab and cargo van vehicles, which only have front seating positions, have an air bag off switch to disable the front passenger air bag and do not have child restraint lower anchorages in the passenger seat. The standard requires passenger seat child seat lower anchorages in vehicles with an air bag off switch. however, the standard does not require vehicles with only front seating positions to have lower anchorage provisions if the vehicle is not equipped with an air bag off switch. REMEDY: To bring the standard cab and cargo van vehicles into compliance, dealers will inject epoxy into the air bag off switch to prevent air bag activation, relocate the switch behind the instrument panel and then install a cover over the resulting opening. The sun visor label and owner's manual will also be changed. the correction for the extended cab vehicle will consist of changing the front passenger seat to a seat that has child restraint lower anchorages. The recall began on September 9, 2004. Owners should contact Chevrolet at 1-800-630-2438 OR GMC AT 1-866-996-9463. NOTES: GM Recall NO. 04038. Customers can also contact The National Highway Traffic Safety Administration's Auto Safety Hotline at 1-888-DASH-2-DOT (1-888-327-4236). Page 12818 Diagnostic Tips Review # 2 - Delphi Legacy Navigation Radio Page 1176 Power Seat Switch: Removal and Replacement Seat Switch Replacement - Power Removal Procedure 1. Remove the power seat switch bezel from the seat. 2. Remove the power seat switch to bezel screws. 3. Remove the power seat switch. Installation Procedure Notice: Refer to Fastener Notice in Service Precautions. 1. Install the power seat switch to bezel screws. Tighten the screws to 2 N.m (18 lb in). 2. Install the power seat switch bezel to the seat. Body/Frame - Revised Crossmember/Body Bolt Service Cross-Member: Technical Service Bulletins Body/Frame - Revised Crossmember/Body Bolt Service Bulletin No.: 05-08-61-005 Date: April 29, 2005 SERVICE MANUAL UPDATE Subject: Revised Crossmember/Body Mount Bolt Installation Information Models: 1999-2005 Cadillac Full-Size Pickup and Utility Models 1999-2005 Chevrolet Full-Size Pickup and Utility Models 1999-2005 GMC Full-Size Pickup and Utility Models This bulletin is being issued to revise all repair procedures that include reinstalling the front engine crossmember-to-frame bolts or any body mount bolts in the Frame and Underbody sub-section of the Service Manual. Please replace the current information in the Service Manual with the following information. The following information has been updated within SI. If you are using a paper version of this Service Manual, please make a reference to this bulletin on the affected page. Before reinstalling front engine crossmember-to-frame bolts or any body mount bolts, you must do the following: 1. Remove all traces of the original thread locking material. 2. Clean the threads of the bolt with denatured alcohol, or equivalent, and allow to dry. 3. Apply Thread locker, P/N 12345493, (Canadian P/N 10953488). Disclaimer Drivetrain - Updated Transfer Case Speed Sensor Conn. Speed Sensor: All Technical Service Bulletins Drivetrain - Updated Transfer Case Speed Sensor Conn. Bulletin No.: 06-04-21-001 Date: May 17, 2006 INFORMATION Subject: Updated Transfer Case Connector Service Kit Now Available For Transfer Case Speed Sensor Wire Harness Connector that Comes Loose Or Connector Retainer Clip Breaks Models: 2007 and Prior GM Light Duty Trucks 2007 and Prior HUMMER H2, H3 2005-2007 Saab 9-7X with Four-Wheel Drive or All-Wheel Drive Technicians may find that when the transfer case speed sensor wire harness connector is removed, the connector lock flexes/bends and does not return to the original position. The transfer case speed sensor wire harness connector then has no locking device. On older vehicles, the plastic connector retainer becomes brittle and the clip may break as soon as it is flexed. In the past, the only service fix was to install a wire harness connector service pack, P/N 88987183. This repair procedure involved splicing a new service connector with an integral connector lock. This connector service kit is of the same design and was still prone to failure over time. A new connector service repair kit is now available, P/N 15306187, that is an updated design. This new kit should be used whenever the speed sensor wire harness connector requires replacement. Parts Information Disclaimer Page 5639 - Inspect the insulator (2) for cracks. All or part of the electrical charge may arc through the crack instead of the electrodes (3, 4). - Inspect for evidence of improper arcing. Measure the gap between the center electrode (4) and the side electrode (3). Refer to Ignition System Specifications. An excessively wide electrode gap can prevent correct spark plug operation. - Inspect for the correct spark plug torque. Refer to Ignition System Specifications. Insufficient torque can prevent correct spark plug operation. An over torqued spark plug, causes the insulator (2) to crack. - Inspect for signs of tracking that occurred near the insulator tip instead of the center electrode (4). - Inspect for a broken or worn side electrode (3). - Inspect for a broken, worn, or loose center electrode (4) by shaking the spark plug. A rattling sound indicates internal damage. - A loose center electrode (4) reduces the spark intensity. - Inspect for bridged electrodes (3, 4). Deposits on the electrodes (3, 4) reduce or eliminates the gap. - Inspect for worn or missing platinum pads on the electrodes (3, 4), if equipped. - Inspect for excessive fouling. - Inspect the spark plug recess area of the cylinder head for debris. Dirty or damaged threads can cause the spark plug not to seat correctly during installation. VISUAL INSPECTION - Normal operation - Brown to grayish-tan with small amounts of white powdery deposits are normal combustion by-products from fuels with additives. - Carbon fouled - Dry, fluffy black carbon, or soot caused by the following conditions: Rich fuel mixtures Leaking fuel injectors - Excessive fuel pressure - Restricted air filter element - Incorrect combustion - Reduced ignition system voltage output Weak ignition coils Page 12095 Check - Vehicle. The Diagnostic System Check will provide the following information: ^ The identification of the control modules which command the system ^ The ability of the control modules to communicate through the serial data circuit ^ The identification of any stored diagnostic trouble codes (DTCs) and their status The use of the Diagnostic System Check will identify the correct procedure for diagnosing the system and where the procedure is located. Visual/Physical Inspection Perform the following visual inspections; ^ Inspect for aftermarket devices which could affect the operation of the Radio/Audio System. Refer to Checking Aftermarket Accessories in SI. ^ Inspect the easily accessible and visible system components for obvious damage or conditions which could cause the symptom. Intermittent Conditions Faulty electrical connections or wiring may be the cause of intermittent conditions. Refer to Testing for Intermittent Conditions and Poor Connections in SI. Symptom List Page 15659 Headlamp Leveling Actuator - Right (Export) Automatic Transmission - 4L60-E/4L65-E Page 11948 monitor the Tech2(R) for the current time and date. REMINDER - Keep in mind that the time displayed on the Tech2(R) is in Greenwich Mean Time (GMT) and the offset is based on the time zones relationship to GMT. If replacement of the VIU/VCIM is necessary, you MUST reconfigure the OnStar® system. Failure to reconfigure the system will result in an additional customer visit for repair. OnStar® VIU, Generations 2 and 3, will require the technician to press the blue OnStar® button to reconfigure the vehicle with an OnStar® advisor. OnStar(R) VCIM, Generations 4-7 will require the technician to reconfigure the vehicle with the use of the TIS2WEB and SPS applications (pass thru only), along with the Tech2(R). The configuration and set-up procedure is a two-step process that must be completed step-by-step without interruption or delay in between each step. This procedure enables an automated activation without a button press by the technician to the OnStar(R) Call Center. Following this procedure, it may take up to 24 hours for all OnStar(R) services to be fully activated. How to Order Parts If the OnStar(R) GPS date/time stamp is non-recoverable and the unit needs to be replaced, dealers in the U.S. should contact Autocraft Electronics select the catalog item that contains this bulletin number. Canadian dealers should contact MASS Electronics. Dealers DO NOT need to call the GM Technical Assistance Center (TAC) for replacement approval. Autocraft Electronics and MASS Electronics will be responsible for verifying that the subject vehicle is a candidate for a replacement VIU/VCIM. Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use the table. Warranty Information (Saab U.S. Models) Page 6524 Disclaimer Heater/Vent Module Replacement Housing Assembly HVAC: Service and Repair Heater/Vent Module Replacement HEATER/VENT MODULE REPLACEMENT REMOVAL PROCEDURE 1. Drain the engine coolant. 2. If equipped remove the auxiliary battery. 3. Reposition the inlet heater hose clamp from the heater core. 4. Remove the inlet heater hose from the heater core. 5. Reposition the outlet heater hose clamp from the heater core. 6. Remove the outlet heater hose from the heater core. 7. Remove the I/P carrier. 8. Remove the heater/vent module drain hose. 9. Disconnect the electrical harnesses and the ground connections. 10. Remove the heater/vent module mounting nuts and the screws. 11. Remove the heater/vent module assembly from the vehicle. INSTALLATION PROCEDURE Air Temperature Sensor Replacement - Upper Right Discharge Air Temperature Sensor / Switch: Service and Repair Air Temperature Sensor Replacement - Upper Right AIR TEMPERATURE SENSOR REPLACEMENT - UPPER RIGHT REMOVAL PROCEDURE 1. Remove the I/P upper trim panel. 2. Disconnect the electrical connector (1) from the upper right air temperature sensor (2). 3. Remove the upper right air temperature sensor (1) from the air distributor duct (3). INSTALLATION PROCEDURE 1. Install the upper right air temperature sensor (1) to the air distributor duct (3). 2. Connect the electrical connector (1) from the upper right air temperature sensor (2). 3. Install the I/P upper trim panel. Page 7351 10. Connect the PNP switch electrical connector (2). 11. If equipped with 4WD, install the front propeller shaft. 12. Lower the vehicle. 13. Check the PNP switch for proper operation. The engine must start in the park (P) or neutral (N) positions only. If proper operation of the switch can not be obtained, replace the switch. Park Lock Pawl and Actuator Replacement Park Lock Pawl and Actuator Replacement Removal Procedure 1. Remove the transmission filter. 2. Remove the park/neutral position (PNP) switch. 3. Remove the manual shaft nut and pin. 4. Remove the detent lever and actuator. 5. Remove the parking pawl bracket bolts. 6. Remove the parking pawl return spring. Page 9130 4. Install the ground, then the washer and then the bolt to the frame. Important: It is important to use the bolts, washers and nuts specified in this bulletin. These parts have been identified due to their conductive finish. 5. Install a washer and nut to the back side of the frame. Tighten Tighten the nut to 9 Nm (79 lb in). 6. Cover the front and back side of the repair area using Rubberized Undercoating. An additional check can be made to ensure a good connection for the battery cable to frame ground. It is possible for this ground to cause similar symptoms with the ABS as described above. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Parts Information Warranty Information Disclaimer Page 8578 cloth below the booster supply port in order to capture any fluid exiting the hydro-boost unit. 10. Install the inlet port adapter, CH 47950-2 (2) into the booster supply port. 11. Using a torque wrench, slowly tighten the inlet port adapter to 16 N.m (12 lb-ft). If the clear tube was removed from the inlet port adapter assembly, be sure it is reinstalled. 12. Before each use of the accumulator pressure clamp, CH 47950-1, be sure to grease the clamp bolt and anti rotation washer with wheel bearing grease. 13. Install the accumulator pressure clamp, CH 47950-1 (1), by sliding it over the accumulator and straddling the hydro-boost housing. 14. Confirm that the accumulator pressure clamp is squarely seated onto the booster housing and accumulator, and place the 3/4 inch containment bolt into the fixture. Install the nut hand-tight onto the containment bolt. 15. Check and make sure that the fixture washer is correctly positioned between the end of the accumulator, and that the pin is engaged in the end of the bolt. The tab on the washer should be rotated clockwise so it is located below the master cylinder mounting flange ear. Caution: Incorrect installation of the washer will result in damage to the accumulator end. 16. Hand-tighten the accumulator pressure clamp bolt. Make sure the clamp is level and the tube is square to the end of the accumulator. 17. Place a shop cloth next to the opening of the inlet port adapter in order to capture any fluid exiting the hydro-boost unit. Important: Do not exceed 65 N.m (48 lb-ft) torque. Important: A torque wrench must be used to tighten the fixture clamp bolt 18. Slowly tighten the fixture clamp bolt while monitoring the inlet port adapter tube for signs of power steering fluid. Stop tightening of the bolt when either fluid is observed (below the maximum 65 N.m (48 lb-ft) torque) OR The 65 N.m (48 lb-ft) maximum bolt torque is achieved (with no fluid Page 755 HVAC Control Module - C2 Part 1 Page 4519 IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. Splicing Twisted or Shielded Cable SPLICING TWISTED OR SHIELDED CABLE Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. - Rewrap the conductors with the mylar tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with mylar tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Control Module References Recall - Brake Booster Pressure Accumulator Cracking Technical Service Bulletin # 05006 Date: 050323 Recall - Brake Booster Pressure Accumulator Cracking Product Safety - Hydro-Boost Accumulator Over-Pressurization # 05006 - (Mar 23, 2005) Models: 2004 Chevrolet Kodiak 2004-2005 Chevrolet Avalanche, Express, Silverado, Suburban 2004 GMC TopKick 2004-2005 GMC Savana, Sierra, Yukon XL Condition General Motors has decided that a defect, which relates to motor vehicle safety, exists in certain 2004 Chevrolet Kodiak and GMC TopKick; 2004-2005 Chevrolet Avalanche, Express, Silverado, Suburban; GMC Savana, Sierra, Yukon XL vehicles. On some of these vehicles, the hydraulic brake booster's pressure accumulator may crack and/or separate from the Hydro-Boost(R) assembly during normal vehicle operating conditions. If a separation were to occur and the hood of the vehicle were open, fragments from the accumulator could cause injury to people in the immediate area. In addition, the presence of this crack or fractured surface could allow the hydraulic fluid to leak from the accumulator circuit of the booster assembly. The loss of fluid would cause increased steering and braking effort. Correction Dealers are to inspect the hydraulic brake booster, and replace it if necessary. Vehicles Involved Involved are certain 2004 Chevrolet Kodiak and GMC TopKick; 2004-2005 Chevrolet Avalanche, Express, Silverado, Suburban; GMC Savana, Sierra, Page 4523 Control Module References Part 4 Page 14111 Driver Door Module (DDM) - C2 (With RPO Code YE9) Part 1 Page 14673 Vehicles Involved For dealers with involved vehicles, a listing with involved vehicles containing the complete vehicle identification number, customer name, and address information has been prepared and will be provided through the GM DealerWorld Recall Information system. Dealers will not have a report available if they have no involved vehicles currently assigned. The listing may contain customer names and addresses obtained from Motor Vehicle Registration Records. The use of such motor vehicle registration data for any purpose other than follow-up necessary to complete this recall is a violation of law in several states/provinces/countries. Accordingly, you are urged to limit the use of this report to the follow-up necessary to complete this recall. Parts Information No parts are required for this recall. Service Procedure General Motors will work with the customer to reach an agreement on the purchase of the vehicle. Dealers will be asked by General Motors to assist in the removal of any aftermarket accessories, inspection of the vehicle, obtaining titles and other documentation required to transfer ownership to General Motors, presenting the customer with a check for the repurchase, and taking possession of the vehicle. General Motors will arrange for transportation of the vehicle from the dealer. Diagrams Ignition Coil: Diagrams Ignition Coil 1 Page 12637 For vehicles repaired under warranty use, the table. Disclaimer Page 1520 Steering Wheel and Column Sub-System Components Page 5864 Speed Sensor: Service and Repair Transfer Case - NVG 261-NP2 Transfer Case Speed Sensor Replacement Removal Procedure 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. Disconnect the speed sensor electrical connector (4). 3. Remove the speed sensor. Installation Procedure 1. Notice: Refer to Fastener Notice in Service Precautions. Install the speed sensor. ^ Tighten the sensor to 15 Nm (11 ft. lbs.). Page 2046 A wheel alignment will generally NOT correct vehicles that follow the road crown since this is within "Normal Operation." Mileage Policy The following mileage policy applies for E2020 and E2000 labor operations: Note Wheel Alignment is NOT covered under the New Vehicle Limited Warranty for Express and Savana Cutaway vehicles as these vehicles require Upfitters to set the wheel alignment after completing the vehicles. - 0-800 km (0-500 mi): E2000/E2020 claims ONLY allowed with Call Center Authorization. Due to the tie down during shipping, the vehicle's suspension requires some time to reach normal operating position. For this reason, new vehicles are generally NOT to be aligned until they have accumulated at least 800 km (500 mi). A field product report should accompany any claim within this mileage range. - 801-12,000 km (501-7,500 mi): - If a vehicle came from the factory with incorrect alignment settings, any resulting off-angle steering wheel, lead/pull characteristics or the rare occurrence of excessive tire wear would be apparent early in the life of the vehicle. The following policy applies: - Vehicles 100% Factory Set/Measured for Caster/Camber/Toe - Escalade/ESV/EXT, Tahoe/Suburban, Yukon/XL/Denali, Silverado/Sierra, Express/Savana, Corvette and Colorado/Canyon: E2000/E2020 Claims: Call Center Authorization Required - All Vehicles NOT 100% Factory Set/Measured for Caster/Camber/Toe as noted above: E2000/E2020 Claims: Dealer Service Manager Authorization Required - 12,001 km and beyond (7,501 miles and beyond): During this period, customers are responsible for the wheel alignment expense or dealers may provide on a case-by case basis a one-time customer enthusiasm claim up to 16,000 km (10,000 mi). In the event that a defective component required the use of the subject labor operations, the identified defective component labor operation will include the appropriate labor time for a wheel alignment as an add condition to the component repair. Important Only one wheel alignment labor operation claim (E2000 or E2020) may be used per VIN. Warranty Documentation Requirements When a wheel alignment service has been deemed necessary, the following items will need to be clearly documented on/with the repair order: - Customer concern in detail - What corrected the customer concern? - If a wheel alignment is performed: - Consult SI for proper specifications. - Document the "Before" AND "After" wheel alignment measurements/settings. - Completed "Wheel Alignment Repair Order Questionnaire" (form attached to this bulletin) 1. Document the customer concern in as much detail as possible on the repair order and in the warranty administration system. Preferred examples: - Steering wheel is off angle in the counterclockwise direction by approximately x degrees or clocking position. - Vehicle lead/pulls to the right at approximately x-y mph. Vehicle will climb the road crown. Severe, Moderate or Slight. - RF and LF tires are wearing on the outside shoulders with severe feathering. Important In the event of a lead/pull or steering wheel angle concern, please note the direction of lead/pull (left or right) or direction of steering wheel angle (clockwise or counterclockwise) on the repair order and within the warranty claim verbatim. Important In the event of a tire wear concern, please note the position on the vehicle and where the wear is occurring on the tire; i.e., the RF tire is wearing on the inside shoulder. 2. Document the technician's findings on cause and correction of the issue. Examples: - Reset LF toe from 0.45 degrees to 0.10 degrees and RF toe from -0.25 degrees to 0.10 degrees to correct the steering wheel angle from 5 degrees counterclockwise to 0 degrees. - Reset LF camber from 0.25 degrees to -0.05 degrees to correct the cross-camber condition of +0.30 degrees to 0.00 degrees on the vehicle. - Front Sum toe was found to be 0.50 degrees, reset to 0.20 degrees. 3. Print-out the "Before" and "After" wheel alignment measurements/settings and attach them to the Repair Order or if print-out capability is not Page 12838 Page 10302 7. Remove the old Loctite® from the threads (2) of the rack (1) and the inner tie rod (3). Installation Procedure Page 1724 Flexible Fuel Sensor: Testing and Inspection Step 1 Steps 2 - 5 Page 13237 Action Taken When the DTCs Sets The module suspends all message transmission. The module uses default values for all parameters received on the serial data circuits. The module inhibits the setting of all other communication DTCs. Conditions for Clearing the DTC A current DTC clears when the malfunction is no longer present. A history DTC clears when the module ignition cycle counter reaches the reset threshold of 50, without a repeat of the malfunction. Circuit/System Verification Refer to Data Link References to determine which serial data system is used for a specific module. This DTC cannot be retrieved with a current status. Diagnosis is accomplished using the following symptom procedures: Scan Tool Does Not Communicate with High Speed GMLAN Device in SI. OR Scan Tool Does Not Communicate with Low Speed GMLAN Device in SI. DTC U0140 - U0184 Circuit Description Modules connected to the GMLAN serial data circuit monitor for serial data communications during normal vehicle operation. Operating information and commands are exchanged among the modules. In addition to this, Node Alive messages are transmitted by each module on the GMLAN serial data circuit. When the module detects one of the following conditions on the GMLAN serial data circuit, a DTC will set. Operating information and commands are exchanged among the modules. In addition to this, Node Alive messages are transmitted by each module on the GMLAN serial data circuit. Conditions for Setting the DTCs Diagnostic algorithms are designed so that a single point failure within a particular node shall result in a single DTC/FTB combination being set. Any recognized faults shall generate one DTC. Recognized faults may include but are not limited to the following: ^ Open or shorted condition on an I/O Circuit outside of normal operation of that circuit. ^ Erratic signal of a circuit, outside of normal operation, which can be readily and repeatedly recognized as erratic. ^ A condition, outside of normal operation, which causes a customer perception of a performance problem. ^ A condition whether hardware or data link error, which causes a device to operate in a default or fail soft mode. ^ A condition which changes or limits system performance. ^ Network supervision/signal supervision errors. ^ ECU Internal errors. ^ Criteria determined by legislation. An initialization or shutdown self-test shall be performed and may include but is not limited to the following: ^ RAM check ^ ROM/EEPROM/Flash check Page 15280 Driver/Vehicle Information Display: Description and Operation DRIVER INFORMATION CENTER (DIC) DESCRIPTION AND OPERATION DRIVER INFORMATION CENTER (DIC) The driver information center (DIC) consists of a single line 22 character vacuum fluorescent (VF) display placed in the lower center area of the instrument panel cluster (IPC). The DIC will display vehicle information, configuration, and warning parameters to the driver. The display parameters are cycled, changed, and acknowledged using 4 DIC buttons. Trip Information Button representation icon appears as a road to the horizon. - Fuel Information Button representation icon appears as a gasoline pump. - Personalization Button representation icon appears as a human next to vehicle. - Select Button representation icon appears as an arrow. DIC DISPLAYS The DIC parameters are displayed by order of priority as follows (from highest to lowest) : Service Diagnostics - Driver Identifier - Feature Programming - Driver Warnings - Vehicle Information VEHICLE INFORMATION Vehicle information provides feedback to the driver on vehicle performance, mileage, maintenance, or related information. Vehicle information can only be displayed with the ignition switch in the RUN position. When the English/Metric status changes, any applicable vehicle information data values will also change. DIC TRIP INFORMATION / RESET CAPABILITIES The available DIC Trip Information and reset capabilities are as follows: Odometer - Cannot be reset - Personal Trip Odometer - Can be reset - Business Trip Odometer - Can be reset - Timer - Can be reset - Hourmeter - Cannot be reset TRIP RESET STEM The trip reset stem on the IPC operates in the following manner with the ignition switch in the RUN position: 1. Each time the trip reset stem is pushed the display will cycle to the next trip parameter. The trip parameters are as follows: - Odometer - Personal Trip odometer - Business Trip odometer - Timer - Hourmeter 2. Holding the trip reset stem for greater than 1 second or depressing the SWC Select button while either Personal Trip or Business Trip odometer is displayed will reset the displayed trip odometer and all other corresponding trip parameters to 0.0 upon release of the stem. The trip odometer will remain displayed after being reset. 3. If a trip information parameter is being displayed, pressing the DIC Trip Information button will display the next trip information parameter. 4. If the next Trip Information parameter to be displayed is Timer, Hourmeter, or blank, pressing the reset stem will return the display to the Odometer. ODOMETER The odometer is capable of displaying values from 0 - 999,999 mi or km. If the ignition is in the OFF or UNLOCK/ACC position, the odometer can be displayed by pressing the trip reset stem. The odometer will remain displayed for 5 seconds. TRIP ODOMETERS The DIC can display Personal Trip or Business Trip odometers. The trip odometers are capable of displaying values from 0 - 999999.9 mi or km. Page 14350 Electrical Symbols Part 11 Interior - Erratic Memory Seat Operation Power Seat Control Module: All Technical Service Bulletins Interior - Erratic Memory Seat Operation Bulletin No.: 04-08-50-016C Date: August 12, 2005 TECHNICAL Subject: Memory Seat May Not Return to Requested Position (Reprogram Driver Seat Module) Models: 2003-2005 Cadillac Escalade, Escalade ESV, Escalade EXT 2003-2005 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2003-2005 GMC Sierra, Yukon, Yukon XL, Yukon Denali All with Seat FRT, Individual (Non BKT) (RPO AN3) 2003-2005 HUMMER H2 with Seat, Front Bucket Deluxe (RPO AR9) Supercede: This bulletin is being revised to update the correction information. Please discard Corporate Bulletin Number 04-08-50-016B (Section 08 - Body and Accessories). Condition Some customers may comment that with repeated cycling of the memory seat between the "exit" and one of the "presets", the position of the seat may "creep" forward or rearward out of expected adjustment. Cause There is a coding deficiency in the software for the memory seat module. Correction Technicians are to reprogram the driver seat module with an updated software calibration. The previous bulletin stated to use a service calibration that was released with TIS satellite data update version 4.5. Feedback has proved that calibration to be ineffective in eliminating the memory seat creep condition. An updated service calibration was released with TIS satellite data update version 6.5 available June 13, 2005. This new calibration has additional memory seat creep protection. As always, make sure your Tech 2(R) is updated with the latest software version. Important: After programming is complete, move the seat all the way rearward and down, then bump the seat slightly forward and up. This position will be just off the end of travel hard stops. Reset both memory seat exit positions at this position. Having the seat set at just off the hard stops will aid in reducing the creep condition. Warranty Information Page 10467 14. Remove the retaining ring from the wheel hub. 15. Remove the outer hub bearing and bearing cup using the J 24426 (2) and the J 8092 (1). Installation Procedure 1. Lubricate the following with a light coat of high melting point EP bearing lubricant: ^ The outer wheel bearing ^ The inner wheel bearing ^ The outer wheel bearing cup ^ The inner wheel bearing cup ^ The axle housing 2. Install the outer bearing into the wheel hub. 3. Install the outer bearing cup into the wheel hub. OnStar(R) - System Inoperative/No LED Lamp ON Fuse: Customer Interest OnStar(R) - System Inoperative/No LED Lamp ON Bulletin No.: 04-08-46-005 Date: December 21, 2004 TECHNICAL Subject: OnStar(R) Generation 6 (Digital) System Inoperative/Has No Power, LED Light Not On (Remove/Reinstall OnStar(R) Fuse and Replace VCIM or Follow SI Diagnostics) Models: 2004-2005 Buick Rainier, Rendezvous 2005 Buick Allure (Canada), LaCrosse, LeSabre, Terrazza 2004-2005 Cadillac Escalade, Escalade ESV, Escalade EXT 2005 Cadillac CTS, DeVille 2004-2005 Chevrolet Avalanche, Silverado, Suburban, Tahoe, TrailBlazer, TrailBlazer EXT 2005 Chevrolet Colorado, Express, Impala, Monte Carlo, Uplander 2004-2005 GMC Denali, Denali XL, Envoy, Envoy XL, Envoy XUV, Sierra, Yukon, Yukon XL 2005 GMC Canyon, Savana 2004-2005 Pontiac Aztek 2005 Pontiac Bonneville, Grand Prix, Montana SV6, Vibe with Digital Gen 6 OnStar(R) (RPO UE1) Condition Some customers may comment any or all of the following conditions: ^ The OnStar(R) system may be inoperative. ^ The OnStar(R) system may have no power. ^ The OnStar(R) LED light may not be on. The technician may also not be able to communicate with the OnStar(R) Vehicle Communication Interface Module VCIM) with a Tech 2(R). Correction Remove the OnStar(R) fuse from the fuse box, wait five minutes and reinstall the fuse. If the OnStar(R) system DOES NOT return to normal functionality, then follow the diagnostics in SI for this condition. If the OnStar(R) system DOES return to normal functionality, you will need to replace the VCIM. If the VCIM is not replaced, there is the possibility that the customer will return to the dealership with the same conditions at a later date. Please contact the GM Technical Assistance Center (TAC), to obtain a new VCIM. The TAC consultant will verify your diagnosis and, if appropriate, order a replacement part. Replacement parts are usually shipped out within 24 hours, and a pre-paid return package label will be included for returning the faulty part. By returning the faulty part, you will avoid a significant non-return core charge. After the VCIM has been replaced, press the blue OnStar(R) button and request a full reconfiguration. When contacting TAC regarding this concern, the availability of certain information from the vehicle will streamline the process for the dealership technician as well as minimize the time necessary for TAC to provide the correct diagnosis. Please refer to Corporate Bulletin Number 01-00-89-011B for further information concerning the information necessary before contacting TAC. Dealers in Canada should refer to GM Service Policies & Procedures Section 5.3.1 "DEALER REQUIREMENTS FOR ASSISTANCE". Warranty Information Page 8181 Bulletin Format ***REPAIR ORDER REQUIRED DOCUMENTATION Page 1940 Parts Information Warranty Information (excluding Saab U.S. Models) Warranty Information (Saab U.S. Models) Locations Instrument Panel Switches-LH Page 9016 Fuse Block - Underhood C2 Part 5 Page 14395 Driver Door Module (DDM) - C4 (With RPO Code YE9) Part 2 Page 8149 8. Inspect the brake caliper mounting bracket guide surfaces for corrosion and wear. Remove and replace the brake caliper mounting bracket if needed. 9. Clean all of the residue from the brake pad guiding surfaces on the brake caliper housing and the brake caliper mounting bracket. 10. Clean all of the parts not included in the repair kit with denatured alcohol. 11. Dry all the parts with non lubricated filtered compressed air. 12. Blow out all passages in the brake caliper housing and the brake caliper bleeder valve. Assembly Procedure 1. Notice: Refer to Fastener Notice in Service Precautions. Install the brake caliper bleed screw. ^ Tighten the brake caliper bleed screw to 12 Nm (106 inch lbs.). 2. Install the brake caliper bleed screw cap. 3. Lubricate the new piston seal and the brake caliper bore seal groove with brake fluid. 4. Install the new seal into the brake caliper bore seal groove. 5. Ensure that the seal is not twisted. 6. Lubricate the brake caliper bore and the piston with brake fluid. 7. Install the boot and piston. 1. Install the boot over the end of the piston so that the fold will face toward the brake caliper housing piston bore opening. 2. Seat the boot into the brake caliper bore groove. Slide the piston into the brake caliper bore. 3. Push down the piston to the bottom of the brake caliper bore. 4. Ensure that the boot is properly seats into the piston groove and into the groove in the brake caliper bore. 8. Install the brake caliper to the vehicle. Interior - Power Seat Switch Knobs Loose/Missing Power Seat Switch: Customer Interest Interior - Power Seat Switch Knobs Loose/Missing Bulletin No.: 05-08-50-017 Date: December 14, 2005 TECHNICAL Subject: Power Front Seat (RPO AN3) Switch Knobs Loose or Missing (Replace Switch Knobs) Models: 2002-2006 Cadillac Escalade, Escalade EXT 2003-2006 Cadillac Escalade ESV 2002-2006 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2002-2006 GMC Sierra, Yukon, Yukon XL with Individual Front Seat Non-Bucket (RPO AN3) and Driver Front Seat Power Adjuster (AG1) and/or Passenger Front Seat Power Adjuster (AG2) Condition Some customers may comment that the power front seat adjuster switch knobs are loose and fall off or are missing. Correction Replace the front seat adjuster switch knob. These knobs were formerly available only as part of the power seat adjuster switch. DO NOT replace the switch if the knob only needs to be replaced. Parts Information Warranty Information Page 9300 Junction Block - I/P Wire Entry Part 1 Page 4224 Ignition Cable: Testing and Inspection SPARK PLUG WIRE INSPECTION Spark plug wire integrity is vital for proper engine operation. A thorough inspection is necessary to accurately identify conditions that may affect engine operation. Inspect for the following conditions: 1. Correct routing of the spark plug wires-Incorrect routing may cause cross-firing. 2. Any signs of cracks or splits in the wires. 3. Inspect each boot for the following conditions: - Tearing - Piercing - Arcing - Carbon tracking - Corroded terminal If corrosion, carbon tracking or arcing are indicated on a spark plug wire boot or terminal, replace the wire and the component connected to the wire. Page 4743 Engine Control Module: Description and Operation Powertrain Control Module (PCM) POWERTRAIN CONTROL MODULE (PCM) DESCRIPTION POWERTRAIN The powertrain has electronic controls to reduce exhaust emissions while maintaining excellent driveability and fuel economy. The powertrain control module (PCM) is the control center of this system. The PCM monitors numerous engine and vehicle functions. The PCM constantly looks at the information from various sensors and other inputs, and controls the systems that affect vehicle performance and emissions. The PCM also performs the diagnostic tests on various parts of the system. The PCM can recognize operational problems and alert the driver via the malfunction indicator lamp (MIL). When the PCM detects a malfunction, the PCM stores a diagnostic trouble code (DTC). The problem area is identified by the particular DTC that is set. The control module supplies a buffered voltage to various sensors and switches. Review the components and wiring diagrams in order to determine which systems are controlled by the PCM. The following are some of the functions that the PCM controls: The engine fueling - The ignition control (IC) - The knock sensor (KS) system - The evaporative emissions (EVAP) system - The secondary air injection (AIR) system (if equipped) - The exhaust gas recirculation (EGR) system - The automatic transmission functions - The generator - The A/C clutch control - The cooling fan control POWERTRAIN CONTROL MODULE FUNCTION The PCM constantly looks at the information from various sensors and other inputs and controls systems that affect vehicle performance and emissions. The PCM also performs diagnostic tests on various parts of the system. The PCM can recognize operational problems and alert the driver via the malfunction indicator lamp (MIL). When the PCM detects a malfunction, the PCM stores a diagnostic trouble code (DTC). The problem area is identified by the particular DTC that is set. The control module supplies a buffered voltage to various sensors and switches. The input and output devices in the PCM include analog-to-digital converters, signal buffers, counters, and output drivers. The output drivers are electronic switches that complete a ground or voltage circuit when turned on. Most PCM controlled components are operated via output drivers. The PCM monitors these driver circuits for proper operation and, in most cases, can set a DTC corresponding to the controlled device if a problem is detected. MALFUNCTION INDICATOR LAMP (MIL) OPERATION Page 2013 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves SPLICING COPPER WIRE USING SPLICE SLEEVES TOOLS REQUIRED J 38125-D Terminal Repair Kit IMPORTANT: Use only GM splice sleeves, other splice sleeves may not protect the splice from moisture or a provide good electrical connection. Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. Page 16310 7. Remove the drive link from the wiper motor crank arm with the J 39232. 8. Remove the 2 bolts retaining the wiper motor. 9. Remove the wiper motor from the wiper transmission assembly. INSTALLATION PROCEDURE NOTE: Refer to Fastener Notice in Service Precautions. 1. Install the wiper motor onto the wiper transmission assembly with the 2 bolts. Tighten Tighten the 2 bolts to 8 N.m (71 lb in). Page 1884 Transmission Position Switch/Sensor: Service and Repair Automatic Transmission 4L80-E/4L85-E Park/Neutral Position Switch Replacement Park/Neutral Position Switch Replacement ^ Tools Required J 41364-A Park Neutral Switch Aligner Removal Procedure 1. Apply the park brake. 2. Shift the transmission into neutral. 3. If equipped with 4-wheel drive (4WD), remove the front propeller shaft. 4. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 5. Disconnect the park/neutral position (PNP) switch electrical connector (2). 6. Remove the range selector cable end (2) from the range selector lever ball stud (1). Page 5503 1. Install the accelerator pedal assembly. NOTE: Refer to the Fastener Notice in Service Precautions. 2. Install the accelerator pedal nuts. Tighten Tighten the nuts to 20 N.m (15 lb ft). 3. Connect the APP sensor electrical connector. 4. Reposition the carpet. 5. Connect a scan tool in order to test for proper throttle-opening and throttle-closing range. 6. Operate the accelerator pedal and monitor the throttle angles. The accelerator pedal should operate freely, without binding, between a closed throttle, and a wide open throttle (WOT). 7. Verify that the vehicle meets the following conditions: - The vehicle is not in a reduced engine power mode. - The ignition is ON. - The engine is OFF. 8. Inspect the carpet fit under the accelerator pedal. Page 5141 Step 3 Page 15252 Compass: Service and Repair COMPASS CALIBRATION AND VARIANCE PROCEDURE COMPASS CALIBRATION Before calibrating the compass, drive the vehicle to an open area that is magnetically clean or free of large metallic objects such as high tension power lines or large steel buildings. Verify there are no magnetized roof antennas, magnets on or hanging from the mirror, or any other magnetized objects on the inside or outside of the vehicle close to the mirror. 1. Start the engine. IMPORTANT: Before calibrating the compass, make sure the mirror has the correct zone number. Refer to Compass Magnetic Variation Adjustment. 2. Press and hold the switch for the compass, which may be depicted as COMP, COMPASS, or on/off (w/UE1) depending on the type of mirror on the vehicle, until the letter "C" or "CAL" is displayed. 3. Drive the vehicle in circles at a speed of less than 8 km/h (5 mph) until the "C" or "CAL" is replaced by a proper vehicle heading. The calibration procedure is now complete. COMPASS MAGNETIC VARIATION ADJUSTMENT Magnetic variation adjustments are required when the compass displays a constant error in heading. Variation is the difference between magnetic north and true north due to geographical location. 1. Locate your current geographic location on the World Magnetic Variation Map. 2. Turn ON the ignition, with the engine OFF. 3. Press and hold the switch for the compass, which may be depicted as COMP, COMPASS, or on/off (w/UE1) depending on the type of mirror on the vehicle, until a zone number appears on the compass display. 4. Depress the switch for the compass to select the desired zone number. 5. Wait 5 seconds. The display will return to a compass heading. The variance procedure is now complete. 6. Calibrate the compass. Refer to Compass Calibration mentioned above. Locations Knock Sensors Electrical - Trailer Brakes Apply With Headlamps ON Trailer Adapter Kit: Customer Interest Electrical - Trailer Brakes Apply With Headlamps ON Bulletin No.: 02-05-22-004C Date: April 05, 2005 TECHNICAL Subject: Trailer Brakes Applied When Headlights/Park Lamps Are On, Brake Controller Illumination (Modify Brake Controller Wiring Harness) Models: 2002-2005 Cadillac Escalade, Escalade EXT 1999-2005 Chevrolet Silverado 2000-2005 Chevrolet Suburban, Tahoe 2002-2005 Chevrolet Avalanche 1999-2005 GMC Sierra 2000-2005 GMC Yukon, Yukon XL 2003-2005 HUMMER H2 Supercede: This bulletin is being revised to add additional model years. Please discard Corporate Bulletin Number 02-05-22-004B (Section 05 - Brakes). Condition Some customers may comment that when the headlamps or park lamps are on, the brakes on the trailer are always applied, or that the back lighting for the trailer brake controller only illuminates when the brakes are applied. Cause The cause of this condition may be due to wiring changes within the vehicle electrical system for the 2003 model year. Correction Inspect the brake controller wiring harness jumper that is plugged into the vehicle relay block-body. The relay block-body is located under the left side of the instrument panel near the left kick panel, behind a plastic cover. Page 692 Disclaimer Page 4650 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground TESTING FOR SHORT TO GROUND NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting With A Digital Multimeter TROUBLESHOOTING WITH A DIGITAL MULTIMETER NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TROUBLESHOOTING WITH A TEST LAMP Page 5829 12. Install the cover. Notice: Refer to Fastener Notice in Service Precautions. 13. Install 2 NEW screws (1) to the casting. ^ Tighten the screws to 2 Nm (18 inch lbs.). 14. Install 2 NEW longer screws (2) to the motor cover. ^ Tighten the screws to 3 Nm (26 inch lbs.). 15. Install the encoder motor. Page 12770 * Dealers using WINs: Add 0.2 hours to the labor time for administrative allowance for the module exchange. Dealers using GWM: Submit 0.2 hours administrative allowance under "Administration Time" for the module exchange. ** The $25 represents the additional net amount allowed for the module exchange. *** Dealers are to claim only administrative allowance of 0.2 hours when the module is replaced by Masscomp's Mobile Unit. Dealers using WINS should submit the 0.2 hours administrative allowance in labor time. Dealer using GWM should submit the 0.2 hours administrative allowance under Administrative Time. Customer Notification OnStar will notify customers of this program on their vehicle. Dealer Program Responsibility All unsold new vehicles in dealers'/retailers' possession and subject to this program must be held and inspected/repaired per the service procedure of this program bulletin before customers take possession of these vehicles. Dealers/retailers are to service all vehicles subject to this program at no charge to customers, regardless of mileage, age of vehicle, or ownership, through April 30, 2011. Customers who have recently purchased vehicles sold from your vehicle inventory, and for which there is no customer information indicated on the dealer/retailer listing, are to be contacted by the dealer/retailer. Arrangements are to be made to make the required correction according to the instructions contained in this bulletin. A copy of the customer letter is provided in this bulletin for your use in contacting customers. Program follow-up cards should not be used for this purpose, since the customer may not as yet have received the notification letter. Page 10217 Electrical Symbols ELECTRICAL SYMBOLS Electrical Symbols Part 1 Page 4524 Control Module References Part 5 Page 9208 C214 I/P Harness To Headliner Harness (With RPO Code U42) Part 1 Page 1512 Steering Wheel and Column Sub-System Components Diagrams Inside Air Temperature Sensor Assembly Page 9892 Note The rivet stud and surrounding panel area MUST BE properly refinished PRIOR to the installation of the electrical ground wire terminal and conductive nut to maintain a secure, stable and corrosion-free electrical ground. 11. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 12. Allow the refinished repair area to cure sufficiently before removing the protective material applied to the rivet stud threads. 13. Remove the painters tape or equivalent from the rivet stud threads. 14. Using GM approved residue-free solvent or equivalent, thoroughly clean the rivet stud threads to remove any adhesive and allow to dry. 15. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive rivet stud. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 16. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 17. Install the electrical ground wire terminal to the M6 conductive rivet stud. 18. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 19. Install the M6 conductive nut to the rivet stud and: Tighten Tighten to 8 Nm (71 lb in) 20. Verify proper system operation. Parts Information Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use: Warranty Information (Saab Models) Page 6781 14. Separate the right carrier case half from the left carrier case half. 15. Remove the differential case assembly from the carrier. 16. Place the differential case in a vise. 17. Remove the differential side bearings using the J 22888-20A. 18. Remove the differential case from the vise. Important: The ring gear bolts have left-hand threads. 19. Remove the ring gear bolts. 20. Remove the ring gear from the differential case. Drive the ring gear off with a brass drift if necessary. 21. Remove the pinion shaft pin. Use a hammer and a drift pin in order to drive out the pin. 22. Remove the pinion shaft. 23. Roll the differential pinion gears out of the case with the pinion gear thrust washers. 24. Remove the differential side gears and the side gear thrust washers. Mark the pinion gears and thrust washers top and bottom and the differential side gears and thrust washers left and right. 25. Lubricate the pinion and side gears using axle lubricant. Use the proper fluid. Refer to the Maintenance and Lubrication subsection. 26. Install the differential side gear thrust washers to the differential side gears. 27. Install the differential side gears and thrust washers into the new differential case. 28. Install the differential pinion gears and thrust washers by performing the following steps: 28.1. Position one pinion gear between the differential side gears. 28.2. Position the second pinion gear between the differential side gear directly opposite of the first gear. 28.3. Rotate the differential side gears until the pinion gears are directly opposite the opening in the differential case. 28.4. Install the thrust washers. Rotate the pinion gears toward the differential case opening in order to permit the sliding in of the thrust washers. 29. Install the pinion gear shaft. 30. Install the pinion gear shaft lock pin using a hammer and a brass drift. Important: The mating surface of the ring gear and the differential case must be clean and free of burrs before installing the ring gear. Page 4056 Important The following information MUST be documented on the repair order. Failure to do so may result in a chargeback. - Customer vehicle condition. - Was a Service Lamp or Service Message illuminated? If yes, specify which Service Lamp or Service Message. - Was a DTC(s) set? If yes, specify which DTC(s) were set. - After following the procedure contained within this bulletin, could the condition be duplicated? ‹› If the condition was not duplicated, then document the affected module/component connector name and number on the repair order. - If the condition was duplicated after the procedure contained within this bulletin was followed, and additional diagnosis led to the replacement of a module or component, the SI Document ID Number MUST be written on the repair order. Parts Information Alternate Distributor For All of North America Note NyoGel(R) 760G Lubricant* is equivalent to GMSPO P/N 12377900, and P/N 10953529 (Canada), specified for use to correct the condition in this bulletin. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to: Warranty Information (Saab Models) Page 8929 Hybrid Control Module (HCM) - Part 2 Page 6803 7. If the level is low, add lubricant until the level is even with the bottom edge of the fill plug opening. Use the proper fluid. 8. Notice: Refer to Fastener Notice in Service Precautions. Install the rear axle fill plug. ^ Tighten the rear axle fill plug to 33 Nm (24 ft. lbs.). 9. Lower the vehicle. 9.75 Inch Axle Lubricant Level Inspection - Rear Drive Axle (9.75 Inch Axle) 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Ensure the vehicle is level. 3. Inspect the rear axle for leaks. Repair as necessary. 4. Clean the area around the rear axle fill plug. 5. Remove the rear axle fill plug. 6. Inspect the lubricant level. The lubricant level should be between 0-4 mm (0-0.16 inch) below the fill plug opening. 7. If the level is low, add lubricant until the level is even with the bottom edge of the fill plug opening. Use the proper fluid. 8. Notice: Refer to Fastener Notice in Service Precautions. Install the rear axle fill plug. ^ Tighten the rear axle fill plug to 21 Nm (15 ft. lbs.). 9. Lower the vehicle. 11.5 Inch Axle Lubricant Level Inspection - Rear Drive Axle (11.5 Inch Axle) 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Make sure the vehicle is level. 3. Inspect the rear axle for leaks. Repair as necessary. 4. Clean the area around the rear axle fill plug. 5. Remove the rear axle fill plug and the seal. 6. Inspect the lubricant level. The lubricant level should be between 17-21 mm (0.6-0.8 inch) below the fill plug opening. Fuse Block - Underhood - Secondary Fuse: Application and ID Fuse Block - Underhood - Secondary Location View Page 6905 1. Place the new small seal clamp (2) onto the small end of the joint seal (1). Compress the joint seal (1) and small seal clamp (2) onto the halfshaft bar. 2. Position the small end of the joint seal (1) into the joint seal groove (3) on the halfshaft bar. 3. Secure the small seal clamp (1) with J 35910 , or equivalent, a breaker bar, and a torque wrench. ^ Tighten the small seal clamp (1) to 136 Nm (100 ft. lbs.). Notice: Refer to Fastener Notice in Service Precautions. 4. Inspect the gap dimension on the clamp ear. Continue tightening until the gap dimension is reached. Page 2151 Steps 1 - 12 The number(s) below refer to the step(s) in the diagnostic table. 2. This inspection is to verify the condition of the drive belt(s). Damage may have occurred to the drive belt(s) when the drive belt(s) fell off the pulley. Inspect the drive belt(s) for cuts, tears, sections of ribs missing, or damaged belt plys. 4. Misalignment of the accessory drive pulley(s) may be caused from improper mounting or incorrect installation of a accessory drive component, or the pulley may be bent inward or outward from a previous repair. Test for a misaligned pulley using a straight edge in the pulley grooves across two or three pulleys. If a misaligned pulley is found, refer to that accessory drive component for the proper removal and installation procedure of that pulley. 5. Inspection of the accessory drive pulley(s) should include inspecting for bends, dents, or other damage that would prevent the drive belt from seating properly in the pulley grooves or on the smooth surface of a pulley when the back side of the drive belt(s) is used to drive the pulley. 6. Accessory drive component brackets that are bent or cracked will also cause the drive belt(s) to fall off. 7. Inspection of the fasteners can eliminate the possibility that a incorrect bolt, nut, spacer, or washer was installed. Missing, loose, or incorrect fasteners may cause pulley misalignment from the accessory drive bracket(s) moving under load. Over tightening the fasteners may cause misalignment of the accessory component bracket(s). Drive Belt Rumbling Drive Belt Rumbling Diagnosis Page 2017 Control Module References Part 2 A/T - 4L60-E/4L65-E New Pump/Seal/Case/Service Case: All Technical Service Bulletins A/T - 4L60-E/4L65-E New Pump/Seal/Case/Service Bulletin No.: 04-07-30-023 Date: May 12, 2004 INFORMATION Subject: Oil Pump Assembly Seal and Transmission Case Change Models: 2002-2004 Cars and Light Duty Trucks with 4L60-E or 4L65-E Automatic Transmissions (RPOs M30, M32 or M33) An improved oil pump to case seal design has been made to the 4L60-E/4L65-E transmission. The new design affects the oil pump, the oil pump seal, the transmission pan bolts and the transmission case. The complete design was implemented in three phases. The first phase, beginning in September 2002, relocated the machining of the oil pump 0-ring seal groove in the pump body. The 0-ring seal groove moved 1.6 mm (0.62 in) inward on the pump body in order to place the sealing surface deeper into the case bore. The relocated pump body groove can be identified by measuring the groove location. Pump bodies that measure 2.3 mm (0.09 in) from the machined surface to the groove opening have the relocated 0-ring seal groove. Pump bodies that measure 3.9 mm (0.15 in) are prior to September 2002 design. Lighting - Headlamp Polycarbonate Lens Damage Prevention Headlamp Lens: Technical Service Bulletins Lighting - Headlamp Polycarbonate Lens Damage Prevention INFORMATION Bulletin No.: 02-08-42-001D Date: June 21, 2010 Subject: Headlamp Lens Overheating When Covered and Chemical Damage to Exterior Polycarbonate Headlamp Lenses Models: 2011 and Prior GM Passenger Cars and Trucks (Including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X Supercede: This bulletin is being revised to add model years and to revise the warning statements. Please discard Corporate Bulletin Number 02-08-42-001C (Section 08 - Body and Accessories). The bulletin is being issued to make dealers and customers aware of chemical damage that may be caused to exterior polycarbonate headlamp lenses. Most late model vehicles have these types of headlamp lenses. This material is used because of its temperature and high impact resistance. A variety of chemicals can cause crazing or cracking of the headlamp lens. Headlamp lenses are very sensitive. Care should be exercised to avoid contact with all exterior headlamp lenses when treating a vehicle with any type of chemical, such as those recommended for rail dust removal. Rubbing compound, grease tar and oil removers, tire cleaners, cleaner waxes and even car wash soaps in too high a concentration may also attribute to this condition. This could result in the need to replace the entire headlamp housing. Warning Use only lukewarm or cold water, a soft cloth and a car washing soap to clean exterior lamps and lenses. Also, crazing or deformations of the lens may occur if a shop mat or fender cover is draped over the fender and covers a portion or all of the headlamp assembly while the DRL or headlamps are on. This action restricts the amount of heat dissipated by the headlamps. Warning Care should be taken to not cover headlamps with shop mats or fender covers if the vehicle is being serviced with the headlamps or DRL illuminated. Covering an illuminated lamp can cause excessive heat build up and crazing/deformation of the lens may occur. The degradation of the lens can be unnoticeable at first and eventually become hairline cracks in the lens. In extreme cases, it could cause the lens to deform. This damage can also be caused by aftermarket shields that are often tinted in color. Once a heat buildup is generated by the headlamp, a degradation of the headlamp lens begins. This degradation of the lens can be unnoticeable at first and eventually manifest as spider cracks. In more extreme cases, it will begin to melt the lens of the headlamp. Notice Headlamps damaged by chemicals, improper cleaning, or overheating due to being covered are not covered under the new vehicle warranty. Disclaimer Page 7953 Four Wheel Drive Selector Switch: Diagrams Drivetrain - Gen II Vs. Gen III Wheel Hub Changes Wheel Hub (Locking): Technical Service Bulletins Drivetrain - Gen II Vs. Gen III Wheel Hub Changes INFORMATION Bulletin No.: 08-03-08-003A Date: March 02, 2009 Subject: Wheel Hub Changes - Gen III vs. Gen II Models: 2008 and Prior Cadillac Escalade Models 2008 and Prior Chevrolet Avalanche, Silverado, Silverado Classic, Suburban, Tahoe 2008 and Prior GMC Sierra, Sierra Classic, Yukon Models Supercede: This bulletin is being revised to update the parts information in the table and to add an Illustrated Hub Gallery depicting all wheel hub part numbers called out below for visual identification purposes. Please discard Corporate Bulletin Number 08-03-08-003 (Section 03 - Suspension). General Motors Vehicle Engineering has introduced a new design Gen III front wheel hub for the above listed vehicles that replaces the Gen II product. These Gen II 4x2 and 4x4 applications that were previously serviced by seven part numbers are now serviced by three Gen III part numbers. Concerns have been expressed by technicians regarding the use of the new supersessions and whether the Gen III hubs will properly fit the vehicles being serviced, especially because of visual and functional differences (splines). This bulletin has been developed to address those concerns. Please refer to the table above for information on the Gen III replacement part for each Gen II application. At the end of the bulletin you will find an illustrated "Hub Gallery" with graphic depictions of both Gen II and replacement style Gen III parts. Using these illustrations you should be able to identify both the Gen II and Gen III wheel hubs. Warning If replacing wheel studs, please refer to the GM Parts Catalog for the correct stud part number for each application. Different types of studs are used depending on the wheel hub application. When replacing an older Gen II design 4x2 hub with a new 4x2/4x4 common Gen III hub, it is acceptable to have a bearing with splines on it for a 4x2 application that previously did not. However, the older Gen II design 4x4 hubs should NOT be used on a 4x2 vehicle. The Gen II 4x4 hub relies on the tension of the wheel drive shaft joint to hold everything together. The roll form feature on the inboard side of the new 4x2/4x4 Gen III hub eliminates this concern. The only hub that is not back serviceable is P/N 15719007 (not pictured) for 1999-2000 C25 applications due to a different hub flange to bearing flange offset. Important: Only the new part numbers referenced in this bulletin are interchangeable between the 4x2 and 4x4 applications with the exception of P/N 15719007 (Not Shown). Under no circumstances should any other 4x4 hub be used in a 4x2 application. Illustrated Hub Gallery Page 8869 Electrical Symbols Part 8 Page 5557 6. The Melco(R) (1) ignition coil is a square design. 7. The Delphi(R) (2) ignition coil is a round design. 8. The Melco(R) ignition coil bracket (1) is a square design. 9. The Delphi(R) ignition coil bracket (2) is a round design. INSTALLATION PROCEDURE 1. Install the spark plug wire to the ignition coil. 2. Install the spark plug wire to the spark plug. 3. Inspect the spark plug wire for proper installation: 3.1. Push sideways on each boot in order to inspect the seating. Page 9626 Fuse Block - Underhood - Secondary Wire Entry (With RPO Code HP2) Part 3 Stationary Window Reveal Molding Repair Windshield Moulding / Trim: Service and Repair Stationary Window Reveal Molding Repair Stationary Window Reveal Molding Repair Removal Procedure Caution: Refer to Glass and Sheet Metal Handling Caution in Service Precautions. Important: The window reveal molding fills the cavity between the body and window. If the reveal molding is stretched or damaged, it cannot be reused and it must be replaced. 1. Lift up on the loose area of the reveal molding. 2. Clean the top edge of the window surface and the reveal molding with a 50/50 mixture of isopropyl alcohol and water by volume on a dampened lint-free cloth. Installation Procedure Caution: Refer to Window Retention Caution in Service Precautions. 1. Verify all primers and urethane adhesive are within expiration dates. Important: Use care when applying the prep, clear #1, to the window. This primer dries almost instantly, and may stain the viewing area of the window if not applied evenly. 2. Use a new dauber in order to apply glass prep, clear #1, to the channel area approximately 13 mm (1/2 in) to the upper edge of the window. 3. Wipe the glass primed area immediately with a clean lint-free cloth. 4. Shake the glass primer, black #2, for at least 1 minute. 5. Use a new dauber in order to apply glass primer, black #2, to the top edge of the window. 6. Apply a small bead of urethane adhesive (2) between the window (1) and the pinch-weld. Page 12681 The module uses a default value for the missing parameter. Conditions for Clearing the DTC A current DTC clears when the malfunction is no longer present. A history DTC clears when the module ignition cycle counter reaches the reset threshold, without a repeat of the malfunction. Diagnostic Aids When multiple Loss of Communication DTCs are set concurrently, the cause is likely to be 2 opens in the ring portion of the class 2 serial data circuit. Use the Control Modules and Devices ‐ Description and Identification Number table in order to determine which modules are not communicating. Use the class 2 serial data circuit schematic in order to determine the location of the opens. Test Description Page 4311 Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. 1. Disconnect the connector from the component. 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. Page 9938 Toe is a measurement of how much the front and/or rear wheels are turned in or out from a straight-ahead position. When the wheels are turned in, toe is positive (+). When the wheels are turned out, toe is negative (-). The actual amount of toe is normally only a fraction of a degree. The purpose of toe is to ensure that the wheels roll parallel. Toe also offsets the small deflections of the wheel support system that occur when the vehicle is rolling forward. In other words, with the vehicle standing still and the wheels set with toe-in, the wheels tend to roll parallel on the road when the vehicle is moving. Improper toe adjustment will cause premature tire wear and cause steering instability. Setback Description Setback applies to both the front and the rear wheels. Setback is the amount that one wheel may be aligned behind the other wheel. Setback may be the result of a road hazard or a collision. The first clue is a caster difference from side-to-side of more than 1 degree. Thrust Angles Description The front wheels aim or steer the vehicle. The rear wheels control tracking. This tracking action relates to the thrust angle (3). The thrust angle is the path that the rear wheels take. Ideally, the thrust angle is geometrically aligned with the body centerline (2). In the illustration, toe-in is shown on the left rear wheel, moving the thrust line (1) off center. The resulting deviation from the centerline is the thrust angle. Lead/Pull Description Definition: At a constant highway speed on a typical straight road, lead/pull is the amount of effort required at the steering wheel to maintain the vehicle's straight path. Lead/pull is usually caused by the following factors: ^ Tire construction ^ Wheel alignment ^ Unbalanced steering gear The way in which a tire is built may produce lead/pull. The rear tires will not cause lead. Fuel System - SES Lamp ON/Gauge Reads Empty/DTC's Set Fuel Gauge: All Technical Service Bulletins Fuel System - SES Lamp ON/Gauge Reads Empty/DTC's Set Bulletin No.: 05-06-04-008A Date: April 14, 2005 TECHNICAL Subject: Diagnostic Trouble Code (DTC) P1172 or P2636, Fuel Gauge Reads Empty, Service Engine Soon (SES) Light On (Relocate Auxiliary Fuel Tank Vent Hose) Models: 2001-2005 Chevrolet Silverado (Cab Chassis Models Only) 2001-2005 GMC Sierra (Cab Chassis Models Only) with Auxiliary Fuel Tank Supercede: This bulletin is being revised to clarify the difference between the auxiliary fuel tank balance hose and vent hose. Please discard Corporate Bulletin Number 05-06-04-008 (Section 06 Engine/Propulsion System). Condition Some customers may comment that the SES light comes on and the fuel gauge reads empty. when This may occur when the vehicle is parked on an incline with the engine running. Diagnosis with a scan tool may reveal a DTC P1172 and/or P2636. Cause Important: A similar condition may occur if the vehicle is fueled with the engine running AND the rear tank is fueled first. The engine must be shut off (as required by law) during vehicle refueling. The auxiliary fuel tank vent hose is located in the same "T" connection on the main tank vent hose as the auxiliary tank balance hose. During fuel transfer, the fuel is pumped out of the auxiliary tank to the main tank via the balance hose. The fuel is then sucked back into the auxiliary tank via the vent hose rather then dumping the fuel into the main tank. When the Powertrain Control Module (PCM) does not detect a fluid level transfer between the main tank and the auxiliary tank, the PCM shuts off the auxiliary tank pump and the fuel gauge goes to empty. Correction Follow the service procedure below to correct this condition. 1. Depending on the body upfitter, it may be necessary to raise the vehicle in order to gain access to the auxiliary tank balance hose. 2. Depending on the body upfitter, it may be necessary to remove the left rear tire/wheel assemblies in order to gain access to the auxiliary tank balance hose. Page 7230 TOOLS REQUIRED J 34142-B 12 V Unpowered Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. When testing for voltage: 1. Attach 1 lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach 1 lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Using Connector Test Adapters USING CONNECTOR TEST ADAPTERS NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-B Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires USING FUSED JUMPER WIRES TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Connector Position Assurance Locks CONNECTOR POSITION ASSURANCE LOCKS The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Terminal Position Assurance Locks TERMINAL POSITION ASSURANCE LOCKS The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Push to Seat Connectors PUSH TO SEAT CONNECTORS TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Front Drive Axle Fluid - Differential: Service and Repair Front Drive Axle Lubricant Level Inspection Lubricant Level Inspection - Front Drive Axle 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Make sure the vehicle is level. 3. Inspect the front axle for leaks. Repair as necessary. 4. Clean the area around the front axle fill plug. 5. Remove the front axle fill plug (1). 6. Inspect the oil level. ^ For the 8.25 inch axle, the oil level should be between 12-16 mm (0.50-0.625 inch) below the fill plug opening. ^ For the 9.25 inch axle, the oil level should be between 0-6 mm (0-0.25 inch) below the fill plug opening. 7. If the level is low, add oil until the level is between 12-16 mm (0.50-0.625 inch) for the 8.25 inch axle or 0-6 mm (0-0.25 inch) for the 9.25 inch axle. Use the correct fluid. 8. Install the fill plug. ^ Tighten the plug to 33 Nm (24 ft. lbs.). Notice: Refer to Fastener Notice in Service Precautions. 9. Lower the vehicle. Lubricant Replacement Lubricant Replacement - Front Drive Axle Removal Procedure 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Remove the front differential carrier shield, if equipped. 3. Clean the area around the front axle fill plug and the drain plug. 4. Remove the fill plug. 5. Remove the drain plug. 6. Drain the fluid from the front differential carrier assembly. Page 4599 Heated Oxygen Sensor (HO2S) Bank 2 Sensor 2 Page 10898 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground TESTING FOR SHORT TO GROUND NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting With A Digital Multimeter TROUBLESHOOTING WITH A DIGITAL MULTIMETER NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TROUBLESHOOTING WITH A TEST LAMP Page 3244 the description. Remove only one drive belt at a time if the vehicle has multiple drive belts. Operate the engine for a few seconds, this will verify if the rumbling noise is related to the drive belt(s) or not. With the drive belt(s) removed the water pump will not operate and the engine may overheat. Also diagnostic trouble codes (DTCs) may set when the engine is operated with the drive belt(s) removed. 4. Inspect the drive belt(s) to ensure that the drive belt(s) is not the cause of the noise. Small cracks across the ribs of the drive belt(s) will not cause the noise. Belt separation is identified by the plys of the belt separating, this may be seen at the edge of the belt or felt as a lump in the belt. 5. Small amounts of pilling is a normal condition and acceptable. When the pilling is severe the drive belt(s) does not have a smooth surface for proper operation. Page 5401 10. Install the fuel tank filler housing to body TORX(R) screws (1) and retainer (2). Tighten Tighten the screws to 2.3 N.m (20 lb in). Service and Repair Center Support: Service and Repair Propeller Shaft Center Support Bearing Replacement Removal Procedure 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Remove the propeller shaft. 3. Remove the center bearing by doing the following: 1. Stand the propeller shaft (2) on end in the press (1) with the center bearing (3) supported by the press bars (4). 2. Press the propeller shaft (2) down and off the center bearing (3). Installation Procedure 1. Install the center bearing (3) onto the propeller shaft (2) by pressing the center bearing onto the shaft using a press (1). 2. Install the propeller shaft. 3. Lower the vehicle. Powertrain Control Module (PCM) C1 Engine Control Module: Diagrams Powertrain Control Module (PCM) C1 A/T - Poor Performance/MIL ON/DTC P0757 Valve Body: All Technical Service Bulletins A/T - Poor Performance/MIL ON/DTC P0757 Bulletin No.: 01-07-30-038D Date: September 12, 2006 TECHNICAL Subject: Diagnostic Trouble Code (DTC) P0757 Set, Malfunction Indicator Lamp (MIL) Illuminated, Poor Performance of Transmission, Transmission Slipping (Clean Transmission Valve Body and Case Oil Passages of Debris) Models: 2007 and Prior GM Passenger Cars and Light Duty Trucks 2003-2007 HUMMER H2 2006-2007 HUMMER H3 2005-2007 Saab 9-7X with 4L60-E/4L65-E/4L70-E Automatic Transmission (RPOs M30/M32/M70) Supercede: This bulletin is being revised to add the 2007 model year and the 4L70-E transmission. Also, information has been added to Condition, Cause and Correction. Please discard Corporate Bulletin Number 01-07-30-038C (Section 07 - Transmission/Transaxle). Condition Some customers may comment on any of the following conditions: An illuminated MIL where DTC P0757 is found as a history code in the PCM or TCM. No 3rd and 4th gear. The transmission does not shift correctly. The transmission feels like it shifts to Neutral or a loss of drive occurs. The vehicle free wheels above 48 km/h (30 mph). High RPM needed to overcome the free wheeling. Cause This condition may be caused by any of the following: Page 14279 WA111B/95 - WA303D/25 Locations Coolant Temperature Sensor/Switch (For Computer): Locations Full Engine View Left Side Locations Oil Pressure Sender: Locations Engine Oil Pressure (EOP) Sensor And CMP Sensor Page 2357 Radiator Hose: Service and Repair Outlet Radiator Hose Replacement - Outlet (4.8, 5.3, and 6.0L Engines) Removal Procedure 1. Drain the cooling system. 2. Loosen the air cleaner outlet duct clamps at the following locations: ^ Throttle body ^ Mass Airflow/Intake Air Temperature (MAF/IAT) sensor 3. Remove the radiator inlet hose clip from the outlet duct. 4. Remove the air cleaner outlet duct. 5. Reposition the outlet hose clamp at the water pump. 6. Remove the outlet hose from the water pump. 7. Reposition the outlet hose clamp at the radiator. 8. Remove the outlet hose from the radiator. Installation Procedure Page 6103 Disclaimer Page 8888 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Weather Pack Connectors WEATHER PACK CONNECTORS The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. Page 12705 Page 6339 For vehicles repaired under warranty, use the table. Disclaimer Page 9586 Junction Block - Rear Lamps - C1 Part 2 Page 3788 High Temperature Conditions Tools Required J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency MEASURING FREQUENCY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage MEASURING VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop MEASURING VOLTAGE DROP NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Page 652 Cruise Control Module (CCM) Part 2 Page 9030 Fuse Block- I/P C1 Part 4 Page 5585 Step 24 Diagrams Fuel Tank Unit: Diagrams Fuel Pump And Sender Assembly Service and Repair Front Door Exterior Handle: Service and Repair Door Handle Replacement - Outside Removal Procedure 1. Remove the trim panel. 2. Remove the water deflector.\ 3. Remove the outside handle rod from the rod clip. 4. Remove the lock cylinder rod from the rod clip. 5. Apply masking tape across the door handle on the outside of the door to secure handle while removing the nuts. 6. Remove the outside handle mounting nuts. 7. Remove the rubber cover in order to gain access to the outboard nut. 8. Remove the door lock cylinder from the outside handle housing. In order to repair a binding lock cylinder, refer to Binding Lock Cylinders. 9. Remove the handle. Installation Procedure Page 9398 Lower Center Of The I/P Components Locations Cabin Air Filter: Locations This vehicle does not have a factory installed Cabin Air Filter. Page 12840 Page 9596 Relay Block - I/P C1 Part 7 Page 15609 INSTALLATION PROCEDURE 1. Install the bulb. 2. Connect the electrical connector. 3. Install the dome lamp assembly into the headliner. 4. Press the lens into place. Page 8101 24. Fill the brake master cylinder reservoir to the maximum-fill level with Delco Supreme 11®, GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. 25. Slowly depress and release the brake pedal. Observe the feel of the brake pedal. 26. If the brake pedal feels spongy perform the following steps: 1. Inspect the brake system for external leaks. 2. Using a scan tool, perform the antilock brake system automated bleeding procedure to remove any air that may have been trapped in the BPMV. Refer to ABS Automated Bleed Procedure in Antilock Brake System. 27. Turn the ignition key ON, with the engine OFF. Check to see if the brake system warning lamp remains illuminated. 28. Important: If the brake system warning lamp remains illuminated, DO NOT allow the vehicle to be driven until it is diagnosed and repaired. If the brake system warning lamp remains illuminated, refer to Symptoms - Hydraulic Brakes. Page 6964 results from the alteration or modification of a vehicle using non-GM approved parts or accessories. Dealers should be especially cautious of accessory companies that claim the installation of their product will not void the factory warranty. Many times these companies have even given direction on how to quickly disassemble the accessory in an attempt to preclude the manufacturer from finding out that is has been installed. Any suspect repairs should be reviewed by the Fixed Operations Manager (FOM), and in Canada by the Warranty Manager (WM) for appropriate repair direction. If it is decided that a goodwill repair is to be made on the vehicle, even with the installation of such non-GM approved components, the customer is to be made aware of General Motors position on this issue and is to sign the appropriate goodwill documentation required by General Motors. It is imperative for dealers to understand that by installing such devices, they are jeopardizing not only the warranty coverage, but also the performance and reliability of the customer's vehicle. Disclaimer Diagrams Clutch Start Switch (M/T) Page 3434 Disclaimer A/C - Hiss Noise From Instrument Panel Hose/Line HVAC: Customer Interest A/C - Hiss Noise From Instrument Panel Bulletin No.: 06-01-38-002 Date: March 17, 2006 TECHNICAL Subject: A/C System Refrigerant Hiss Noise (Replace Liquid Line) Models: 2003-2006 Cadillac Escalade Models 2003-2006 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2003-2006 GMC Sierra, Yukon Models with 4.3L, 4.8L, 5.3L, 6.0L or 8.1L Engine (VINs X, V, T, Z, B, U, N, G - RPOs LU3, LR4, LM7, L59, L33, LQ4, LQ9, L18) and Air Conditioning (RPOs CJ2, CJ3 and C69) Condition Some customers may comment on a hiss noise coming from the instrument panel. The noise has also been described as sounding like a gurgle or water spattering. The noise occurs when the Air Conditioning (A/C) compressor engages and may continue for 5 to 10 seconds after the compressor disengages or the A/C system is turned off. The noise is most noticeable when the vehicle is at idle or is being driven at low speeds. The noise is undetectable after about one minute when the A/C system has been turned off or the vehicle has been turned off. Cause This condition may be caused by the expanding refrigerant as it passes through the orifice tube. Correction Technicians are to verify that the customer concern is only as described in the condition statement above. If the customer concern is a refrigerant hiss noise, then technicians are to perform the normal diagnostic procedures for an A/C system concern. The ACR2000 should be used to check the A/C system performance, charge level and discharge temperatures. This will eliminate the possibility that another condition is contributing to this customer concern. If the A/C system is performing properly, and all other possible sources of this noise are eliminated, then technicians are to replace the A/C liquid line. Use the proper part number as described in the parts information box below. Verify that the noise has been eliminated and that the A/C system operates normally. Parts Information Important: The trucks affected by this bulletin that have rear air conditioning were built with two different length condensers. The short condenser is 762 mm (30.0 in) long. The long condenser is 914 mm (36.0 in) long. Be sure to measure the length of the condenser before ordering one of the tubes listed below for vehicles with rear air conditioning. Page 14388 Control Module References Part 7 Service and Repair Oil Pressure Sensor: Service and Repair Engine Oil Pressure Sensor and/or Switch Replacement ^ Tools Required J 41712 Oil Pressure Switch Socket Removal Procedure 1. If necessary, remove the engine sight shield. 2. Disconnect the oil pressure sensor electrical connector (1). 3. Using J 41712 or equivalent, remove the oil pressure sensor. Installation Procedure Page 332 Action Taken When the DTCs Sets The module suspends all message transmission. The module uses default values for all parameters received on the serial data circuits. The module inhibits the setting of all other communication DTCs. Conditions for Clearing the DTC A current DTC clears when the malfunction is no longer present. A history DTC clears when the module ignition cycle counter reaches the reset threshold of 50, without a repeat of the malfunction. Circuit/System Verification Refer to Data Link References to determine which serial data system is used for a specific module. This DTC cannot be retrieved with a current status. Diagnosis is accomplished using the following symptom procedures: Scan Tool Does Not Communicate with High Speed GMLAN Device in SI. OR Scan Tool Does Not Communicate with Low Speed GMLAN Device in SI. DTC U0140 - U0184 Circuit Description Modules connected to the GMLAN serial data circuit monitor for serial data communications during normal vehicle operation. Operating information and commands are exchanged among the modules. In addition to this, Node Alive messages are transmitted by each module on the GMLAN serial data circuit. When the module detects one of the following conditions on the GMLAN serial data circuit, a DTC will set. Operating information and commands are exchanged among the modules. In addition to this, Node Alive messages are transmitted by each module on the GMLAN serial data circuit. Conditions for Setting the DTCs Diagnostic algorithms are designed so that a single point failure within a particular node shall result in a single DTC/FTB combination being set. Any recognized faults shall generate one DTC. Recognized faults may include but are not limited to the following: ^ Open or shorted condition on an I/O Circuit outside of normal operation of that circuit. ^ Erratic signal of a circuit, outside of normal operation, which can be readily and repeatedly recognized as erratic. ^ A condition, outside of normal operation, which causes a customer perception of a performance problem. ^ A condition whether hardware or data link error, which causes a device to operate in a default or fail soft mode. ^ A condition which changes or limits system performance. ^ Network supervision/signal supervision errors. ^ ECU Internal errors. ^ Criteria determined by legislation. An initialization or shutdown self-test shall be performed and may include but is not limited to the following: ^ RAM check ^ ROM/EEPROM/Flash check A/C - Ticking Noise From Instrument Panel/DTC's Set Control Module HVAC: All Technical Service Bulletins A/C - Ticking Noise From Instrument Panel/DTC's Set Bulletin No.: 06-01-38-003 Date: April 27, 2006 TECHNICAL Subject: Intermittent Ticking Noise from I/P, Poor A/C Performance, HVAC DTCs B0229, B0414, B0424, B3770 (Reprogram HVAC Control Module) Models: 2004-2006 Cadillac Escalade Models 2004-2006 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2004-2006 GMC Sierra Models, Yukon Models with Air Conditioning (RPOs CJ2, CJ3) Condition Some customers may comment on one or more of the following concerns: ^ Intermittent ticking/clicking noise from the instrument panel. ^ Recirculation mode does not work or Air Conditioning (A/C) system performance is poor during high ambient temperatures. ^ Unable to control the driver side temperature. ^ Unable to control the passenger side temperature. ^ Unable to change the front system modes. Cause This condition may be caused by the Heating, Ventilation and Air Conditioning (HVAC) actuators that may hunt for the correct commanded position. This cycling may cause a clicking or ticking noise. An overtravel of the HVAC system control doors may cause one or more of the concerns listed above. If an overtravel occurs, a Diagnostic Trouble Code (DTC) will be set, and the door will go to a preset default position. When a system door defaults, that door will stay at the default position until the DTC is cleared. After the DTC is cleared, the door will operate properly until the overtravel condition re-occurs. The table lists the HVAC system doors and the DTC associated with it. Correction Technicians are to perform the normal diagnostic procedures in SI for these concerns. If diagnostics show that the HVAC system door(s) travel below 5 counts (out of the lower range) or above 250 counts (out of the upper range), then update the software calibrations in the HVAC control module. The new calibrations were made available to dealerships as part of TIS2000 incremental satellite update version 2.5, which was broadcast to dealers in February 2006. Diagram Information and Instructions Power Window Switch: Diagram Information and Instructions Truck Zoning TRUCK ZONING Truck Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that corresponds to where they are located in the vehicle. The table explains the numbering system. Page 1766 Right Side Impact Sensor (With RPO Code HP2) Page 4066 Note The rivet stud and surrounding panel area MUST BE properly refinished PRIOR to the installation of the electrical ground wire terminal and conductive nut to maintain a secure, stable and corrosion-free electrical ground. 11. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 12. Allow the refinished repair area to cure sufficiently before removing the protective material applied to the rivet stud threads. 13. Remove the painters tape or equivalent from the rivet stud threads. 14. Using GM approved residue-free solvent or equivalent, thoroughly clean the rivet stud threads to remove any adhesive and allow to dry. 15. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive rivet stud. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 16. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 17. Install the electrical ground wire terminal to the M6 conductive rivet stud. 18. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 19. Install the M6 conductive nut to the rivet stud and: Tighten Tighten to 8 Nm (71 lb in) 20. Verify proper system operation. Parts Information Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use: Warranty Information (Saab Models) Page 5628 Knock Sensor (KS) Page 11450 Inflatable Restraint Sensing and Diagnostic Module (SDM) - Part 3 Page 6383 Page 13058 9. Erase the diagnostic trouble codes. 10. Set the date and time, see WIS - 3. Electrical system - Information display (SID) - Technical description. Air Temperature Sensor - Upper Left Air Temperature Sensor - Upper Left Page 9893 For vehicles repaired under warranty, use the table. Disclaimer Diagrams Clearance Lamp: Diagrams Clearance Lamp - LF (With RPO Code NY5 Or E63) Page 1475 Door Latch Assembly (Door Jamb Switch) - LR - C2 (Crew Cab Only) Page 1025 Steering Control Module: Service and Repair Rear Wheel Steering Control Module Replacement Rear Wheel Steering Control Module Replacement Removal Procedure 1. Notice: Refer vehicle Lifting. Raise the vehicle. Refer to Vehicle Lifting. 2. Remove the spare tire from the vehicle to gain access to the control module. 3. Disconnect the electrical connectors from the control module. 4. Remove the bolts (1) retaining the control module (2) to the bracket. 5. Remove the control module from the vehicle. Installation Procedure 1. Install the control module to the vehicle. 2. Notice: Refer to Fastener Notice in Service Precautions. Install the control module (2) retaining bolts (1). ^ Tighten the bolts to 24 Nm (18 ft. lbs.). Page 7884 1. Disconnect the shift control module electrical connectors. 2. Unsnap and remove the shift control module from the bracket. Installation Procedure Page 3254 Inspect the fan clutch for smooth operation. Inspect for a bent fan shaft or bent mounting flange. 9. Inspect the water pump drive shaft for being bent. Also inspect the water pump bearings for smooth operation and excessive play. Compare the water pump with a known, good water pump. 10. Accessory drive component brackets that are bent, cracked, or loose may put an extra strain on that accessory drive component causing it to vibrate. Drive Belt Whine Drive Belt Whine Diagnosis Diagnostic Aids The drive belt(s) will not cause the whine. If the whine is intermittent, verify that it is not the accessory drive component(s) by varying their loads, making sure they are operating to their maximum capacity. An overcharged air conditioning (A/C) system, a power steering system restriction or the incorrect fluid, or a failing generator are suggested items to inspect. Test Description Steps 1 - 5 The number(s) below refer to the step(s) in the diagnostic table. 3. This test is to verify that the whine is being caused by the accessory drive component(s). Remove the drive belt(s) and operate the engine for a few seconds, this will verify if the whining noise is related to the accessory drive component. With the drive belt(s) removed the water pump will not operate and the engine may overheat. Also diagnostic trouble codes (DTCs) may set when the engine is operated with the drive belt(s) removed. 4. This inspection should include checking the drive belt tensioner and the drive belt idler pulley bearings. The drive belt(s) may have to be installed and the accessory drive components operated separately by varying their loads. Refer to the suspected accessory drive component for the proper removal and installation procedure. Locations Upper Steering Column Specifications Ignition Cable: Specifications Spark Plug Wire Resistance ................................................................................................................ .................................................... 1000 ohms per foot Page 7887 1. If a NEW control module is being installed, program the new module. 2. Install the shift control module to the bracket. 3. Connect the shift control module electrical connectors. 4. Start the engine and test the automatic transfer case system for proper shift operation. Transfer Case Control Module Reprogramming Transfer Case Control Module Reprogramming Set-up for Module Programming/Reprogramming Important: Ensure that the vehicle battery is fully charged and that a battery charger is no longer connected. If performing this procedure for module replacement, install a new module before proceeding. Before reprogramming, close the doors and wait two minutes to allow other modules to stop communicating via the class 2 data line. Failure to do so could result in a failed reprogramming procedure. ^ Turn OFF all accessories. ^ Turn ON the ignition, with the engine OFF. Transfer Case - NVG 246-NP8 Four Wheel Drive Selector Switch: Service and Repair Transfer Case - NVG 246-NP8 Transfer Case Shift Control Switch Replacement Removal Procedure 1. Remove the instrument panel (I/P) cluster bezel. 2. Using a flat-tipped screwdriver, gently pry the retaining clips open on the housing. 3. Slide out the selector switch until the electrical connector are accessible. 4. Disconnect the selector switch electrical connectors (2, 3). 5. Remove the selector switch from the housing. Installation Procedure 1. Position the selector switch close to the housing so the electrical connectors can be connected. Page 3488 Steps 7 - 9 Page 11342 1. Remove the instrument panel accessory trim plate. 2. Remove the screws from the HVAC control module. 3. Depress the control assembly retaining tabs and remove the HVAC control module from the instrument panel. 4. Disconnect the electrical connectors from the HVAC control module. INSTALLATION PROCEDURE IMPORTANT: The Key should be in the off position when connecting the electrical connectors to ensure proper calibration. 1. Connect the electrical connectors to the HVAC control module. 2. Install the HVAC control module into the instrument panel, ensuring that the HVAC control module retaining tabs lock into place. NOTE: Refer to Fastener Notice in Service Precautions. 3. Install the screws from the HVAC control module. Tighten Tighten the screws to 1.9 N.m (17 lb in). 4. Install the instrument panel accessory trim plate IMPORTANT: Do not adjust any controls on the HVAC control module while the HVAC control module is calibrating. If interrupted improper HVAC performance will result. 5. Start the vehicle and let run for one minute. Service and Repair Gear Sensor/Switch: Service and Repair Encoder Motor Sensor Replacement Removal Procedure Important: For ease of reassembly, shift the transfer case to 2HI prior to removing any components. 1. Remove the encoder motor. 2. Place the encoder motor on a clean work bench, 3. Remove the 2 screws (2) from the motor cover. 4. Remove the 2 screws (1) from the casting. 5. Remove the cover. 6. Remove and save the shim on the output gear. 7. Remove and discard the orange rubber seal from the cover. 8. Remove the output gear (1). Page 4484 Electrical Symbols Part 6 Page 2278 Refrigerant Filter: Service and Repair Replacement AIR CONDITIONING (A/C) REFRIGERANT FILTER REPLACEMENT TOOLS REQUIRED J 39400-A Halogen Leak Detector REMOVAL PROCEDURE 1. Recover the refrigerant from the system. Refer to Refrigerant Recovery and Recharging. 2. Remove the air cleaner. IMPORTANT: The nuts (4) and the ferrules (3) will remain on the evaporator tube. Do not try to remove. 3. Remove the nuts (4) from the A/C refrigerant filter (1). 4. Remove the A/C refrigerant filter (3) from the evaporator tube (2). INSTALLATION PROCEDURE Page 8386 7. Remove the brake cable from the lever. 8. Remove the cable (2) from the rear brake cable mounting bracket (3) by depressing the locking tabs (1) on the brake cable. 9. Remove the brake cable from the guides and the body mounts. Installation Procedure 1. Install the new brake cable (2) into the rear brake cable mounting bracket (3) by pushing the cable into place until the locking tabs (1) snap into place. Service and Repair Oil Level Sensor: Service and Repair Engine Oil Level Sensor and/or Switch Replacement Removal Procedure 1. Drain the engine oil. 2. Disconnect the oil level sensor electrical connector (3). 3. Remove the oil level sensor from the oil pan. Installation Procedure 1. Notice: Refer to Fastener Notice in Service Precautions. Page 5856 Page 11708 NOTE: Refer to Fastener Notice in Service Precautions. 4. Install the fasteners (2) to the inflatable restraint side impact sensor (1) using only hand tools. Tighten Tighten the fasteners to 10 N.m (89 lb in). 5. Install the door trim panel. 6. Enable the SIR system. Refer to SIR Disabling and Enabling Zone 6. Page 9237 C320 Seat Jumper Harness To Seat Harness (With RPO Code AN3) Part 1 Page 12567 Page 5962 Shift Solenoid: Diagrams Automatic Transmission - 4L80-E/4L85-E Page 13254 Page 14601 Driver Seat (1 Of 2) Page 361 5.2 Cut off the cable tie (B), detach the connector's rear end face (C) and pull out the connecting rail (D). 5.3. Remove pin 39, cut off the cable terminal and insulate the end with tape (E). Fold back the cable and secure it with tape (F). 5.4. Fit the connecting rail and end face. 5.5. Plug in the connector (A) and secure the cables with cable ties (B). 6. Install the floor console over the handbrake. Do not press the console down into place, but instead allow it to fit loosely. 7. Install the switch: 7.1. Install the switch for the roof lighting (B) and plug in its connector. 7.2. Guide the connectors for the window lift module and rear seat heater, if equipped, through the hole for each respective unit. Plug in the window lift module's connector and install the module (A). Emblem Replacement - Grille (Cadillac) Body Emblem: Service and Repair Emblem Replacement - Grille (Cadillac) Emblem Replacement - Grille (Cadillac) Removal Procedure 1. Mask grille in the area surrounding the emblem to prevent damage to the painted surface. 2. Remove the emblem (1) from the grille (2) using a small plastic flat-bladed tool. 3. Remove all traces of adhesive from the grille surface using an oil-free naphtha or alcohol. Installation Procedure 1. Remove the protective tape from the adhesive strip on the grille emblem (1). 2. Install the emblem (1) onto the grille (2) centering the emblem on the mating surface. 3. Remove the masking tape from the painted surface surrounding the emblem. Page 15779 Door Switch: Diagrams Door Latch Assembly (Door Jamb Switch) - LR C2 (Crew Cab Only) Door Latch Assembly (Door Jamb Switch) - LR C2 (Crew Cab Only) Service and Repair Clutch Release Bearing: Service and Repair Release Bearing Replacement Removal Procedure 1. Remove the manual transmission. 2. Remove the clutch release bearing. ^ Rotate the bearing in either direction ^ The compression spring load will push the release bearing off the end of the clutch actuator bearing. Installation Procedure Important: DO NOT use cleaners or chemicals to clean the quill and DO NOT grease the quill. 1. Using a clean dry cloth, clean the exposed area of the actuator cylinder quill. 2. Install the NEW clutch release bearing to the clutch actuator cylinder. ^ Firmly push the clutch release bearing into place. ^ The release bearing will snap over the retainer tab and will be self-retained to the actuator cylinder. 3. Install the manual transmission. Service and Repair Compressor Clutch Hub: Service and Repair COMPRESSOR CLUTCH PLATE/HUB ASSEMBLY REPLACEMENT REMOVAL PROCEDURE 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. Remove the engine protection shield. 3. Install a ratchet into the air conditioning (A/C) belt tensioner adapter opening. 4. Rotate the A/C belt tensioner clockwise in order to relieve the tension on the belt. 5. Remove the A/C belt from the A/C compressor. 6. Slowly release the tension on the A/C belt tensioner. 7. Remove the clutch plate retaining bolt (1). 8. Remove the clutch plate assembly (2). 9. Remove the clutch hub/bearing snap ring (3). 10. Remove the clutch hub/bearing assembly (4). 11. Remove the snap ring (5) from the clutch coil (6). 12. Remove the clutch coil (6) from the A/C compressor (7). INSTALLATION PROCEDURE Door Window Weatherstrip Rear Door Window Glass Weatherstrip: Service and Repair Door Window Weatherstrip Weatherstrip Replacement - Rear Door Window Removal Procedure 1. Remove the window. 2. Pull the weatherstrip from the front window run channel. 3. Pull the weatherstrip from the rear window run channel. 4. Pull the weatherstrip from the window frame flange. Installation Procedure 1. Align the weatherstrip in the window frame flange. 2. Press the weatherstrip into the window frame flange until fully seated. 3. Press the weatherstrip into the rear window run channel until fully seated. 4. Press the weatherstrip into the front window run channel until fully seated. 5. Install the window. Procedures Body Control Module: Procedures BODY CONTROL MODULE (BCM) PROGRAMMING/RPO CONFIGURATION INTRODUCTION The procedures below are designed to set-up the body control module (BCM) correctly during BCM related service. Before you start, read these procedures carefully and completely. IMPORTANT: The following procedures must be followed: 1. Programming the BCM. 2. Programming Theft Deterrent System Components, if equipped with Passlock System. PROGRAMMING THE BCM IMPORTANT: After the procedure is completed, the personalization settings of the BCM are set to a default setting. Inform the customer that the personalization must be set again. Perform the BCM special function Request BCM Info. for service programming system (SPS), then follow the SPS instructions. Refer to Service Programming System (SPS) in Programming. PROGRAMMING THEFT DETERRENT SYSTEM COMPONENTS IMPORTANT: This procedure has to be performed only for vehicles equipped with Passlock System. Perform the Programming Theft Deterrent System Components in Theft Deterrent after successfully finishing the Setup New BCM procedure. If the Programming Theft Deterrent System Components in the Theft Deterrent procedure is not performed after a BCM replacement, one of the following conditions will occur: The vehicle will not be protected against theft by the PASSLOCK system. - The engine will not crank or start. IMPORTANT: After programming, perform the following to avoid future misdiagnosis: 1. Turn the ignition OFF for 10 seconds. 2. Connect the scan tool to the data link connector. 3. Turn the ignition ON, with the engine OFF. 4. Use the scan tool in order to retrieve history DTCs from all modules. 5. Clear all history DTCs. Page 13008 In summary, whenever a vehicle subject to this program enters your vehicle inventory, or is in your dealership/facility for service through April 30, 2011, you must take the steps necessary to be sure the program correction has been made before selling or releasing the vehicle. Disclaimer Service Procedure Service Procedure Note Do NOT replace the inside rear view mirror in tandem with this concern. The mirror has no bearing on this specific issue. 1. Remove the OnStar(R) module (referred to as the Communication Interface Module (CIM) or Vehicle Communication Interface Module (VCIM) in SI). Refer to SI for module removal instructions. Note Inform customer that all Bluetooth devices must be paired with the new VCIM. Bluetooth devices that have not been paired to the new VCIM will not function properly. 2. Install the new OnStar(R) module (referred to as the Communication Interface Module (CIM) or Vehicle Communication Interface Module (VCIM) in SI). Refer to SI for module installation instructions. Service and Repair Lifter / Lash Adjuster: Service and Repair Valve Lifter Replacement ^ Tools Required J 3049-A Valve Lifter Remover Removal Procedure 1. Remove the cylinder head and gasket. 2. Remove the valve lifter guide bolts. 3. Remove the valve lifters and guide. 4. Important: Some valve lifters may be stuck in their bores because of gum or varnish deposits. Use J 3049-A or equivalent in order to remove the valve lifters (if required). Drivetrain - Transfer Case Control Module Replacement Control Module: All Technical Service Bulletins Drivetrain - Transfer Case Control Module Replacement Bulletin No.: 05-04-21-002 Date: March 10, 2005 INFORMATION Subject: Guidelines for Replacement of Transfer Case Control Module (TCCM) Models: 2005 and Prior Light Duty Trucks with New Venture Gear (NVG) Transfer Case (RPOs NP1, NP4, NP8) Dealers are replacing the TCCM unnecessarily. Dealers are replacing the TCCM with codes stored in HISTORY only. The TCCM does not have a current fault condition when tested. Parts reviewed at the Warranty Parts Center (WPC) have a 75% No Trouble Found (NTF) rate. The only two legitimate reasons to replace the TCCM are: ^ Diagnostic Trouble Code (DTC) C0550 ^ NO Communication with a scan tool. DTC C0550 This DTC indicates that the module has an internal fault and should be replaced. No Communication ^ The no communication conditions referenced here are also caused by a module internal fault to a point where the module physically will not talk. A technician cannot pull DTCs from the module because it will not communicate. The module is electrically dead. ^ No communication is not to be confused with a U1026 code. This code tells the technician that the module may still be functioning but is temporarily off line. This code may be set by the Instrument Panel (IP) or the Powertrain Control Module (PCM) against the TCCM. The technician needs to figure out why the module went off line. These are typically caused by connection concerns. There is no need to replace a TCCM for a U1026 DTC. Diagnostic Aids ^ When diagnosing a transfer case electrical control system, ALWAYS check power and ground wiring first. ^ Test the connections for intermittent or poor connections, complete plug insertion, bent pins, pushed out terminals and water contamination. Page 1013 Inflatable Restraint Sensing and Diagnostic Module (SDM) - Part 2 Page 327 Page 14710 - Wear/cracking/peeling - Discoloration/dye transfer from customer clothing (if discoloration/dye transfer is not removed after using GM Leather and Vinyl Plastic Cleaner, P/N 88861401 (in Canada, P/N 88861409), replace the covers.) Disclaimer Page 10885 Electrical Symbols Part 8 Page 9629 Junction Block - I/P Wire Entry Part 1 Page 4437 Page 5966 6. Connect the internal wiring harness electrical connectors to the following components: ^ Transmission fluid pressure switch (1) ^ 1-2 shift control solenoid (2) ^ 2-3 shift control solenoid (3) ^ Pressure control solenoid (4) ^ TCC PWM solenoid (5) ^ 3-2 control solenoid (6) 7. Install the 1-2 accumulator, if necessary. 8. Install the transmission filter. Page 5675 Page 11769 Disclaimer Capacity Specifications Fluid - Differential: Capacity Specifications Differential Fluid Capacity Differential Oil Capacity Front Drive Axle (8.25") ....................................................................................................................... ............................................ 1.43 liters (1.51 quarts) Front Drive Axle (9.25") .................................... ............................................................................................................................... 1.73 liters (1.83 quarts) Rear Drive Axle (8.6") ............................................................................................................. ......................................................... 2.03 liters (2.15 quarts) Rear Drive Axle (9.5") .......................... ............................................................................................................................................ 2.60 liters (2.75 quarts) Rear Drive Axle (9.75") .................................................................................................. .................................................................. 2.84 liters (3.00 quarts) Rear Drive Axle (10.5") ............... ..................................................................................................................................................... 2.60 liters (2.75 quarts) Rear Drive Axle (11.5") .......................................................................................... .......................................................................... 3.00 liters (3.17 quarts) Lubricant Level - 8.6 Inch Axle Differential Oil Capacity Capacity .................................................................................................................................................... 15-40 mm from bottom edge of the fill plug hole Lubricant Level - 9.5, 10.5 Inch Axles Differential Oil Capacity Capacity ............................................................................................................................................... ........................ 0-10 mm below the fill plug opening Lubricant Level - 9.75 Inch Axel Differential Oil Capacity Capacity ............................................................................................................................................... .......................... 0-4 mm below the fill plug opening Lubricant Level - 11.5 Inch Axle Differential Oil Capacity Capacity ............................................................................................................................................... ...................... 17-21 mm below the fill plug opening Page 14003 Drink Holders: Service and Repair Cupholder Replacement (Non-Luxury) Cupholder Replacement (Non-Luxury) Removal Procedure 1. Grab the middle of the cup holder firmly and pull outwards to release the clips (1). 2. Remove the cup holder from the console. Installation Procedure 1. Install the cup holder by pushing inwards till the clips (1) click in place. 2. Ensure around the corners of the cup holder is seated properly. Page 10892 Auxiliary Blower Motor: Diagnostic Aids Basic Knowledge Required BASIC KNOWLEDGE REQUIRED Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the Service Data. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories CHECKING AFTERMARKET ACCESSORIES Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: - Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions INDUCING INTERMITTENT FAULT CONDITIONS In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: - Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. Page 12434 In summary, whenever a vehicle subject to this program enters your vehicle inventory, or is in your dealership/facility for service through April 30, 2011, you must take the steps necessary to be sure the program correction has been made before selling or releasing the vehicle. Disclaimer Service Procedure Service Procedure Note Do NOT replace the inside rear view mirror in tandem with this concern. The mirror has no bearing on this specific issue. 1. Remove the OnStar(R) module (referred to as the Communication Interface Module (CIM) or Vehicle Communication Interface Module (VCIM) in SI). Refer to SI for module removal instructions. Note Inform customer that all Bluetooth devices must be paired with the new VCIM. Bluetooth devices that have not been paired to the new VCIM will not function properly. 2. Install the new OnStar(R) module (referred to as the Communication Interface Module (CIM) or Vehicle Communication Interface Module (VCIM) in SI). Refer to SI for module installation instructions. Locations Driver Door Page 2472 Fluid - A/T: Service and Repair Automatic Transmission - 4L80-E/4L85-E Automatic Transmission Fluid/Filter Replacement Removal Procedure 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. Place a drain pan under the transmission oil pan. 3. Remove the oil pan drain plug, if equipped. 4. Allow the transmission fluid to drain completely. 5. Apply a small amount of sealant GM P/N 12346004 (Canadian P/N 10953480), or equivalent to the treads of the drain plug, if equipped. Notice: Refer to Fastener Notice in Service Precautions. 6. Install the oil pan drain plug. ^ Tighten the oil pan drain plug to 18 Nm (13 ft. lbs.). 7. Remove the drain pan from under the transmission oil pan. 8. Support the transmission with a transmission jack. 9. Remove the transmission mount nuts. 10. Remove the transmission support bolts and nuts. 11. Remove the transmission support side bracket bolts and bracket. 12. Remove the transmission support. 13. Disconnect the range selector cable end (2) from the transmission range selector lever ball stud (1). Steering/Suspension - Pitman Arm Shaft Seal Service Kit Pitman Arm: Technical Service Bulletins Steering/Suspension - Pitman Arm Shaft Seal Service Kit INFORMATION Bulletin No.: 10-02-33-001A Date: October 13, 2010 Subject: Information on Pitman Arm Shaft Seal Service Kit Models: 2004-2005 Buick Rainier 2000-2006 Cadillac Escalade, Escalade ESV, Escalade EXT 2000-2005 Chevrolet Blazer, S-10 2000-2011 Chevrolet Avalanche, Express, Silverado, Suburban, Tahoe 2000-2005 GMC Jimmy, Sonoma 2000-2011 GMC Savana, Sierra, Yukon, Yukon Denali, Yukon XL, Yukon Denali XL 2000-2004 Oldsmobile Bravada 2003-2009 HUMMER H2 with Recirculating Ball Steering Gears Supercede: This bulletin is being revised to update the model years and models involved. Please discard Corporate Bulletin Number 10-02-33-001 (Section 02 - Steering). Note Do not replace the entire steering gear for a pitman seal leak. Technicians have been replacing entire steering gears due to not being able to service just the leaking pitman shaft seal. The seal is serviced as a kit and is not called out separately in the catalog illustration. The seal package is cataloged in Group 06.855 as Seal Kit - GM Part Number 26002516 - Steering Gear Pitman Shaft, which includes the seal, washer, retaining ring and dust seal or G/M P/N 19256667, which includes the seal and retainer. Refer to Steering Gear Pitman Shaft Seal in SI. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 4760 1. Install the accelerator pedal assembly. NOTE: Refer to the Fastener Notice in Service Precautions. 2. Install the accelerator pedal nuts. Tighten Tighten the nuts to 20 N.m (15 lb ft). 3. Connect the APP sensor electrical connector. 4. Reposition the carpet. 5. Connect a scan tool in order to test for proper throttle-opening and throttle-closing range. 6. Operate the accelerator pedal and monitor the throttle angles. The accelerator pedal should operate freely, without binding, between a closed throttle, and a wide open throttle (WOT). 7. Verify that the vehicle meets the following conditions: - The vehicle is not in a reduced engine power mode. - The ignition is ON. - The engine is OFF. 8. Inspect the carpet fit under the accelerator pedal. Page 1107 Door Lock Switch - Front Passenger (Base Only) Page 13265 switch lighting connector. 3.3. Undo the floor console's retaining bolts (C). 3.4. Take out the rear ashtray/cover (D). 3.5. Remove the screw (E) for the rear cover. 3.6. Remove the floor console's retaining nuts (E). 3.7. Detach the floor console (G) by pulling it straight back and lifting it slightly. 3.8. If required, detach the switch for the rear seat heater and unplug the connector. 4. Remove the switch and the floor console: 4.1. Detach the window lift module (A) by loosening it in the front edge (snap fastener). Unplug the window lift module's connector. 4.2. Detach the switch for the roof lighting (B) and unplug its connector. Lift away the floor console. 5. Pry out the signal line from the SRS control module to the OnStar(R) control module and secure it: 5.1. Unplug the SRS control module's connector (A). Page 2227 14. Important: It is not necessary to remove the selector cable from the bracket. Remove the transmission range selector cable bracket (2) bolts and bracket from the transmission. Reposition the bracket with cable. 15. Remove the oil pan bolts. 16. Important: The transmission oil pan gasket is reusable. Inspect the gasket and replace as needed. Remove the oil pan and gasket. 17. Remove the magnet from the bottom of the pan, if necessary. 18. Remove the oil filter. 19. Remove the filter neck seal. 20. Clean the transmission case and the oil pan gasket surfaces with solvent. Installation Procedure OnStar(R) - No Power/Inoperative/No LED Emergency Contact Module: All Technical Service Bulletins OnStar(R) - No Power/Inoperative/No LED TECHNICAL Bulletin No.: 05-08-46-001D Date: May 02, 2008 Subject: OnStar(R) Generation 5 or 6 (Digital) System Inoperative/Has No Power, LED Light Not On (Remove/Reinstall OnStar(R) Fuse and Replace VCIM or Follow SI Diagnostics) Models Supercede: This bulletin is being revised to update the information on VCIM ordering instructions in step 3 of the Correction statement. Please discard Corporate Bulletin Number 05-08-46-001C (Section 08 - Body & Accessories). Condition Some customers may comment any or all of the following conditions: ^ The OnStar(R) system may be inoperative. ^ The OnStar(R) system may have no power. ^ The OnStar(R) LED light may not be on. The technician may also not be able to communicate with the OnStar(R) Vehicle Communication Interface Module (VCIM) with a Tech 2(R). Correction Notice: On 2006 Chevrolet Impala and Monte Carlo models, make sure the ignition is OFF and the vehicle has "RAP"ed out prior to removing the OnStar(R) fuse. Disconnecting power to the OnStar(R) module while the ignition is ON may discharge and permanently damage the OnStar(R) back-up battery. Page 7360 Page 7787 Pressure Regulating Solenoid: Connector Locations Page 14696 If any of the involved vehicles are in the used car inventory of your dealership or were recently sold by you or a customer brings in an involved vehicle for service, please contact the GM Reacquired Vehicle Disclosure Center (RVDC). Claim Information Submit a Product Recall Claim with the information shown. Refer to the General Motors WINS Claims Processing Manual for details on Product Recall Claim Submission. Customer Notification General Motors will notify customers of this recall on their vehicle (see copy of customer letter shown in this bulletin). Dealer Recall Responsibility The customer will contact General Motors to begin the repurchase process. General Motors will work with the customer to reach an agreement on the purchase of the vehicle. Dealers will be contacted by General Motors to assist in the removal of any aftermarket accessories, inspection of the vehicle, obtaining titles and other documentation required to transfer ownership to General Motors, presenting the customer with a check for the purchase, and taking possession of the vehicle. General Motors will arrange for transportation of the vehicle from the dealer. Whenever a vehicle subject to this recall enters your vehicle inventory, or is in your dealership for service in the future, you must contact the GM Reacquired Vehicle Disclosure Center (RVDC). Disclaimer Page 15709 Park/Turn Signal Lamp - RF Inflatable Restraint I/P Module Disable Switch (HD Model) Air Bag Deactivation Switch: Description and Operation Inflatable Restraint I/P Module Disable Switch (HD Model) INFLATABLE RESTRAINT I/P MODULE DISABLE SWITCH (HD MODEL PICKUPS) The instrument panel (I/P) module disable switch is a manual 2-position key switch. The I/P module disable switch allows the vehicle operator the ability to enable or disable the I/P module (passenger frontal air bag). The I/P module disable switch interfaces with the inflatable restraint sensing and diagnostic module (SDM) to request the enabling or disabling of the I/P module. The occupants are notified of the enabling or disabling of the I/P module via the I/P module disable switch ON/OFF indicators located on the I/P module disable switch. Page 3153 Disclaimer Page 9751 C275 Steering Column Harness To Steering Wheel Module Coil (With RPO Code HVY) Page 2944 hot particles embed themselves in the chrome layer and create a small pit. If the material is allowed to sit on the wheel while it is exposed to moisture or salt, it will corrode the wheel beneath the chrome leaving a pit or small blister in the chrome. Heavy brake dust build-up should be removed from wheels by using GM Chrome Cleaner and Polish, P/N 1050173 (in Canada use 10953013). For moderate cleaning, light brake dust build-up or water spots use GM Swirl Remover Polish, P/N 12377965 (in Canada, use Meguiars Plast-X(TM) Clear Plastic Cleaner and Polish #G12310C**). After cleaning, the wheel should be waxed using GM Cleaner Wax, P/N 12377966 (in Canada, use Meguiars Cleaner Wax #M0616C**), which will help protect the wheel from brake dust and reduce adhesion of any brake dust that gets on the wheel surface. For general maintenance cleaning, PEEK Metal Polish† may be used. It will clean and shine the chrome and leave behind a wax coating that may help protect the finish. Warranty of Stardust Corroded Chrome Wheels Wheels returned with pitting or spotting as a result of neglect and brake dust build-up may be replaced one time. Important Notify the customer that this is a one time replacement. Please stress to the customer the vital importance of keeping the wheels clean and free of prolonged exposure to brake dust build-up. "GM of Canada" dealers require prior approval by the District Manager - Customer Care and Service Process (DM-CCSP). Customer Assistance and Instructions GM has looked for ways customers may improve the appearance of wheels damaged by acidic cleaners. The following product and procedure has been found to dramatically improve the appearance of stained wheels. For wheels that have milky stains caused by acidic cleaners try the following: Notice THE 3M CHROME AND METAL POLISH REQUIRED FOR THIS PROCEDURE IS AN EXTREMELY AGGRESSIVE POLISH/CLEANER. THE WHEELS MUST BE CLEANED BEFORE APPLICATION TO AVOID SCRATCHING THE WHEEL SURFACE. THIS PRODUCT WILL REDUCE THE THICKNESS OF THE CHROME PLATING ON THE WHEEL AND IF USED INCORRECTLY OR EXCESSIVELY MAY REMOVE THE CHROME PLATING ALL TOGETHER, EXPOSING A LESS BRIGHT AND BRASSY COLORED SUB-LAYER. FOLLOW INSTRUCTIONS EXACTLY. 1. Wash the wheels with vigorously with soap and water. This step will clean and may reduce wheel staining. Flood all areas of the wheel with water to rinse. 2. Dry the wheels completely. Notice Begin with a small section of the wheel and with light pressure buff off polish and examine results. ONLY apply and rub with sufficient force and time to remove enough staining that you are satisfied with the results. Some wheels may be stained to the extent that you may only achieve a 50% improvement while others may be able to be restored to the original lustre. IN ALL CASES, only apply until the results are satisfactory. 3. Apply 3M Chrome and Metal Polish #39527* with a clean terry cloth towel. As you apply the polish, the staining will be diminished. 4. When dry, buff off the polish with a clean portion of the towel. 5. Repeat application of the 3M Chrome and Metal Polish until satisfied with the results. If continued applications fail to improve the appearance further discontinue use. This procedure will improve the appearance of the wheels and may, with repeated applications, restore the finish dramatically. For wheels that exhibit spotting from road chemicals the above procedure may marginally improve the condition but will not restore the finish or remove the pitting. In this type of staining the wheel finish has actually been removed in spots and no manner of cleaning will restore the finish. †*We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Parts Information Page 6817 Pinion Bearing: Service and Repair 9.75 Inch Axle Drive Pinion Bearings Replacement (9.75 Inch Axle) ^ Tools Required J 22536 Pinion Driver - J 22912-01 Split-Plate Bearing Puller - J 42176 Universal Driver Handle - Non-Threaded - J 45703 Pinion Bearing Race Remover - Dana 248 - J 45704 Pinion Bearing Race Installer - Dana 248 - J 45705 Pinion Bearing Race Remover - Dana 248/267 - J 7818 Inner Bearing Race Installer - J 8092 Universal Drive Handle - 3⁄4 in - 10 Removal Procedure 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Remove the differential assembly. 3. Remove the pinion yoke and the pinion oil seal. 4. Remove the thrust washer. 5. Install the J 22536 as shown. Ensure that the J 22536 is firmly seated on the pinion. 6. Drive the pinion out using the J 22536 and a hammer.Strike the J 22536 slowly. Do not let the pinion fall out of the rear axle housing. 7. Remove the pinion preload shims from the drive pinion and set aside. 8. Remove the inner pinion bearing cup and the oil deflector using the J 45703 (2) and the J 42176 (1). 9. Remove the outer pinion bearing cup using the J 45705 and the J 42176. Page 2216 Important The new canister vent valve will be installed in a new location, outside of the frame. 7. Position and secure the new valve assembly to the frame bracket on the outside of the frame using the existing hole and mounting bolt. Tighten Tighten the bracket mounting bolt to 12 Nm (106 lb in). 8. Connect the vent valve pipe to the EVAP canister. 9. Install the two vent valve pipe clips into the existing underbody holes. 10. Connect the EVAP canister vent valve electrical connector, if equipped. 11. Attach bulk 5/8" heater hose to the vent valve port and secure using a clamp. Run a length as needed along the frame rail routing to the area above the transmission. 12. Cut the hose to determined length and install the supplied filter box. Secure using a clamp. 13. Remove the transmission support and lower the transmission assembly as necessary to allow for access to the new filter box location. 14. Secure the filter box to the transmission vent hose just forward of the hose tee-section using a tie strap. DO NOT pinch or restrict the transmission vent hose. The filter box opening should be pointing downward. 15. Raise the transmission and reinstall the transmission support. 16. Tie strap the hose as needed along the frame rail in order to keep the hose away from pinch-points and heat sources. 17. Lower the vehicle. 2004-2007 Model Year (Use Service Kit P/N 19152349) 1. Raise the vehicle. Suitably support the vehicle. 2. Disconnect the EVAP canister vent valve electrical connector. 3. Disconnect the canister pipe from the vent valve. 4. Push in the retainer and remove the existing canister vent valve from the fuel tank clip or mounting bracket. Discard the old valve. 5. Cut back the existing canister pipe approximately 51 mm (2 in) to remove the quick connect end. Crew Cab Short Box Shown Below, Other Configurations Similar Page 10720 1. Install the wheel hub and bearing (3) to the vehicle. 2. Install the wheel hub and bearing retaining bolts. ^ Tighten the bolts to 180 Nm (132 ft. lbs.). 3. Notice: Refer to Fastener Notice in Service Precautions. Install the wheel drive shaft retaining nut. ^ Tighten the nut to 250 Nm (184 ft. lbs.). 4. Install the retainer (3) and cotter pin (2) to the wheel drive shaft nut. 5. Install the dust cap (4). 6. Install the brake rotor. 7. Install the tire and wheel. 8. Lower the vehicle. Page 5753 Remote Programming Feature 1. Connect the scan tool to the vehicle. 2. Power-up the scan tool and select the Service Programming feature. 3. Select the appropriate vehicle. 4. Press the Request Info button on the scan tool. 5. Connect the scan tool to the computer station. 6. Follow the menu select items for reprogramming and provide information about the type of device you are programming and whether you are reprogramming or replacing the electronic control unit (ECU). 7. Select "vehicle" from the selection menu. 8. Select the module you wish to program. 9. Select "Normal" for Programming Type. 10. Select the applicable software calibrations. 11. Transfer data file to the scan tool. 12. Connect the scan tool to the vehicle. 13. Turn ON the ignition, with the engine OFF. 14. Select the Service Programming feature on the scan tool. 15. Press the Program button on the scan tool. Programming Using Scan Tool Pass-Through Connection 1. Connect the scan tool to vehicle and power it up. 2. Connect the computer station to the scan tool. 3. Select "PC Using Scan Tool Connection" from the programming menu on the computer station. 4. Follow the menu select items for reprogramming and provide information about the type of device you are programming and whether you are reprogramming or replacing the electronic control unit (ECU). 5. Select "vehicle" from the selection menu. 6. Select the module you wish to program. 7. Select "Normal" for Programming Type. 8. Select the applicable software calibrations. 9. Transfer data file to the scan tool. Page 4968 Put unused material on the shelf for future use. Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Emissions - MIL ON/DTC P0446 Stored In ECM Canister Purge Control Valve: All Technical Service Bulletins Emissions - MIL ON/DTC P0446 Stored In ECM TECHNICAL Bulletin No.: 02-06-04-037I Date: September 16, 2010 Subject: Check Engine Light On, Fuel Tank Hard to Fill, DTCs P0442, P0446, P0455 or P0449 Set (Replace Evaporative Emission (EVAP) Vent Valve Solenoid Assembly and Add/Relocate Filter Box Using Service Kit) Models: 1999-2007 Chevrolet Silverado (Classic) Models 1999-2007 GMC Sierra (Classic) Models 2007-2010 Chevrolet Silverado Models (Including Hybrid) 2007-2010 GMC Sierra Models (Including Hybrid) Supercede: This bulletin is being revised to add the 2010 model year and to include the Hybrid models. Please discard Corporate Bulletin Number 02-06-04-037H (Section 06 - Engine/Propulsion System). Condition Some customers may comment about the check engine light being illuminated. They may also comment that their vehicle is difficult to fill with fuel or when filling, the pump continuously shuts off before the tank is full. When checking the vehicle for DTCs, the ECM may report one or more of the following DTCs set as current or in history: P0442, P0446, P0449 or P0455. Cause The EVAP canister vent solenoid (CVS) valve draws fresh air into the system through a vent. Under certain operating conditions, dirt and dust intrusion into the EVAP CVS fresh air intake/venting system, may result in restricted air flow. Under certain operating conditions, water, if ingested into the EVAP CVS fresh air intake/venting system, may reach the CVS valve causing corrosion in the CVS valve, and may cause restrictions in the fresh air intake path, when the valve is in the closed position. Correction (1999-2007 Classic/Old Style Models) After following the published SI diagnostics and determining that the EVAP canister vent valve is the cause of the MIL light, replace the existing EVAP canister vent valve assembly with a new assembly. This new assembly is a sealed unit that is designed to be vented through a remote filter box. To ensure correct installation, follow the procedures below. Important DO NOT replace the EVAP canister assembly for this concern unless it fails the leak test. 1999-2003 Model Year (Use Service Kit P/N 19207762) 1. Raise the vehicle. Suitably support the vehicle. 2. Disconnect the EVAP canister vent valve electrical connector, if equipped. 3. Disengage the two vent valve pipe clips securing the pipe to the underbody. Remove the clips from the underbody and discard. 4. Disconnect the vent valve pipe at the EVAP canister. 5. Remove and retain the EVAP canister vent valve bracket mounting bolt. 6. Remove the complete EVAP canister vent valve assembly with bracket attached and discard. Page 16167 Control Module References Part 1 Tire Monitor System - TPM Sensor Information Tire Pressure Monitor Receiver / Transponder: Technical Service Bulletins Tire Monitor System TPM Sensor Information INFORMATION Bulletin No.: 08-03-16-003 Date: May 12, 2008 Subject: Warranty Reduction - Transfer of Tire Pressure Monitoring (TPM) Sensors to Replacement Wheels and Allowable TPM Sensor Replacements Models: 2000-2009 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2009 HUMMER H2 2006-2009 HUMMER H3 2005-2009 Saab 9-7x with On-Wheel TPM Sensors TPM Sensor / Wheel Warranty Reviews During the last warranty review period it was noted that wheels being returned under the GM New Vehicle Warranty were being shipped back to General Motors with the TPM sensor still attached to the wheel. Return rates ran as high as 60% with the TPM sensors still attached. Operational TPM sensors should not be returned to GM and are to be transferred to replacement wheels if they become necessary. Important: Operational TPM Sensors that are returned under warranty to General Motors will be charged back to the dealer.Sensors have a 10 year /150,000 mile (240,000 km) battery life, and should be transferred if one or more wheels are replaced. TPM Valve Stem / Grommet (0-ring) Replacement When the TPM sensors are transferred to new wheels you should replace the component used to seal the TPM sensor stem to the wheel. On sensors with an aluminum stem and visible nut on the outside of the wheel a replacement grommet (0-ring) should be used to assure a proper seal. The sensor retaining nut (except Aveo) should be tightened to 7 N.m (62 lb in) for all vehicles except Pontiac Vibe (4.0 N.m (35.4 lb in)). Important: ^ DO NOT overtorque the retaining nut. Notice: ^ Factory installed TPM Sensors come with plastic aluminum or nickel-plated brass stem caps. These caps should not be changed. Chrome plated steel caps may cause corrosion of aluminum valve stems due to incompatibility of the metals. On current style sensors the entire rubber stem is replaceable. The service interval on the revised TPM sensor with replaceable stem is the same as for any other traditional valve stem. Replace the stem at the time of tire replacement sensor transfer or whenever air seepage is suspected at the valve stem. When replacing the valve stem tighten the screw to 1.3 N.m (11.5 lb in). For either style of TPM sensor see the service parts guide for the correct GM part numbers to order and use. Disclaimer Page 12781 Page 3603 3. Install the surge tank inlet hose to the radiator. 4. Position the surge tank inlet hose clamp to the radiator. 5. Fill the cooling system. Page 10480 Axle Nut: Specifications Axle Shaft Nut ...................................................................................................................................... ................................................ 240 Nm (177 ft. lbs.) Connector Views Fuse Block: Connector Views Fuse Block - I/P C4 (Crew Cab) Page 7942 Page 5140 Fuel Pressure: Testing and Inspection Fuel System Diagnosis FUEL SYSTEM DIAGNOSIS SYSTEM DESCRIPTION The control module enables the fuel pump relay when the ignition switch is turned ON. The control module will disable the fuel pump relay within two seconds unless the control module detects ignition reference pulses. The control module continues to enable the fuel pump relay as long as ignition reference pulses are detected. The control module disables the fuel pump relay within two seconds if ignition reference pulses cease to be detected and the ignition remains ON. The Fuel System is a returnless on-demand design. The fuel pressure regulator is a part of the fuel sender assembly, eliminating the need for a return pipe from the engine. A returnless fuel system reduces the internal temperature of the fuel tank by not returning hot fuel from the engine to the fuel tank. Reducing the internal temperature of the fuel tank results in lower evaporative emissions. The fuel tank stores the fuel supply. An electric turbine style fuel pump attaches to the fuel sender assembly inside the fuel tank. The fuel pump supplies high pressure fuel through the fuel filter and the fuel feed pipe to the fuel injection system. The fuel pump provides fuel at a higher rate of flow than is needed by the fuel injection system. The fuel pump also supplies fuel to a venturi pump located on the bottom of the fuel sender assembly. The function of the venturi pump is to fill the fuel sender assembly reservoir. The fuel pressure regulator, a part of the fuel sender assembly, maintains the correct fuel pressure to the fuel injection system. The fuel pump and sender assembly contains a reverse flow check valve. The check valve and the fuel pressure regulator maintain fuel pressure in the fuel feed pipe and the fuel rail in order to prevent long cranking times. TEST Steps 1 - 2 Page 5282 Fuel Injector: Testing and Inspection Fuel Injector Balance Test with Tech 2 FUEL INJECTOR BALANCE TEST WITH TECH 2 DESCRIPTION The scan tool is first used to energize the fuel pump. The scan tool is then used to pulse each injector for a precise amount of time, allowing a measured amount of fuel into the manifold. This causes a drop in system fuel pressure that can be recorded and used to compare the flow through each injector. TEST DESCRIPTION Steps 1 - 2 Page 11201 15. Discard all of the used sealing washers. Cap all of the open connections. INSTALLATION PROCEDURE 1. Install the front evaporator tube to the vehicle. 2. Uncap all of the open connections 3. Install the evaporator tube to the condenser using new sealing washers. NOTE: Refer to Fastener Notice in Service Precautions. 4. Install the evaporator tube nut to the condenser. Tighten Tighten the nut to 16 N.m (12 lb ft). 5. Install the grille to the vehicle. 6. Install the right park/turn signal lamp. Page 1873 Steps 1-9 Test Description The numbers below refer to the step numbers on the diagnostic table. 2. This step tests for a faulty tow/haul switch. 3. This step tests for voltage input from the BCM to the tow/haul switch. 6. This step tests for ground integrity. Page 2471 4. Install the oil pan and NEW gasket. 5. Notice: Refer to Fastener Notice in Service Precautions. Install the oil pan bolts. ^ Tighten the bolts alternately and evenly to 11 Nm (97 inch lbs.). 6. If previously removed, install the range selector cable bracket and bolts. ^ Tighten the bolts to 25 Nm (18 ft. lbs.). 7. Apply a small amount of sealant GM P/N 12346004 (Canadian P/N 10953480), or equivalent to the threads of the oil pan drain plug, if equipped. 8. Install the oil pan drain plug, if equipped. ^ Tighten the plug to 18 Nm (13 ft. lbs.). 9. Lower the vehicle. 10. Fill the transmission to the proper level with DEXRON® III transmission fluid. 11. Check the COLD fluid level reading for initial fill only. 12. Inspect the oil pan gasket for leaks. Page 13995 4. Wait 1 minute before working on the system. Enabling Procedure - Air Bag Fuse 1. Place the ignition in the OFF position. 2. Install the fuse(s) supplying power to the SDM. 3. Turn the ignition switch to the ON position. The AIR BAG indicator will flash then turn OFF. 4. Perform the Diagnostic System Check - Vehicle if the AIR BAG warning indicator does not operate as described. Disabling Procedure - Negative Battery Cable 1. Turn the steering wheel so that the vehicles wheels are pointing straight ahead. 2. Place the ignition in the OFF position. 3. Disconnect the negative battery cable from the battery. 4. Wait 1 minute before working on system. Enabling Procedure - Negative Battery Cable 1. Place the ignition in the OFF position. 2. Connect the negative battery cable to the battery. 3. Turn the ignition switch to the ON position. The AIR BAG indicator will flash then turn OFF. 4. Perform the Diagnostic System Check - Vehicle if the AIR BAG warning indicator does not operate as described. Page 11905 NV 3500 Shift Boot: Service and Repair NV 3500 Control Lever and/or Boot Replacement Removal Procedure 1. Important: DO NOT move the shift lever assembly adjustment nut if replacing the control lever. Remove the control lever. 2. Remove the control lever boot retainer plastic retainers, if necessary. 3. Remove the control lever boot retainer, if necessary. 4. Remove the control lever boot screws, if necessary. 5. Remove the control lever boot, if necessary. 6. Remove the control lever insulator, if necessary. Installation Procedure Page 12814 Page 9425 Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA and/or the secondary locks. Micro .64 Connectors MICRO .64 CONNECTORS TOOLS REQUIRED J 38125-D Terminal Repair Kit REMOVAL PROCEDURE Follow the steps below in order to remove terminals from Micro 64 connectors. 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. 2. Disconnect the connector from the component. SRS - Air Bag Lamp ON/DTC B0092 Set Seat Occupant Sensor: All Technical Service Bulletins SRS - Air Bag Lamp ON/DTC B0092 Set Bulletin No.: 02-09-41-002A Date: March 24, 2004 TECHNICAL Subject: Air Bag Lamp On, Passenger Air Bag Indicator Always Reads OFF, DTC B0092 Set (Repair Passenger Presence System (PPS) Sensor Harness) Models: 2003-2004 Cadillac Escalade, Escalade EXT 2003-2004 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2003-2004 GMC Sierra, Yukon, Yukon XL with Sensor Indicator Inflatable Restraint Front Passenger/Child Presence Detector (RPO ALO) Supercede: This bulletin is being revised to add the 2004 model year. Please discard Corporate Bulletin Number 02-09-41-002 (Section 09 - Restraints). Condition Some customers may comment that the Air Bag Lamp is on and the Passenger Air Bag indicator always reads OFF. Upon investigation, the technician may find DTC B0092 set. Cause The cause of this condition may be a shorted Passenger Presence System (PPS) sensor wire. The PPS sensor harness is located under the front passenger seat. This harness may be pinched between the seat frame and the track/riser. Correction Locate the PPS sensor (1) and inspect the harness for proper routing. If the harness is pinched between the seat frame and the track/riser, use the procedure listed below to repair wire(s). 1. Move the front passenger seat to the full rearward and full tilt up position. 2. Loosen the seat frame to track/riser nut and remove the harness. 3. Tighten the seat frame to track/riser nut. 4. Repair any damaged wires. Refer to Wiring Repairs in the Wiring Systems sub-section of the Service Manual. Warranty Information Page 8638 Ambient Light Sensor: Service and Repair AMBIENT LIGHT SENSOR REPLACEMENT REMOVAL PROCEDURE 1. Remove the instrument panel top cover. 2. Disconnect the electrical connector (1) to the ambient light sensor on the underside of the IP top cover. 3. Turn the ambient light sensor 1/4 turn and remove it from the IP top cover. INSTALLATION PROCEDURE 1. Install the ambient light sensor to the underside of the IP top cover, turning it 1/4 turn to secure it in place. 2. Connect the electrical connector (1) to the ambient light sensor on the underside of the IP top cover. 3. Install the instrument panel top cover. Page 6930 6. Install the tripot spider assembly (3) onto the halfshaft bar (2). 7. Install the spacer ring (1) in the groove at the end of the halfshaft bar (2). Page 3856 Remove all rust from the ground terminal, the cylinder head and the retaining nut or bolt. Position the main engine wiring harness ground terminal and install the nut or bolt. Tighten: Tighten the retaining nut or bolt to 16 N.m (12 lb ft). Apply some type of electrical moisture sealant to protect the harness terminal from further corrosion. Disclaimer Page 13700 5. At the pilot hole location, drill 11.5 mm (29/64 in) hole through the pillar. Important: Prior to refinishing, refer to Publication GM 4901M-D-2000 GM Approved Refinish Materials for recommended products. Do not combine paint systems. Refer to paint manufacturer's recommendations. 6. Apply an approved anti-corrosion primer to all bare metal surfaces. 7. Feed fish wire GM P/N 15017229 through the hinge, the hinge pillar and out the conduit hole in the pillar. 8. Install stud GM P/N 15017230 into the end of the fish wire and pull the stud into position. 9. Hold the stud in position with the hinge and remove the fish wire. 10. Install nut GM P/N 11516746 on the stud and draw the stud through the pillar. This will seat the stud and prevent it from splitting. 11. Repeat steps 7-10 on the remaining stud locations. 12. Remove the nuts and hinge. 13. Apply a full-bodied caulk to the entire hinge mounting surface to ensure a proper seal. 14. Align the hinge and install using fasteners supplied. 15. Torque the hinge bolts to 25 N.m (18 ft lb). 16. Modify the door side hinge lower extensions (1), if installing the original access door without a door side service hinge or a used access door. Page 1365 Door Switch: Diagrams Door Latch Assembly (Door Jamb Switch) - RR C2 (Crew Cab Only) Door Latch Assembly (Door Jamb Switch) - RR C2 (Crew Cab Only) Page 11312 The new calibrations have been updated to compensate for the actuator overtravel condition, the actuator hunting and the ticking/clicking noises. The new calibrations effectively eliminate the codes listed above, the default position of the doors associated with the DTCs and opens up the feedback position value. The new calibrations should not be used unless the vehicle has one or more of the customer concerns listed above or a DTC listed above has been set. The new calibrations will not correct any other DTC or NC system performance concern. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 1324 Air Temperature Sensor - Upper Right Page 7175 1. Position the NEW seal in the front case with the part number facing out. 2. Using J 44731 install the input shaft seal. 3. Notice: Refer to Fastener Notice in Service Precautions. Position the clutch actuator cylinder. 4. Install the clutch actuator cylinder bolts. ^ Tighten the bolts to 8 Nm (71 inch lbs.). 5. Install the transmission. 6. Install the rear propeller shaft. 7. Check the transmission fluid level. Add if necessary. 8. Lower the vehicle. Transmission Output Shaft Seal Replacement Transmission Output Shaft Seal Replacement ^ Tools Required J 6125-1B Slide Hammer - J 44732 Output Shaft Oil Seal Installer - J 23129 Universal Seal Remover - J 8614-01 Pinion Flange Holder Removal Procedure Page 4181 Knock Sensor: Service and Repair KNOCK SENSOR (KS) REPLACEMENT REMOVAL PROCEDURE 1. Remove the intake manifold. 2. Gently pry up the rubber covers. 3. Disconnect the knock sensor electrical connectors. 4. Remove the knock sensors. INSTALLATION PROCEDURE NOTE: Refer to Fastener Notice in Service Precautions. Page 10292 Steering Shaft: Service and Repair Intermediate Steering Shaft Replacement - Lower Intermediate Steering Shaft Replacement - Lower ^ Tools Required J 42640 Steering Column Anti-Rotation Pin Removal Procedure Caution: Refer to SIR Caution in Service Precautions. Notice: The wheels of the vehicle must be straight ahead and the steering column in the LOCK position before disconnecting the steering column or intermediate shaft from the steering gear. Failure to do so will cause the SIR coil assembly to become uncentered, which may cause damage to the coil assembly. 1. Set the front wheels in the straight-ahead position. 2. Install the J 42640 in the steering column lower access hole. 3. For vehicles equipped with a 6.6L Diesel, remove the left charge air cooler hose. 4. Mark the relationship of the intermediate shaft components in order to assure proper installation. 1. Mark the relationship of the upper intermediate shaft to the lower intermediate shaft. 2. Mark the relationship of the lower shaft coupler to the steering gear input shaft. 5. Remove the bolt from the upper to lower shaft connection. 6. Remove the bolt from the lower shaft coupler. 7. Remove the intermediate shaft assembly. Slide the shaft towards the dash in order to get the lower shaft coupler clear of the steering gear input shaft. 8. Slide the intermediate shaft down out of the upper shaft. Installation Procedure Page 9604 Relay Block - I/P C9 Part 2 Page 15109 1. Install the weatherstrip (1) to the door opening flange. 2. Install the rear quarter trim panel. 3. Install the center pillar molding. 4. Install the rear door sill plate. 5. Close the rear door. Restraints - Passenger Presence System Information Seat Occupant Sensor: All Technical Service Bulletins Restraints - Passenger Presence System Information INFORMATION Bulletin No.: 06-08-50-009F Date: December 23, 2010 Subject: Information on Passenger Presence Sensing System (PPS or PSS) Concerns With Custom Upholstery, Accessory Seat Heaters or Other Comfort Enhancing Devices Models: 2011 and Prior GM Passenger Cars and Trucks Equipped with Passenger Presence Sensing System Supercede: This bulletin is being revised to update the model years. Please discard Corporate Bulletin Number 06-08-50-009E (Section 08 - Body and Accessories). Concerns About Safety and Alterations to the Front Passenger Seat Important ON A GM VEHICLE EQUIPPED WITH A PASSENGER SENSING SYSTEM, USE THE SEAT COVERS AND OTHER SEAT-RELATED EQUIPMENT AS RELEASED BY GM FOR THAT VEHICLE. DO NOT ALTER THE SEAT COVERS OR SEAT-RELATED EQUIPMENT. ANY ALTERATIONS TO SEAT COVERS OR GM ACCESSORIES DEFEATS THE INTENDED DESIGN OF THE SYSTEM. GM WILL NOT BE LIABLE FOR ANY PROBLEMS CAUSED BY USE OF SUCH IMPROPER SEAT ALTERATIONS, INCLUDING ANY WARRANTY REPAIRS INCURRED. The front passenger seat in many GM vehicles is equipped with a passenger sensing system that will turn off the right front passenger's frontal airbag under certain conditions, such as when an infant or child seat is present. In some vehicles, the passenger sensing system will also turn off the right front passenger's seat mounted side impact airbag. For the system to function properly, sensors are used in the seat to detect the presence of a properly-seated occupant. The passenger sensing system may not operate properly if the original seat trim is replaced (1) by non-GM covers, upholstery or trim, or (2) by GM covers, upholstery or trim designed for a different vehicle or (3) by GM covers, upholstery or trim that has been altered by a trim shop, or (4) if any object, such as an aftermarket seat heater or a comfort enhancing pad or device is installed under the seat fabric or between the occupant and the seat fabric. Aftermarket Seat Heaters, Custom Upholstery, and Comfort Enhancing Pads or Devices Important ON A GM VEHICLE EQUIPPED WITH A PASSENGER SENSING SYSTEM, USE ONLY SEAT COVERS AND OTHER SEAT-RELATED EQUIPMENT RELEASED AS GM ACCESSORIES FOR THAT VEHICLE. DO NOT USE ANY OTHER TYPE OF SEAT COVERS OR SEAT-RELATED EQUIPMENT, OR GM ACCESSORIES RELEASED FOR OTHER VEHICLE APPLICATIONS. GM WILL NOT BE LIABLE FOR ANY PROBLEMS CAUSED BY USE OF SUCH IMPROPER SEAT ACCESSORIES, INCLUDING ANY WARRANTY REPAIRS MADE NECESSARY BY SUCH USE. Many types of aftermarket accessories are available to customers, upfitting shops, and dealers. Some of these devices sit on top of, or are Velcro(R) strapped to the seat while others such as seat heaters are installed under the seat fabric. Additionally, seat covers made of leather or other materials may have different padding thickness installed that could prevent the Passenger Sensing System from functioning properly. Never alter the vehicle seats. Never add pads or other devices to the seat cushion, as this may interfere with the operation of the Passenger Sensing System and either prevent proper deployment of the passenger airbag or prevent proper suppression of the passenger air bag. Disclaimer Page 8603 visible in the clear adapter tube). If fluid is seen coming out of the inlet port adapter up to 65 Nm (48 lb-ft) maximum torque, the hydro-boost booster assembly is "OK", Proceed to Step 19. A. If NO fluid is seen exiting from the inlet port adapter, complete Steps 19-27 and then repeat Steps 1-18. B. If no fluid is visible from the second evaluation, replace the hydro-boost unit. Proceed to the appropriate procedure found in this bulletin. 19. Loosen the clamp bolt, remove the clamp containment bolt, and remove the accumulator pressure clamp. Remove the inlet port adapter from the supply port of the booster. Wipe the excess power steering fluid off of the adapter with a clean, lint-free shop cloth. Store the adapter in a clean location, such as a plastic bag. 20. Reinstall the supply hose/tube to the booster. Tighten Tighten to 28 N.m (21 lb-ft). 21. Clean any spilled fluid from the outside of the booster. 22. For Express/Savana only: ^ Connect the reservoir outlet hose to the booster unit. Keeping the hose end higher than reservoir, reposition the reservoir onto the mounting studs. A. Install the remote power steering reservoir mounting nuts. Tighten Tighten to 7 Nm (58 lb in). 23. Start the engine and run at idle. Depress the brake pedal 5 times. Turn the steering wheel to the "steering lock" position. Hold for 1-2 seconds. Check to see if there is any leakage from the ports/fittings. 24. Turn the engine off. 25. If leaks were observed, re-check that the fittings are at the recommended torque values. Repeat Steps 17 and 18. 26. Check the power steering reservoir fluid level, add fluid if necessary. 27. Close the hood. Hydro-Boost(R) Replacement - Avalanche, Express, Savana, Silverado, Sierra, Suburban, Yukon XL Tools Required ^ J 35555 Metal Mityvac ^ J 43485 Power Steering Bleeder Adapter Removal 1. Apply the park brake and block the wheels. Page 8459 Use clean, new power steering fluid only. 12. Fill the pump reservoir with fluid to the FULL COLD level. 13. Attach J 43485, Power Steering Bleeder Adapter, to J 35555, Metal Mityvac, or equivalent. 14. Place J 43485 on or in the pump reservoir filler neck. 15. Apply a vacuum of 68 kPa (20 in Hg) maximum. 16. Wait 1 minute. 17. Remove J 43485 and J 35555. 18. Reinstall the pump reservoir cap. 19. Start the engine. Allow the engine to idle. 20. Turn the steering wheel 180-360 degrees in both directions 5 times. 21. Switch the ignition off 22. Verify the fluid level. 23. Release the park brake and unblock the wheels. Hydro-Boost(R) Replacement -- Kodiak, TopKick Tools Required ^ J 35555 Metal Mityvac ^ J 43485 Power Steering Bleeder Adapter Removal 1. Block the wheels. 2. Disconnect the electrical connectors from the electrohydraulic pump and the flow switch. Page 1483 Fog Lamp Switch Rear (With RPO Code T79) Automatic Transmission - 4L60-E/4L65-E Shift Solenoid: Locations Automatic Transmission - 4L60-E/4L65-E Automatic Transmission Electronic Component Views (M30/M32) Automatic Transmission Electronic Component Views (M30/M32) Electronic Components Page 8715 Wheel Speed Sensor: Locations ABS Component Views Wheel Speed Sensor (WSS) - RF and LF Page 7233 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the cover up until the dress cover releases. Repeat this procedure for the other locking tab. 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. 5. If the connector has a nose piece, use a small flat-blade tool to remove the nose piece by inserting the blade into the slot on the front of the connector and prying up on the nose piece. IMPORTANT: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 6. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. IMPORTANT: Be careful not to angle or rock the J 38125-13A tool when inserting it into the connector or the tool may break. Page 10990 ^ Reinstall the fuse and fuse panel cover. ^ Press the "Enter" button to perform the "Refresh" function. ^ "Test in Progress" will be displayed and the right front passenger door lock will cycle once. ^ The screen will display "Procedure Completed". ^ Press the "Exit" button as necessary to return to the main menu screen. 3. Using the switches in the right front passenger door, verify that the power window and power door lock located in that door function properly. Important: The calibrations required for performing SPS reprogram in the next step are based on the type of exterior rearview mirror the vehicle has. To determine the correct calibration, check the Service Parts Identification Label on the vehicle for the RPO code for exterior mirrors. 4. Follow normal Service Programming System (SPS) to reprogram the passenger door module with the current calibration available in TIS 2000. 5. After reprogramming is complete, using the switches in the right front passenger door, verify that the power window and power door lock located in that door function properly. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 5802 1. Lubricate the output speed sensor seal with automatic transmission fluid. 2. Install the output speed sensor (2). Notice: Refer to Fastener Notice in Service Precautions. 3. Install the output speed sensor bolt. ^ Tighten the bolt to 11 Nm (96 inch lbs.). 4. Connect the output speed sensor (2) electrical connector. 5. Lower the vehicle. Page 7039 Page 3799 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Weather Pack Connectors WEATHER PACK CONNECTORS The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. Diagram Information and Instructions Body Control Module: Diagram Information and Instructions Truck Zoning TRUCK ZONING Truck Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that corresponds to where they are located in the vehicle. The table explains the numbering system. Page 14227 Disclaimer Page 13234 The control module ID number list above provides a method for determining which module is not communicating. A module with a class 2 serial data circuit malfunction or which loses power during the current ignition cycle will have a Loss of Communication DTC set by other modules that depend on information from that failed module. The modules that can communicate will set a DTC indicating the module that cannot communicate. Diagnostic Order When more than one Loss of Communication DTC is set in either one module or in several modules, diagnose the DTCs in the following order: 1. Current DTCs before history DTCs unless told otherwise in the diagnostic table. 2. The DTC which is reported the most times. 3. From the lowest number DTC to the highest number DTC. Conditions for Running the DTC The following DTCs do not have a current status: ^ B1327 ^ B1328 ^ U1300 ^ U1301 ^ U1305 AND ^ The vehicle power mode requires serial data communication to occur. Conditions for Setting the DTC A node alive message has not been received from a module with a learned identification number within the last 5 seconds. Action Taken When the DTC Sets Page 10995 Blower Motor Resistor: Service and Repair Blower Motor Replacement (Delphi) BLOWER MOTOR REPLACEMENT (DELPHI) REMOVAL PROCEDURE 1. If equipped, remove the sound insulator panel. 2. Remove the blower motor insulating cover screws. 3. Disconnect the electrical connector from the blower motor. 4. Remove the blower motor insulating cover. 5. Pull the retaining tab down while turning the blower motor counterclockwise in order to disengage the blower motor from the heater/ventilation module. Drivetrain - Excessive Effort When Shift 2HI to 4HI Differential Fluid - M/T: All Technical Service Bulletins Drivetrain - Excessive Effort When Shift 2HI to 4HI TECHNICAL Bulletin No.: 09-04-19-002A Date: February 17, 2011 Subject: 4WD System Shift Performance in Cold Ambient Temperatures (Use Synthetic Fluid in Light Duty Front Axles with 8.5" Ring Gears) Models: 1999-2011 Chevrolet Silverado 1500 Series Models 1999-2011 GMC Sierra 1500 Series Models Equipped with 4WD and 8.25" Front Axle Ring Gears (Transfer Case RPOs NP2, NQG) Attention: It is important to determine the RPO for the transfer case in GWM/IVH prior to applying this bulletin. This bulletin applies ONLY to vehicles equipped with 8.25" front axle ring gears, used in conjunction with a manual transfer case (RPOs NP2, NQG). Supercede: This bulletin is being revised to add the 2011 model year. Please discard Corporate Bulletin Number 09-04-19-002 (Section 04 - Driveline/Axle). Condition Some customers may comment about the effort required to shift from 2HI to 4HI in cold ambient temperatures at -6°C (20°F) or below. Cause This condition may be caused by the standard front axle being equipped with conventional mineral oil axle fluid. In cold ambient temperatures, prior to complete warm up, the fluid viscosity is thick. This may affect transfer case shift performance prior to full warm up. Correction Drain the front axle fluid and refill with GM SAE 75W-90 Synthetic Axle Fluid, P/N 89021677 (in Canada, 89021678). Refer to Front Axle Lubricant Replacement in SI. It is important to use synthetic fluid in this 8.25" axle to improve the performance of the 4WD system in cold ambient temperatures. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 14951 Important: After drilling the holes, apply the appropriate anti-corrosion primer. Refer to the GM Refinish Material Booklet # 4901 M-D (English) or # 4901-D-F (French) for additional information. 6. Center punch the marked location and drill a 6.35 mm (1/4 in) hole. Install the plastic retainer in the hole (1) of the mud flap. 7. Tighten fastener at the hole (2) location of the mud flap. Tighten Tighten the fastener to 25 N.m (18 lb ft). 8. For vehicles with short box, use the following procedure: 8.1. Push the mud flap to make contact with the rear side of the underbody cross sill and mark the location of the hole (3) of the mud flap. 8.2. Center punch the marked location and drill a 5.159 mm (13/64 in) hole. 8.3. Install the screw. Tighten Tighten the screw to 4 N.m (35 lb in). 8.4. Repeat the above steps for hole locations 4 and 6. 9. For vehicles with long box, use the following procedure: Page 1582 5. Connect the fuel pump electrical connector. 6. Install the sending unit. Service and Repair Air Bag(s) Arming and Disarming: Service and Repair SIR Disabling and Enabling The SIR Identification Views shown below illustrate the approximate location of all SIR components available for the vehicle. This will assist in determining the appropriate SIR Disabling and Enabling for a given service procedure. Refer to See: Restraint Systems/Air Bag Systems/Locations/SIR Zone Identification Views There are several reasons for disabling the SIR system, such as repairs to the SIR system or servicing a component near or attached to an SIR component. There are several ways to disable the SIR system depending on what type of service is being performed. The following information covers the proper procedures for disabling/enabling the SIR system. SIR Service Precautions Caution: When performing service on or near the SIR components or the SIR wiring, the SIR system must be disabled. Failure to observe the correct procedure could cause deployment of the SIR components. Serious injury can occur. Failure to observe the correct procedure could also result in unnecessary SIR system repairs. The inflatable restraint sensing and diagnostic module (SDM) maintains a reserved energy supply. The reserved energy supply provides deployment power for the air bags if the SDM loses battery power during a collision. Deployment power is available for as much as 1 minute after disconnecting the vehicle power. Waiting 1 minute before working on the system after disabling the SIR system prevents deployment of the air bags from the reserved energy supply. General Service Instructions The following are general service instructions which must be followed in order to properly repair the vehicle and return it to its original integrity: - Do not expose inflator modules to temperatures above 65°C (150°F). - Verify the correct replacement part number. Do not substitute a component from a different vehicle. - Use only original GM replacement parts available from your authorized GM dealer. Do not use salvaged parts for repairs to the SIR system. Discard any of the following components if it has been dropped from a height of 91 cm (3 feet) or greater: - Inflatable restraint sensing and diagnostic module (SDM) - Any Inflatable restraint air bag module - Inflatable restraint steering wheel module coil - Any Inflatable restraint sensor - Inflatable restraint seat belt pretensioners - Inflatable restraint Passenger Presence System (PPS) module or sensor Disabling Procedure - Air Bag Fuse 1. Turn the steering wheel so that the vehicles wheels are pointing straight ahead. 2. Place the ignition in the OFF position. Important: The SDM may have more than one fused power input. To ensure there is no unwanted SIR deployment, personal injury, or unnecessary SIR system repairs, remove all fuses supplying power to the SDM. With all SDM fuses removed and the ignition switch in the ON position, the AIR BAG warning indicator illuminates. This is normal operation, and does not indicate a SIR system malfunction. 3. Locate and remove the fuse(s) supplying power to the SDM. Page 16051 Control Module References Part 5 Page 375 4.2. Release the back end of the connector (C) and remove from the contact rail (D). 4.3. M00-01: Disconnect pin 39, cut off the cable terminal and insulate the end using tape (E). Fold back the cable and secure using tape (F). 4.4. M02-04: Disconnect pin 58, cut off the cable terminal and insulate the end using tape (E). Fold back the cable and secure using tape (F). 4.5. Assemble the contact rail and end. 4.6. Connect connector (A) and secure the cable using a cable tie (B). 5. Assemble the gear shift housing (A). AUT: Connect connector (B). 6. Assemble the center console, see WIS - Body - Interior. 7. Remove the OnStar(R) control module and secure the cable harness: 7.1. 5D: Remove the right-hand cover from the luggage compartment floor. Locations Air Temperature Sensor - Outside Page 15108 Rear Door Weatherstrip: Service and Repair Rear Door Weatherstrip Replacement Weatherstrip Replacement - Rear Door Removal Procedure 1. Open the rear door. 2. Remove the rear door sill plate. 3. Remove the center pillar molding. 4. Remove the rear quarter trim panel. 5. Remove the weatherstrip (1) from the door opening flange. Installation Procedure Page 10268 Steering Mounted Controls Transmitter: Service and Repair Steering Wheel Control Switch Assembly Replacement Removal Procedure 1. Remove the steering wheel. 2. Remove the shroud retaining screws from the back of the steering wheel. 3. Remove the shroud from the steering wheel. 4. Position a blunt ended tool into the wire harness cavity (1) and apply moderate pressure in order to partially remove the steering wheel control switch from the steering wheel. 5. Disconnect the steering wheel control switch electrical connector. 6. Important: The bulbs in the steering wheel control switches are not serviceable. The switches should be replaced only as an assembly. Remove the steering wheel control switch from the steering wheel. Installation Procedure Page 14198 Power Door Lock Switch: Removal and Replacement Switch Replacement - Door Lock and Side Window - Driver Switch Replacement - Door Lock and Side Window - Driver Removal Procedure 1. Remove the front door trim panel. 2. Disconnect the electrical connectors. 3. Remove the screw that retains the switch panel bezel (1) from the front door panel. 4. Remove the switch panel bezel from the door panel using a flat-bladed tool. 5. Using a wide plastic flat-bladed tool, release the retaining clips on both sides of the door module. 6. Remove the door module from the switch panel bezel. Page 2745 Junction Block - I/P Wire Entry Part 4 Page 11367 Air Temperature Sensor - Lower Right Page 6090 4. Tighten the bolt on J 29714-A in order to compress the servo cover. 5. Install the servo cover ring. 6. Remove the J 29714-A. 7. Notice: Refer to Fastener Notice in Service Precautions. Install the oil pan bolt. ^ Tighten the bolt to 11 Nm (97 inch lbs.). 8. Install the heat shield and bolts. ^ Tighten the bolts to 17 Nm (13 ft. lbs.). 9. Install the exhaust pipe. 10. Fill the transmission to the proper level with DEXRON® III transmission fluid. Page 15107 Rear Door Weatherstrip: Service and Repair Weatherstrip Replacement - Side Door Opening Weatherstrip Replacement - Side Door Opening Removal Procedure 1. Open both doors. 2. Remove the sill plate. 3. Remove the hinge pillar trim pillar. 4. Remove the windshield pillar molding. 5. Remove the weather-strip from the rear side door pinch-weld flange. Installation Procedure 1. Install the weather-strip from the rear side door opening fully seating the weather-strip into the pinch-weld flange. 2. Install the windshield pillar molding. 3. Install the hinge pillar trim pillar. 4. Install the sill plate. 5. Inspect the door closing effort and seal to door fit. Page 3167 3. Notice: The heater cord must not touch the engine, hot pipes, manifold, or any moving parts. Route the cord to the left front of the engine compartment securing with tie straps as necessary to prevent damage. Connect the coolant heater electrical connector (2). 4. Lower the vehicle. 5. Fill the cooling system. Page 2012 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Page 2207 Important The new canister vent valve will be installed in a new location, outside of the frame. 7. Position and secure the new valve assembly to the frame bracket on the outside of the frame using the existing hole and mounting bolt. Tighten Tighten the bracket mounting bolt to 12 Nm (106 lb in). 8. Connect the vent valve pipe to the EVAP canister. 9. Install the two vent valve pipe clips into the existing underbody holes. 10. Connect the EVAP canister vent valve electrical connector, if equipped. 11. Attach bulk 5/8" heater hose to the vent valve port and secure using a clamp. Run a length as needed along the frame rail routing to the area above the transmission. 12. Cut the hose to determined length and install the supplied filter box. Secure using a clamp. 13. Remove the transmission support and lower the transmission assembly as necessary to allow for access to the new filter box location. 14. Secure the filter box to the transmission vent hose just forward of the hose tee-section using a tie strap. DO NOT pinch or restrict the transmission vent hose. The filter box opening should be pointing downward. 15. Raise the transmission and reinstall the transmission support. 16. Tie strap the hose as needed along the frame rail in order to keep the hose away from pinch-points and heat sources. 17. Lower the vehicle. 2004-2007 Model Year (Use Service Kit P/N 19152349) 1. Raise the vehicle. Suitably support the vehicle. 2. Disconnect the EVAP canister vent valve electrical connector. 3. Disconnect the canister pipe from the vent valve. 4. Push in the retainer and remove the existing canister vent valve from the fuel tank clip or mounting bracket. Discard the old valve. 5. Cut back the existing canister pipe approximately 51 mm (2 in) to remove the quick connect end. Crew Cab Short Box Shown Below, Other Configurations Similar Page 15940 Electrical Symbols Part 13 Page 15032 2. Install the cable to the Anchor Bolt. 3. Close the endgate. Page 4935 1. Lubricate a NEW O-ring seal with transmission fluid. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the VSS and bolt. ^ Tighten the bolt to 10 Nm (89 inch lbs.). 3. If equipped with the 8.1L engine, connect the VSS electrical connector (5). 4. If equipped with the 6.6L engine, connect the VSS electrical connector (4). 5. Lower the vehicle. 6. Check the transmission fluid level. Add if necessary. Electrical - No Module Communication/DTCs/Warning Lamps Wiring Harness: All Technical Service Bulletins Electrical - No Module Communication/DTCs/Warning Lamps Bulletin No.: 03-08-50-014A Date: January 20, 2006 TECHNICAL Subject: No Communication with Any Modules, Memory Seat May Not Recall, Multiple U-DTCs Set or Instrument Panel Cluster (IPC) Warning Indicators, Crank No Start (Inspect/Repair Affected Wiring Harness) Models: 2003-2006 Cadillac Escalade, Escalade ESV, Escalade EXT 2003-2006 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2003-2006 GMC Sierra, Yukon, Yukon XL with Front, Individual (Non-Bkt) Seat (RPO AN3) and/or Active Brake Control (Stabilitrak(R)) (RPO JL4) Supercede: This bulletin is being revised to update the various conditions and add the 2004-2006 model years, additional diagnostic and warranty information. Please discard Corporate Bulletin Number 03-08-50-014 (Section 08 - Body & Accessories). Condition Some customers may comment on any of the following conditions: ^ Various IPC Warning indicators are coming on. ^ Driver Information Center (DIC) displays "Unknown Driver". ^ Memory seat may not recall. ^ RKE fobs may be inoperative. ^ Radio or HVAC may shut off. ^ Engine cranks but will not start. Upon investigation, the Technician may find multiple U-DTCs set. Cause On RPO AN3 equipped vehicles, a chafed or pinched seat wiring harness under the driver seat may be a cause of this condition. Because of the routing, a portion of the seat wiring harness may rest on the inboard edge of the seat track or frame. Over time, the harness may be pinched or chafed because of the seat movement. Refer to the above illustration. The illustration shows the inverted position of the seat bottom. The arrow shows the primary location Page 7723 1. Notice: Refer to Fastener Notice in Service Precautions. Install the left rear speed sensor. ^ Tighten the speed sensor to 15 Nm (11 ft. lbs.). 2. Connect the left rear speed sensor electrical connector (4) 3. Lower the vehicle. Transfer Case Speed Sensor Replacement - Right Rear Transfer Case Speed Sensor Replacement - Right Rear Removal Procedure 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. Disconnect the right rear speed sensor electrical connector (3). Page 13221 Page 13707 Rear Door Latch: Service and Repair Latch Replacement - Side Door Lower Latch Replacement - Side Door Lower Removal Procedure 1. Remove the door trim panel. 2. Remove the latch retaining nuts. 3. Disconnect the latch rod from the latch. Installation Procedure 1. Install the latch rod to the latch. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the latch to the door. Tighten the bolts to 9 N.m (80 lb in). 3. Install the latch retaining bolts. Page 2756 Junction Block - I/P Wire Entry Part 1 Page 1435 Ambient Light Sensor: Service and Repair AMBIENT LIGHT SENSOR REPLACEMENT REMOVAL PROCEDURE 1. Remove the instrument panel top cover. 2. Disconnect the electrical connector (1) to the ambient light sensor on the underside of the IP top cover. 3. Turn the ambient light sensor 1/4 turn and remove it from the IP top cover. INSTALLATION PROCEDURE 1. Install the ambient light sensor to the underside of the IP top cover, turning it 1/4 turn to secure it in place. 2. Connect the electrical connector (1) to the ambient light sensor on the underside of the IP top cover. 3. Install the instrument panel top cover. Page 4341 Body Control Module (BCM) - C6 Part 1 Page 15359 Malfunction Indicator Lamp: Service and Repair SERVICE VEHICLE SOON INDICATOR The "SERVICE VEHICLE SOON" light will come on if there are certain non-emission related vehicle problems. These problems may not be obvious and may affect vehicle performance or durability. The light will come on briefly when the ignition is turned on to show that it is working properly. This light does NOT come on at certain mileage intervals. There is probably a PCM or a BCM Code set that will aid you in diagnosis. RESET PROCEDURE The only way to get the light to go off is to clear the PCM or BCM code(s). This light can NOT be reset or shut off any other way. PCM/BCM codes should be read & repaired before clearing them. Page 9309 Junction Block - Rear Lamps - C2 Page 5819 Page 6860 9. Measure the torque required in order to rotate the pinion. Use an inch-pound torque wrench. Record the torque value for reassembly. This will give the combined preload for the following components: ^ The pinion bearings ^ The pinion seal ^ The carrier bearings ^ The axle bearings ^ The axle seals 10. Scribe an alignment line between the pinion shaft and the pinion yoke. 11. Install the J 8614-01 onto the pinion as shown. 12. Remove the pinion nut while holding the J 8614-01. Page 12332 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly, Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Pull to Seat Connectors PULL TO SEAT CONNECTORS TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Page 12353 Control Module References Part 2 Page 3121 Compression Check: Testing and Inspection Engine Compression Test 1. Charge the battery if the battery is not fully charged. 2. Disable the ignition system. 3. Disable the fuel injection system. 4. Remove all the spark plugs. 5. Turn the ignition to the ON position. 6. Depress the accelerator pedal to position the throttle plate wide open. 7. Start with the compression gage at zero and crank the engine through four compression strokes, four puffs. 8. Check the compression for each cylinder. Record the readings. 9. If a cylinder has low compression, inject approximately 15 ml (1 tablespoon) of engine oil into the combustion chamber through the spark plug hole. Check the compression again and record the reading. 10. The minimum compression in any one cylinder should not be less than 70 percent of the highest cylinder. No cylinder should read less than 690 kPa (100 psi). For example, if the highest pressure in any one cylinder is 1 035 kPa (150 psi), the lowest allowable pressure for any other cylinder would be 725 kPa (105 psi). (1 035 x 70% = 725) (150 x 70% = 105). ^ Normal - Compression builds up quickly and evenly to the specified compression for each cylinder. ^ Piston Rings Leaking - Compression is low on the first stroke. Compression builds up with the following strokes, but does not reach normal. Compression improves considerably when you add oil. ^ Valves Leaking - Compression is low on the first stroke. Compression usually does not build up on the following strokes. Compression does not improve much when you add oil. ^ If two adjacent cylinders have lower than normal compression, and injecting oil into the cylinders does not increase the compression, the cause may be a head gasket leaking between the cylinders. Locations Mass Air Flow (MAF) Sensor: Locations Right Side Of The Engine Compartment Page 10883 Electrical Symbols Part 5 Diagram Information and Instructions Body Control Module: Diagram Information and Instructions Truck Zoning TRUCK ZONING Truck Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that corresponds to where they are located in the vehicle. The table explains the numbering system. Page 442 - HVAC Actuator - Inflatable Restraint Sensing and Diagnostic Module (SDM) - Any AIR BAG module - Seatbelt Lap Anchor Pretensioner - Seatbelt Retractor Pretensioner - An SIR system connection or connector condition resulting in the following DTCs being set: B0015, B0016, B0019, B0020, B0022, or B0023 - Powertrain Control Module (PCM) - Remote Control Door Lock Receiver (RCDLR) - Transmission Control Module (TCM) Correction Important DO NOT replace the control module, wiring or component for the following conditions: - The condition is intermittent and cannot be duplicated. - The condition is present and by disconnecting and reconnecting the connector the condition can no longer be duplicated. Use the following procedure to correct the conditions listed above. 1. Install a scan tool and perform the Diagnostic System Check - Vehicle. Retrieve and record any existing history or current DTCs from all of the control modules (refer to SI). ‹› If any DTC(s) are set, refer to Diagnostic Trouble Code (DTC) List - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). ‹› If DTCs are not set, refer to Symptoms - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). 2. When identified, use the appropriate DTC Diagnostics, Symptoms, Schematics, Component Connector End Views and Component Locator documents to locate and disconnect the affected harness connector(s) which are causing the condition. Note Fretting corrosion looks like little dark smudges on electrical terminals and appear where the actual electrical contact is being made. In less severe cases it may be unable to be seen or identified without the use of a magnifying glass. Important DO NOT apply an excessive amount of dielectric lubricant to the connectors as shown, as hydrolock may result when attempting to mate the connectors. Use ONLY a clean nylon brush that is dedicated to the repair of the conditions in this bulletin. 3. With a one-inch nylon bristle brush, apply dielectric lubricant to both the module/component side and the harness side of the affected connector(s). 4. Reconnect the affected connector(s) and wipe away any excess lubricant that may be present. 5. Attempt to duplicate the condition by using the following information: - DTC Diagnostic Procedure - Circuit/System Description - Conditions for Running the DTC - Conditions for Setting the DTC - Diagnostic Aids - Circuit/System Verification ‹› If the condition cannot be duplicated, the repair is complete. ‹› If the condition can be duplicated, then follow the appropriate DTC, Symptom or Circuit/System Testing procedure (refer to SI). Repair Order Documentation Page 14944 Important: After drilling the holes, apply the appropriate anti-corrosion primer. Refer to the GM Refinish Material Booklet # 4901 M-D (English) or # 4901-D-F (French) for additional information. 6. Center punch the marked location and drill a 6.35 mm (1/4 in) hole. Install the plastic retainer in the hole (1) of the mud flap. 7. Tighten fastener at the hole (2) location of the mud flap. Tighten Tighten the fastener to 25 N.m (18 lb ft). 8. For vehicles with short box, use the following procedure: 8.1. Push the mud flap to make contact with the rear side of the underbody cross sill and mark the location of the hole (3) of the mud flap. 8.2. Center punch the marked location and drill a 5.159 mm (13/64 in) hole. 8.3. Install the screw. Tighten Tighten the screw to 4 N.m (35 lb in). 8.4. Repeat the above steps for hole locations 4 and 6. 9. For vehicles with long box, use the following procedure: Page 4334 Body Control Module (BCM) - C2 Part 2 Page 15374 Page 10849 3. Connect the electrical connection at the mode actuator (10). 4. Install the floor air outlet duct extension (1) to the floor air duct (2). Recirculation Actuator (Delphi) RECIRCULATION ACTUATOR REPLACEMENT (DELPHI) REMOVAL PROCEDURE 1. Remove the air distribution duct. 2. Disconnect the electrical connection from the recirculation actuator (1). Locations SEO Harness Routing Page 5976 Torque Converter Clutch Solenoid: Service and Repair Torque Converter Clutch Pulse Width Modulation (TCC PWM) Solenoid, TCC Solenoid, and Wiring Harness ^ Tools Required J 28458 Seal Protector Retainer Installer Removal Procedure 1. Remove the transmission filter. 2. Disconnect the transmission harness 20-way connector (1) from the transmission internal harness pass-through connector. Depress both tabs on the connector and pull straight up; do not pry the connector. 3. Important: Removal of the valve body is not necessary for the following procedure. Remove the 1-2 accumulator. Do not remove the spacer plate. 4. Disconnect the internal wiring harness electrical connectors from the following components: ^ Transmission fluid pressure switch (1) ^ 1-2 shift control solenoid (2) ^ 2-3 shift control solenoid (3) ^ Pressure control solenoid (4) ^ Torque converter clutch pulse width modulation (TCC PWM) solenoid (5) ^ 3-2 control solenoid (6) 5. Remove the TCC PWM solenoid retainer. 6. Remove the TCC PWM solenoid in order to access one of the TCC solenoid bolts. Page 7049 Installation Procedure 1. Inspect the splines of the slip yoke for a sufficient coating of grease. If the splines of the slip yoke does not have a sufficient coating of grease, lubricate the shaft with grease, GM P/N 12345879 or equivalent, RWD w/ Automatic Transmission Only. 2. Install the propeller shaft into the transmission or transfer case. Align the reference marks made during removal. 3. Install the propeller shaft (3) to the rear axle pinion yoke (4). Align the reference marks made during removal. 4. Install the yoke retainers (2) and bolts (1). ^ Tighten the yoke retainer bolts to 25 Nm (18 ft. lbs.). Notice: Refer to Fastener Notice in Service Precautions. 5. Lower the vehicle. Page 7242 circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links CIRCUIT PROTECTION - FUSIBLE LINKS Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Flat Wire Repairs FLAT WIRE REPAIRS NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Heated Oxygen Sensor (HO2S) Wiring Repairs HEATED OXYGEN SENSOR (HO2S) WIRING REPAIRS TOOLS REQUIRED J 38125-D Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: - Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-D. Repairing Damaged Wire Insulation REPAIRING DAMAGED WIRE INSULATION Page 11607 2. Install the nut to the seat belt retractor. Tighten Tighten the nut to 52 N.m (38 lb ft). 3. Install the J-Clip under the center armrest. 4. Install the rear seat armrest. 5. Install the seat belt guide cover (1). Page 4680 Body Control Module (BCM) - C2 Part 1 Page 14301 WA8555/41 - WA8555/41 Page 16092 If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Sir/SRS Wiring Repairs SIR/SRS WIRING REPAIRS TOOLS REQUIRED J 38125-D Terminal Repair Kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-D contains the following items: - Special sealed splices - in order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping tool - A heat torch - An instruction manual The sealed splices have the following 2 critical features: - A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-D also serves as a generic terminal repair kit. The kit contains the following items: - A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors Engine, A/T - Shift/Driveability Concerns/MIL ON Air Filter Element: All Technical Service Bulletins Engine, A/T - Shift/Driveability Concerns/MIL ON Bulletin No.: 04-07-30-013B Date: February 01, 2007 INFORMATION Subject: Automatic Transmission Shift, Engine Driveability Concerns or Service Engine Soon (SES) Light On as a Result of the Use of an Excessively/Over-Oiled Aftermarket, Reusable Air Filter Models: 2007 and Prior GM Cars and Light Duty Trucks 2007 and Prior Saturn Models 2003-2007 HUMMER H2 2006-2007 HUMMER H3 2005-2007 Saab 9-7X Supercede: This bulletin is being revised to add models and model years. Please discard Corporate Bulletin Number 04-07-30-013A (Section 07 - Transmission/Transaxle). The use of an excessively/over-oiled aftermarket, reusable air filter may result in: Service Engine Soon (SES) light on Transmission shift concerns, slipping and damaged clutch(es) or band(s) Engine driveability concerns, poor acceleration from a stop, limited engine RPM range The oil that is used on these air filter elements may be transferred onto the Mass Air Flow (MAF) sensor causing contamination of the sensor. As a result, the Grams per Second (GPS) signal from the MAF may be low and any or all of the concerns listed above may occur. When servicing a vehicle with any of these concerns, be sure to check for the presence of an aftermarket reusable, excessively/over-oiled air filter. The MAF, GPS reading should be compared to a like vehicle with an OEM air box and filter under the same driving conditions to verify the concern. The use of an aftermarket reusable air filter DOES NOT void the vehicle's warranty. If an aftermarket reusable air filter is used, technicians should inspect the MAF sensor element and the air induction hose for contamination of oil prior to making warranty repairs. Transmission or engine driveability concerns (related to the MAF sensor being contaminated with oil) that are the result of the use of an aftermarket reusable, excessively/over-oiled air filter are not considered to be warrantable repair items. Page 14593 Memory Seat Module - C3 Part 2 Page 7886 Control Module: Service and Repair NVG 263-NP1 Transfer Case Shift Control Module Replacement Transfer Case Shift Control Module Replacement Removal Procedure 1. Disconnect the shift control module electrical connectors. 2. Unsnap and remove the shift control module from the bracket. Installation Procedure Page 7248 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves SPLICING COPPER WIRE USING SPLICE SLEEVES TOOLS REQUIRED J 38125-D Terminal Repair Kit IMPORTANT: Use only GM splice sleeves, other splice sleeves may not protect the splice from moisture or a provide good electrical connection. Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. Page 11294 - Proof of ownership at time of repair. - Original paid receipt confirming the amount of unreimbursed repair expense(s) (including Service Contract deductibles), a description of the repair, and the person or entity performing the repair. If the work was done by someone other than a GM dealership, the amount of reimbursement will be limited to the amount that the repair would have cost GM to have it completed by a GM dealership. Courtesy Transportation The General Motors Courtesy Transportation program is intended to minimize customer inconvenience when a vehicle requires a repair that is covered by the New Vehicle Limited Warranties. The availability of courtesy transportation to customers whose vehicles are within the warranty coverage period and involved in a product program is very important in maintaining customer satisfaction. Dealers are to ensure that these customers understand that shuttle service or some other form of courtesy transportation is available and will be provided at no charge. Dealers should refer to the General Motors Service Policies and Procedures Manual for Courtesy Transportation guidelines. Warranty Transaction Information Submit a transaction using the table below. * The amount identified in "Net Item" should represent the dollar amount reimbursed to the customer. Disclaimer Page 4501 Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA and/or the secondary locks. Micro .64 Connectors MICRO .64 CONNECTORS TOOLS REQUIRED J 38125-D Terminal Repair Kit REMOVAL PROCEDURE Follow the steps below in order to remove terminals from Micro 64 connectors. 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. 2. Disconnect the connector from the component. Page 14369 6. Use fingers to squeeze the 2 locking legs of the cover. 7. Apply pressure and gently rock the cover until one locking leg is unseated. 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. Page 8877 High Temperature Conditions Tools Required J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency MEASURING FREQUENCY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage MEASURING VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop MEASURING VOLTAGE DROP NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Page 9281 Location View Page 13368 For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to refer to the table above. Disclaimer Page 9233 C306 Infotainment Jumper Harness To Console Harness (With RPO Code Y91) Part 2 Page 14309 WA913L/56 - WA9260/74 Page 8885 Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA and/or the secondary locks. Micro .64 Connectors MICRO .64 CONNECTORS TOOLS REQUIRED J 38125-D Terminal Repair Kit REMOVAL PROCEDURE Follow the steps below in order to remove terminals from Micro 64 connectors. 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. 2. Disconnect the connector from the component. Page 10251 SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-D. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: - The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair Tools Required J 38125-D Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-D. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Page 3949 Left Side Of Engine Page 8087 Wheel Speed Sensor: Diagrams ABS Connector End Views Wheel Speed Sensor (WSS) - LF Page 3779 Electrical Symbols Part 6 Page 14984 Involved are certain 2000 Chevrolet CK, 2000-2004 model year Chevrolet Silverado and GMC Sierra trucks, and 2002-2004 model year Cadillac Escalade EXT and Chevrolet Avalanche trucks, and 2003-2004 Chevrolet Kodiak and GMC TopKick trucks built within the VIN breakpoints shown. Important: Dealers should confirm vehicle eligibility through GMVIS (GM Vehicle Inquiry System) before beginning recall repairs. [Not all vehicles within the above breakpoints may be involved.] For US For dealers with involved vehicles, a Campaign Initiation Detail Report containing the complete Vehicle Identification Number, customer name and address data has been prepared and will be loaded to the GM DealerWorld, Recall Information website. Dealers that have no involved vehicles currently assigned will not have a report available in GM DealerWorld. For Canada For dealers with involved vehicles, a Campaign Initiation Detail Report containing the complete Vehicle Identification Number, customer name and address data has been prepared and is being furnished to involved dealers. Dealers that have no involved vehicles currently assigned will not receive a Page 6513 7. Remove the pressure control solenoid retainer bolt (364A) and retainer (378). 8. Remove the pressure control solenoid (377). 9. Remove the TCC solenoid bolts and the valve body bolts which retain the internal wiring harness. 10. Using J 28458 , release the pass-through electrical connector from the transmission case. 1. Use the small end of the J 28458 over the top of the connector. 2. Twist in order to release the four tabs retaining the connector. 3. Pull the harness connector down through the transmission case. 11. Remove the TCC solenoid (with O-ring seal) and wiring harness. Page 11394 Sunload Sensor (With RPO Code CJ2) Page 15232 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves SPLICING COPPER WIRE USING SPLICE SLEEVES TOOLS REQUIRED J 38125-D Terminal Repair Kit IMPORTANT: Use only GM splice sleeves, other splice sleeves may not protect the splice from moisture or a provide good electrical connection. Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. Specifications Ball Joint: Specifications Lower Ball Joint Stud Nut .................................................................................................................... .................................................. 100 Nm (74 ft. lbs.) Lower Ball Joint to Lower Control Arm Nuts .......................................................................................................................................... 70 Nm (52 ft. lbs.) Upper Ball Joint Stud Nut ........................................................................................................ ................................................................ 50 Nm (37 ft. lbs.) Wear Limit ............................................. .............................................................................................................................................. 3.18 mm (0.125 inch) Page 6398 Vehicle Speed Sensor (VSS) Tow/Haul Switch Location Exhaust System - Popping/Snapping Noise When Hot/Idling Heat Shield: Customer Interest Exhaust System - Popping/Snapping Noise When Hot/Idling Bulletin No.: 03-06-05-008D Date: March 05, 2007 TECHNICAL Subject: Exhaust Popping/Snapping Noise When Vehicle is Hot, at Idle, or Immediately After Vehicle is Shut Off (Replace Muffler Heat Shield) Models: 2002-2006 Cadillac Escalade, Escalade EXT 2003-2006 Cadillac Escalade ESV 2002-2006 Chevrolet Avalanche, Suburban, Tahoe, Silverado, Silverado HD 2007 Chevrolet Silverado Classic, Silverado HD Classic 2002-2006 GMC Sierra, Sierra HD , Yukon, Yukon Denali, Yukon Denali XL 2007 GMC Sierra Classic, Sierra HD Classic 2003-2006 HUMMER H2 with 4.8L, 5.3L, 6.0L or 8.1L Gasoline Engine (VINs V, B, T, Z, N, V, G - RPOs LR4, L33, LM7, L59, LQ9, LQ4, L18) Supercede: This bulletin is being revised to add the 2006 and 2007 (Classic Only) model years and the 5.3L (L33) engine. Please discard Corporate Bulletin Number 03-06-05-008C (Section 06 Engine/Propulsion System). Condition Some customers may comment on a popping/snapping noise from underneath the vehicle at idle or immediately after the vehicle is shut off. Some popping/snapping noise from the exhaust system during cool down is a normal condition. The noise may be intermittent depending on the outside temperature and or temperature of the exhaust system at the time of testing. Cause As the exhaust system warms and cools, the muffler and the muffler heat shield expand and contract at different rates and may cause a popping and/or snapping noise. Some popping/snapping noise from the exhaust system during cool down is a normal condition. The customer should be made aware that this service procedure is designed to reduce but not eliminate all exhaust system popping and snapping during cool down. Correction Follow the service procedure below to correct this condition. Some popping/snapping noise from the exhaust system during cool down is a normal condition. The customer should be made aware that this service procedure is designed to reduce but not eliminate all exhaust system popping and snapping during cool down. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information. In order to avoid being burned, do not service the exhaust system while it is still hot. Service the system when it is cool. Always wear protective goggles and gloves when removing exhaust parts as falling rust and sharp edges could result in serious personal injury. Page 4028 Important The following information MUST be documented on the repair order. Failure to do so may result in a chargeback. - Customer vehicle condition. - Was a Service Lamp or Service Message illuminated? If yes, specify which Service Lamp or Service Message. - Was a DTC(s) set? If yes, specify which DTC(s) were set. - After following the procedure contained within this bulletin, could the condition be duplicated? ‹› If the condition was not duplicated, then document the affected module/component connector name and number on the repair order. - If the condition was duplicated after the procedure contained within this bulletin was followed, and additional diagnosis led to the replacement of a module or component, the SI Document ID Number MUST be written on the repair order. Parts Information Alternate Distributor For All of North America Note NyoGel(R) 760G Lubricant* is equivalent to GMSPO P/N 12377900, and P/N 10953529 (Canada), specified for use to correct the condition in this bulletin. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to: Warranty Information (Saab Models) Page 12168 Page 8890 Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. 1. Disconnect the connector from the component. 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. Page 15881 Turn Signal Lamp: Description and Operation TURN SIGNAL/HAZARD LAMPS The IGN E 10-amp fuse in the underhood fuse block supplies battery positive voltage to the turn signal/hazard switch assembly. The FLASH 25-amp fuse in the instrument panel (I/P) fuse block supplies battery positive voltage to the turn signal/flasher module and ground is supplied at G200. When the turn signal switch is placed in either the LEFT or RIGHT position, a voltage signal is completed from the turn signal switch to the turn sign/flasher module. When the hazard flasher switch is activated, a ground signal is completed from the turn signal/hazard switch to the turn sign/flasher module. The turn sign/flasher module then sends an on-off voltage signal through the LT TRLR, RT TRLR, LT TURN or RT TURN 10-amp fuses in the I/P fuse block to the appropriate turn signal or to all 4 fuses for hazard operation. The instrument panel cluster (IPC) indicators receive voltage from the LT TURN and RT TURN fuses as well as the driver door module (DDM)/passenger door module (PDM) for the mirror turn signals. The DDM/PDM has no function or control of the mirror turn signals other that a pass through connection for the circuits. The audio chime is also activated when the turn signals are ON. When the hazard switch is pressed, all turn signal lamps will flash including both IPC turn indicators. The front turn signals are grounded at G100. The rear turn signals are grounded at G401. The Mirror turn signals are grounded by the DDM/PDM. Page 4280 Body Control Module: Locations Body Control Module (BCM) A/T - 4T65-E Fluid Leaks From Reverse Servo Cover Band Apply Servo: All Technical Service Bulletins A/T - 4T65-E Fluid Leaks From Reverse Servo Cover Bulletin No.: 04-07-30-028A Date: January 12, 2006 TECHNICAL Subject: 4T65-E Automatic Transmission Fluid Leak From Reverse Servo Cover (Replace Reverse Servo Cover Seal) Models: 2005 and Prior Cars and Light Duty Trucks with Automatic Transmission 4T65-E (RPOs MN3, MN7, M15, M76) Supercede: This bulletin is being revised to announce an improved reverse servo cover seal is available from GMSPO and to advise technicians that it is no longer necessary to replace the reverse servo cover when replacing the seal. The 2005 model year vehicles are also being added. Please discard Corporate Bulletin Number 04-07-30-028 (Section 07 - Transmission/Transaxle). Condition Some customers may comment on a fluid leak under the vehicle. A transmission fluid leak may be noted during the Pre-delivery Inspection (PDI). Cause A possible cause of a transmission fluid leak usually only during cold ambient temperatures below -6.7°C (20°F) may be the reverse servo cover seal. The reverse servo cover seal may shrink in cold ambient temperatures causing a transmission fluid leak. Correction Follow the diagnosis and repair procedure below to correct this condition. 1. Diagnose the source of the fluid leak. 2. If the source of the transmission fluid leak is the reverse servo cover, replace the reverse servo cover seal with P/N 24235894. Refer to Reverse Servo Replacement in the appropriate Service Manual. Page 883 IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections TESTING FOR INTERMITTENT AND POOR CONNECTIONS TOOLS REQUIRED - J 35616-C GM-Approved Terminal Test Kit - J 38125-D Terminal Repair Kit - J 42675 Flat-Wire Probe Adapter Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector. - Poor terminal to wire connection - Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. - Wire insulation which is rubbed through - This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. - Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. Testing For Proper Terminal Contact It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-D or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-D, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. Page 4927 Page 3926 1. Install the accelerator pedal assembly. NOTE: Refer to the Fastener Notice in Service Precautions. 2. Install the accelerator pedal nuts. Tighten Tighten the nuts to 20 N.m (15 lb ft). 3. Connect the APP sensor electrical connector. 4. Reposition the carpet. 5. Connect a scan tool in order to test for proper throttle-opening and throttle-closing range. 6. Operate the accelerator pedal and monitor the throttle angles. The accelerator pedal should operate freely, without binding, between a closed throttle, and a wide open throttle (WOT). 7. Verify that the vehicle meets the following conditions: - The vehicle is not in a reduced engine power mode. - The ignition is ON. - The engine is OFF. 8. Inspect the carpet fit under the accelerator pedal. Page 8908 Control Module References Part 5 Locations Crankshaft Position (CKP) Sensor Location Fuel System - Cranks But No Start/Inaccurate Fuel Gauge Fuel Gauge Sender: All Technical Service Bulletins Fuel System - Cranks But No Start/Inaccurate Fuel Gauge Bulletin No.: 04-08-49-018E Date: January 05, 2005 TECHNICAL Subject: Cranks But No Start, Stall, Inaccurate/Incorrect Fuel Gauge Reading, No Fuel, Vehicle is Out of Fuel and Fuel Gauge Reads Above Empty (Replace Fuel Level Sensor) Models: 2001-2004 Cadillac Trucks 1999-2004 Chevrolet and GMC Trucks with Gasoline Engine (VINs Z, X, V, T, U, N, G, 6, 8 - RPOs LU3, LR4, LM7, LQ4, LQ9, L59, L18,LK5 L52) Attention: Parts are currently available for vehicles with Variable Fuel (VIN Z - RPO L59) vehicles. Please refer to Corporate Bulletin Number 04-06-04-01 2B or newer for Variable Fuel (VIN Z - RPO L59) vehicles. Supercede: This bulletin is being revised to include information on the Chevrolet Colorado and the GMC Canyon. Please discard Corporate Bulletin Number 04-08-49-018D (Section 08 - Body and Accessories). Condition Some customers may comment on the vehicle stalling and will not restart, vehicle ran out of fuel, vehicle appears to be out of fuel but the fuel gauge reads above empty. The fuel gauge may read 1/4 tank. Cause Contamination on the fuel sending card may cause inaccurate/incorrect fuel gauge readings. Correction Follow the service procedure below for diagnosis and repair of this concern. 1. Confirm that the vehicle is actually out of fuel. ^ If the vehicle is not out of fuel but Engine Cranks but Does Not Run, refer to the appropriate Service Information. ^ If the vehicle is out of fuel and the gauge does not read empty, test the fuel gauge. Refer to the following information: - Fuel Gage Inaccurate or Inoperative Single Tank - Fuel Gage Inaccurate or Inoperative Dual Tanks - Fuel Gage Inaccurate or Inoperative Colorado and Canyon 2. If testing reveals that the fuel gauge is operating correctly, replace the fuel sensor assembly and auxiliary tank fuel level sensor if equipped. 3. Replace the fuel level sensor. Refer to the following appropriate service information: ^ Fuel Level Sensor Replacement 4.8L and 5.3L Engines ^ Fuel Level Sensor Replacement 6.0L Engine - Front Tank ^ Fuel Level Sensor Replacement 6.0L Engine - Rear Tank ^ Fuel Level Sensor Replacement 8.1L vehicles with Front Tank ^ Fuel Level Sensor Replacement 8.1 L vehicles with Rear Tank Page 12016 Important: The optic cable must not be bent with a radius less than 25 mm (1 in). 6.12. Place the optic cable in the wiring harness channels on the right-hand side. Thread through the existing cable ties (C) if possible, otherwise, secure with a cable tie to the existing one. Close the cover on the channels. Ensure the catches lock. 6.13. Secure the optic cable along the right-hand rear wheel housing, next to the ordinary wiring harness securing points and by the SRS unit (D). 6.14. Thread the optic cable up next to the safety belt by the old optic cable and place on the parcel shelf. 6.15. Unplug the connectors (E) from the OnStar(R) control modules. 6.16. Remove the console (F) together with the OnStar(R) control modules. Page 9332 4. Connect the wiring connectors to the fuse block. Refer to Electrical Center Identification Views to ensure the right connections are made. 5. Install the right side end panel. Page 14199 Installation Procedure 1. Install the door module into the switch panel bezel until it snaps into place. 2. Install the switch panel bezel and module to the door panel. Notice: Refer to Fastener Notice in Service Precautions. 3. Install the screw that retains the switch panel bezel (1) to the front door panel. Tighten the screw to 2 N.m (18 lb in). 4. Connect the electrical connectors. 5. Install the front door trim panel. 6. If equipped with camper mirrors program the door module. Refer to Service Programming System (SPS) in Programming. See: Testing and Inspection/Programming and Relearning Switch Replacement - Door Lock and Side Window - Passenger Page 5782 Transmission Position Switch/Sensor: Service and Repair Automatic Transmission 4L80-E/4L85-E Park/Neutral Position Switch Replacement Park/Neutral Position Switch Replacement ^ Tools Required J 41364-A Park Neutral Switch Aligner Removal Procedure 1. Apply the park brake. 2. Shift the transmission into neutral. 3. If equipped with 4-wheel drive (4WD), remove the front propeller shaft. 4. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 5. Disconnect the park/neutral position (PNP) switch electrical connector (2). 6. Remove the range selector cable end (2) from the range selector lever ball stud (1). Page 5995 Page 10913 SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-D. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: - The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair Tools Required J 38125-D Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-D. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Page 7512 Page 1580 5. Remove the fuel level sensor retaining clip. 6. Remove the fuel level sensor. INSTALLATION PROCEDURE 1. Install the fuel level sensor. Page 6297 When Servicing transmissions with the new seal design, use the following precautions: ^ The outer diameter of the pump assembly and case bore must be clean and free of burrs or raised surfaces. Be aware of sharp edges that could damage the seal during installation. ^ The seal should be clean and dry before installation. It does not require lubrication for installation. ^ The seal should be inspected prior to installation for obvious damage. ^ It is preferable to hand-start the seal positioning the seal evenly around the case bore before installing the torque converter housing. ^ The seal can be easily removed by prying it out, typical of a pressed-on seal. ^ The seal may be reused, however a thorough inspection must be performed. Inspect the seal for the following conditions: ^ Distortion of the metal carrier or separation from the rubber seal. ^ A cut, deformed, or damaged seal. ^ Refer to the appropriate unit repair information in SI for seal removal and installation procedures. Parts Interchangeability Information In order to properly service the different designs, it is necessary to correctly identify and select corresponding parts for each level. This table provides a summary of the part usage for the different design levels. Page 1266 Wheel Speed Sensor (WSS) - RF Page 5265 Fuel Injector 2 Page 15991 Steps 5-10 Page 4690 Body Control Module: Electrical Diagrams Door Control Module Diagram 1 Automatic Transmission Input Shaft Speed (AT ISS) Sensor Connector Page 382 ^ Pay the dealer the regular retail price (no discounts are available) for one of the following 1-year, non-refundable OnStar(R) Analog-to-Digital Transition (ADT) Service Subscription Plans: ^ 1-year Safe & Sound Subscription: $199 ($289 in Canada) ^ 1-year Directions & Connections Subscription: $399 ($579 in Canada) ^ Pay the dealer the applicable state and local sales taxes on the subscription: ^ U.S. Dealers: Taxes only apply in these states: CT, DC, FL, HI, ND, NJ, NM, NY, SC, SD, TX, and WV ^ Canadian Dealers: All applicable taxes ^ Pay the dealer a one-time charge of $15 for the upgrade: ^ U.S. Dealers: Do not collect taxes on the $15 ^ Canadian Dealers: Collect all applicable taxes on the $15 Note: Dealers should NOT remit OnStar(R) ADT-related taxes to their taxing authority as OnStar(R) is responsible for tax remittance. Please Be Sure To Read these Important Points: ^ The 1-year OnStar(R) subscription is not refundable or transferable to another person. Upgraders can apply unused subscription months to a new or Certified Pre-Owned digital OnStar-equipped GM vehicle purchase or lease. As noted above, the digital upgrade program requires the subscriber to purchase a one-year prepaid OnStar(R) subscription. Assuming the subscriber intends to keep their vehicle, but subsequently purchases or leases a 2006 model year or newer OnStar(R)-equipped new or certified used GM vehicle, in the interest of subscriber satisfaction, they may apply remaining unused whole months of the subscription to the new vehicle. The subscription may not be applied to another person's vehicle. Important: This is a customer satisfaction measure that would usually occur several months after an upgrade. It is not intended to be leveraged as part of a new/used vehicle purchase or lease transaction. ^ The $15 charge is not refundable. ^ Dealer ADT kit orders are VIN specific. Dealer kit orders require a VIN and must be exchanged with the OnStar(R) unit in the vehicle with that VIN. Proper activation and enrollment depends on this step. ^ You must put the actual miles on the Repair Order. Do not estimate. ^ Customers will receive a Hands-Free Calling number once the digital hardware is installed and configured. ^ Any nametags that were stored in the old system will need to be re-set by the subscriber once the new hardware is installed. ^ Customers are responsible for the charges described above regardless of whether their vehicle is in or out of the New Vehicle Warranty period. In addition, customers should not be charged labor costs. Dealers can charge GM the labor for the upgrade as specified at the end of this bulletin using the listed labor operation. ^ Vehicles eligible for an OnStar(R) hardware upgrade are listed in this bulletin. Vehicle upgradeability can also be determined by typing the VIN into the field entitled "Determine VIN Hardware Functionality" on the OnStar(R) Online Enrollment website, located in the sales or service workbench tab of GM GlobalConnect. Canadian Dealers can use a similar tool that is available within InfoNET. ^ Access to the sales and/or service workbench in the GM GlobalConnect website can be granted by the dealership's Partner Security Coordinator (PSC). If you are unsure who the PSC is, check with the Sales Manager. Ordering the Upgrade Kit/Upgrade kit Installation Ordering the Upgrade Kit 1. To order a kit, you will need to access the OnStar(R) Online Enrollment webpage, located under the sales or service workbench of GM GlobalConnect (infoNET for Canadian upgrade orders). These kits cannot be ordered from GMSPO. Page 15298 3. Locate the auxiliary fuel tank vent hose. The vent hose is the smaller diameter of the two hoses that comes from the auxiliary fuel tank and feeds into the main tank vent hose. 4. Disconnect the auxiliary tank vent hose from the main tank vent hose connection. 5. Install the cap supplied with kit, P/N 15213990, to the main tank vent hose connector where the auxiliary tank vent hose was just removed. 6. Locate the section of vent hose on the main tank between the fuel filler neck and the metal pipe. The smaller of the two hoses on the filler neck. 7. Cut the main tank vent hose between the filler neck and the metal pipe using an appropriate cutting tool. 8. Install the "T" and the two hose clamps supplied with kit, P/N 15213990, into the main tank vent hose. Tighten Tighten the hose clamps to 2.5 N.m (22 lb in). 9. Install the new auxiliary tank vent hose and clamp supplied with kit, P/N 15213990, to the "T" that was just installed. Tighten Tighten the hose clamp to 2.5 N.m (22 lb in). 10. Connect the new vent hose to the original auxiliary tank hose. 11. Secure the newly installed vent hose and the original auxiliary tank vent hose with plastic ties supplied in kit, P/N 15213990. 12. If necessary, reinstall the left rear tires/wheels assemblies. Electrical - MIL ON/DTC's Set By Various Control Modules Relay Module: All Technical Service Bulletins Electrical - MIL ON/DTC's Set By Various Control Modules TECHNICAL Bulletin No.: 09-06-03-004D Date: December 08, 2010 Subject: Intermittent No Crank/No Start, No Module Communication, MIL, Warning Lights, Vehicle Messages or DTCs Set by Various Control Modules - Diagnosing and Repairing Fretting Corrosion (Disconnect Affected Connector and Apply Dielectric Lubricant) Models: 2011 and Prior GM Passenger Cars and Trucks Attention: This repair can be applied to ANY electrical connection including, but not limited to: lighting, body electrical, in-line connections, powertrain control sensors, etc. DO NOT over apply lubricant to the point where it prevents the full engagement of sealed connectors. A light coating on the terminal surfaces is sufficient to correct the condition. Supercede: This bulletin is being revised to update the Attention statement and add the 2011 model year. Please discard Corporate Bulletin Number 09-06-03-004C (Section 06 Engine/Propulsion System). Condition Some customers may comment on any of the following conditions: - An intermittent no crank/no start - Intermittent malfunction indicator lamp (MIL) illumination - Intermittent service lamp illumination - Intermittent service message(s) being displayed The technician may determine that he is unable to duplicate the intermittent condition. Cause This condition may be caused by a buildup of nonconductive insulating oxidized debris known as fretting corrosion, occurring between two electrical contact surfaces of the connection or connector. This may be caused by any of the following conditions: - Vibration - Thermal cycling - Poor connection/terminal retention - Micro motion - A connector, component or wiring harness not properly secured resulting in movement On low current signal circuits this condition may cause high resistance, resulting in intermittent connections. On high current power circuits this condition may cause permanent increases in the resistance and may cause a device to become inoperative. Representative List of Control Modules and Components The following is only a representative list of control modules and components that may be affected by this connection or connector condition and DOES NOT include every possible module or component for every vehicle. - Blower Control Module - Body Control Module (BCM) - Communication Interface Module (CIM) - Cooling Fan Control Module - Electronic Brake Control Module (EBCM) - Electronic Brake and Traction Control Module (EBTCM) - Electronic Suspension Control (ESC) Module - Engine Control Module (ECM) - Heating, Ventilation and Air Conditioning (HVAC) Control Module Page 9428 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Weather Pack Connectors WEATHER PACK CONNECTORS The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. Page 5960 Page 9722 C154 I/P Harness To ATC Harness (With RPO Codes NP1/NP8) Service and Repair Parking Brake Lever: Service and Repair Park Brake Release Handle Assembly Replacement Removal Procedure 1. Caution: Refer to Battery Disconnect Caution in Service Precautions. Disconnect the negative battery cable. 2. Remove the park brake release lever mounting bolt. 3. Remove the park brake release lever handle from the knee bolster. 4. Remove the MID-bussed electrical center from the bracket. 5. Remove the park brake release cable housing from the pedal assembly. 6. Remove the park brake release cable from the pedal assembly. 7. Note the routing of the cable as you remove the park brake release handle assembly from the vehicle. Installation Procedure 1. Install the park brake release handle assembly to the vehicle. Install the cable using the same routing as the original cable. 2. Install the park brake release cable to the pedal assembly. 3. Install the park brake release cable housing to the pedal assembly. 4. Install the MID-bussed electrical center to the bracket. 5. Install the park brake release lever handle to the knee bolster. 6. Notice: Refer to Fastener Notice in Service Precautions. Install the park brake release lever mounting bolt. ^ Tighten the bolt to 25 Nm (18 ft. lbs.). 7. Connect the negative battery cable. Page 3778 Electrical Symbols Part 5 Page 4306 Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA and/or the secondary locks. Micro .64 Connectors MICRO .64 CONNECTORS TOOLS REQUIRED J 38125-D Terminal Repair Kit REMOVAL PROCEDURE Follow the steps below in order to remove terminals from Micro 64 connectors. 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. 2. Disconnect the connector from the component. Page 3322 Parts Information Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 5122 14. Install the fuel line clip(s) to the bracket(s) on the transmission. 15. Install the HO2S sensor connector to the bracket. 16. Install the fuel pipe bracket to the bellhousing stud. 17. Install the fuel pipe bracket nut. Tighten Tighten the nut to 10 N.m (89 lb in). 18. Lower the vehicle. 19. Remove the caps from the fuel rail and EVAP lines. 20. Connect the EVAP canister purge tube (2) fitting. 21. Connect the fuel feed line (1) fitting at the engine. 22. Install the fuel fill cap. 23. Connect the negative battery cable. 24. Use the following procedure in order to inspect for leaks: 24.1. Turn the ignition ON, with the engine OFF, for 2 seconds. 24.2. Turn the ignition OFF for 10 seconds. 24.3. Turn the ignition ON, with the engine OFF. 24.4. Inspect for fuel leaks. EVAP Hoses/Pipes Replacement - Chassis (Cab/Chassis) EVAPORATIVE EMISSION (EVAP) HOSES/PIPES REPLACEMENT - CHASSIS (CAB/CHASSIS) REMOVAL PROCEDURE IMPORTANT: Clean the fuel and evaporative emission (EVAP) connections and surrounding areas prior to disconnecting the lines in order to avoid possible system contamination. Page 8685 Electronic Brake Control Module: Service and Repair Electronic Brake Control Module (EBCM) Replacement Removal Procedure Important: After installation, calibrate the new EBCM to the tire size that is appropriate to the vehicle. 1. Caution: Refer to Battery Disconnect Caution in Service Precautions. Disconnect the negative battery cable. 2. Raise and suitably support the vehicle. 3. Important: The area around the EHCU MUST be free from loose dirt to prevent contamination of disassembled ABS components. Thoroughly wash all contaminants from around the EHCU. 4. Disconnect the chassis electrical connectors from the EBCM. Page 12108 A current DTC clears when the condition for setting the DTC is no longer present. A history DTC clears after 50 malfunction-free ignition cycles. Circuit/System Testing Without RPO UAV 1. Turn OFF the ignition and all electrical components, including the scan tool. 2. Disconnect the harness connector at the cellular microphone. 3. Test for less than 5 Ohms between the low reference circuit terminal A and ground. ^ If greater than the specified range, test the low reference circuit for an open/high resistance. If the circuit tests normal, replace the VCIM. 4. Ignition ON, test for 9 - 11 volts between the signal circuit terminal B and ground. ^ If greater than the specified range, test the signal circuit for a short to voltage. If the circuit tests normal, replace the VCIM. ^ If less than the specified range, test the signal circuit for a short to ground or an open/high resistance. If the circuit tests normal, replace the VCIM. Refer to the appropriate vehicle in SI. 5. If all circuits test normal, test or replace the cellular microphone. Circuit/System Testing With RPO UAV 1. Turn OFF the ignition and all electrical components, including the scan tool. 2. Disconnect the X4 harness connector at the navigation radio and the harness connector at the cellular microphone. 3. Test for less than 5 Ohms between the low reference circuit terminal A and ground. ^ If greater than the specified range, test the low reference circuit for an open/high resistance. If the circuit tests normal, replace the VCIM. Refer to the appropriate vehicle in SI. 4. Ignition ON, test for 9 - 11 volts between the signal circuit terminal B and ground. ^ If greater than the specified range, test the signal circuit for a short to voltage. If the circuit tests normal, replace the VCIM. ^ If less than the specified range, test the signal circuit for a short to ground or an open/high resistance. If the circuit tests normal, replace the VCIM. 5. If all circuits test normal, test or replace the cellular microphone. 6. Connect the X4 harness connector at the navigation radio. 7. With a scan tool, verify that DTC B2455 is not set as current in the navigation radio. ^ If DTC B2455 is set as current, replace the navigation radio. Refer to the appropriate vehicle in SI. DTC B2462, B2483, or B2484 Circuit/System Description The vehicle communication interface module (VCIM) receives information from a specific navigation antenna located on the outside of the vehicle. The navigation antenna is connected to the VCIM via a shielded coaxial cable. The antenna cable also provides a path for DC current for powering the antenna. DTC Descriptors DTC B2462 02: Global Positioning System (GPS) Antenna Malfunction Short to Ground DTC B2462 04: Global Positioning System (GPS) Antenna Malfunction Open Circuit Page 14621 Seat Horizontal Position Sensor - Driver (With RPO Code AN3) Page 4959 Put unused material on the shelf for future use. Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Page 16043 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Page 4494 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors USING CONNECTOR TEST ADAPTERS IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-B Connector Test Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Page 482 IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections TESTING FOR INTERMITTENT AND POOR CONNECTIONS TOOLS REQUIRED - J 35616-C GM-Approved Terminal Test Kit - J 38125-D Terminal Repair Kit - J 42675 Flat-Wire Probe Adapter Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector. - Poor terminal to wire connection - Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. - Wire insulation which is rubbed through - This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. - Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. Testing For Proper Terminal Contact It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-D or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-D, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. Page 15214 TOOLS REQUIRED J 34142-B 12 V Unpowered Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. When testing for voltage: 1. Attach 1 lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach 1 lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Using Connector Test Adapters USING CONNECTOR TEST ADAPTERS NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-B Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires USING FUSED JUMPER WIRES TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Connector Position Assurance Locks CONNECTOR POSITION ASSURANCE LOCKS The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Terminal Position Assurance Locks TERMINAL POSITION ASSURANCE LOCKS The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Push to Seat Connectors PUSH TO SEAT CONNECTORS TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Page 8088 Wheel Speed Sensor (WSS) - RF Page 9444 Control Module References Part 1 Page 9844 Junction Block - I/P Wire Entry Part 4 Manual Transmission - NV 3500 Vehicle Speed Sensor: Service and Repair Manual Transmission - NV 3500 Vehicle Speed Sensor (VSS) Replacement Removal Procedure 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. Disconnect the vehicle speed sensor (VSS) electrical connector (1). 3. Remove the VSS and O-ring seal. Installation Procedure Page 10066 4. Remove the bolts (2) retaining the power steering cooler from the radiator support. 5. Remove the power steering cooler from the vehicle. Installation Procedure 1. Notice: Refer to Fastener Notice in Service Precautions. Install the power steering cooler (1) to the vehicle. ^ Tighten the power steering cooler retaining bolts to 5 Nm (44 inch lbs.). 2. Connect the power steering outlet hose (3) to the power steering gear (4). 3. Install the retaining clamp. 4. Connect the power steering inlet hose to the power steering pump. 5. Install the retaining clamp. 6. Bleed the power steering system. Refer to Bleeding the Power Steering System. 7. Inspect all the hose connections for leaks. 8. Install the front grille. Refer to Grille Replacement (GMC) Grille Replacement (Chevrolet) in Exterior Trim. (Parallel Hybrid Truck) Power Steering Cooler Pipe/Hose Replacement (Parallel Hybrid Truck) Removal Procedure 1. Disconnect the energy storage box before servicing the vehicle. 2. Remove the front grille. Refer to Grille Replacement (GMC) Grille Replacement (Chevrolet) in Exterior Trim. Page 3375 1. Align the splined surfaces of the crankshaft sprocket and the oil pump drive gear and install the oil pump. 2. Install the oil pump onto the crankshaft sprocket until the pump housing contacts the face of the engine block. Notice: Refer to Fastener Notice in Service Precautions. 3. Install the oil pump bolts. ^ Tighten the bolts to 25 Nm (18 ft. lbs.). 4. Install the crankshaft oil deflector and nuts until snug. 5. Lubricate a NEW oil pump screen O-ring seal with clean engine oil. 6. Install the NEW O-ring seal onto the oil pump screen. Important: Push the oil pump screen tube completely into the oil pump prior to tightening the bolt. Do not allow the bolt to pull the tube into the pump. Align the oil pump screen mounting brackets with the correct crankshaft bearing cap studs. 7. Install the oil pump screen. 8. Install the oil pump screen bolt and nuts. 1. Tighten the bolt to 12 Nm (106 inch lbs.). 2. Tighten the nuts to 25 Nm (18 ft. lbs.). 9. Install the engine front cover. 10. Install the oil pan. Page 12468 Important: The optic cable must not be bent with a radius less than 25 mm (1 in). 12.5. Cars with brackets for e.g. an amplifier: Fit the cable tie (11 900 515) to the wiring harness approx. 100 mm (4 in) from H2-9, fit the cable tie (H) to the bracket. Gather the optic cable in a gentle loop (I) and then place the loop behind the bracket. Important: The optic cable must not be bent with a radius less than 25 mm (1 in). 12.6. Cars without brackets for e.g. an amplifier: Gather the optic cable in a gentle loop (J) and secure with cable tie. 13. CV: Fit the left-hand, rear side hatch trim in accordance with WIS - 8. Body - Interior equipment - Adjustment/Replacement. 14. Fit the ground cable to the battery's negative terminal. 15. Carry out procedures after disconnecting the battery, see WIS - 3. Electrical System - Charging system - Adjustment/Replacement. Important: Follow Tech 2(R) on-screen instructions. 16. Add ECU ICM, choose without OnStar(R). See WIS-General-Tech 2(R) - Description and Operation - Add/Remove. 2000-2004 Saab 9-5 2000-2004 Saab 9-5 Page 5570 Ignition Coil: Service and Repair IGNITION COIL(S) REPLACEMENT REMOVAL PROCEDURE 1. If equipped with regular production option (RPO) HP2, disconnect the energy storage box (ESB). 2. Remove the spark plug wire from the ignition coil. 3. Disconnect the ignition coil electrical connector. 4. If equipped with regular production option (RPO) HP2, remove the auxiliary heater water pump bracket bolts. 5. Remove the auxiliary heater water pump from the studs, and reposition out of the way. Page 9715 C148 Engine Harness To Coil Jumper Harness Component Locations Pressure Regulating Solenoid: Component Locations Automatic Transmission - 4L60-E/4L65-E Automatic Transmission Electronic Component Views (M30/M32) Electronic Components Page 7636 1. Disconnect the shift control module electrical connectors. 2. Unsnap and remove the shift control module from the bracket. Installation Procedure Page 15320 Fuel Pump And Sender Assembly Components Page 5449 13. If necessary, lower the vehicle. 14. Using a scan tool, clear the DTCs. 15. Start the vehicle and inspect for leaks. Important: Advise the customer that a similar condition may occur if the vehicle is fueled with the engine running AND the rear tank is fueled first. The engine must be shut off (as required by law) during vehicle refueling. Parts Information Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 1778 NOTE: Refer to Fastener Notice in Service Precautions. 4. Install the fasteners (2) to the inflatable restraint side impact sensor (1) using only hand tools. Tighten Tighten the fasteners to 10 N.m (89 lb in). 5. Install the door trim panel. 6. Enable the SIR system. Refer to SIR Disabling and Enabling Zone 6. Page 14068 Electrical Symbols Part 8 Junction Block - I/P Relay Box: Application and ID Junction Block - I/P Location View Location View Page 3722 Remove the nuts securing the muffler to the catalytic converter. On 6.0L and 8.1L equipped vehicles only, loosen the exhaust pipe clamp. Do not use oil base lubricants on the rubber exhaust hangers. Apply a soapy solution to the exhaust pipe hanger rods in order to ease the removal of the exhaust hangers. Pry the exhaust hangers free from the exhaust pipe hanger rods. It is not necessary to remove the muffler from the vehicle to replace the muffler heat shield. Reposition the muffler to gain access to the muffler heat shield. Use extreme caution not to damage the muffler when removing the heat shield from the muffler. Using an air-powered hack saw blade, or equivalent, cut off the existing muffler heat shield just as the heat shield rises off of the muffler. See the illustration above. Remove the heat shield from the muffler. Hammer flush the remaining heat shield to the muffler. The new heat shield should not come in contact with the remaining muffler heat shield. The new heat shield should not come in contact with the horizontal lock seam on the muffler. Page 5296 2. Push both sides of the fittings together in order to snap the retaining tabs into place. 3. Once installed, pull on both sides of the connection in order to make sure the connection is secure. 4. If equipped with the 5.3L (L59) engine, install the retainers to the fuel feed and return line to engine quick-connect fittings. 5. Install the retainer to the fuel feed line quick-connect fitting. 6. Install the fuel fill cap. 7. Connect the negative battery cable. Instruments - Trip Odometer Apparently Inoperative Odometer: All Technical Service Bulletins Instruments - Trip Odometer Apparently Inoperative Bulletin No.: 04-08-49-007 Date: February 26, 2004 INFORMATION Subject: Personal Trip/Business Trip Feature - Must be On for Trip Odometer to Accumulate Models: 2003-2004 Cadillac Escalade, Escalade ESV, Escalade EXT 2003-2004 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2003-2004 GMC Sierra, Sierra Denali, Yukon, Yukon XL, Yukon Denali The purpose of this bulletin is to prevent the inadvertent replacement of the instrument cluster if a customer comes in to your dealership stating that the trip odometer is inoperative or does not accumulate. For vehicles with steering wheel controls, the Personal Trip (or Business Trip) feature must be turned On in order for the trip odometer to accumulate. When the display reads Personal Trip: On (or Business Trip: On), the trip odometer shall accumulate. The Personal Trip and Business Trip features can be turned on or off by pressing the select button. Refer to Driver Information Center (DIC) in the Owner's Manual for additional information. Page 11212 11. Remove the HVAC module (2) from the vehicle (1). INSTALLATION PROCEDURE 1. If replacing the HVAC module, transfer the components from the old HVAC module as necessary. 2. Install the HVAC module (2) to the vehicle (1). NOTE: Refer to Fastener Notice in Service Precautions. 3. Install the nuts (4) to the HVAC module (2). Tighten Tighten the nuts to 9 N.m (80 lb in). 4. Install the bolts (4) to the HVAC module (2). Tighten Tighten the bolts to 4 N.m (35 lb in). 5. Connect the electrical harnesses and the ground connections. 6. Install the HVAC module drain hose. 7. Install the instrument panel carrier. 8. Install the accumulator. 9. Install the surge tank outlet hose to the heater core. Firmly push the quick connect onto the heater core pipe until you hear an audible click. 10. Install the inlet heater hose to the heater core. Firmly push the quick connect onto the heater core pipe until you hear an audible click. 11. Fill the cooling system. Refer to Draining and Filling Cooling System (with HP2)Draining and Filling Cooling System (without HP2) in Cooling System. Page 5586 Step 25 - 27 Page 10494 9. Install the nut (2) and washer (3) retaining the wheel drive shaft assembly to the wheel hub and bearing. ^ Tighten the nut to 240 Nm (177 ft. lbs.). 10. Install the wheel speed sensor and brake hose mounting bracket bolt to the steering knuckle. ^ Tighten the brake hose clip bolt to 12 Nm (106 inch lbs.). 11. Install the rotor. Refer to Brake Rotor Replacement - Front in Disc Brakes. 12. Install the tire and wheel. 13. Lower the vehicle. Page 9293 8. Install the left side end panel. Page 5210 Fuel: Testing and Inspection Without Special Tool ALCOHOL/CONTAMINANTS-IN-FUEL DIAGNOSIS (WITHOUT SPECIAL TOOL) DESCRIPTION Water contamination in the fuel system may cause driveability conditions such as hesitation, stalling, no start, or misfires in one or more cylinders. Water may collect near a single fuel injector at the lowest point in the fuel injection system, and cause a misfire in that cylinder. If the fuel system is contaminated with water, inspect the fuel system components for rust, or deterioration. Alcohol concentrations of 10 percent or greater in fuel can be detrimental to fuel system components. Alcohol contamination may cause fuel system corrosion, deterioration of rubber components, and subsequent fuel filter restriction. Some types of alcohol are more detrimental to fuel system components than others. Ethanol is commonly used in gasoline, but in concentrations of no more than 10 percent. Some fuels, such as E85, contain a very high percentage of ethanol. Fuel with more than 10 percent ethanol may cause driveability conditions such as hesitation, lack or power, stalling, or no start. ALCOHOL IN FUEL TESTING PROCEDURE The fuel sample should be drawn from the bottom of the tank so that any water present in the tank will be detected. The sample should be bright and clear. If alcohol contamination is suspected then use the following procedure to test the fuel quality. 1. Using a 100 ml specified cylinder with 1 ml graduation marks, fill the cylinder with fuel to the 90 ml mark. 2. Add 10 ml of water in order to bring the total fluid volume to 100 ml and install a stopper. 3. Shake the cylinder vigorously for 10-15 seconds. 4. Carefully loosen the stopper in order to release the pressure. 5. Re-install the stopper and shake the cylinder vigorously again for 10-15 seconds. 6. Put the cylinder on a level surface for approximately 5 minutes in order to allow adequate liquid separation. If alcohol is present in the fuel, the volume of the lower layer, which would now contain both alcohol and water, will be more than 10 ml. For example, if the volume of the lower layer is increased to 15 ml, this indicates at least 5 percent alcohol in the fuel. The actual amount of alcohol may be somewhat more because this procedure does not extract all of the alcohol from the fuel. PARTICULATE CONTAMINANTS IN FUEL TESTING PROCEDURE The fuel sample should be drawn from the bottom of the tank so that any water present in the tank will be detected. The sample should be bright and clear. If the sample appears cloudy, or contaminated with water, as indicated by a water layer at the bottom of the sample, use the following procedure to diagnose the fuel. 1. Using an approved fuel container, draw approximately 0.5 liter of fuel. 2. Place the cylinder on a level surface for approximately 5 minutes in order to allow settling of the particulate contamination. Particulate contamination will show up in various shapes and colors. Sand will typically be identified by a white or light brown crystals. Rubber will appear as black and irregular particles. If particles are found clean the entire fuel system thoroughly. Refer to Fuel System Cleaning. Page 3751 1. Install the exhaust manifold pipe seal(s). 2. Raise the catalytic converter or exhaust manifold pipe using the adjustable jackstands. 3. Notice: Refer to Fastener Notice in Service Precautions. If equipped with a 6.0L or 8.1L engine, perform the following: 1. Install the exhaust hanger mounting bracket bolts. 2. Install the left exhaust manifold pipe nuts. ^ Tighten the bolts to 12 Nm (106 inch lbs.). ^ Tighten the nuts to 50 Nm (39 ft. lbs.). 4. If equipped with a 6.0L or 8.1L engine, install the right exhaust manifold pipe nuts. Tighten the nuts to 50 Nm (39 ft. lbs.). 5. If equipped with a 4.3L, 4.8L, or 5.3L engine, install the right exhaust manifold pipe nuts. Page 2057 Toe is a measurement of how much the front and/or rear wheels are turned in or out from a straight-ahead position. When the wheels are turned in, toe is positive (+). When the wheels are turned out, toe is negative (-). The actual amount of toe is normally only a fraction of a degree. The purpose of toe is to ensure that the wheels roll parallel. Toe also offsets the small deflections of the wheel support system that occur when the vehicle is rolling forward. In other words, with the vehicle standing still and the wheels set with toe-in, the wheels tend to roll parallel on the road when the vehicle is moving. Improper toe adjustment will cause premature tire wear and cause steering instability. Setback Description Setback applies to both the front and the rear wheels. Setback is the amount that one wheel may be aligned behind the other wheel. Setback may be the result of a road hazard or a collision. The first clue is a caster difference from side-to-side of more than 1 degree. Thrust Angles Description The front wheels aim or steer the vehicle. The rear wheels control tracking. This tracking action relates to the thrust angle (3). The thrust angle is the path that the rear wheels take. Ideally, the thrust angle is geometrically aligned with the body centerline (2). In the illustration, toe-in is shown on the left rear wheel, moving the thrust line (1) off center. The resulting deviation from the centerline is the thrust angle. Lead/Pull Description Definition: At a constant highway speed on a typical straight road, lead/pull is the amount of effort required at the steering wheel to maintain the vehicle's straight path. Lead/pull is usually caused by the following factors: ^ Tire construction ^ Wheel alignment ^ Unbalanced steering gear The way in which a tire is built may produce lead/pull. The rear tires will not cause lead. Page 5517 Flexible Fuel Sensor: Service and Repair FUEL COMPOSITION SENSOR REPLACEMENT REMOVAL PROCEDURE 1. Relieve the fuel system pressure. Refer to Fuel Pressure Relief Procedure. 2. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 3. Disconnect the fuel composition sensor electrical connector. 4. Remove the fuel line retainers (1). 5. Disconnect the fuel pipes from the fuel composition sensor. 6. Remove the fuel composition sensor nuts. 7. Remove the fuel composition sensor. 8. If required, remove the fuel composition sensor bolts and remove the sensor from the bracket. Page 7429 3. Remove the right rear speed sensor. Installation Procedure 1. Notice: Refer to Fastener Notice in Service Precautions. Install the right rear speed sensor. ^ Tighten the speed sensor to 15 Nm (11 ft. lbs.). 2. Connect the right rear speed sensor electrical connector (3). 3. Lower the vehicle. Page 2358 1. Install the outlet hose to the radiator. 2. Position the outlet hose clamp at the radiator. 3. Install the outlet hose to the water pump. 4. Position the outlet hose clamp at the water pump. 5. Important: Align the arrow at the throttle body end of the duct with the throttle body attaching stud. Install the air cleaner outlet duct. 6. Install the radiator inlet hose clip to the outlet duct. 7. Tighten the air cleaner outlet duct clamps at the following locations: ^ Throttle body ^ MAF/IAT sensor Tighten the air cleaner outlet duct clamp screws to 7 Nm (62 inch lbs.). 8. Fill the cooling system. Page 13487 The information shown is for the 1999-2002 wiring harnesses and for the 2003-05 wiring harness. To modify a 12171982, 15366255 or 15086884 harness for use in a 2003-05 vehicle, switch the wires in cavities "A" and "D". To modify a 15085418 harness for use in a 1999-2002 vehicle (see model list at the front of this bulletin for applicable models), switch the wires in cavities "A" and "D". Warranty Information When the correct wiring harness P/N is matched to the specific model year of the vehicle, everything works properly. Therefore, conversion of an incorrect wiring jumper to match the vehicle would not be considered a warrantable repair. Disclaimer Page 8461 Tighten Tighten the nuts to 50 N.m (37 lb-ft). 3. Install the booster pump rod to the lever. 4. Install the stop lamp switch to the lever. 5. Install the booster pump rod retainer. 6. Connect the power brake booster outlet hose, the steering gear inlet hose, and the power brake booster inlet hose. Tighten ^ Tighten the power brake booster inlet hose to 28 N.m (20 lb-ft). ^ Tighten the steering gear inlet hose to 28 N.m (20 lb-ft). 7. Install the master cylinder. 8. Install the mounting nuts. Tighten Tighten the mounting bolts to 50 Nm (37 lb-ft). 9. Install the electrical connectors to the electrohydraulic pump and the flow switch. 10. Fill the hydraulic pump reservoir. Important: Maintain the fluid level throughout the bleed procedure. 11. Remove the pump reservoir cap. Important: Page 8930 Energy Storage Control Module (ESCM) Page 6632 Right Side Control Valve Body Assembly Be sure all solenoids are installed with the electrical connectors facing the non-machined (cast) side of the valve body; otherwise the solenoids will bind against the transmission case as the valve body bolts are tightened and damage may occur. Disassembly/Reassembly If a valve is restricted by a metal burr from machining that bore, remove the valve and burr, then inspect movement in the valve's normal position. If no Page 7582 Page 6289 Fluid Pressure Sensor/Switch: Connector Locations OnStar(R) - Analog/Digital System Information Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Analog/Digital System Information INFORMATION Bulletin No.: 06-08-46-008C Date: September 18, 2008 Subject: Information on OnStar(R) Dual-Mode (Analog/Digital) Systems Models Supercede: This bulletin is being revised to correct the model year range for the Chevrolet Impala and Monte Carlo and update the reference to GM Dealerworld. Please discard Corporate Bulletin Number 06-08-46-008B (Section 08 - Body and Accessories). All 2000-2003 model year vehicles equipped with OnStar® from the list above were built with Analog/Digital-Ready OnStar(R) Hardware. Some of these vehicles may have been upgraded to Dual-Mode (Analog/Digital). Certain 2004-2005 model year vehicles equipped with OnStar(R) from the list above may have been either: ^ Originally built at the factory with Dual-Mode (Analog/Digital) OnStar(R) Hardware with Dual-Mode (Analog/Digital) OnStar(R) Hardware OR ^ Upgraded to Dual-Mode (Analog/Digital) Hardware All 2006 model year and newer vehicles equipped with OnStar(R) were built at the factory with Dual-Mode (Analog/Digital) OnStar(R) Hardware. If a vehicle has Dual-Mode (Analog/Digital) OnStar(R) Hardware, then the system is capable of operating on both the analog and digital cellular AWD/4WD - AWD/4WD Lamps/System Inop./DTC C0550 Control Module: All Technical Service Bulletins AWD/4WD - AWD/4WD Lamps/System Inop./DTC C0550 Bulletin No.: 02-04-21-006E Date: July 20, 2006 TECHNICAL Subject: Inoperative 4WD/AWD Lamps, Inoperative 4WD/AWD System, DTC C0550 Set, No Communication with TCCM (Reprogram Transfer Case Control Module) Models: 2004 Buick Rainier 2002-2004 Chevrolet TrailBlazer, TrailBlazer EXT 2003-2004 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2002-2004 GMC Envoy, Envoy XL 2003-2004 GMC Sierra, Yukon, Yukon XL 2004 GMC Envoy XUV 2002-2004 Oldsmobile Bravada with Electronic Shift or Active Transfer Case (RPOs NP1, NP4 or NP8) Supercede: This bulletin is being revised to add Subject information and change the labor operation. This bulletin cancels and supersedes Bulletin Number 03-04-21-006. Please discard Corporate Bulletin Numbers 02-04-21-006D and 03-04-21-006 (Section 04 - Driveline/Axle). Condition Some customers may comment that the 4WD/AWD indicator lights on the selector switch do not work, or the 4WD/AWD system may be inoperative and/or the service 4WD light is illuminated. The condition is typically intermittent and always occurs at key-up. Upon investigation, the technician may find DTC C0550 set. Cause The Transfer Case Control Module (TCCM) has not received the wake-up call during key-up and has remained in the "sleep mode". When the TCCM is in the "sleep mode", it will not communicate with the class II bus or the Tech 2(R). Correction 1. Try to communicate with the TCCM. If no communication, go to step 2. If communication is possible, go to step 5. 2. Remove the underhood (ATCM or TREC) TCCM fuse. 3. Wait 30 seconds. 4. Reinstall the fuse. The module should wake up and communicate with the Tech 2(R). 5. Check for codes in the TCCM. If a C0550 is found current or in history with or without other codes, replace the module and go to step 6. 6. Reprogram the TCCM with the latest TIS software using normal SPS procedures. 7. Verify operation and that no codes are present. Important: For the 2002 model year, the TCCM must be replaced and reprogrammed. Warranty Information Page 14728 1. Remove the front nuts (2) on the underside of the seat cushion. 2. Remove the front seat trim panel. 3. Unsnap the lumbar cable (6). Disconnect the lumbar wire harness if equipped with power lumbar. 4. Disconnect the electrical connectors. 5. Remove the pressure sensor (2) from the front passenger seat frame, if equipped with the Inflatable Restraint Passenger Presence System. Service and Repair Rear Wheel Steering Switch: Service and Repair Rear Wheel Steering Mode Switch Replacement Removal Procedure 1. Remove the dash trim bezel. 2. Grasp the rear wheel steering mode switch housing (2) and pull outward to remove the switch assembly. 3. Disconnect the electrical connector (3) from the rear wheel steering mode switch. 4. Remove the rear wheel steering mode switch assembly (1) from the vehicle. Installation Procedure 1. Reconnect the rear wheel steering mode switch (3) electrical connectors. 2. Install the rear wheel steering mode switch (1) into the dash. 3. Reinstall the dash trim bezel. Page 12548 Rear Wheel Steering Control Module Bracket Replacement Steering Control Module: Service and Repair Rear Wheel Steering Control Module Bracket Replacement Rear Wheel Steering Control Module Bracket Replacement Removal Procedure 1. Remove the rear wheel steering control module from the bracket. 2. Remove the bolts retaining the bracket (2) to the frame. 3. Remove the bracket (2) from the vehicle. Installation Procedure 1. Install the bracket (2) to the vehicle. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the bolts retaining the bracket (2) to the frame. ^ Tighten the bracket retaining bolts to 10 Nm (81 inch lbs.). 3. Install the rear wheel steering control module to the vehicle. Page 7666 2. Important: Ensure the drain hole on the boot of the rear output shaft seal is facing down toward the ground Using the J 37668-A, install the rear output shaft seal. 3. Install the rear propeller shaft. 4. Check the fluid level, add fluid if necessary. 5. Install the transfer case shield, if necessary. Transfer Case Input Shaft Seal Replacement Transfer Case Input Shaft Seal Replacement ^ Tools Required J 42738 Seal Installer Removal Procedure 1. Remove the transfer case. 2. Using a flat-tipped screwdriver, remove the input shaft seal. Installation Procedure Important: When installing the input shaft seal, make sure that the part numbers on the seal are facing outward (away from the body of the transfer case). Page 9983 ^ A foam ring (3) ^ An alignment tab (2) for installing into the adapter and bearing assembly ^ A view of the inside of the connector 7. Important: If reusing the existing sensor, you must align the marks on the flush rotor flange cuff before installation. The alignment mark must stay aligned until the sensor is seated into the adapter and bearing assembly. If installing a new sensor, it will come with a pin installed in the sensor. Do not remove the pin until the sensor is seated. If the new sensor did not come with a pin installed, you must reorder a new sensor. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install into the adapter and bearing assembly. 8. Install the connector to the sensor. 9. From the technicians point of view, the FRONT of the sensor will have: ^ A pin hole (3) for the centering pin. Note location of the pin hole. ^ A raised rotor flange cuff (5) ^ An alignment mark (4) for installation 10. From the technicians point of view, the BACK of the sensor will have: ^ Double D flats (1) ^ An alignment tab (2) for installing into the adapter and bearing assembly 11. Important: If reusing the existing sensor, you must align the marks on the raised rotor flange cuff before installation. The alignment mark must stay aligned until the sensor is seated into the adapter and bearing assembly. If installing a new sensor, it will come with a pin installed in the sensor. Do not remove the pin until the sensor is seated. If the new sensor did not come with a pin installed, you must reorder a new sensor. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install into the adapter and bearing assembly. 12. Install the connector to the sensor. 13. From the technicians point of view, the FRONT of the sensor will have: ^ A pin hole (2) for the centering pin. Note the location of the pin hole. ^ A raised rotor flange cuff (4) ^ An alignment mark (3) for installation 14. From the technicians point of view, the BACK of the sensor will have an alignment tab (1) for installation. This sensor does not have double D flats. 15. Important: If reusing the existing sensor, you must align the marks on the raised rotor flange cuff before installation. The alignment mark must stay aligned Page 5433 Fuel Gauge Sender: Description and Operation Fuel System Description (Cab Chassis) FUEL LEVEL SENSOR The fuel level sensor is a part of the fuel sender assembly. The position of the float arm indicates the fuel level. The fuel level sensor contains a variable resistor which changes resistance in correspondence with the amount of fuel in the fuel tank. On models that are equipped with a single fuel tank, the fuel level sensor is wired directly to the instrument panel (IP) cluster. On models equipped with dual fuel tanks, both fuel level sensors are wired to the PCM. The PCM calculates the total fuel level in both tanks. The instrument panel (IP) fuel gage displays the total fuel level in both fuel tanks. Page 14623 Seat Lumbar Motor/Position Sensor - Driver (With RPO Code AN3) Page 11362 Air Temperature Sensors - Lower Right Page 10063 Removal Procedure 1. Remove the front grille. Refer to Grille Replacement (GMC) Grille Replacement (Chevrolet) in Exterior Trim. 2. Notice: Refer to Power Steering Hose Disconnected Notice in Service Precautions. Remove the power steering outlet hose (4) from the power steering gear (3). 3. Remove the power steering inlet hose from the power steering pump (1). 4. Remove the bolts (2) retaining the cooler to the radiator support. 5. Remove the power steering cooler from the vehicle. Installation Procedure 1. Notice: Refer to Fastener Notice in Service Precautions. Install the power steering cooler (1) to the vehicle. ^ Tighten the power steering cooler retaining bolts to 5 Nm (44 inch lbs.). Page 1089 3. Notice: Refer to Fastener Notice in Service Precautions. Install a new 4 mm bolt (1), with LOCTITETM , to the brake pedal position sensor. ^ Tighten the bolt to 9 Nm (80 inch lbs.). 4. Calibrate the brake pedal position sensor. Page 10901 Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA and/or the secondary locks. Micro .64 Connectors MICRO .64 CONNECTORS TOOLS REQUIRED J 38125-D Terminal Repair Kit REMOVAL PROCEDURE Follow the steps below in order to remove terminals from Micro 64 connectors. 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. 2. Disconnect the connector from the component. Page 7600 For vehicles repaired under warranty, use the table. Disclaimer Page 2759 Junction Block - I/P Wire Entry Part 4 Page 11594 Involved are certain 2003-2005 Cadillac Escalade, Escalade ESV, Escalade EXT; Chevrolet Avalanche, Silverado Crew Cab, Suburban, Tahoe; GMC Sierra Crew Cab, Yukon, Yukon XL; and 2004-2005 HUMMER H2 vehicles built within the VIN breakpoints shown. Important: Dealers should confirm vehicle eligibility through GMVIS (GM Vehicle Inquiry System) prior to beginning recall repairs. [Not all vehicles within the above breakpoints may be involved.] For US and Canada For dealers with involved vehicles, a Campaign Initiation Detail Report containing the complete Vehicle Identification Number, customer name and address data has been prepared and will be loaded to the GM DealerWorld (US) Recall Information, GMinfoNet (Canada) Recall Reports. Dealers will not have a report available if they have no involved vehicles currently assigned. For Export For dealers with involved vehicle, a Campaign Initiation Detail Report containing the complete Vehicle Identification Number, customer name and address data has been prepared, and is being furnished to involved dealers. Dealers will not receive a report with the recall bulletin if they have no involved vehicles currently assigned. The Campaign Initiation Detail Report may contain customer names and addresses obtained from Motor Vehicle Registration Records. The use of such motor vehicle registration data for any purpose other than follow-up necessary to complete this recall is a violation of law in several states/provinces/countries. Accordingly, you are urged to limit the use of this report to the follow-up necessary to complete this recall. Parts Information Page 7300 Pay particular attention to the terminal connections at the module. Spread or open terminal connections may create an intermittent contact. Do a pin drag test. Refer to the terminal testing information in the table shown. ^ After repairs are complete, ALWAYS clear DTCs from the module prior to a system function test. If codes are not cleared first, the system will not function after repair. The technician may erroneously think that the system is still down and that further repairs are needed. Warranty Dealers who unnecessarily replace the TCCM that are found to have No Trouble Found (NTF) at the WPC will be returned to the AVM (Area Service Manager), or the DSM (District Service Manager) in Canada, through the Regional Feedback Process and may be charged back for the repair through the WINS system. Disclaimer Page 8989 Application Table Part 3 Page 5355 9. Remove the fuel line clip(s) from the bracket(s) on the transmission. 10. Remove the fuel line clip from the bracket on the transfer case, if equipped with 4 wheel drive (4WD). 11. Remove the clip from the bracket on the frame. 12. Remove the transfer case harness from the clip bracket. IMPORTANT: The area around the electro-hydraulic control unit (EHCU) MUST be free from loose dirt to prevent contamination of disassembled anti-lock brake (ABS) components. 13. Thoroughly wash all contaminants from around the EHCU. 14. Disconnect the chassis electrical harness connectors from the electronic brake control module (EBCM). 15. Disconnect the brake lines from the brake pressure modulator valve (BPMV). 16. Remove the bolts (4) attaching the EHCU bracket to the frame (5). 17. Remove the EHCU (1). Page 13202 monitor the Tech2(R) for the current time and date. REMINDER - Keep in mind that the time displayed on the Tech2(R) is in Greenwich Mean Time (GMT) and the offset is based on the time zones relationship to GMT. If replacement of the VIU/VCIM is necessary, you MUST reconfigure the OnStar® system. Failure to reconfigure the system will result in an additional customer visit for repair. OnStar® VIU, Generations 2 and 3, will require the technician to press the blue OnStar® button to reconfigure the vehicle with an OnStar® advisor. OnStar(R) VCIM, Generations 4-7 will require the technician to reconfigure the vehicle with the use of the TIS2WEB and SPS applications (pass thru only), along with the Tech2(R). The configuration and set-up procedure is a two-step process that must be completed step-by-step without interruption or delay in between each step. This procedure enables an automated activation without a button press by the technician to the OnStar(R) Call Center. Following this procedure, it may take up to 24 hours for all OnStar(R) services to be fully activated. How to Order Parts If the OnStar(R) GPS date/time stamp is non-recoverable and the unit needs to be replaced, dealers in the U.S. should contact Autocraft Electronics select the catalog item that contains this bulletin number. Canadian dealers should contact MASS Electronics. Dealers DO NOT need to call the GM Technical Assistance Center (TAC) for replacement approval. Autocraft Electronics and MASS Electronics will be responsible for verifying that the subject vehicle is a candidate for a replacement VIU/VCIM. Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use the table. Warranty Information (Saab U.S. Models) Page 12093 these systems will then completely power OFF. OnStar(R) Module Expected Current Draw The expected current draw of the OnStar(R) module in various ignition modes are as follows: ^ Ignition ON ‐ 240 to 400 mA ^ Ignition OFF ‐ 3 to 20 mA for 48 hours ^ Ignition OFF ‐ 0.2 to 0.8 mA after 48 hours (120 hours on specified vehicle communication platforms (VCPs)). Note During extended voltage testing for battery parasitic draw, it is possible to observe a voltage spike caused by the following: ^ A cellular registration call that was triggered by the local cellular system. ^ The OnStar(R) system has set a monthly trigger for a vehicle data upload call for the OnStar(R) Vehicle Diagnostic E‐mail upload. OnStar(R) System States of Readiness The OnStar(R) system will use the following 4 states of readiness, depending upon the type of cellular market the vehicle is in when the ignition is turned OFF. ^ High power ^ Low power ^ Sleep ^ Digital standby The high power state is in effect whenever the ignition is in the ON or RUN position, retained accessory power (RAP) is enabled, and/or the OnStar(R) system is sending or receiving calls or when the system is performing a remote function. The low power state is in effect when the OnStar(R) system is idle with the ignition in the ON or RUN position, or with RAP enabled. The sleep state is entered after the vehicle has been shut OFF and the RAP has timed out. At a predetermined time recorded within the VCIM, the system re-enters the low power state to listen for a call from the OnStar(R) Call Center for 1 minute. After this interval, the system will again return to the sleep state for 9 minutes. If a call is sent during the 1 minute interval, the OnStar(R) system will receive the call and immediately go into the high power mode to perform any requested functions. If a call is not received during the 1 minute interval, the system will go back into the sleep mode for another 9 minutes. This process will continue for up to 48 hours, after which the OnStar(R) system will turn OFF until the ignition is turned to the ON or RUN position. The digital standby power state is entered after the vehicle has been shut off and the RAP has timed out while in a digital cellular area. When in digital standby mode, the OnStar(R) module is able to perform all remote functions as commanded by an OnStar(R) advisor at any time, for a continuous 48 hours. After 48 hours, the OnStar(R) module will go into sleep mode until a wake up signal from the vehicle is seen by the CIM. If the OnStar module loses the digital cellular signal it will revert to analog mode and follow the standard sleep state (9 minutes OFF, 1 minute standby) based on the time of the GPS signals, this will continue until a digital cellular signal is again received. If the OnStar(R) system loses battery power while the system is in a standby or sleep mode, the system will remain OFF until battery power is restored and the ignition is turned to the ON or RUN position. Deactivated OnStar(R) Accounts In the event that a customer has not upgraded their vehicle to a digital system, the account has been deactivated. The customers have been previously notified of the steps required to upgrade their vehicles. After the OnStar(R) account has been deactivated, customers will experience the following: ^ The OnStar(R) status LED will not illuminate ^ The OnStar(R) system will NOT attempt to connect to the OnStar(R) Call Center in the event of a collision or if the vehicle's front air bags deploy for any other reason. ^ An emergency button press will result in a demo message being played, indicating the service has been deactivated and needs to be upgraded. Drivetrain - Updated Transfer Case Speed Sensor Conn. Speed Sensor: All Technical Service Bulletins Drivetrain - Updated Transfer Case Speed Sensor Conn. Bulletin No.: 06-04-21-001 Date: May 17, 2006 INFORMATION Subject: Updated Transfer Case Connector Service Kit Now Available For Transfer Case Speed Sensor Wire Harness Connector that Comes Loose Or Connector Retainer Clip Breaks Models: 2007 and Prior GM Light Duty Trucks 2007 and Prior HUMMER H2, H3 2005-2007 Saab 9-7X with Four-Wheel Drive or All-Wheel Drive Technicians may find that when the transfer case speed sensor wire harness connector is removed, the connector lock flexes/bends and does not return to the original position. The transfer case speed sensor wire harness connector then has no locking device. On older vehicles, the plastic connector retainer becomes brittle and the clip may break as soon as it is flexed. In the past, the only service fix was to install a wire harness connector service pack, P/N 88987183. This repair procedure involved splicing a new service connector with an integral connector lock. This connector service kit is of the same design and was still prone to failure over time. A new connector service repair kit is now available, P/N 15306187, that is an updated design. This new kit should be used whenever the speed sensor wire harness connector requires replacement. Parts Information Disclaimer Page 8625 Use clean, new power steering fluid only. 12. Fill the pump reservoir with fluid to the FULL COLD level. 13. Attach J 43485, Power Steering Bleeder Adapter, to J 35555, Metal Mityvac, or equivalent. 14. Place J 43485 on or in the pump reservoir filler neck. 15. Apply a vacuum of 68 kPa (20 in Hg) maximum. 16. Wait 1 minute. 17. Remove J 43485 and J 35555. 18. Reinstall the pump reservoir cap. 19. Start the engine. Allow the engine to idle. 20. Turn the steering wheel 180-360 degrees in both directions 5 times. 21. Switch the ignition off 22. Verify the fluid level. 23. Release the park brake and unblock the wheels. Hydro-Boost(R) Replacement -- Kodiak, TopKick Tools Required ^ J 35555 Metal Mityvac ^ J 43485 Power Steering Bleeder Adapter Removal 1. Block the wheels. 2. Disconnect the electrical connectors from the electrohydraulic pump and the flow switch. Page 15069 9. Install the LH and RH rear taillamp assemblies. 10. Place the LH and RH center reinforcement into position on the pickup box. ^ On the 2.4 m (8 ft) long pickup box models, this center reinforcement fits over the existing center stake hole. ^ On the 1.7 m (5 ft., 8 in) and 2 m (6.5 ft) short box models, these center reinforcements are recommended to be installed. The reinforcements should be centered between the front and rear reinforcements on the pickup box. 12. Mark the holes necessary for drilling and remove the brackets. 13. Drill 7.5 mm (0.30 in) holes into the weld flange of the side outer panel. 14. Touch-up the drilled holes as necessary. Refer to step 6 under the Front Reinforcement Installation procedure. 15. Place the center reinforcements back onto the pickup box. 16. Install the M6 bolts through the reinforcement and side panel with the nuts. Tighten Tighten the bolts to 9 Nm (79 lb-in). 17. Remove any metal shavings from the pickup box after installation. *Maximum Equipment Weight Capacities (Equipment and Cargo) ^ Ladder Rack and Cargo - 340 kg (750 lb) ^ Cross Toolbox and Cargo - 181 kg (400 lb) ^ Side Tool Boxes and Cargo - 113 kg (250 lb) (per side) *The combined weight for all rail-mounted equipment should not exceed 454 kg (1,000 lb). Excluded is the 1500 Series Crew Cab models with 5'8" pick-up box length. A reinforcement kit for rail-mounted add-on equipment is recommended as described in this bulletin. Ladder racks are not recommended for 1500 Series Crew Cab models with 5'8"pick-up box. Maximum recommended cross-mounted tool box and cargo weight is 136 kg (300 lb) for the 1500 Series Crew Cab with 5'8"pick-up box. Page 2694 Relay Block - I/P C5 Part 2 Page 12206 Page 7496 For vehicles repaired under warranty, use the table. Disclaimer Page 3053 8. Remove the wheel hub and the 15-series bearing mounting bolts (4). 9. Remove the wheel hub and bearing (4) mounting bolts, 25/35 series. 10. Remove the wheel hub and bearing and splash shield from the vehicle. 11. Remove the O-ring seal from the steering knuckle bore, 25/35 series. 12. Remove the wheel speed sensor mounting bolt (5). 13. Clean and inspect the O-ring seal, 25/35 series. 14. Replace the seal if the following conditions exist: ^ Nicks ^ Cuts ^ Dry or brittle ^ Compression set Installation Procedure 1. Clean all corrosion or contaminates from the steering knuckle bore and the hub and bearing assembly. 2. Lubricate the steering knuckle bore with wheel bearing grease or the equivalent. 3. Install the O-ring (7) to the steering knuckle, the 25/35 series. 4. Notice: Refer to Fastener Notice in Service Precautions. Install the wheel speed sensor mounting bolt to the wheel hub and bearing. ^ Tighten the sensor mounting bolt to 18 Nm (13 ft. lbs.). 5. Install the wheel hub and bearing and splash shield to the vehicle, 25/35 series. Page 16282 1. Install the washer solvent container into the vehicle. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the lower bolts. Tighten Tighten the bolts to 9 N.m (80 lb in). 3. Install the upper bolt. Tighten Tighten the bolt to 9 N.m (80 lb in). 4. Connect the electrical connector to the washer pump. 5. Connect the electrical connector to the washer solvent level sensor. 6. Connect the washer hose to the washer pump. 7. Install the inner wheel housing. 8. Install the battery and battery tray. Service and Repair Front Door Limiter: Service and Repair Door Check Link Replacement Removal Procedure 1. Fully open the door. 2. Remove the door trim panel. 3. Remove the water deflector. 4. Remove the body-side check strap bolt. 5. Remove the check strap plug. 6. Remove the door-side check strap nuts. 7. Pull the check strap from the inside of the door. Installation Procedure 1. Install the check strap in the door. 2. Install the check strap in the body. Notice: Refer to Fastener Notice in Service Precautions. 3. Install the check strap nuts. Tighten the nuts to 9 N.m (80 lb in). 4. Install the check strap bolt. Tighten the bolt to 25 N.m (18 lb in). 5. Install the water deflector. 6. Install the door trim panel. Page 15739 Ambient Light Sensor (With RPO Code CJ3) Page 9847 Application Table Page 14619 Seat Lumbar Motor/Position Sensor - Driver (With RPO Code AN3) Door Window Channel Front Door Window Glass Weatherstrip: Service and Repair Door Window Channel Window Run Channel Replacement - Front Door Removal Procedure 1. Remove the window. 2. Remove the window glass weatherstrip. 3. Remove the window run channel bolts. 4. Remove the front and the rear window run channels from the door. Installation Procedure 1. Install the front and the rear window run channels to the door. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the front and the rear window run channel bolts. 1. Tighten the front bolt to 9 N.m (80 lb in). 2. Tighten the rear bolt to 9 N.m (80 lb in). 3. Install the window glass weatherstrip. 4. Install the window. Page 6833 12. Install the axle shafts (10.5 inch, 11.5 inch axle). 13. Install the brake rotors (8.6 inch, 9.5 inch axles). 14. Install the brake calipers (8.6 inch, 9.5 inch axles). 15. Install the tire and wheel assemblies. 16. Inspect and add axle lubricant to the axle housing, if necessary. 17. Lower the vehicle. 9.75 Inch Axle Drive Pinion Flange/Yoke and/or Oil Seal Replacement (9.75 Inch Axle) ^ Tools Required J 8614-01 Flange and Pulley Holding Tool - J 45710 Pinion Bearing Oil Seal Installer Removal Procedure 1. Important: Observe and mark the positions of all the driveline components, relative to the propeller shaft and the axles, prior to disassembly. These components include the propeller shafts, drive axles, pinion flanges, output shafts, etc. Reassemble all the components in the exact places in which you removed the parts. Follow any specifications, torque values, and any measurements made prior to disassembly. Raise the vehicle. Refer to Vehicle Lifting. 2. Disconnect the propeller shaft from the rear axle pinion yoke. 3. Place an alignment mark between the pinion and the pinion yoke. 4. Install the J 8614-01 as shown. 5. Remove the pinion nut while holding the J 8614-01. Page 7806 Vehicle Speed Sensor (VSS) Tow/Haul Switch Location Automatic Transmission Electronic Component Views (M33 Only) Automatic Transmission Electronic Component Views (M33 Only) Page 6488 Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer OnStar(R) - Aftermarket Device Interference Information Navigation System: All Technical Service Bulletins OnStar(R) - Aftermarket Device Interference Information INFORMATION Bulletin No.: 08-08-46-004 Date: August 14, 2008 Subject: Information on Aftermarket Device Interference with OnStar(R) Diagnostic Services Models: 2009 and Prior GM Passenger Car and Truck (including Saturn) 2009 and Prior HUMMER H2, H3 Models 2009 and Prior Saab 9-7X with OnStar(R) (RPO UE1) This bulletin is being issued to provide dealer service personnel with information regarding aftermarket devices connected to the Diagnostic Link Connector (DLC) and the impact to OnStar(R) diagnostic probes and Vehicle Diagnostic e-mails. Certain aftermarket devices, when connected to the Diagnostic Link Connector, such as, but not limited to, Scan Tools, Trip Computers, Fuel Economy Analyzers and Insurance Tracking Devices, interfere with OnStar's ability to perform a diagnostic probe when requested (via a blue button call) by a subscriber. These devices also prohibit the ability to gather diagnostic and tire pressure data for a subscriber's scheduled OnStar(R) Vehicle Diagnostic (OVD) e-mail. These aftermarket devices utilize the Vehicles serial data bus to perform data requests and/or information gathering. When these devices are requesting data, OnStar(R) is designed not to interfere with any data request being made by these devices as required by OBD II regulations. The OnStar(R) advisor is unable to definitively detect the presence of these devices and will only be able to inform the caller or requester of the unsuccessful or incomplete probe and may in some cases refer the subscriber/requester to take the vehicle to a dealer for diagnosis of the concern. When performing a diagnostic check for an unsuccessful or incomplete OnStar(R) diagnostic probe, or for concerns regarding completeness of the OnStar(R) Vehicle Diagnostic (OVD) e-mail, verify that an aftermarket device was not present at the time of the requested probe. Regarding the OVD e-mail, if an aftermarket device is interfering (including a Scan Tool of any type), the e-mail will consistently display a "yellow" indication in diagnostics section for all vehicle systems except the OnStar(R) System and Tire Pressure data (not available on all vehicles) will not be displayed (i.e. section is collapsed). Successful diagnostic probes and complete OVD e-mails will resume following the removal or disconnecting of the off-board device. Disclaimer Automatic Transmission - 4L60-E/4L65-E Transmission Position Switch/Sensor: Adjustments Automatic Transmission - 4L60-E/4L65-E Park/Neutral Position Switch Adjustment Important: ^ The following procedure is for vehicles that have not had the park/neutral position (PNP) switch removed or replaced. If the PNP switch has been removed or replaced, refer to Park/Neutral Position Switch Replacement for the proper adjustment procedure. ^ Apply the park brake. ^ The engine must start in the park (P) or neutral (N) positions only. ^ Check the PNP switch for proper operation. If adjustment is required, proceed as follows: 1. Place the transmission range selector in the neutral (N) position. 2. With an assistant in the drivers seat, raise and suitably support the vehicle. Refer to Vehicle Lifting. 3. Loosen the park/neutral position (PNP) switch bolts. 4. With the vehicle in the neutral (N) position, rotate the switch while the assistant attempts to start the engine. 5. Following a successful start, turn the engine off. 6. Notice: Refer to Fastener Notice in Service Precautions. ^ Tighten the PNP switch bolts. ^ Tighten the bolts to 25 Nm (18 ft. lbs.). 7. Lower the vehicle. 8. Check the PNP switch for proper operation. The engine must start in the park (P) or neutral (N) positions only. 9. Replace the PNP switch if proper operation can not be achieved. Page 14426 ^ Reinstall the fuse and fuse panel cover. ^ Press the "Enter" button to perform the "Refresh" function. ^ "Test in Progress" will be displayed and the right front passenger door lock will cycle once. ^ The screen will display "Procedure Completed". ^ Press the "Exit" button as necessary to return to the main menu screen. 3. Using the switches in the right front passenger door, verify that the power window and power door lock located in that door function properly. Important: The calibrations required for performing SPS reprogram in the next step are based on the type of exterior rearview mirror the vehicle has. To determine the correct calibration, check the Service Parts Identification Label on the vehicle for the RPO code for exterior mirrors. 4. Follow normal Service Programming System (SPS) to reprogram the passenger door module with the current calibration available in TIS 2000. 5. After reprogramming is complete, using the switches in the right front passenger door, verify that the power window and power door lock located in that door function properly. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 15864 Steering Wheel And Column Sub-System Components Page 14608 Seat Bolster Motor - Front Passenger (With RPO Code AN3) Page 386 ^ On 2002 Sevilles and DeVilles, the GPS jumper cable MUST be unclipped from the back seat cross brace, or unplugged from the VCIM first. DO NOT pull back on the mounting bracket until the GPS antenna jumper cable is unclipped from the back seat cross brace or unplugged from the VCIM. The short length of jumper cable does not allow the VCIM mounting bracket to be pulled back very far, and could lead to a break at the VCIM connector. ^ On 2000-2002 Bonnevilles and LeSabres and 2001-2002 Auroras you will need to follow these steps: 1. Remove the 4 nuts that secure the VCU/VIU bracket assembly to the rear seat back brace. Note: Save these nuts for later use. 2. Remove and discard the plastic VCU/VIU bracket assembly from the vehicle. 3. Remove the upper right stud (1) from the rear seat back brace and re-install in the middle lower slot (2) on the brace. Tighten the fastener to 4 Nm (36 lb in). 4. Position the new VCIM in the vehicle over the studs on the rear seat back brace. 5. Install two of the nuts saved from step (1). Tighten the nuts to 4 Nm (36 lb in). 6. Connect the new OnStar jumper harness supplied in the kit to the VCIM (two white connectors) and the body wiring harness (C345 connector). 7. Connect the small coaxial jumper cable supplied in the kit, to the VCIM, with the end that has a blue plastic housing connector. Plug the other end of this coaxial jumper cable to the OnStar Global Positioning Satellite (GPS) antenna coaxial cable at the right angle connector. Note: The GPS cable in the new OnStar jumper harness is not utilized. 8. Connect the cellular coaxial cable to the OnStar VCIM. On 2001 Impala and Monte Carlos you will need to follow these steps: 9. Remove the Vehicle Communications Unit (VCU) and Vehicle Interface Unit (VIU) following the procedures listed in SI. Save the bracket nuts for later use. Page 5792 Park Neutral Position (PNP) Switch C175 Page 6361 For vehicles repaired under warranty, use the table. Disclaimer Technical Service Bulletin # 01-07-30-032E Date: 080929 A/T - 4T65E Fluid Leaking From A/T Vent TECHNICAL Bulletin No.: 01-07-30-032E Date: September 29, 2008 Subject: Transmission Oil Leaking From Transmission Vent (Replace Transmission Case Cover (Channel Plate) Gasket) Models: 1997-2009 GM Passenger Cars and Light Duty Trucks (including Saturn) with Hydra-Matic 4T65-E Automatic Transmission (RPOs MN3, MN7, M15, M76) Supercede: This bulletin is being revised to add the 2008 and 2009 model years. Please discard Corporate Bulletin Number 01-07-30-032D (Section 07 - Transmission/Transaxle). Condition Some customers may comment on a transmission oil leak. Cause This condition may be caused by an improperly torqued channel plate gasket. Correction Page 9935 Alignment: Specifications Wheel Alignment Specifications Wheel Alignment Specifications Diagrams Engine Oil Level Switch Fuel System Description Fuel Level Sensor: Description and Operation Fuel System Description FUEL LEVEL SENSOR The fuel level sensor consists of a float, a wire float arm, and a ceramic resistor cord. The position of the float arm indicates the fuel level. The fuel level sensor contains a variable resistor, which changes resistance in correspondence to the amount of fuel in the fuel tank. The powertrain control module (PCM) sends the fuel level information via the class 2 circuit to the instrument panel (I/P) cluster. This information is used for the I/P fuel gage and the low fuel warning indicator, if applicable. The PCM also monitors the fuel level input for various diagnostics. Page 6041 4. Important: When installing the pressure control solenoid, the electrical connector (2) must be in the position shown. Install the pressure control solenoid (377). 5. Install the pressure control solenoid retainer (378) and retainer bolt (364A). ^ Tighten the bolt to 11 Nm (97 inch lbs.). 6. Install the TCC PWM solenoid to the control valve body. 7. Install the TCC PWM solenoid retainer. 8. Connect the internal wiring harness electrical connectors to the following components: ^ Transmission fluid pressure switch (1) ^ 1-2 shift control solenoid (2) ^ 2-3 shift control solenoid (3) ^ Pressure control solenoid (4) Page 3243 Drive Belt: Testing and Inspection Drive Belt Rumbling Drive Belt Rumbling Diagnosis Diagnostic Aids Vibration from the engine operating may cause a body component or another part of the vehicle to make rumbling noise. The drive belt(s) may have a condition that can not be seen or felt. Sometimes replacing the drive belt(s) may be the only repair for the symptom. If after replacing the drive belt(s) and completing the diagnostic table, the rumbling is only heard with the drive belt(s) installed, there might be an accessory drive component failure. Varying the load on the accessory drive component(s) may aid in identifying which component is causing the rumbling noise. Test Description Steps 1 - 8 The number(s) below refer to the step(s) in the diagnostic table. 2. This test is to verify that the symptom is present during diagnosing. Other vehicle components may cause a similar symptom. 3. This test is to verify that the drive belt(s) is causing the rumbling. Rumbling may be confused with an internal engine noise due to the similarity in Page 15564 Numerous & Various Size Drops of Water Collecting on the Inside Surface of the Lamp Lens After the Vehicle Has Been Exposed to Rain or a Car Washing Environment - A condition that covers more than half the surface of the lamp lens. - An accumulation of water in the bottom of the lamp assembly. - A condition that WON'T clear when the vehicle is parked in a dry environment, or when the vehicle is driven with the lights ON. - A comparison of the equivalent lamp on the opposing side of the vehicle indicates a different performance. Any of the above conditions would indicate the need to service the lens or lamp assembly. Disclaimer Page 11231 11. If the vehicle is a 2003 model year Chevrolet Express or GMC Savana van, the vehicle may require a new accumulator. Refer to Corporate Bulletin Number 03-01-38-016 for more information. This bulletin refers to an updated design accumulator that may improve the performance of the A/C system. 12. Install a new serpentine belt tensioner and serpentine belt if they have been damaged due to A/C system slugging or an A/C compressor seizure. The serpentine belt tensioner may have broken stop tabs and/or a missing front cap. 13. Verify proper operation of the A/C system. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 16015 Electrical Symbols Part 11 Page 2225 4. Install the oil pan and NEW gasket. 5. Notice: Refer to Fastener Notice in Service Precautions. Install the oil pan bolts. ^ Tighten the bolts alternately and evenly to 11 Nm (97 inch lbs.). 6. If previously removed, install the range selector cable bracket and bolts. ^ Tighten the bolts to 25 Nm (18 ft. lbs.). 7. Apply a small amount of sealant GM P/N 12346004 (Canadian P/N 10953480), or equivalent to the threads of the oil pan drain plug, if equipped. 8. Install the oil pan drain plug, if equipped. ^ Tighten the plug to 18 Nm (13 ft. lbs.). 9. Lower the vehicle. 10. Fill the transmission to the proper level with DEXRON® III transmission fluid. 11. Check the COLD fluid level reading for initial fill only. 12. Inspect the oil pan gasket for leaks. Locations Manifold Pressure/Vacuum Sensor: Locations Full Engine View Left Side Page 9290 Relay Box: Service and Repair Body Wiring Harness Junction Block Replacement BODY WIRING HARNESS JUNCTION BLOCK REPLACEMENT REMOVAL PROCEDURE 1. Remove the cover retaining nut. 2. Remove the cover by pushing in the tabs. 3. Remove the harness from the front of the junction block. 4. Remove the junction block from the bracket by pressing to release the tabs. 5. Remove the junction block in order to gain access to the rear of the block to remove the retaining bolts. 6. Remove the retaining bolts. 7. Separate the wire harness block from the junction block by inserting a screw driver in between. 8. Remove the junction block from the vehicle. INSTALLATION PROCEDURE 1. Install the wire harness block to the junction block. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the retaining bolts. Tighten Tighten the bolts to 6 N.m (53 lb in). 3. Install the junction block to the bracket. Page 8457 2. Remove the master cylinder from the booster. Do not remove the pipes from the master cylinder. Set the master cylinder aside in the engine compartment. 3. Disconnect the power brake booster inlet hose, the steering gear inlet hose, and the power brake booster outlet hose from the booster assembly. 4. Disconnect the electrical connector from the stop lamp switch. 5. Remove the retainer from the brake pedal pin. 6. Remove the stop lamp switch and the pushrod to the power brake booster from the brake pedal pin. 7. Unsnap the stop lamp switch from the power brake booster pushrod. 8. Remove the 4 booster to bulkhead nuts. 9. Remove the booster assembly. 10. Remove the gasket. Installation Page 5996 Pressure Regulating Solenoid: Connector Locations Specifications Wheel Bearing: Specifications Front Hub and Bearing Assembly to Steering Knuckle Bolts ............................................................................................................... 180 Nm (133 ft. lbs.) Page 1920 Four Wheel Drive Selector Switch: Diagrams Page 12470 4.2. Release the back end of the connector (C) and remove from the contact rail (D). 4.3. M00-01: Disconnect pin 39, cut off the cable terminal and insulate the end using tape (E). Fold back the cable and secure using tape (F). 4.4. M02-04: Disconnect pin 58, cut off the cable terminal and insulate the end using tape (E). Fold back the cable and secure using tape (F). 4.5. Assemble the contact rail and end. 4.6. Connect connector (A) and secure the cable using a cable tie (B). 5. Assemble the gear shift housing (A). AUT: Connect connector (B). 6. Assemble the center console, see WIS - Body - Interior. 7. Remove the OnStar(R) control module and secure the cable harness: 7.1. 5D: Remove the right-hand cover from the luggage compartment floor. Page 8405 7. Remove the brake cable from the lever. 8. Remove the cable (2) from the rear brake cable mounting bracket (3) by depressing the locking tabs (1) on the brake cable. 9. Remove the brake cable from the guides and the body mounts. Installation Procedure 1. Install the new brake cable (2) into the rear brake cable mounting bracket (3) by pushing the cable into place until the locking tabs (1) snap into place. Page 2344 3. Install the booster outlet hose to the power steering pump nipple and retaining clamp (2). 4. Install the booster inlet hose (1) to the booster. 5. Install the gear inlet hose to the booster. ^ Tighten both power steering inlet hose fittings to 32 Nm (24 ft. lbs.). Notice: Refer to Fastener Notice in Service Precautions. 6. Install the booster outlet hose (3) to the booster and install the retaining clamp (2). 7. Remove the drain pan from under the vehicle. 8. Bleed the power steering system. Refer to Bleeding the Power Steering System. 9. Connect the energy storage box before after servicing the vehicle. (Rack and Pinion) Power Steering Cooler Pipe/Hose Replacement (Rack and Pinion) Page 15176 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves SPLICING COPPER WIRE USING SPLICE SLEEVES TOOLS REQUIRED J 38125-D Terminal Repair Kit IMPORTANT: Use only GM splice sleeves, other splice sleeves may not protect the splice from moisture or a provide good electrical connection. Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. Page 6858 8. If both the left side bearing and seal was removed, perform the following step. Install the inner axle shaft into the differential case side gear using a soft-faced mallet until the retaining ring on the inner axle shaft is fully seated within the groove in the differential case side gear. - Pull back on the inner axle shaft to ensure that the inner axle shaft is properly retained in the differential case side gear. 9. If both the left side bearing and seal was removed, perform the following step. Install the front differential carrier assembly. 10. If only the left side seal was removed, perform the following step. Install the seal using the J 45225 and a soft-faced mallet. - Tap only on the center portion of the J 45225 in order to drive the seal in evenly. Page 6834 6. Remove the washer. 7. Install the J 8614-2 (2) and the J 8614-3 (3) into the J 8614-01 (1) as shown. 8. Remove the pinion yoke by turning the J 8614-3 (3) clockwise while holding the J 8614-01 (1).Use a container in order to retrieve the lubricant. 9. Remove the pinion oil seal. Use a suitable seal removal tool. Do not damage the axle housing. Installation Procedure 1. Apply a light coat of axle lubricant, GM P/N 12378557 or equivalent meeting GM Specification 9986207, to the lip of the pinion seal. 2. Install the new seal using the J 45710. 3. Install the pinion yoke. 4. Notice: Refer to Pinion Flange/Yoke Installation Notice in Service Precautions. Page 10822 Recirculation Actuator Page 13101 these systems will then completely power OFF. OnStar(R) Module Expected Current Draw The expected current draw of the OnStar(R) module in various ignition modes are as follows: ^ Ignition ON ‐ 240 to 400 mA ^ Ignition OFF ‐ 3 to 20 mA for 48 hours ^ Ignition OFF ‐ 0.2 to 0.8 mA after 48 hours (120 hours on specified vehicle communication platforms (VCPs)). Note During extended voltage testing for battery parasitic draw, it is possible to observe a voltage spike caused by the following: ^ A cellular registration call that was triggered by the local cellular system. ^ The OnStar(R) system has set a monthly trigger for a vehicle data upload call for the OnStar(R) Vehicle Diagnostic E‐mail upload. OnStar(R) System States of Readiness The OnStar(R) system will use the following 4 states of readiness, depending upon the type of cellular market the vehicle is in when the ignition is turned OFF. ^ High power ^ Low power ^ Sleep ^ Digital standby The high power state is in effect whenever the ignition is in the ON or RUN position, retained accessory power (RAP) is enabled, and/or the OnStar(R) system is sending or receiving calls or when the system is performing a remote function. The low power state is in effect when the OnStar(R) system is idle with the ignition in the ON or RUN position, or with RAP enabled. The sleep state is entered after the vehicle has been shut OFF and the RAP has timed out. At a predetermined time recorded within the VCIM, the system re-enters the low power state to listen for a call from the OnStar(R) Call Center for 1 minute. After this interval, the system will again return to the sleep state for 9 minutes. If a call is sent during the 1 minute interval, the OnStar(R) system will receive the call and immediately go into the high power mode to perform any requested functions. If a call is not received during the 1 minute interval, the system will go back into the sleep mode for another 9 minutes. This process will continue for up to 48 hours, after which the OnStar(R) system will turn OFF until the ignition is turned to the ON or RUN position. The digital standby power state is entered after the vehicle has been shut off and the RAP has timed out while in a digital cellular area. When in digital standby mode, the OnStar(R) module is able to perform all remote functions as commanded by an OnStar(R) advisor at any time, for a continuous 48 hours. After 48 hours, the OnStar(R) module will go into sleep mode until a wake up signal from the vehicle is seen by the CIM. If the OnStar module loses the digital cellular signal it will revert to analog mode and follow the standard sleep state (9 minutes OFF, 1 minute standby) based on the time of the GPS signals, this will continue until a digital cellular signal is again received. If the OnStar(R) system loses battery power while the system is in a standby or sleep mode, the system will remain OFF until battery power is restored and the ignition is turned to the ON or RUN position. Deactivated OnStar(R) Accounts In the event that a customer has not upgraded their vehicle to a digital system, the account has been deactivated. The customers have been previously notified of the steps required to upgrade their vehicles. After the OnStar(R) account has been deactivated, customers will experience the following: ^ The OnStar(R) status LED will not illuminate ^ The OnStar(R) system will NOT attempt to connect to the OnStar(R) Call Center in the event of a collision or if the vehicle's front air bags deploy for any other reason. ^ An emergency button press will result in a demo message being played, indicating the service has been deactivated and needs to be upgraded. Page 5550 Crankshaft Position Sensor: Service and Repair Crankshaft Position (CKP) Sensor Replacement CRANKSHAFT POSITION (CKP) SENSOR REPLACEMENT REMOVAL PROCEDURE IMPORTANT: Perform the CKP System Variation Learn Procedure whenever the crankshaft position sensor is removed or replaced. 1. Remove the starter. 2. Disconnect the crankshaft position (CKP) sensor electrical connector. 3. Clean the area around the CKP sensor before removal in order to avoid debris from entering the engine. 4. Remove the CKP sensor bolt. 5. Remove the CKP sensor. INSTALLATION PROCEDURE Page 13863 The moldings are available in factory colors; however, quantities are limited. When these quantities are exhausted, the moldings will only be available in paint to match only. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 15281 When the maximum value is reached, the trip odometer will roll over to 0.0. TIMER The Timer is displayed as XX (hours) : XX (minutes) : XX (seconds). The Timer is started and stopped using the DIC Select button. Holding the Select button for longer than 1 second while the Timer parameter is displayed will reset the Timer to 00:00:00. The Timer status and data value is retained in memory when the ignition is turned OFF. When the ignition is turned ON again, the Timer status and data value is resumed. The Timer maximum value is 99:59:59. When the maximum is reached, the Timer rolls over to 00:00:00 and continues to operate. FUEL INFORMATION DIC Fuel Information / Reset Capabilities The available DIC Fuel Information and reset capabilities are as follows: Range. Can not be reset - Avg. Fuel Economy. Can be reset - Inst. Fuel Economy. Can not be reset - Engine Oil Life. Can be reset Range The range display is the estimated distance that the vehicle can travel under current fuel economy and fuel level conditions. This range is calculated from odometer information and class 2 messages. Fuel Range is capable of displaying values from 0-999 mi or km. Display appears as: RANGE: XXX MILES (English), RANGE: XXX km (Metric). If the range is less than 40 miles, RANGE: LOW will be displayed. Average Fuel Economy The Average Fuel Economy (AFE) value is calculated by the cluster based on Trip Distance and Trip Fuel Used. Pressing the Select button for longer than 1 second while the Average Fuel Economy is displayed in the DIC will reset to 0.0. Average Fuel Economy is capable of displaying values from 0.0-99.9. Display appears as: AVG ECON XX.X (English) MPG, AVG ECON XX.X L/100km (Metric). Trip Distance and Trip Fuel Used accumulated values are stored in memory when the ignition is turned OFF. Instantaneous Fuel Economy Instantaneous Fuel Economy values are calculated by the cluster from odometer information and class 2 messages. The cluster calculates instantaneous fuel economy based on distance and fuel. Instantaneous fuel economy is capable of displaying values from 0.0 - 99.9. Display appears as INST ECON XX.X (English), INST ECON XX.X L/100km (Metric). Values for the Instantaneous fuel economy are not stored when the ignition is turned OFF. Engine Oil Life Engine Oil Life percentage values are based on class 2 messages to the IPC. The IPC requests this value when Engine Oil Life is selected on the DIC. Engine Oil Life is capable of displaying values from 0-100 percent and the OIL LIFE RESET driver warning will be displayed. Pressing the Select button for longer than 5 seconds while Engine Oil Life is displayed on the DIC the value will reset to 100 percent. Display appears as ENGINE OIL LIFE: XXX%. Page 12478 Disclaimer Page 9008 Fuse Block - Underhood C1 Part 2 Page 10649 It will be necessary to reprogram the PCM for speedometer accuracy. Contact Techline to obtain a VCI number. Then refer to the table for the appropriate calibration part number based on the model year and axle ratio. Calibration Information Documentation Make a copy of the "Accessory Wheel and Tire Information Form" included in this bulletin. Page 13836 1. Install the emblem (1) onto the grille (2). Notice: Refer to Fastener Notice in Service Precautions. 2. Install the retaining nuts (3) and tighten. Tighten the retaining nuts to 3 N.m (27 lb in). 3. Reinstall the upper grille baffle. Emblem/Nameplate Replacement - Door (W/O SS) Emblem/Nameplate Replacement - Door (W/O SS) Tools Required J 25070 Heat Gun Removal Procedure Important: Use the tape for protection and alignment marks for alignment of the new emblem. 1. Apply tape to the area around the door emblem. 2. Heat the emblem/nameplate, using a heat gun J 25070 152 mm (6.0 in) from the surface. 3. Apply the heat using a circular motion for about 30 seconds. Notice: Refer to Exterior Trim Emblem Removal Notice in Service Precautions. Page 2684 Relay Block - I/P C1 Part 2 NV 3500 Shifter M/T: Service and Repair NV 3500 Shift Lever Assembly Replacement Removal Procedure Important: ^ Ensure that the control lever is positioned into the mechanical third or fourth gear prior to removal of the shift lever from the transmission. The transmission must remain in this state when the shift lever is removed. ^ Do not disassemble the transmission shift lever. Internal parts for this shift lever are not available. Opening the shift lever voids the warranty. ^ When removing the shift lever from the transmission, use the exposed bolts on the base of the lever. 1. Remove the control lever and boot. 2. Remove the boot. 3. Remove the shift lever bolts. 4. Remove the shift lever and seal. 5. Remove the shift lever insulator. Installation Procedure 1. Install a NEW shift lever insulator. 2. Install the shift lever seal and lever. Notice: Refer to Fastener Notice in Service Precautions. 3. Install the shift lever bolts. ^ Tighten the bolts to 20 Nm (15 ft. lbs.). 4. Install the boot. 5. Install the control lever and boot. Page 13294 5. Choose the outstanding core you wish to process, by selecting the Virtual Core Button on the far right side of the screen. 6. Enter the information in the required fields and select the submit button. Record the confirmation number. Canadian Dealers 1. Return the removed Analog / Digital-Ready OnStar(R) VCIM to the Parts Manager. 2. The Parts Manager will log onto https://adt.onstar.gm.mass.ca and enter information as prompted. All Dealers If the website indicates that the VCIM needs to be physically returned to the distributor, please use the pre-paid shipping label that was included in the kit to return the removed VCIM. Important: To avoid a $250 core non-return charge, you must do one of the following within 30 days of kit shipment: 1. Submit the necessary VCIM data through the website, as indicated above. 2. Mail the removed core from the customer's vehicle back to the distributor. 3. Return the unused digital upgrade kit back to the distributor using the pre-paid shipping label that is included in the kit box. Returning the Upgraded Vehicle to the Customer Returning the Upgraded Vehicle to the Customer 1. Place the new OnStar Subscriber Information (Owner's Manual kit) in the customer's vehicle where they can review some of the new features of the Digital-Capable system. The continuous digit dialing feature should be highlighted to the customer to avoid a return to the dealership for dialing instructions. Advise the customer to discard any existing OnStar(R) Owner's Manuals that may be in the vehicle. 2. Have the Service Advisor, Service Manager or Sales Consultant review the new OnStar(R) Hands-Free Calling procedure with the customer. The customer is uses to their analog OnStar(R) Hands-Free Calling system, which uses individual digit dial to make a call. The Generation 6 Digital-Capable system uses continuous digit dial, and the customer needs to be made aware of this change. 3. U.S. Dealers Only: Staple the "Tip Sheet - OnStar(R) Generation 6 Digitally-Capable System", that was included in the kit, to the customer's copy of the repair order. This tip sheet will help your customer better understand their new OnStar(R) system. 4. Canadian Dealers Only: Refer the customer to the Hands-Free Calling Quick Review Card from the new OnStar(R) Owner's Manual kit for help with the new dialing procedure. 5. Fill out the form entitled "GM Limited Warranty for Upgraded OnStar(R) Digital Equipment Program Participants" and staple a copy of this to the customer's repair order. You may want to keep a copy for your records. 6. Encourage your customer to press their blue OnStar(R) button the next day. The OnStar(R) Advisor will be able to review some of the new features of their digital OnStar(R) system. Closing the Onstar(R) Upgrade Exchange Closing the OnStar(R) Upgrade Exchange 1. Collect payment from the customer. Your dealership's open account (sales) will be charged for the cost of the chosen subscription plan, any applicable subscription taxes, and the $15 upgrade charge after the vehicle has been configured through the TIS2WEB process. 2. None of the costs associated with the OnStar Digital Upgrade program may be claimed as a GM goodwill event. These costs must be paid by the customer, and may not be included in any goodwill offered to the customer. GM employees or representatives or field personnel are not able to offer goodwill for this program. If the dealership decides to pay for the upgrade for their customer, be aware that your GM or OnStar(R) contact will not be able to reimburse you for this cost. 3. Use labor code Z2096 to submit your claim for the labor time published below plus 0.2 hr Administrative Allowance and an additional $20.00 Net Amount. ^ For all dealer claim submissions (excluding U.S. Saturn), use Complaint Code MH - Technical Bulletin, and Failure Code 93 - Technical Service Bulletin. Page 4593 Disclaimer Page 1686 Page 4818 Intake Air Temperature (IAT) Sensor: Service and Repair MASS AIR FLOW (MAF)/INTAKE AIR TEMPERATURE (IAT) SENSOR REPLACEMENT REMOVAL PROCEDURE IMPORTANT: Use care when handling the mass air flow/intake air temperature (MAF/IAT) sensor. Do not dent, puncture, or otherwise damage the honeycell located at the air inlet end of the MAF/IAT. Do not touch the sensing elements or allow anything including cleaning solvents and lubricants to come in contact with them. Use a small amount of a non-silicone based lubricant, on the air duct only, to aid in installation. 1. Remove the air cleaner outlet duct. 2. Pull out the gray connector position assurance (CPA) retainer. 3. Push down on the black clip in order to disconnect the MAF/IAT sensor electrical connector (4). 4. Loosen the MAF/IAT clamp. 5. Remove the MAF/IAT sensor from the air cleaner assembly. INSTALLATION PROCEDURE IMPORTANT: The embossed arrow on the MAF/IAT sensor indicates the proper air flow direction. The arrow must point toward the engine. Fuel Pump Relay Fuel Pump Relay: Locations Fuel Pump Relay FUEL PUMP RELAY Fuse Block-Underhood Page 3745 3. Notice: Refer to Fastener Notice in Service Precautions. Install the exhaust muffler nuts. Tighten the nuts to 40 Nm (30 ft. lbs.). Page 8278 Disclaimer A/C - Underhood Rattle Noise on Hard Acceleration Refrigerant Filter: All Technical Service Bulletins A/C - Underhood Rattle Noise on Hard Acceleration File In Section: 01 - HVAC Bulletin No.: 03-01-38~019A Date: September, 2004 TECHNICAL Subject: Underhood Rattle Noise Heard On Acceleration (Check A/C System Performance and Compressor Operation) Models: 2003-2004 Cadillac CTS 2002-2004 Cadillac Escalade, Escalade EXT 2003-2004 Cadillac Escalade ESV 2002-2004 Chevrolet Avalanche, Express, Silverado, Suburban, Tahoe 2002-2004 GMC Denali, Denali XL, Savana, Sierra, Yukon, Yukon XL 2002-2004 Commercial Upfitter Chassis Vehicles with Air Conditioning (A/C) This bulletin is being revised to update the service procedure and parts information. Please discard Corporate Bulletin Number 03-01-38-019 (Section 01 - HVAC). Condition Some customers may comment about an underhood rattle noise heard on acceleration or a sudden loss of A/C system performance. Cause This condition may be caused by liquid slugging of the A/C compressor. This condition may cause an internal failure in the A/C compressor. The serpentine belt tensioner and serpentine belt may also be damaged. Correction Technicians are to check the A/C system performance and compressor operation using the following repair procedure: 1. Open the hood and inspect the A/C compressor for damage and to see if the compressor is seized. Verify that the serpentine belt is not damaged or missing. If the A/C compressor is seized, proceed to Step 5. 2. Perform the A/C System Performance test. Refer to the Heating, Ventilation and Air Conditioning (HVAC) section of SI. Correct any performance concerns or refrigerant leaks that are found. 3. Inspect the vehicle for other possible sources of A/C compressor noise or performance concerns. Refer to Corporate Bulletin Number 01-01-38-013 for more information. 4. After all other possible sources of A/C compressor noise or performance concerns have been eliminated, only then should the A/C compressor be replaced. 5. Remove the A/C compressor. Refer to the A/C Compressor Replacement procedure in the HVAC section of SI. 6. Inspect the transmission cooler lines for damage due to contact from the serpentine belt. Replace the transmission cooler lines if necessary. 7. Install an inline A/C system filter. Refer to Corporate Bulletin Number 01-01-38-006C for more information about A/C system flushing and filter installation procedures. An A/C system flush is not to be done unless prior authorization is given by the GM Area Service Manager (in Canada, the District Service Manager). 8. Install an A/C Suction Screen. Refer to Corporate Bulletin Number 01-01-39-003A for more information about A/C suction screen repair recommendations and procedures. 9. Install a new A/C compressor. Refer to the Compressor Replacement procedure in the HVAC section of SI. 10. Install a new orifice tube for the front A/C system. Refer to the Expansion (Orifice) Tube Replacement procedure in SI. Component Locations Pressure Regulating Solenoid: Component Locations Automatic Transmission - 4L60-E/4L65-E Automatic Transmission Electronic Component Views (M30/M32) Electronic Components Capacity Specifications Power Steering Fluid: Capacity Specifications Power Steering ............................................................................................................................................................. 0.77 - 1.25 liters (0.81 - 1.32 quarts) NOTE: ALL capacity specifications are approximate. When replacing or adding fluids, fill to the recommended level and recheck fluid level. Page 15079 Truck Bed: Service and Repair Pickup Box Replacement Removal Procedure 1. Disconnect the tail/turn signal lamp wiring connectors (1) at the rear lamps bussing block at the rear of the vehicle. 2. Remove the tail lamp assembly. 3. Open the fuel filler door. 4. Remove the screws and the push-pin holding the fuel filler neck to the side panel. 5. Remove the end gate. 6. Remove the pickup box fasteners (1) from the frame rails. 7. With the an assistant remove the box from the vehicle. Installation Procedure 1. Align the pickup box on the frame rails. A/T - Cracked Case Diagnosis Case: All Technical Service Bulletins A/T - Cracked Case Diagnosis Bulletin No.: 02-07-30-024B Date: August 18, 2005 INFORMATION Subject: Diagnosis of Cracked or Broken Transmission Case Models: 2006 and Prior Cars and Light Duty Trucks 2006 and Prior HUMMER H2 2006 HUMMER H3 2005-2006 Saab 9-7X with 4L60/4L60-E/4L65-E or 4L80-E/4L85-E or Allison(R) Series 1000 Automatic Transmission Supercede: This bulletin is being revised to add models and model years. Please discard Corporate Bulletin Number 02-07-30-024A (Section 07 - Transmission/Transaxle). Diagnosing the cause of a cracked or broken transmission case requires additional diagnosis and repair or a repeat failure will occur. A cracked or broken transmission case is most often the result of abnormal external torsional forces acting on the transmission case. If none of the conditions listed below are apparent, an internal transmission component inspection may be required. Repairs of this type may be the result of external damage or abuse for which General Motors is not responsible. They are not the result of defects in materials or workmanship. If in doubt, contact your General Motors Service Representative. The following items should be considered: ^ It is important to inspect the vehicle for signs of an out of line condition, impact damage or foreign material to the following components: - The transmission - The engine mounts - The transmission rear mount and crossmember - Vehicle frame damage that alters the front to rear alignment of the driveshaft - The driveshafts (both front and rear) - The wheels (caked with mud, concrete, etc.) - The tires (roundness, lack of cupping, excessive balance weights) - The transfer case (if the vehicle is 4WD) ^ A worn or damaged driveshaft U-Joint has shown to be a frequent cause of transmission case cracking, especially on vehicles that see extended periods of highway driving. Always inspect the U-joint condition when diagnosing this condition. ^ For driveshaft damage or imbalance, Inspect the driveshafts (both front and rear) for dents, straightness/runout or signs of missing balance weights. Also, inspect for foreign material such as undercoat sprayed on the driveshaft. ^ The driveshaft working angles may be excessive or non-canceling, especially if the vehicle carrying height has been altered (lifted or lowered) or if the frame has been extended or modified. ^ Damaged or worn upper or lower rear control arms or bushings. ^ A rear axle that is not seated in the rear spring properly (leaf spring vehicles). ^ Broken rear springs and or worn leaf spring bushings. Page 9708 C106 Engine Harness To I/P Harness (With RPO Code PTO) Page 3054 6. Install the wheel hub and bearing (5) and splash shield (6) to the vehicle, 15 series. 7. Install the wheel hub and bearing mounting bolts, the 15 series. 8. Install the wheel hub and bearing mounting bolts, 25/35 series. ^ Tighten the wheel hub to knuckle bolts to 180 Nm (133 ft. lbs.). 9. Install the nut (2) and washer (3) retaining the wheel drive shaft assembly to the wheel hub and bearing. ^ Tighten the nut to 240 Nm (177 ft. lbs.). 10. Install the wheel speed sensor and brake hose mounting bracket bolt to the steering knuckle. ^ Tighten the brake hose clip bolt to 12 Nm (106 inch lbs.). 11. Install the rotor. Refer to Brake Rotor Replacement - Front in Disc Brakes. 12. Install the tire and wheel. 13. Lower the vehicle. Diagram Information and Instructions Rear Defogger: Diagram Information and Instructions Truck Zoning TRUCK ZONING Truck Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that corresponds to where they are located in the vehicle. The table explains the numbering system. NVG 246-NP8 Control Module: Locations NVG 246-NP8 Transfer Case Shift Control Module Transfer Case Shift Control Module 1 - I/P Harness 2 - Transfer Case Shift Control Module Connectors 3 - Transfer Case Shift Control Module 4 - Instrument Panel Page 6663 5. Important: When installing bolts throughout this procedure, be sure to use the correct bolt size and length in the correct location as specified. Do not install the transmission fluid indicator stop bracket and bolt at this time.Install but do not tighten the valve body bolts which retain only the valve body directly. Each numbered bolt location corresponds to a specific bolt size and length, as indicated by the following: ^ M6 X 1.0 X 65.0 (1) ^ M6 X 1.0 X 54.4 (2) ^ M6 X 1.0 X 47.5 (3) ^ M6 X 1.0 X 35.0 (4) ^ M8 X 1.0 X 20.0 (5) ^ M6 X 1.0 X 12.0 (6) ^ M6 X 1.0 X 18.0 (7) 6. Install the manual detent spring. 7. Install but do not tighten the manual detent spring bolt. 8. Install the transmission fluid pressure switch. 9. Install but do not tighten the valve body bolts which retain the transmission fluid pressure switch to the valve body. Page 10354 9. Remove the steering knuckle. Installation Procedure 1. Clean all grease and contaminants from the tapered section and the threads of the upper ball joint, the lower ball joint, and the tie rod end. 2. Clean and inspect the taper holes and the mounting surfaces of the steering knuckle. If any of the tapered holes are elongated, out of round, or damaged, replace the steering knuckle. 3. Install the steering knuckle. 4. Notice: Refer to Fastener Notice in Service Precautions. Connect the lower ball joint to the steering knuckle and install the retaining nut. ^ Tighten the lower control arm retaining nut to 100 Nm (74 ft. lbs.). 5. Connect the upper ball joint to the steering knuckle and install the retaining nut. ^ Tighten the upper control arm retaining nut to 50 Nm (37 ft. lbs.). 6. Install the brake hose and the bracket retaining bolt to the steering knuckle ^ Tighten the bolt to 9 Nm (80 inch lbs.). 7. Connect the outer tie rod to the steering knuckle. Refer to Tie Rod Replacement in Steering Linkage (Non-Rack and Pinion). 8. Install the wheel hub and bearing assembly. Refer to Wheel Hub, Bearing, and Seal Replacement (RWD) Wheel Hub, Bearing, and Seal Replacement (4WD). 9. Install the tire and wheel. 10. Remove the lower control arm support. 11. Lower the vehicle. 12. Align the vehicle. Refer to Measuring Wheel Alignment (w/Rear Wheel Steering) Measuring Wheel Alignment (w/o Rear Wheel Steering) in Diagrams Door Latch Assembly (Key Cylinder Switch) - Driver C3 Page 7737 Parts Information Warranty Information (excluding Saab U.S. Models) Warranty Information (Saab U.S. Models) Page 3795 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly, Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Pull to Seat Connectors PULL TO SEAT CONNECTORS TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Page 2147 Drive Belt: Testing and Inspection Drive Belt Chirping Drive Belt Chirping Diagnosis Diagnostic Aids The chirping noise may be intermittent due to moisture on the drive belt(s) or the accessory drive pulley(s). In order to duplicate the customer's concern, it may be necessary to spray a small amount of water onto the drive belt(s). If spraying water onto the drive belt(s) duplicates the symptom, cleaning the accessory drive pulley(s) may be the most probable solution. A loose or improper installation of a body or suspension component, or other item(s) on the vehicle may also cause the chirping noise. Test Description Page 14006 Drink Holders: Service and Repair Cupholder Replacement - Front Seat Cupholder Replacement - Front Seat Removal Procedure 1. Remove the center seat. Caution: Eye protection must be worn when drilling rivets to reduce the chance of personal injury. 2. Remove the rivets (1) retaining the cupholder from the bottom of the center seat. 3. Remove the cupholder. Installation Procedure 1. Install the cupholder. 2. Install the rivets (1) retaining the cupholder to the bottom of the center seat. 3. Install the center seat. Accessory Drive Belt: Service and Repair Accessory Drive Belt Replacement - Accessory (4.8L, 5.3L, and 6.0L Engines) Removal Procedure 1. Loosen the air cleaner outlet duct clamps at the following locations: ^ The throttle body ^ The mass airflow/intake air temperature (MAF/IAT) sensor 2. Disconnect the radiator inlet hose clip from the outlet duct. 3. Remove the air cleaner outlet duct. 4. Install a breaker bar with hex-head socket to the drive belt tensioner bolt. 5. Rotate the drive belt tensioner clockwise in order to relieve tension on the belt (1). 6. Remove the belt (1) from the pulleys and the drive belt tensioner. 7. Slowly release the tension on the drive belt tensioner. 8. Remove the breaker bar and socket and from the drive belt tensioner bolt. 9. Clean and inspect the belt surfaces of all the pulleys. Installation Procedure 1. Route the drive belt (1) around all the pulleys except the idler pulley. 2. Install the breaker bar with hex-head socket to the belt tensioner bolt. 3. Rotate the belt tensioner clockwise in order to relieve the tension on the tensioner. 4. Install the drive belt (1) under the idler pulley. 5. Slowly release the tension on the belt tensioner. 6. Remove the breaker bar and socket from the belt tensioner bolt. Page 12859 10.4. Remove the end cap from the new optic cable, connect to the connector and refit the secondary catch (D). Fit the terminal housing (C) to the connector and refit the locking strip (B). 10.5. Secure the old optic cable together with the new one (E). Important: The optic cable must not be bent with a radius less than 25 mm (1 in). Important: Secure the wiring harness so that there is no risk of chafing and rattling. 11. CV: Remove the rear seat in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. The O-bus connector H2-9 is located behind the left speaker. 12. M04-05: Disconnect the optic cables on the OnStar(R) control modules and join the cables: 12.1. Cut off the cable tie holding the connector (H2-9) against REC. Page 14589 Driver Seat (1 Of 2) Page 16113 INSTALLATION PROCEDURE 1. Install the door module into the switch panel bezel until it snaps into place. 2. Install the switch panel bezel and module to the door panel. NOTE: Refer to Fastener Notice in Service Precautions. 3. Install the screw that retains the switch panel bezel (1) to the front door panel. Tighten Tighten the screw to 2 N.m (18 lb in). 4. Connect the electrical connectors. Page 13904 5. Install the lower bolts to the rear of the fender. Tighten the bolts to 25 N.m (18 lb ft). 6. Install the bolts in order to retain the fender to the rear pillar. Tighten the bolts to 23 N.m (17 lb ft). 7. Install the rear taillamp assembly to the vehicle. 8. Install the bolts to the front of the fender. Tighten the bolts to 23 N.m (17 lb ft). 9. Install the fuel filler neck to the vehicle, if removed. Page 6455 Shift Cable: Adjustments Automatic Transmission - 4L80-E/4L85-E Automatic Transmission Range Selector Cable Adjustment 1. Ensure that the steering column shift lever is in the park (P) position. 2. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 3. Ensure that the transmission manual shaft lever is in the park (P) position. 4. Grasp the shift cable shifter end (1) in the left hand and the shift cable transmission end (2) in the right hand. 5. Align the outside diameter of the transmission end (2) with the inside diameter of the shifter end (1). 6. Push the end of the transmission cable (3) inside the shifter end until the blue spring (2) on the transmission end (3) is fully compressed, this will engage the inner wire and lock both wires together. Page 7583 Page 1606 Manifold Absolute Pressure (MAP) Sensor Page 840 Relay Box: Service and Repair Body Wiring Harness Junction Block Replacement BODY WIRING HARNESS JUNCTION BLOCK REPLACEMENT REMOVAL PROCEDURE 1. Remove the cover retaining nut. 2. Remove the cover by pushing in the tabs. 3. Remove the harness from the front of the junction block. 4. Remove the junction block from the bracket by pressing to release the tabs. 5. Remove the junction block in order to gain access to the rear of the block to remove the retaining bolts. 6. Remove the retaining bolts. 7. Separate the wire harness block from the junction block by inserting a screw driver in between. 8. Remove the junction block from the vehicle. INSTALLATION PROCEDURE 1. Install the wire harness block to the junction block. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the retaining bolts. Tighten Tighten the bolts to 6 N.m (53 lb in). 3. Install the junction block to the bracket. Page 15695 Map Light: Description and Operation READING LAMPS The inadvertent power supply voltage circuit of the BCM provides battery positive voltage to the reading lamps. The reading lamps and switch are integral to the courtesy/reading lamp assembly. When the switch is closed, voltage is supplied and the lamp illuminates. In the event that any of these lamps were to remain illuminated for a period of more than 10 minutes with the ignition switch in the OFF position, the BCM will deactivate the inadvertent power supply voltage circuit to prevent a total battery discharge condition. Ground is provided to the reading lamps at G203. Page 5975 Engine Controls - MIL ON/Misfire/Misfire DTC's Set Engine Control Module: All Technical Service Bulletins Engine Controls - MIL ON/Misfire/Misfire DTC's Set Bulletin No.: 06-06-04-046 Date: September 12, 2006 INFORMATION Subject: Information on Engine Misfire MIL/SES Light Illuminated or Flashing DTC P0300, P0301, P0302, P0303, P0304, P0305, P0306, P0307, P0308, P0420 or P0430 Models: 1999-2007 Cadillac, Chevrolet, GMC Full-Size Pickup and/or Utility Trucks with 4.8L, 5.3L, 5.7L, 6.0L or 6.2L VORTEC GEN III, GEN IV, V-8 Engine (VINs V, C, T, Z, B, 3, M, 0, J, R, U, N, Y, K, 8 - RPOs LR4, LY2, LM7, L59, L33, LC9, LH6, LMG, LY5, L31, LQ4, LQ9, L76, LY6, L92) with Active Fuel Management(TM) and E85 Flex Fuel If you encounter vehicles that exhibit the above conditions, refer to SI for the appropriate DTC(s) set. If no trouble is found, the cause may be due to an ECM ground terminal that has corroded with rust over time. Inspect the main engine wiring harness ground terminal (G103) for this condition. The wire terminal (G103) attaches either to the front or to the rear of the right side cylinder head, depending on the model year of the Full Size Pickup and/or Utility Trucks. If the ECM ground terminal has been found to be corroded, then follow the service procedure outlined in this bulletin to correct the corrosion issue. Remove either the nut or bolt securing the main engine wiring harness ground terminal (G103) to the right cylinder head. Refer to the above illustration to determine where the ground is located on the vehicle (1). Page 1376 Parts Information Parts are currently available from GMSPO. Warranty Information Engine Controls - Aftermarket Accessory Usage Engine Control Module: All Technical Service Bulletins Engine Controls - Aftermarket Accessory Usage INFORMATION Bulletin No.: 04-06-04-054B Date: November 18, 2010 Subject: Info - Non-GM Parts and Accessories (Aftermarket) Models: 2011 and Prior GM Passenger Cars and Trucks Supercede: This bulletin is being revised to add model years and update to the new U.S. Fixed Operation Manager (FOM) and Canada Warranty Manager (WM) names. Please discard Corporate Bulletin Number 04-06-04-054A (Section 06 - Engine/Propulsion System). The recent rise and expansion of companies selling non-GM parts and accessories has made it necessary to issue this reminder to dealers regarding GM's policy on the use and installation of these aftermarket components. When a dealer is performing a repair under the New Vehicle Limited Warranty, they are required to use only genuine GM or GM-approved parts and accessories. This applies to all warranty repairs, special policy repairs or any repairs paid for by GM. Parts and accessories advertised as being "the same" as parts manufactured by GM, but not sold through GM, do not qualify for use in warranty repairs, special policy repairs or any repairs paid for by GM. During a warranty repair, if a GM original equipment part is not available through GM Customer Care and Aftersales (GM CC&A;), ACDelco(R) distributors, other GM dealers or approved sources, the dealer is to obtain comparable, non-GM parts and clearly indicate, in detail, on the repair order the circumstances surrounding why non-GM parts were used. The dealer must give customers written notice, prior to the sale or service, that such parts or accessories are not marketed or warranted by General Motors. It should also be noted that dealers modifying new vehicles and installing equipment, parts and accessories obtained from sources not authorized by GM are responsible for complying with the National Traffic and Motor Vehicle Safety Act. Certain non-approved parts or assemblies, installed by the dealer or its agent not authorized by GM, may result in a change to the vehicle's design characteristics and may affect the vehicle's ability to conform to federal law. Dealers must fully understand that non-GM approved parts may not have been validated, tested or certified for use. This puts the dealer at risk for potential liability in the event of a part or vehicle failure. If a GM part failure occurs as the result of the installation or use of a non-GM approved part, the warranty will not be honored. A good example of non-authorized modification of vehicles is the result of an ever increasing supply of aftermarket devices available to the customer, which claim to increase the horsepower and torque of the Duramax(TM) Diesel Engines. These include the addition of, but are not limited to one or more of the following modifications: - Propane injection - Nitrous oxide injection - Additional modules (black boxes) that connect to the vehicle wiring systems - Revised engine calibrations downloaded for the engine control module - Calibration modules which connect to the vehicle diagnostic connector - Modification to the engine turbocharger waste gate Although the installation of these devices, or modification of vehicle components, can increase engine horsepower and torque, they may also negatively affect the engine emissions, reliability and/or durability. In addition, other powertrain components, such as transmissions, universal joints, drive shafts, and front/rear axle components, can be stressed beyond design safety limits by the installation of these devices. General Motors does not support or endorse the use of devices or modifications that, when installed, increase the engine horsepower and torque. It is because of these unknown stresses, and the potential to alter reliability, durability and emissions performance, that GM has adopted a policy that prevents any UNAUTHORIZED dealer warranty claim submissions to any remaining warranty coverage, to the powertrain and driveline components whenever the presence of a non-GM (aftermarket) calibration is confirmed - even if the non-GM control module calibration is subsequently removed. Refer to the latest version of Bulletin 09-06-04-026 (V8 Gas Engines) or 06-06-01-007 (Duramax(TM) Diesel Engines) for more information on dealer requirements for calibration verification. These same policies apply as they relate to the use of non-GM accessories. Damage or failure from the use or installation of a non-GM accessory will not be covered under warranty. Failure resulting from the alteration or modification of the vehicle, including the cutting, welding or disconnecting of the vehicle's original equipment parts and components will void the warranty. Additionally, dealers will NOT be reimbursed or compensated by GM in the event of any legal inquiry at either the local, state or federal level that Page 3030 Refer to the Model Application Chart shown to verify usage. Supercede: This bulletin is being revised to include 2007 model year and calibration information. Please discard Corporate Bulletin Number 03-03-10-006E (Section 03 - Suspension). Tires GM has designed 20" wheels based on the Goodyear Eagle LS and LS2 P275/55R20 tire. The Goodyear Eagle LS tire has a Tire Performance Criteria spec # 1235 and the LS2 has a Tire Performance Criteria spec # 1245. These tires have been designed to GM's specific Tire Performance Criteria. GM's Tire Performance Criteria specifications meet or exceed all Federal safety guidelines. When mounting the tires, rubber lubricant, P/N 12345884 (in Canada, P/N 5728223), MUST be used. The vehicle should not be driven aggressively (hard acceleration or braking) for at least 6-8 hours after tire mounting to allow the lube to dry. Failure to do so may cause the tire to slip on the rim. This condition will affect wheel balance which could result in a vibration. Spare Tire A P265/75R16 or P265/70R17 tire should be used as a spare. Re-use the vehicle's original spare wheel to mount the spare tire. The spare tire should be used to drive the vehicle to a tire repair/replacement facility and is not intended for extended driving conditions. Tire Changers Dealers must have the correct level of tire changing equipment to perform tire changing services. GM requirements and recommendations for servicing glamour wheels are as follows: ^ Rim Clamp design ^ Runflat capable (preferred) ^ Side mounted bead breaking to reduce stress on the wheel and tire ^ No metal contact to the wheel at the clamping jaws Protective devices to prevent damage during mounting and dismounting operations Regulated air pressure to protect user and wheel assembly. Approved lubricant (P/N 12345884 [in Canada, P/N 5728223]) to avoid wheel slip and damage to the wheel For further information regarding equipment meeting the requirements for this program, call 1-800-GM-TOOLS. Balancing MC style coated weights are recommended and will provide the best balancing of the tire-wheel assembly. If stick-on weights are used, be sure to follow the manufacturers recommended installation procedure (SI Document ID # 664222) making sure the surface is clean and dry. Using the incorrect type of weights will result in improper fit, and such weights may fall off the wheel. Page 9027 Fuse Block- I/P C1 Part 1 Diagrams Roof Beacon Relay (With RPO Code 5X7, 5G4, TRW, Or 5Y0) Page 510 Control Module References Part 6 Deflector Replacement - Instrument Panel Air - Center Air Register: Service and Repair Deflector Replacement - Instrument Panel Air - Center DEFLECTOR REPLACEMENT - INSTRUMENT PANEL AIR - CENTER REMOVAL PROCEDURE 1. Remove the instrument panel (I/P) bezel. 2. Remove the I/P trim panel. 3. Remove the deflector mounting screws. 4. Remove the deflector from the I/P. INSTALLATION PROCEDURE 1. Install the deflector to the I/P. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the deflector mounting screws. Tighten Tighten the screw to 1.6 N.m (14 lb in). 3. Install the I/P trim panel. 4. Install the I/P bezel. Page 9637 1. Install the engine electrical center bracket assembly to the front fender. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the 4 retaining bolts (1). Tighten Tighten the 4 retaining bolts (1) to 9 N.m (80 lb in). 3. Align the electrical center block (1) stubs in the slots so that the tabs (2) retains it in place. Page 10841 Air Door Actuator / Motor: Service and Repair HVAC System - Manual Air Temperature Actuator AIR TEMPERATURE ACTUATOR REPLACEMENT REMOVAL PROCEDURE 1. Remove the IP insulator. 2. Disconnect the electrical connector (8) from the air temperature actuator (9). 3. Remove the air temperature actuator retaining screws. 4. Remove the air temperature actuator. Page 13567 Body Control Module (BCM) - C5 Page 14891 Seat Adjuster Switch- Front Passenger (With RPO Code AN3) Part 1 Page 8822 Alternator: Description and Operation GENERATOR The AD-230 and AD-244 generators are non-repairable. They are electrically similar to earlier models. The generators feature the following major components: The delta stator - The rectifier bridge - The rotor with slip rings and brushes - A conventional pulley - Dual internal fans - A voltage regulator The pulley and the fan cool the slip ring and the frame. The AD stands for air-cooled dual internal fan; the 2 is an electrical design designator; the 30/44 denotes the outside diameter of the stator laminations in millimeters, over 100 millimeters. The generators is rated at 102 and 130 amperes respectively. The generator features permanently lubricated bearings. Service should only include the tightening of mounting components. Otherwise, the generator is replaced as a complete unit. Page 13934 The 1999 though early 2003 wiring harness jumper that plugs into the relay block will have a reddish/brown 6-way connector and a tag with the last four digits of the wiring harness part number. Second design 2003-05 may have a white plastic connector with part number 5418 as well. ^ The 1999 jumper is/was P/N 12171982 with a pink/purple tag identifier of 1982. This number has been superseded to 15366255, with a pink/purple tag identifier of 6255. ^ The 2000 jumper harness is P/N 15366255. The pink/purple tag identifier is 6255. ^ The 2001-2002 jumper is P/N 15086884. The orange tag identifier is 6884. ^ The 2003-05 jumper is P/N 15085418. The orange tag identifier is 5418. When transferring the brake controller with the wiring jumper attached from a 2001-2002 vehicle to a 2003-05 vehicle, a change to the jumper harness connector must be performed. Page 13428 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-8 (12085115) crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-8 (12085115) until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes SPLICING INLINE HARNESS DIODES Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate Service Data wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. 9. Tape the diode to the harness or connector using electrical tape. Drivetrain - Whine or Click Type Noises from Front Axle Carrier Bearings: All Technical Service Bulletins Drivetrain - Whine or Click Type Noises from Front Axle TECHNICAL Bulletin No.: 09-04-19-001 Date: April 28, 2009 Subject: Whine or Click Type Noises from Front Axle/New Design Front Axle Side Bearing Adjusters (Inspect/Replace with New Lock Rings) Models: 2002-2009 Cadillac Escalade, Escalade ESV, Escalade EXT 2002-2009 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2002-2009 GMC Sierra, Yukon, Yukon XL All Equipped with 8.25" Front Axle Condition Some customers may comment about whine or click type noises from the front axle. Upon further investigation, disassembly of the front differential may reveal chipped pinion or ring gear teeth. Cause This condition may be caused by an oversize front bearing side adjuster lock ring allowing the adjuster to move. New Design Lock Adjusters Vs Old Design T-Lock Adjusters Note Front axle housings for old-style (Classic - GMT800) and new-style (GMT900) vehicles are not interchangeable. The new design eliminates the side bearing adjusters movement. The lock adjusters are retained by a pressed in lock ring that maintains the adjuster setting for backlash and side bearing preload. All front axle housings for all model years will use the new design adjusters, and use the new lock ring. The t-lock adjusters are still available, but if a housing replacement is needed, it is necessary to order the lock ring style housing, two of the new adjusters and two of the lock rings. Part numbers are available through the GM Parts catalog. A newly designed 8.25" front axle is in production. The new design eliminates the t-lock side bearing adjusters. The new adjusters are retained by a pressed in lock ring that maintains the adjuster setting for backlash and side bearing preload. This design was phased into production during September, 2006. As a result, in the 2007 model year, both old-style (Classic - GMT800) and new-style (GMT900) vehicles built before the change have the t-lock design adjusters, and both types of vehicles built after the change have the lock ring design adjusters. Correction If no damage is visible and the concern was a whine or click noise, follow the inspect procedure in this bulletin and replace the lock ring. Complete assembly replacement is not necessary if an oversized slipping lock ring was found. Important The bearing adjuster lock rings are not reusable. Inspect New Replacement Part Prior to Installation Page 6406 Transmission Speed Sensor: Service and Repair Output Shaft Speed Sensor Replacement Output Shaft Speed Sensor Replacement Removal Procedure Important: This procedure is for 2-wheel drive (2WD) vehicles only. If the vehicle is equipped with 4-wheel drive (4WD), the output speed sensor is located on the transfer case. 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. Disconnect the output speed sensor (2) electrical connector. 3. Remove the output speed sensor bolt. 4. Remove the output speed sensor (2). 5. Inspect the output speed sensor (2) for any evidence of damage. Installation Procedure Drivetrain - Wheel Drive Shaft Nut Torque Revision Axle Nut: Technical Service Bulletins Drivetrain - Wheel Drive Shaft Nut Torque Revision Bulletin No.: 04-04-95-001 Date: March 02, 2004 SERVICE MANUAL UPDATE Subject: Revised Wheel Drive Shaft Nut Torque Specification Models: 2002-2004 Cadillac Escalade, Escalade EXT 2003-2004 Cadillac Escalade ESV 1999-2004 Chevrolet Silverado 2000-2004 Chevrolet Suburban 2002-2004 Chevrolet Avalanche 2003-2004 Chevrolet Astro, Express 1999-2004 GMC Sierra 2000-2004 GMC Yukon, Yukon XL 2003-2004 GMC Safari, Savana 2003-2004 HUMMER H2 This bulletin is being issued to revise the torque specification for the wheel drive shaft nut in the Wheel Drive Shafts sub-section of the Service Manual. Please replace the current information in the Service Manual with the following information. The following information has been updated within SI. If you are using a paper version of this Service Manual, please make a reference to this bulletin on the affected page. Page 2819 Oil Change Reminder Lamp: Service and Repair GM OIL LIFE SYSTEM - RESETTING The engine oil life monitor will indicate when to change the engine oil - usually between 5 000 km (3,000 miles) and 16 000 km (10,000 miles) since the last oil change. Under severe conditions, the "CHANGE OIL SOON" light may be displayed before 5 000 km (3,000 miles). The vehicle must not be driven more than 16 000 km (10,000 miles) or 12 months without an oil change. Reset the oil life monitor when the oil has been changed, use the following procedure: 1. Turn the ignition key to the RUN position. 2. Fully push and release the accelerator pedal 3 times within 5 seconds. 3. If the Change Oil Soon light flashes, the system is resetting. 4. Start the vehicle. 5. The oil life will change to 100%. 6. If the Change Oil Soon light comes back on, the system has not reset. Repeat the procedure. Page 9619 Location View Page 9562 Fuse Block - Underhood C4 Part 2 Recall 05V043000: Brake Hydro-Boost Unit Defect Hydraulic Brake Booster: Recalls Recall 05V043000: Brake Hydro-Boost Unit Defect MAKE/MODELS: MODEL/BUILD YEARS: Chevrolet/Avalanche 2004-2005 Chevrolet/Express 2004-2005 Chevrolet/Kodiak 2004-2005 Chevrolet/Silverado 2004-2005 Chevrolet/Suburban 2004-2005 GMC/Savana 2004-2005 GMC/Sierra 2004-2005 GMC/Topkick 2004-2005 GMC/Yukon XL 2004-2005 Hummer/H2 2004-2005 MANUFACTURER: General Motors Corp. NHTSA CAMPAIGN ID Number: 05V043000 RECALL DATE: Feb 04, 2005 COMPONENT: Service Brakes, Hydraulic POTENTIAL NUMBER OF UNITS AFFECTED: 155465 SUMMARY: Certain trucks, sport utility vehicles, and vans equipped with Bosch Hydro-Boost brake assemblies, the hydraulic brake booster pressure accumulator may crack and separate from the hydro-boost assembly during normal operating conditions. CONSEQUENCE: If a separation occurred and the hood of the vehicle were open, fragments from the accumulator could cause injury to people in the immediate area. The presence of this crack or fractured surface could allow the hydraulic fluid to leak from the accumulator circuit of the booster assembly. The loss of fluid would cause increased steering and braking effort and a crash may occur without prior warning. REMEDY: Dealers will test the Hydro-Boost assembly for functional operation of the two-function valve. If the Hydro-Boost assembly fails the test, dealers are to replace the assembly. The recall is expected to begin during March 2005. Owners should contact Chevrolet at 1-800-630-2438, GMC Trucks at 1-866-996-9463 and Hummer at 1-800-732-5493. NOTES: GM recall No. 05006. Customers can also contact The National Highway Traffic Safety Administration's Auto Safety Hotline at 1-888-327-4236. Engine Controls - MIL ON/Rough Idle/Misfire/DTC's Set Oxygen Sensor: Customer Interest Engine Controls - MIL ON/Rough Idle/Misfire/DTC's Set Bulletin No.: 05-06-04-063 Date: October 12, 2005 TECHNICAL Subject: LM7, L59 or L33 Engines with Cold Start Rough or Incorrect Idle, Misfire, Malfunction Indicator Lamp (MIL) or Flashing Requiring 02 Sensor Replacement (Reprogram PCM) Models: 2004-2005 Cadillac Escalade 2004-2005 Chevrolet Avalanche, Silverado 1500, Suburban, Tahoe 2005 Chevrolet Silverado Hybrid (HP2) 2004-2005 GMC Sierra 1500, Yukon, Yukon XL 2005 GMC Sierra Hybrid (PH2) with Vortec 5300 5.3L V-8 Engine (VINs T, Z, B - RPOs LM7, L59, L33) Condition Some customers may comment on a Malfunction Indicator Lamp (MIL) On or that the MIL is flashing. An actual engine misfire may or may not be felt along with an incorrect idle speed. Typically this occurs during cold winter months, on cold engine starts. Some vehicles may have been previously serviced for the same condition. Technicians may also find the following DTCs stored with the Tech 2(R) P0131, P0133, P0134, P0137, P0138, P0140, P0151, P0153, P0154, P0157, P1133, which may be in conjunction with P0171, P0174, P0300 and P1138. Cause Water shock occurs when water droplets are present in the exhaust. The water in the exhaust contacts the sensor element inside the H02 sensor, causing the H02 sensor element to crack. Correction Upon diagnostic investigation, the technician may find that the H02 sensor requires replacement. In addition to replacing the affected H02 sensor, these vehicles should also be reflashed with the latest PCM calibration. An updated PCM calibration will be available to dealerships as part of TIS 2000 incremental satellite update 11.0 (NAO version 25.010) or greater. Always, make sure your Tech 2 is updated with the latest software version. Important: If a DTC P0420 or P0430 is stored along with DTC(s) P0300, the catalytic converter diagnostics in Service Information (SI) must be followed to determine if the catalytic converters are operating properly. Warranty Information For vehicles repaired under warranty, use the table. Page 16089 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. REPLACEMENT PROCEDURE After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Insure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the Terminal Removal Procedure. Repairing Connector Terminals REPAIRING CONNECTOR TERMINALS TOOLS REQUIRED J 38125-D Terminal Repair Kit Use the following repair procedures in order to repair the following: - Push to Seat terminals - Pull to Seat terminals - Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-D contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100 World terminals. Soldering Micro-Pack 100 World terminals may damage the terminal. Circuit Protection - Circuit Breakers CIRCUIT PROTECTION - CIRCUIT BREAKERS A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Page 807 For vehicles repaired under warranty, use the table. Disclaimer Page 7645 8. Insert a flat-tipped screwdriver or small pry bar into the space between the lip of the outer race of the seal and the transfer case. 9. Pry the outer race out of the transfer case. 10. Remove the outer part of the seal. Installation Procedure Page 12364 Garage Door Opener Transmitter: Symptom Related Diagnostic Procedures - Symptoms - Garage Door Opener SYMPTOMS - GARAGE DOOR OPENER IMPORTANT: Review the system description and operation in order to familiarize yourself with the system functions. Refer to Garage Door Opener Description and Operation. Visual/Physical Inspection Inspect for aftermarket devices which could affect the operation of the garage door opener. - Inspect the easily accessible or visible system components for obvious damage or conditions which could cause the symptom. Intermittent Faulty electrical connections or wiring may be the cause of intermittent conditions. Symptom List Refer to Garage Door Opener Inoperative in order to diagnose the symptom. Steps 1-3 Page 7227 When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage TESTING FOR A SHORT TO VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity TESTING FOR CONTINUITY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents TESTING FOR ELECTRICAL INTERMITTENTS Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground - Testing for Continuity - Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 msRECORD and emits an audible tone (beep). Page 4126 Vehicle Speed Sensor: Service and Repair Manual Transmission - NV 4500 Vehicle Speed Sensor (VSS) Replacement Removal Procedure 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. Disconnect the vehicle speed sensor (VSS) electrical connector (3). 3. Remove the VSS and seal. Installation Procedure 1. Coat the NEW O-ring seal with a thin film of transmission fluid, use GM P/N 12346190 (Canadian P/N 10953477), or equivalent. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the VSS. ^ Tighten the VSS to 16 Nm (12 ft. lbs.). Page 13232 Page 12219 Important: The optic cable must not be bent with a radius less than 25 mm (1 in). 6.12. Place the optic cable in the wiring harness channels on the right-hand side. Thread through the existing cable ties (C) if possible, otherwise, secure with a cable tie to the existing one. Close the cover on the channels. Ensure the catches lock. 6.13. Secure the optic cable along the right-hand rear wheel housing, next to the ordinary wiring harness securing points and by the SRS unit (D). 6.14. Thread the optic cable up next to the safety belt by the old optic cable and place on the parcel shelf. 6.15. Unplug the connectors (E) from the OnStar(R) control modules. 6.16. Remove the console (F) together with the OnStar(R) control modules. Page 5562 Ignition Coil 2 Page 8284 19. Important: Care must be used when removing the piston boot and seal from the caliper. Use a small plastic or wood tool for removal. Do not use a metal tool because it may damage the caliper bore or seal groove. Remove the piston boots from the brake caliper. 20. Remove the piston seals from the brake caliper. 21. Remove the brake caliper bleeder valve and cap from the brake caliper. 22. Important: Do not use abrasives to clean the brake caliper piston. Clean the brake caliper piston bore and seal counterbore, and the caliper piston with denatured alcohol, or equivalent. 23. Dry the caliper piston bores and counterbores, and the piston with non-lubricated, filtered air. 24. Inspect all of the brake caliper parts as follows. ^ Piston - Inspect for scoring, nicks, cracks, wear, or corrosion. Replace the pistons if any damage is found. ^ Caliper Bore - Inspect for scoring, nicks, cracks, wear, or corrosion. Use crocus cloth to polish out light corrosion. Otherwise, replace the caliper. Do not hone the caliper bore. ^ Seal groove in the caliper bore for nicks or burrs. If found, replace the caliper. 25. Install the brake caliper bleeder valve and bleeder valve cap into the brake caliper. 26. Lubricate the new piston seal with Delco Supreme 11®, GM P/N 12377967 (Canadian P/N 10953488) or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. 27. Install the lubricated, new piston seals into the caliper bores. 28. Install the caliper piston into the caliper bore. 29. Install the new piston dust boot seal over the piston. 30. Using the J 45515 , fully seat the piston dust boot seal in the caliper. 31. Install the brake caliper to the vehicle. Refer to Brake Caliper Replacement - Front. Page 13236 The number above refers to the step number on the diagnostic table. DTC U0073 or U2100 DTC Descriptors DTC U0073 00: Control Module Communication Bus Off DTC U0073 71: ECU HS Bus Off DTC U0073 72: ECU LS Bus Off DTC U2100 00: Controller Area Network (CAN) Bus Communication DTC U2100 47: Controller Area Network (CAN) Bus Communication Circuit/System Description The serial data circuits are serial data buses used to communicate information between the control modules. The serial data circuits also connect directly to the data link connector (DLC). Conditions for Running the DTCs Supply voltage at the modules are in the normal operating range. The vehicle power mode requires serial data communications. Conditions for Setting the DTC The module setting the DTC has attempted to establish communications on the serial data circuits more than 3 times. Page 4421 Remove all rust from the ground terminal, the cylinder head and the retaining nut or bolt. Position the main engine wiring harness ground terminal and install the nut or bolt. Tighten: Tighten the retaining nut or bolt to 16 N.m (12 lb ft). Apply some type of electrical moisture sealant to protect the harness terminal from further corrosion. Disclaimer Page 13651 Front Door Hinge: Service and Repair Hinge Replacement - Front Door - Door Side Hinge Replacement - Front Door - Door Side Removal Procedure 1. Remove all of the related panels and components. 2. Remove any excess sealer surrounding the existing hinge and scribe the location of the hinge on the hinge pillar. 3. Lightly hand-sand the existing hinge with 100 grit or finer sandpaper in order to locate the 4 welds that attach the hinge to the door. Important: Punch the center of the weld so that as much of the weld as possible is removed during the drilling. 4. Center punch each of the four weld marks on the original hinge base. Important: Do not drill into the door (1). 5. Drill through the hinge base (2) only, at each punch location. Use a 13 mm (1/2 in) rotabroach hole saw (3) or equivalent. 6. Remove the hinge. If necessary, use a chisel in order to separate the hinge from the door. 7. Remove all of the remaining weld from the door surface in order to ensure a flush fit of the service hinge. Installation Procedure 1. Repair any damage done to the door during the drilling or the removal of the hinge. 2. Clean and prepare the backing plate mounting surfaces in order to ensure a flush fit of the backing plate. Page 5555 Ignition Cable: Testing and Inspection SPARK PLUG WIRE INSPECTION Spark plug wire integrity is vital for proper engine operation. A thorough inspection is necessary to accurately identify conditions that may affect engine operation. Inspect for the following conditions: 1. Correct routing of the spark plug wires-Incorrect routing may cause cross-firing. 2. Any signs of cracks or splits in the wires. 3. Inspect each boot for the following conditions: - Tearing - Piercing - Arcing - Carbon tracking - Corroded terminal If corrosion, carbon tracking or arcing are indicated on a spark plug wire boot or terminal, replace the wire and the component connected to the wire. Page 5424 Parts Information Parts are currently available from GMSPO. Warranty Information Page 13417 6. Use fingers to squeeze the 2 locking legs of the cover. 7. Apply pressure and gently rock the cover until one locking leg is unseated. 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. Page 6975 Seals and Gaskets: Service and Repair Rear Axle Shaft Seal Replacement - Inner Rear Axle Shaft Seal Replacement - Inner ^ Tools Required J 33049 Camshaft Bearing Service Set - J 45177 Differential Seal Installer - Inner Removal Procedure 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Remove the tire and wheel assembly. 3. Remove the axle shafts. 4. Remove the differential assembly. 5. Install the smallest expanding driver (3) and the small driving washer (1) onto the expander assembly (2). 6. Align the separation lines between the expanding driver and the expander assembly. 7. Assemble the expander assembly (2) onto the driver bar extension (1). 8. Assemble the drive bar extension onto the driver bar. Page 4668 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Page 9166 For vehicles repaired under warranty, use the table. Disclaimer Page 10232 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors USING CONNECTOR TEST ADAPTERS IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-B Connector Test Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Page 7724 3. Remove the right rear speed sensor. Installation Procedure 1. Notice: Refer to Fastener Notice in Service Precautions. Install the right rear speed sensor. ^ Tighten the speed sensor to 15 Nm (11 ft. lbs.). 2. Connect the right rear speed sensor electrical connector (3). 3. Lower the vehicle. Drivetrain - Gen II Vs. Gen III Wheel Hub Changes Wheel Hub (Locking): Technical Service Bulletins Drivetrain - Gen II Vs. Gen III Wheel Hub Changes INFORMATION Bulletin No.: 08-03-08-003A Date: March 02, 2009 Subject: Wheel Hub Changes - Gen III vs. Gen II Models: 2008 and Prior Cadillac Escalade Models 2008 and Prior Chevrolet Avalanche, Silverado, Silverado Classic, Suburban, Tahoe 2008 and Prior GMC Sierra, Sierra Classic, Yukon Models Supercede: This bulletin is being revised to update the parts information in the table and to add an Illustrated Hub Gallery depicting all wheel hub part numbers called out below for visual identification purposes. Please discard Corporate Bulletin Number 08-03-08-003 (Section 03 - Suspension). General Motors Vehicle Engineering has introduced a new design Gen III front wheel hub for the above listed vehicles that replaces the Gen II product. These Gen II 4x2 and 4x4 applications that were previously serviced by seven part numbers are now serviced by three Gen III part numbers. Concerns have been expressed by technicians regarding the use of the new supersessions and whether the Gen III hubs will properly fit the vehicles being serviced, especially because of visual and functional differences (splines). This bulletin has been developed to address those concerns. Please refer to the table above for information on the Gen III replacement part for each Gen II application. At the end of the bulletin you will find an illustrated "Hub Gallery" with graphic depictions of both Gen II and replacement style Gen III parts. Using these illustrations you should be able to identify both the Gen II and Gen III wheel hubs. Warning If replacing wheel studs, please refer to the GM Parts Catalog for the correct stud part number for each application. Different types of studs are used depending on the wheel hub application. When replacing an older Gen II design 4x2 hub with a new 4x2/4x4 common Gen III hub, it is acceptable to have a bearing with splines on it for a 4x2 application that previously did not. However, the older Gen II design 4x4 hubs should NOT be used on a 4x2 vehicle. The Gen II 4x4 hub relies on the tension of the wheel drive shaft joint to hold everything together. The roll form feature on the inboard side of the new 4x2/4x4 Gen III hub eliminates this concern. The only hub that is not back serviceable is P/N 15719007 (not pictured) for 1999-2000 C25 applications due to a different hub flange to bearing flange offset. Important: Only the new part numbers referenced in this bulletin are interchangeable between the 4x2 and 4x4 applications with the exception of P/N 15719007 (Not Shown). Under no circumstances should any other 4x4 hub be used in a 4x2 application. Illustrated Hub Gallery Page 5068 Important The new canister vent valve will be installed in a new location, outside of the frame. 7. Position and secure the new valve assembly to the frame bracket on the outside of the frame using the existing hole and mounting bolt. Tighten Tighten the bracket mounting bolt to 12 Nm (106 lb in). 8. Connect the vent valve pipe to the EVAP canister. 9. Install the two vent valve pipe clips into the existing underbody holes. 10. Connect the EVAP canister vent valve electrical connector, if equipped. 11. Attach bulk 5/8" heater hose to the vent valve port and secure using a clamp. Run a length as needed along the frame rail routing to the area above the transmission. 12. Cut the hose to determined length and install the supplied filter box. Secure using a clamp. 13. Remove the transmission support and lower the transmission assembly as necessary to allow for access to the new filter box location. 14. Secure the filter box to the transmission vent hose just forward of the hose tee-section using a tie strap. DO NOT pinch or restrict the transmission vent hose. The filter box opening should be pointing downward. 15. Raise the transmission and reinstall the transmission support. 16. Tie strap the hose as needed along the frame rail in order to keep the hose away from pinch-points and heat sources. 17. Lower the vehicle. 2004-2007 Model Year (Use Service Kit P/N 19152349) 1. Raise the vehicle. Suitably support the vehicle. 2. Disconnect the EVAP canister vent valve electrical connector. 3. Disconnect the canister pipe from the vent valve. 4. Push in the retainer and remove the existing canister vent valve from the fuel tank clip or mounting bracket. Discard the old valve. 5. Cut back the existing canister pipe approximately 51 mm (2 in) to remove the quick connect end. Crew Cab Short Box Shown Below, Other Configurations Similar Page 8319 Brake Hose/Line: Service and Repair Brake Hose Replacement - Rear (Caliper) Brake Hose Replacement - Rear (Caliper) Removal Procedure Caution: Refer to Brake Fluid Irritant Caution in Service Precautions. Notice: Refer to Brake Fluid Effects on Paint and Electrical Components Notice in Service Precautions. 1. Raise and suitably support the vehicle. 2. Remove the tire and wheel assembly. 3. Clean all dirt and foreign material from the brake hose and brake pipe fittings. 4. Important: Install a rubber cap or plug to the exposed brake pipe fitting ends in order to prevent brake fluid loss and contamination. Use a backup wrench on the hose fitting end (1), disconnect the brake pipe fitting (2) from the brake hose (1), then cap or plug the brake pipe fitting end. 5. Remove the brake hose retaining clip (3) from the hose mounting bracket. 6. Remove the brake hose (1) from the mounting bracket. 7. Remove the brake hose to caliper bolt from the brake caliper. 8. Remove the brake hose from the brake caliper. 9. Remove and discard the 2 copper brake hose gaskets. These gaskets may be stuck to the brake caliper housing or the brake hose end. Installation Procedure Page 14926 Seat Heater Switch: Service and Repair Heated Seat Switch Replacement - Rear HEATED SEAT SWITCH REPLACEMENT - REAR REMOVAL PROCEDURE 1. Remove the center console end panel. 2. Disconnect the electrical connector. 3. Remove the seat heater switch retaining screws. 4. Remove the switch from the vehicle. INSTALLATION PROCEDURE 1. Install the switch to the console panel. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the retaining screw. Tighten Tighten the screws to 1.6 N.m (14 lb in). 3. Connect the electrical connector. 4. Install the center console end panel. Page 4337 Body Control Module (BCM) - C3 Part 2 Page 2345 Removal Procedure 1. Remove the front grille. Refer to Grille Replacement (GMC) Grille Replacement (Chevrolet) in Exterior Trim. 2. Notice: Refer to Power Steering Hose Disconnected Notice in Service Precautions. Remove the power steering outlet hose (4) from the power steering gear (3). 3. Remove the power steering inlet hose from the power steering pump (1). 4. Remove the bolts (2) retaining the cooler to the radiator support. 5. Remove the power steering cooler from the vehicle. Installation Procedure 1. Notice: Refer to Fastener Notice in Service Precautions. Install the power steering cooler (1) to the vehicle. ^ Tighten the power steering cooler retaining bolts to 5 Nm (44 inch lbs.). Page 8372 1. Install the cable. 2. Snap the retainer tabs into the body mount. 3. Connect the front cable to the intermediate cable. 4. Route the cable in through the floor pan and engage the grommet. 5. Remove the safety stands. 6. Lower the vehicle. 7. Roll the carpet into place. 8. Install the park brake pedal. Refer to Park Brake Pedal Assembly Replacement. 9. Adjust the park brake system. Page 4089 7. Remove the HO2S. INSTALLATION PROCEDURE IMPORTANT: A special anti-seize compound is used on the HO2S threads. The compound consists of liquid graphite and glass beads. The graphite tends to burn away, but the glass beads remain, making the sensor easier to remove. New, or service replacement sensors already have the compound applied to the threads. If the sensor is removed from an exhaust component and if for any reason the sensor is to be reinstalled, the threads must have anti-seize compound applied before the reinstallation. 1. If reinstalling the old sensor, coat the threads with anti-seize compound GM P/N 12377953, or equivalent. NOTE: Refer to Component Fastener Tightening Notice in Service Precautions. 2. Install the HO2S. Page 12270 For vehicles repaired under warranty, use the table. Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table. Disclaimer Service and Repair PCV Valve Hose: Service and Repair Crankcase Ventilation Hoses/Pipes Replacement Removal Procedure 1. Remove the engine sight shield. 2. Remove the positive crankcase ventilation (PCV) hose from the intake manifold and valve rocker arm cover. 3. Remove the vent hose from the throttle body and the valve rocker arm cover. 4. Replace the hose as necessary. Installation Procedure Page 4266 1. Locate the air flow direction arrow (2) on the MAF/IAT sensor. 2. Install the MAF/IAT sensor to the air cleaner assembly. NOTE: Refer to Fastener Notice in Service Precautions. 3. Tighten the MAF/IAT clamp. Tighten Tighten the clamp to 7 N.m (62 lb in). 4. Connect the MAF/IAT sensor electrical connector (4). 5. Push in the gray CPA retainer. 6. Install the air cleaner outlet duct. Page 10221 Electrical Symbols Part 5 Page 10510 Tire Pressure Sensor: Technical Service Bulletins Tire Monitor System - TPM Sensor Information INFORMATION Bulletin No.: 08-03-16-003 Date: May 12, 2008 Subject: Warranty Reduction - Transfer of Tire Pressure Monitoring (TPM) Sensors to Replacement Wheels and Allowable TPM Sensor Replacements Models: 2000-2009 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2009 HUMMER H2 2006-2009 HUMMER H3 2005-2009 Saab 9-7x with On-Wheel TPM Sensors TPM Sensor / Wheel Warranty Reviews During the last warranty review period it was noted that wheels being returned under the GM New Vehicle Warranty were being shipped back to General Motors with the TPM sensor still attached to the wheel. Return rates ran as high as 60% with the TPM sensors still attached. Operational TPM sensors should not be returned to GM and are to be transferred to replacement wheels if they become necessary. Important: Operational TPM Sensors that are returned under warranty to General Motors will be charged back to the dealer.Sensors have a 10 year /150,000 mile (240,000 km) battery life, and should be transferred if one or more wheels are replaced. TPM Valve Stem / Grommet (0-ring) Replacement When the TPM sensors are transferred to new wheels you should replace the component used to seal the TPM sensor stem to the wheel. On sensors with an aluminum stem and visible nut on the outside of the wheel a replacement grommet (0-ring) should be used to assure a proper seal. The sensor retaining nut (except Aveo) should be tightened to 7 N.m (62 lb in) for all vehicles except Pontiac Vibe (4.0 N.m (35.4 lb in)). Important: ^ DO NOT overtorque the retaining nut. Notice: ^ Factory installed TPM Sensors come with plastic aluminum or nickel-plated brass stem caps. These caps should not be changed. Chrome plated steel caps may cause corrosion of aluminum valve stems due to incompatibility of the metals. On current style sensors the entire rubber stem is replaceable. The service interval on the revised TPM sensor with replaceable stem is the same as for any other traditional valve stem. Replace the stem at the time of tire replacement sensor transfer or whenever air seepage is suspected at the valve stem. When replacing the valve stem tighten the screw to 1.3 N.m (11.5 lb in). For either style of TPM sensor see the service parts guide for the correct GM part numbers to order and use. Disclaimer Procedures Body Control Module: Procedures BODY CONTROL MODULE (BCM) PROGRAMMING/RPO CONFIGURATION INTRODUCTION The procedures below are designed to set-up the body control module (BCM) correctly during BCM related service. Before you start, read these procedures carefully and completely. IMPORTANT: The following procedures must be followed: 1. Programming the BCM. 2. Programming Theft Deterrent System Components, if equipped with Passlock System. PROGRAMMING THE BCM IMPORTANT: After the procedure is completed, the personalization settings of the BCM are set to a default setting. Inform the customer that the personalization must be set again. Perform the BCM special function Request BCM Info. for service programming system (SPS), then follow the SPS instructions. Refer to Service Programming System (SPS) in Programming. PROGRAMMING THEFT DETERRENT SYSTEM COMPONENTS IMPORTANT: This procedure has to be performed only for vehicles equipped with Passlock System. Perform the Programming Theft Deterrent System Components in Theft Deterrent after successfully finishing the Setup New BCM procedure. If the Programming Theft Deterrent System Components in the Theft Deterrent procedure is not performed after a BCM replacement, one of the following conditions will occur: The vehicle will not be protected against theft by the PASSLOCK system. - The engine will not crank or start. IMPORTANT: After programming, perform the following to avoid future misdiagnosis: 1. Turn the ignition OFF for 10 seconds. 2. Connect the scan tool to the data link connector. 3. Turn the ignition ON, with the engine OFF. 4. Use the scan tool in order to retrieve history DTCs from all modules. 5. Clear all history DTCs. Page 4860 7. Remove the HO2S. INSTALLATION PROCEDURE IMPORTANT: A special anti-seize compound is used on the HO2S threads. The compound consists of liquid graphite and glass beads. The graphite tends to burn away, but the glass beads remain, making the sensor easier to remove. New, or service replacement sensors already have the compound applied to the threads. If the sensor is removed from an exhaust component and if for any reason the sensor is to be reinstalled, the threads must have anti-seize compound applied before the reinstallation. 1. If reinstalling the old sensor, coat the threads with anti-seize compound GM P/N 12377953, or equivalent. NOTE: Refer to Component Fastener Tightening Notice in Service Precautions. 2. Install the HO2S. Page 12111 DTC B2476 04: Cellular Phone Select Service Switch Open Circuit DTC B2476 59: Cellular Phone Select Service Switch Stuck Button DTC B2482 00: Cellular Phone Select Service Switch Range/Performance Circuit Short to Ground Open / High Resistance Short to Voltage Signal Performance Circuit/System Description The OnStar(R) button assembly consists of 3 buttons, Call/Answer, OnStar(R) Call Center, and OnStar(R) Emergency. The vehicle communication interface module (VCIM) supplies the OnStar(R) button assembly with 10 volts via the keypad supply voltage circuit. Each of the buttons, when pressed, completes the circuit across a resistor allowing a specific voltage to be returned to the VCIM over the keypad signal circuit. Depending upon the voltage range returned, the VCIM is able to identify which button has been activated. Conditions for Running the DTCs The ignition is ON. System voltage is between 9 - 16 volts. Conditions for Setting the DTCs B2476 04: The VCIM detects an open/high resistance on the keypad supply voltage circuit. B2482 and B2476 59: The VCIM detects a valid signal on the keypad signal circuit for more than 15 seconds. If one of the OnStar(R) buttons is held or stuck for 15 seconds or more, the VCIM will set these DTCs. Action Taken When the DTCs Set The OnStar(R) status LED turns red. No calls can be placed. The VCIM will ignore all inputs from the OnStar® button assembly. Conditions for Clearing the DTCs The condition responsible for setting the DTC no longer exists. A history DTC will clear once 100 consecutive malfunction-free ignition cycles have occurred. Engine Controls - MIL ON/Rough Idle/Misfire/DTC's Set Oxygen Sensor: All Technical Service Bulletins Engine Controls - MIL ON/Rough Idle/Misfire/DTC's Set Bulletin No.: 05-06-04-063 Date: October 12, 2005 TECHNICAL Subject: LM7, L59 or L33 Engines with Cold Start Rough or Incorrect Idle, Misfire, Malfunction Indicator Lamp (MIL) or Flashing Requiring 02 Sensor Replacement (Reprogram PCM) Models: 2004-2005 Cadillac Escalade 2004-2005 Chevrolet Avalanche, Silverado 1500, Suburban, Tahoe 2005 Chevrolet Silverado Hybrid (HP2) 2004-2005 GMC Sierra 1500, Yukon, Yukon XL 2005 GMC Sierra Hybrid (PH2) with Vortec 5300 5.3L V-8 Engine (VINs T, Z, B - RPOs LM7, L59, L33) Condition Some customers may comment on a Malfunction Indicator Lamp (MIL) On or that the MIL is flashing. An actual engine misfire may or may not be felt along with an incorrect idle speed. Typically this occurs during cold winter months, on cold engine starts. Some vehicles may have been previously serviced for the same condition. Technicians may also find the following DTCs stored with the Tech 2(R) P0131, P0133, P0134, P0137, P0138, P0140, P0151, P0153, P0154, P0157, P1133, which may be in conjunction with P0171, P0174, P0300 and P1138. Cause Water shock occurs when water droplets are present in the exhaust. The water in the exhaust contacts the sensor element inside the H02 sensor, causing the H02 sensor element to crack. Correction Upon diagnostic investigation, the technician may find that the H02 sensor requires replacement. In addition to replacing the affected H02 sensor, these vehicles should also be reflashed with the latest PCM calibration. An updated PCM calibration will be available to dealerships as part of TIS 2000 incremental satellite update 11.0 (NAO version 25.010) or greater. Always, make sure your Tech 2 is updated with the latest software version. Important: If a DTC P0420 or P0430 is stored along with DTC(s) P0300, the catalytic converter diagnostics in Service Information (SI) must be followed to determine if the catalytic converters are operating properly. Warranty Information For vehicles repaired under warranty, use the table. Page 1403 Fuel Gauge Sender: Specifications FUEL LEVEL SPECIFICATIONS Page 13243 DTC B2476 04: Cellular Phone Select Service Switch Open Circuit DTC B2476 59: Cellular Phone Select Service Switch Stuck Button DTC B2482 00: Cellular Phone Select Service Switch Range/Performance Circuit Short to Ground Open / High Resistance Short to Voltage Signal Performance Circuit/System Description The OnStar(R) button assembly consists of 3 buttons, Call/Answer, OnStar(R) Call Center, and OnStar(R) Emergency. The vehicle communication interface module (VCIM) supplies the OnStar(R) button assembly with 10 volts via the keypad supply voltage circuit. Each of the buttons, when pressed, completes the circuit across a resistor allowing a specific voltage to be returned to the VCIM over the keypad signal circuit. Depending upon the voltage range returned, the VCIM is able to identify which button has been activated. Conditions for Running the DTCs The ignition is ON. System voltage is between 9 - 16 volts. Conditions for Setting the DTCs B2476 04: The VCIM detects an open/high resistance on the keypad supply voltage circuit. B2482 and B2476 59: The VCIM detects a valid signal on the keypad signal circuit for more than 15 seconds. If one of the OnStar(R) buttons is held or stuck for 15 seconds or more, the VCIM will set these DTCs. Action Taken When the DTCs Set The OnStar(R) status LED turns red. No calls can be placed. The VCIM will ignore all inputs from the OnStar® button assembly. Conditions for Clearing the DTCs The condition responsible for setting the DTC no longer exists. A history DTC will clear once 100 consecutive malfunction-free ignition cycles have occurred. Page 6470 12. Ensure the tangs fully seat (snap) into the steering column bracket. 13. Install the cable end to the steering column ball stud. 14. Install the retainer securing the cable to the steering column. 15. Position the carpet and insulation around the driver's area. 16. Install the driver's seat. 17. Install the instrument panel knee bolster. 18. Test the transmission for proper shift operation. 19. If all of the gear positions cannot be achieved, adjust the cable. Range Selector Cable Bracket Replacement Automatic Transmission Range Selector Cable Bracket Replacement Removal Procedure 1. Apply the parking brake. 2. Shift the transmission into neutral. 3. Raise the vehicle. Refer to Vehicle Lifting. 4. Disconnect the transmission range selector cable from the shift lever and the bracket (2). 5. Remove the bolts (1) securing the transmission range selector cable bracket (2) to the transmission. 6. Remove the transmission range selector cable bracket from the vehicle. Installation Procedure 1. Install the transmission range selector cable bracket to the vehicle. 2. Notice: Page 9243 C323 Seat Motor Jumper Harness To Seat Jumper Harness (With RPO Code AG1) Page 12013 Important: Secure the wiring harness so that there is no risk of chafing and rattling. 9.4. Fold back the wiring harness and tape over the connectors (C). Fold back the wiring harness once more and secure with cable ties (D). 9.5. Install the right-hand rear luggage compartment in accordance with WIS - 8. Body - Interior equipment - Adjustment/Replacement. 10. Install the ground cable to the battery's negative terminal. 11. Clear the diagnostic trouble codes. 12. Set the date and time, see WIS - 3. Electrical system - Information display (SID_ - Technical description. 2003-2005 Saab 9-3 (9400) 4D/5D; 2004-2005 Saab 9-3 (9400) CV 2003-2005 Saab 9-3 (9440) 4D/5D; 2004-2005 Saab 9-3 (9440) CV Notice: Handle the fiber optic cables with care or the signal may be distorted. ^ It is very important that the two leads in the connector are not confused with one another. ^ Do not splice the cables. ^ Do not bend the cable in a radius smaller than 25 mm (1 in). ^ Do not expose the cable to temperatures exceeding 185°F (85°C). ^ Keep the cable ends free from dirt and grime. ^ Do not expose the cable to impact as this may cause the transparent plastic to whiten, thereby reducing the intensity of the light and causing possible communication interruptions. ^ The cable should not lie against any sharp edges as this may cause increased signal attenuation. 1. Remove the ECU CU with a Tech 2(R) according to the following: Fault diagnosis - Select model year - Select Saab 9-3 Sport (9440) - All - Add/Remove - Control Module - CU/PU - Remove. 2. Remove the ground cable from the battery's negative terminal. 3. Remove the floor console in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 4. Pry out the signal line from the SRS control module to the OnStar(R) control module and secure it: Page 15799 Upper Steering Column Locations Fuel Pump And Sender Assembly Components Page 9196 C160 Chassis Harness To Brake/Clutch Harness (With RPO Codes 5X7/5Y0) Page 1561 1. If installing the old sensor, coat the threads with sealant GM P/N 12346004 (Canadian P/N 10953480) or equivalent. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the ECT sensor. Tighten Tighten the sensor to 20 N.m (15 lb ft). 3. Connect the ECT sensor electrical connector (5). 4. Refill the cooling. Refer to Draining and Filling Cooling System in Cooling System. Page 9456 Auxiliary Power Outlet 120-Volt AC - Interior (With RPO Code HP2) Page 4139 Accelerator Pedal Position Sensor: Service and Repair ACCELERATOR PEDAL POSITION (APP) SENSOR REPLACEMENT REMOVAL PROCEDURE NOTE: Handle the electronic throttle control components carefully. Use cleanliness in order to prevent damage. Do not drop the electronic throttle control components. Do not roughly handle the electronic throttle control components. Do not immerse the electronic throttle control components in cleaning solvents of any type. 1. Remove the connector position assurance (CPA) retainer. 2. Disconnect the accelerator pedal position (APP) sensor electrical connector. 3. Reposition the carpet to access the lower nut. 4. Remove the accelerator pedal nuts. 5. Remove the accelerator pedal assembly. INSTALLATION PROCEDURE Page 7809 Vehicle Speed Sensor(VSS) Page 15835 Numerous & Various Size Drops of Water Collecting on the Inside Surface of the Lamp Lens After the Vehicle Has Been Exposed to Rain or a Car Washing Environment - A condition that covers more than half the surface of the lamp lens. - An accumulation of water in the bottom of the lamp assembly. - A condition that WON'T clear when the vehicle is parked in a dry environment, or when the vehicle is driven with the lights ON. - A comparison of the equivalent lamp on the opposing side of the vehicle indicates a different performance. Any of the above conditions would indicate the need to service the lens or lamp assembly. Disclaimer Page 10861 Air Duct: Service and Repair Air Outlet Duct Replacement - Floor, RH AIR OUTLET DUCT REPLACEMENT - FLOOR, RH REMOVAL PROCEDURE 1. Remove the right closeout/insulator panel. 2. Remove the screw from the right floor air outlet duct (3). 3. Remove the right floor air outlet duct (3) from the HVAC module (2). INSTALLATION PROCEDURE 1. Install the right floor air outlet duct (3) to the HVAC module (2). NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the screw to the right floor air outlet duct (3). Tighten Tighten the screw to 1.6 N.m (14 lb in). 3. Install the right closeout/insulator panel. Page 7309 Control Module: Locations NVG 263-NP1 Transfer Case Shift Control Module Transfer Case Shift Control Module 1 - I/P Harness 2 - Transfer Case Shift Control Module Connectors 3 - Transfer Case Shift Control Module 4 - Instrument Panel Page 4511 circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links CIRCUIT PROTECTION - FUSIBLE LINKS Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Flat Wire Repairs FLAT WIRE REPAIRS NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Heated Oxygen Sensor (HO2S) Wiring Repairs HEATED OXYGEN SENSOR (HO2S) WIRING REPAIRS TOOLS REQUIRED J 38125-D Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: - Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-D. Repairing Damaged Wire Insulation REPAIRING DAMAGED WIRE INSULATION Page 4351 Body Control Module: Removal and Replacement BODY CONTROL MODULE REPLACEMENT REMOVAL PROCEDURE CAUTION: Refer to Battery Disconnect Caution in Service Precautions. 1. Disconnect the negative battery cable(s). 2. Remove the knee bolster. 3. Disconnect the brown connector. 4. Disconnect all other connectors (1). 5. Remove the BCM from the sliding bracket. INSTALLATION PROCEDURE Page 3787 Body Control Module: Diagnostic Aids Basic Knowledge Required BASIC KNOWLEDGE REQUIRED Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the Service Data. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories CHECKING AFTERMARKET ACCESSORIES Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: - Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions INDUCING INTERMITTENT FAULT CONDITIONS In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: - Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. Page 970 Page 9543 Body Harness Page 8884 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly, Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Pull to Seat Connectors PULL TO SEAT CONNECTORS TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Page 15246 Cigar Lighter/Auxiliary Outlets Diagram 3 Page 8779 Electrical Symbols Part 9 Page 3306 9. If equipped with a 8.1L engine, perform the following: 1. Remove the oil cooler hoses from the clip. 2. Gently pull the oil cooler pipe fittings straight out from the radiator quick connect fittings. 3. Raise and suitably support the vehicle. 10. If equipped, remove the engine shield bolts. 11. Remove the engine shield. 12. If equipped with a 6.0L engine, perform the following: 1. Remove the oil cooler hose bracket bolt (1). 2. Remove the oil cooler hose adapter bolts (2). 3. Remove the oil cooler hose assembly and gasket. Discard the gasket. 4. Inspect the fittings, connectors and cooler hoses for damage or distortion. Page 12614 Parts Information Page 13399 Electrical Symbols Part 12 Manual Transmission - NV 3500 Vehicle Speed Sensor: Service and Repair Manual Transmission - NV 3500 Vehicle Speed Sensor (VSS) Replacement Removal Procedure 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. Disconnect the vehicle speed sensor (VSS) electrical connector (1). 3. Remove the VSS and O-ring seal. Installation Procedure Page 473 Electrical Symbols Part 11 Recall - Tailgate Support Cable Inspection/Replacement Technical Service Bulletin # 04007B Date: 051121 Recall - Tailgate Support Cable Inspection/Replacement Product Safety - Tailgate Support Cable # 04007B - (Nov 21, 2005) Models: 2002-2004 Cadillac Escalade EXT 2000 Chevrolet CK 2000-2004 Chevrolet Silverado 2002-2004 Chevrolet Avalanche 2003-2004 Chevrolet Kodiak 2000-2004 GMC Sierra 2003-2004 GMC TopKick THIS BULLETIN IS BEING REVIED TO INCLUDE SOME 2003 AND 2004 MODEL YEAR MEDIUM DUTY VEHICLES THAT WERE MODIFIED TO INCLUDE A TAILGATE. PLEASE DISCARD ALL COPIES OF BULLETIN 04007A, ISSUED OCTOBER 2004. Condition General Motors has decided that a defect which relates to motor vehicle safety exists in certain 2000 model year Chevrolet CK, 2000-2004 model year Chevrolet Silverado and GMC Sierra trucks, and 2002-2004 model year Cadillac Escalade EXT and Chevrolet Avalanche trucks, and 2003-2004 Chevrolet Kodiak and GMC TopKick trucks. On some of these vehicles, the galvanized steel tailgate support cables that retain the tailgate in the full open (horizontal) position may corrode, weaken, and eventually fracture. If one cable fractures, the remaining cable may retain the tailgate in a horizontal position. However, if the remaining cable is sufficiently weakened by corrosion, it could fracture within moments of the first cable fracturing, especially if there is a load on the tailgate. If both cables fracture, the tailgate would suddenly drop and strike the top surface of the rear bumper. Anyone sitting or standing on the tailgate when both cable fracture could be injured by falling from the tailgate. On vehicles that have had the bumper removed, the tailgate may drop even lower. Additionally, if there is cargo on the tailgate, the cargo may become unstable and fall if the support cables fracture. Correction Dealers are to replace the galvanized support cables with stainless steel support cables. In addition, dealers are to inspect the tailgate hinge and replace it, if necessary. Vehicles Involved Page 15474 The values in the table are approximate values based on information obtained from properly operating vehicles. Actual results may vary slightly. Page 3035 Page 842 Relay Box: Service and Repair I/P Electrical Center or Junction Block Replacement - Left INSTRUMENT PANEL ELECTRICAL CENTER OR JUNCTION BLOCK REPLACEMENT - LEFT REMOVAL PROCEDURE 1. Remove the left side end panel. 2. Remove the knee bolster. 3. Disconnect all the wiring connectors from the fuse block. 4. Remove all the fuses. 5. Remove the turn signal relay from the back of the fuse block. 6. From behind the fuse block, remove the retaining bolt. 7. Insert a screw driver between the fuse block and the wire harness block to separate. 8. Push on the retainers in order to remove the fuse block. 9. Remove the fuse block from the vehicle. INSTALLATION PROCEDURE 1. Install the fuse block onto the I/P assembly until it clicks in place. 2. Install the wire harness block to the back of the fuse block. NOTE: Refer to Fastener Notice in Service Precautions. 3. Install the bolt. Tighten Tighten the bolt to 6 N.m (53 lb in). 4. Install the turn signal relay to the back of the fuse block. 5. Using the wiring diagram on the cover of the fuse panel, install the fuses. 6. Install the electrical connectors. 7. Install the knee bolster. Page 4253 1. Install the accelerator pedal assembly. NOTE: Refer to the Fastener Notice in Service Precautions. 2. Install the accelerator pedal nuts. Tighten Tighten the nuts to 20 N.m (15 lb ft). 3. Connect the APP sensor electrical connector. 4. Reposition the carpet. 5. Connect a scan tool in order to test for proper throttle-opening and throttle-closing range. 6. Operate the accelerator pedal and monitor the throttle angles. The accelerator pedal should operate freely, without binding, between a closed throttle, and a wide open throttle (WOT). 7. Verify that the vehicle meets the following conditions: - The vehicle is not in a reduced engine power mode. - The ignition is ON. - The engine is OFF. 8. Inspect the carpet fit under the accelerator pedal. Page 5385 10. Install the fuel pipe bracket to the bellhousing stud. 11. Install the fuel pipe bracket nut. Tighten Tighten the nut to 10 N.m (89 lb in). 12. Lower the vehicle. 13. Remove the caps from the fuel rail. 14. Connect the EVAP canister purge tube line (2). 15. Connect the fuel feed line (1) at the engine. 16. Install the fuel fill cap. 17. Connect the negative battery cable. 18. Perform the following procedure in order to inspect for leaks. 18.1. Turn the ignition ON, with the engine OFF, for 2 seconds. 18.2. Turn the ignition OFF for 10 seconds. 18.3. Turn the ignition ON, with the engine OFF. 18.4. Inspect for fuel leaks. Fuel Hose/Pipes Replacement - Chassis (Cab/Chassis-Rear) FUEL HOSE/PIPES REPLACEMENT - CHASSIS (CAB/CHASSIS - REAR) REMOVAL PROCEDURE IMPORTANT: Clean the fuel and evaporative emission (EVAP) connections and surrounding areas prior to disconnecting the lines in order to avoid possible system contamination. Interior - Erratic Memory Seat Operation Power Seat Control Module: All Technical Service Bulletins Interior - Erratic Memory Seat Operation Bulletin No.: 04-08-50-016C Date: August 12, 2005 TECHNICAL Subject: Memory Seat May Not Return to Requested Position (Reprogram Driver Seat Module) Models: 2003-2005 Cadillac Escalade, Escalade ESV, Escalade EXT 2003-2005 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2003-2005 GMC Sierra, Yukon, Yukon XL, Yukon Denali All with Seat FRT, Individual (Non BKT) (RPO AN3) 2003-2005 HUMMER H2 with Seat, Front Bucket Deluxe (RPO AR9) Supercede: This bulletin is being revised to update the correction information. Please discard Corporate Bulletin Number 04-08-50-016B (Section 08 - Body and Accessories). Condition Some customers may comment that with repeated cycling of the memory seat between the "exit" and one of the "presets", the position of the seat may "creep" forward or rearward out of expected adjustment. Cause There is a coding deficiency in the software for the memory seat module. Correction Technicians are to reprogram the driver seat module with an updated software calibration. The previous bulletin stated to use a service calibration that was released with TIS satellite data update version 4.5. Feedback has proved that calibration to be ineffective in eliminating the memory seat creep condition. An updated service calibration was released with TIS satellite data update version 6.5 available June 13, 2005. This new calibration has additional memory seat creep protection. As always, make sure your Tech 2(R) is updated with the latest software version. Important: After programming is complete, move the seat all the way rearward and down, then bump the seat slightly forward and up. This position will be just off the end of travel hard stops. Reset both memory seat exit positions at this position. Having the seat set at just off the hard stops will aid in reducing the creep condition. Warranty Information Page 5114 14. Thoroughly wash all contaminants from around the EHCU. 15. Disconnect the chassis electrical harness connectors from the electronic brake control module (EBCM). IMPORTANT: Make sure that brake lines are tagged and kept in order for proper reassembly. 16. Disconnect the brake lines from the brake pressure modulator valve (BPMV). 17. Remove the bolts (4) attaching the EHCU bracket to the frame (5). 18. Remove the EHCU (1). 19. If equipped with 4WD, remove the torsion bar bracket. 20. Disconnect the fuel feed and return pipes at the fuel tank. 21. Cap the fuel pipes at the fuel tank. Page 4442 Conditions for Setting the DTC occur, the PCM executes the Action Taken When the DTC Sets. Some DTCs alert the driver via the MIL or a message. Other DTCs do not trigger a driver warning, but are stored in memory. The PCM also saves data and input parameters when most DTCs are set. This data is stored in the Freeze Frame and/or Failure Records. The DTCs are categorized by type. The DTC type is determined by the MIL operation and the manner in which the fault data is stored when a particular DTC fails. In some cases there may be exceptions to this structure. Therefore, when diagnosing the system it is important to read the Action Taken When the DTC Sets and the Conditions for Clearing the DTC in the supporting text. There are different types of DTCs and different actions taken when the DTCs set. Refer to Diagnostic Trouble Code (DTC) Type Definitions for a description of the general characteristics of each DTC type. DTC STATUS When the scan tool displays a DTC, the status of the DTC is also displayed. The following DTC statuses are indicated only when they apply to the DTC that is set. Fail This Ign. (Fail This Ignition): Indicates that this DTC failed during the present ignition cycle. Last Test Fail: Indicates that this DTC failed the last time the test ran. The last test may have run during a previous ignition cycle if an A or B type DTC is displayed. For type C DTCs, the last failure must have occurred during the current ignition cycle to appear as Last Test Fail. MIL Request: Indicates that this DTC is currently requesting the MIL. This selection will report type B DTCs only when they have requested the MIL (failed twice). Test Fail SCC (Test Failed Since Code Clear): Indicates that this DTC that has reported a failure since the last time DTCs were cleared. History: Indicates that the DTC is stored in the PCM History memory. Type B DTCs will not appear in History until they have requested the MIL (failed twice). History will be displayed for all type A DTCs and type B DTCs (which have requested the MIL) that have failed within the last 40 warm-up cycles. Type C DTCs that have failed within the last 40 warm-up cycles will also appear in History. Not Run SCC (Not Run Since Code Clear): DTCs will be listed in this category if the diagnostic has not run since DTCs were last cleared. This status is not included with the DTC display since the DTC can not be set if the diagnostic has not run. This information is displayed when DTC Info is requested using the scan tool. Page 1124 Seat Horizontal Position Sensor - Driver (With RPO Code AN3) Page 14071 Electrical Symbols Part 11 Page 13250 Page 6288 Page 4385 Data Link Connector: Description and Operation DATA LINK CONNECTOR (DLC) The data link connector (DLC) is a standardized 16 cavity connector. Connector design and location is dictated by an industry wide standard, and is required to provide the following: - Scan tool power battery positive voltage at terminal 16 - Scan tool power ground at terminal 4 - Common signal ground at terminal 5 - Class 2 signal at terminal 2 - High speed GMLAN serial data bus (+) at terminal 6 - High speed GMLAN serial data bus (-) at terminal 14 Page 9547 Fuse Block - Underhood C1 Part 1 Capacity Specifications Coolant: Capacity Specifications ENGINE COOLING SYSTEM A/T ....................................................................................................................................................... ....................................... 12.7 liters (13.4 quarts) A/T with Optional Air Conditioning ............................................................................................................................................ 14.1 liters (14.9 quarts) NOTE: ALL capacity specifications are approximate. When replacing or adding fluids, fill to the recommended level and recheck fluid level. Page 4892 Page 5295 4. Using compressed air, blow any dirt or debris from around the fitting. 5. Using the correct tool from J 41769 , insert the tool into the female connector, then push inward in order to release the quick connect locking tabs. 6. If the vehicle is a cab/chassis, it may be necessary to use J 43178 in order to release the quick connect locking tabs. 7. Pull the fuel line connection apart. NOTE: If necessary, remove rust or burrs from the fuel pipes with an emery cloth. Use a radial motion with the fuel pipe end in order to prevent damage to the O-ring sealing surface. Use a clean shop towel in order to wipe off the male tube ends. Inspect all the connections for dirt and burrs. Clean or replace the components and assemblies as required. 8. Use a clean shop towel in order to wipe off the male connection end. 9. Inspect both ends of the fitting for dirt and burrs. Clean or replace the components as required. INSTALLATION PROCEDURE CAUTION: In order to reduce the risk of fire and personal injury, before connecting fuel pipe fittings, always apply a few drops of clean engine oil to the male pipe ends. This will ensure proper reconnection and prevent a possible fuel leak. During normal operation, the O-rings located in the female connector will swell and may prevent proper reconnection if not lubricated. 1. Apply a few drops of clean engine oil to the male connection end. Page 15098 Front Door Window Glass Weatherstrip: Service and Repair Door Window Weatherstrip Weatherstrip Replacement - Front Door Window Removal Procedure 1. Remove the door trim panel. 2. Remove the water deflector. 3. Remove the window. 4. Remove the screws. 5. Pull the weatherstrip from the following locations: * The front of the glass run channel * The top of the window frame flange * The rear of the glass run channel 6. Remove the weatherstrip from the door. Installation Procedure 1. Install the weatherstrip to the following locations: * The front of the glass run channel * The top of the window frame flange * The rear of the glass run channel Notice: Refer to Fastener Notice in Service Precautions. 2. Install the bolts. Tighten to 6 N.m (53 lb in). 3. Install the window. 4. Install the water deflector. 5. Install the door trim panel. 6. Inspect operation of window. Page 2724 Junction Block - I/P Wire Entry Part 3 Page 7727 Speed Sensor: Service and Repair Transfer Case - NVG 263-NP1 Transfer Case Speed Sensor Replacement Removal Procedure 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. Disconnect the speed sensor electrical connector. 3. Remove the speed sensor. Installation Procedure 1. Notice: Refer to Fastener Notice in Service Precautions. Install the speed sensor. ^ Tighten the sensor to 15 Nm (11 ft. lbs.). Page 9841 Junction Block - I/P Wire Entry Part 1 Page 985 Tighten Tighten the bolts to 8 N.m (71 lb in). 5. Install the PCM cover. 6. If equipped with RPO NYS, install the harness ground clip to the PCM cover. 7. Connect the negative battery cable. 8. If a NEW PCM was installed, program the PCM. Refer to Service Programming System (SPS) in Programming. See: Testing and Inspection/Programming and Relearning 9. Perform the crankshaft position (CKP) system variation learn procedure. Refer to CKP System Variation Learn Procedure. See: Testing and Inspection/Programming and Relearning 10. If necessary, reset the engine oil life monitor. Refer to GM Oil Life System - Resetting in Maintenance and Lubrication. Page 4570 Manifold Pressure/Vacuum Sensor: Service and Repair MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR REPLACEMENT REMOVAL PROCEDURE 1. Remove the engine sight shield. 2. Disconnect the manifold absolute pressure (MAP) sensor electrical connector (1). 3. Remove the MAP sensor (1). INSTALLATION PROCEDURE IMPORTANT: Lightly coat the MAP sensor seal with clean engine oil before installing the sensor. 1. Install the MAP sensor (1). Page 2707 Application Table Part 1 Locations Coolant Temperature Sensor/Switch (For Computer): Locations Full Engine View Left Side Page 15150 Electrical Symbols Part 14 Page 16169 Control Module References Part 3 Page 12380 1. Install the cable retainers to the roof and pillar. 2. Connect the cables (3) to the module. 3. Connect the cables to the antenna base. IMPORTANT: Ensure the cables are routed properly and there is no sharp bends in the cables. 4. Install the headliner. 5. Install the I/P trim panel. Page 5365 Fuel Supply Line: Service and Repair Fuel Hose/Pipes Replacement - Chassis 1 FUEL HOSE/PIPES REPLACEMENT - CHASSIS (PICKUP) REMOVAL PROCEDURE IMPORTANT: Clean the fuel and evaporative emission (EVAP) connections and surrounding areas prior to disconnecting the lines in order to avoid possible system contamination. 1. Relieve the fuel system pressure. Refer to Fuel Pressure Relief Procedure. 2. Disconnect the fuel feed line (1) at the engine. 3. Disconnect the EVAP canister purge tube line (2). 4. Cap the fuel rail and EVAP lines in order to avoid possible system contamination. 5. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 6. Remove the fuel pipe bracket nut. 7. Remove the fuel pipe bracket from the bellhousing stud. 8. Remove the heated oxygen sensor (HO2S) sensor connector from the bracket. Fuel Pressure Gage Installation and Removal Fuel Pressure: Testing and Inspection Fuel Pressure Gage Installation and Removal FUEL PRESSURE GAGE INSTALLATION AND REMOVAL INSTALLATION PROCEDURE TOOLS REQUIRED J 34730-1A Fuel Pressure Gage CAUTION: - Refer to Gasoline/Gasoline Vapors Caution in Service Precautions. - Refer to Fuel Gage Leak Caution in Service Precautions. 1. Remove the engine sight shield. 2. Remove the fuel rail pressure fitting cap. 3. Connect the J 34730-1A to the fuel pressure valve. Wrap a shop towel around the fitting while connecting the gage in order to avoid spillage. 4. Install the bleed hose on J 34730-1A into an approved container. REMOVAL PROCEDURE 1. Remove the bleed hose on the J 34730-1A from the approved container. 2. Remove the shop towel from around the fitting and discard into an approved container. 3. Disconnect the J 34730-1A from the fuel pressure valve. 4. Install the fuel rail pressure fitting cap. 5. Install the engine sight shield. Page 15615 Door Switch: Diagrams Door Latch Assembly (Door Jamb Switch) - Front Passenger C2 Door Latch Assembly (Door Jamb Switch) - Front Passenger C2 Page 5366 9. Remove the fuel line clip(s) from the bracket(s) on the transmission. 10. If equipped with 4-wheel drive (4WD), remove the fuel line clip from the bracket on the transfer case. 11. Remove the clip from the bracket on the frame. 12. Remove the transfer case harness from the clip bracket. IMPORTANT: The area around the electro-hydraulic control unit (EHCU) MUST be free from loose dirt to prevent contamination of disassembled anti-lock brake (ABS) components. 13. Thoroughly wash all contaminants from around the EHCU. 14. Disconnect the chassis electrical harness connectors from the electronic brake control module (EBCM). IMPORTANT: Make sure the brake lines are tagged and kept in order for proper reassembly. 15. Disconnect the brake lines from the brake pressure modulator valve (BPMV). 16. Remove the bolts (4) attaching the EHCU bracket to the frame (5). 17. Remove the EHCU (1). Page 10328 8. Verify the wheel alignment. Refer to Wheel Alignment Specifications in Wheel Alignment. Disclaimer Page 3274 1. Position the left engine mount to the engine. 2. Notice: Refer to Fastener Notice in Service Precautions. Install the engine mount bolts. ^ Tighten the engine mount bolts to 50 Nm (37 ft. lbs.). 3. Lower the engine. 4. Remove the adjustable jack stands. 5. Install the front propeller shaft. 6. Position the engine shield to the vehicle. 7. Install the engine shield bolts. ^ Tighten the engine shield bolts to 20 Nm (15 ft. lbs.). 8. Lower the vehicle. 9. Install the engine mount-to-engine mount bracket bolts. (Right side shown, left side similar). Page 6015 Vehicle Speed Sensor (VSS) Tow/Haul Switch Location Automatic Transmission Electronic Component Views (M33 Only) Automatic Transmission Electronic Component Views (M33 Only) Drivetrain - Updated Transfer Case Speed Sensor Conn. Speed Sensor: All Technical Service Bulletins Drivetrain - Updated Transfer Case Speed Sensor Conn. Bulletin No.: 06-04-21-001 Date: May 17, 2006 INFORMATION Subject: Updated Transfer Case Connector Service Kit Now Available For Transfer Case Speed Sensor Wire Harness Connector that Comes Loose Or Connector Retainer Clip Breaks Models: 2007 and Prior GM Light Duty Trucks 2007 and Prior HUMMER H2, H3 2005-2007 Saab 9-7X with Four-Wheel Drive or All-Wheel Drive Technicians may find that when the transfer case speed sensor wire harness connector is removed, the connector lock flexes/bends and does not return to the original position. The transfer case speed sensor wire harness connector then has no locking device. On older vehicles, the plastic connector retainer becomes brittle and the clip may break as soon as it is flexed. In the past, the only service fix was to install a wire harness connector service pack, P/N 88987183. This repair procedure involved splicing a new service connector with an integral connector lock. This connector service kit is of the same design and was still prone to failure over time. A new connector service repair kit is now available, P/N 15306187, that is an updated design. This new kit should be used whenever the speed sensor wire harness connector requires replacement. Parts Information Disclaimer Page 13394 Electrical Symbols Part 6 Page 10407 9. Close the hood. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Drivetrain - Service 4WD Light/DTC C0374 Set Speed Sensor: All Technical Service Bulletins Drivetrain - Service 4WD Light/DTC C0374 Set TECHNICAL Bulletin No.: 05-04-21-003C Date: April 15, 2008 Subject: Service 4WD Light Illuminated, DTC C0374 Set (Inspect Wiring Harness to Transfer Case Speed Sensors,, Replace Wiring Harness) Models: 2004-2007 Buick Rainier 2003-2006 Chevrolet Avalanche, Suburban, Tahoe 2003-2007 Chevrolet Silverado Classic, TrailBlazer, TrailBlazer EXT 2003-2006 GMC Yukon, Yukon XL 2003-2007 GMC Envoy, Envoy XL, Sierra Classic 2003-2004 Oldsmobile Bravada 2005-2007 Saab 9-7X With Four Wheel Drive or All-Wheel Drive and Active All-Wheel Drive (RPO NP4) or Active Two-Speed (RPO NP8) Transfer Case Supercede: This bulletin is being revised to update the Model and Warranty Information. Please discard Corporate Bulletin Number 05-04-21-003B (Section 04 - Driveline/Axle). Condition Some customers may comment on intermittent illumination of the Service 4WD light. Upon investigation, the technician may find DTC C0374 set. The customer may also comment on intermittent erratic operation of the 4WD or AWD system after driving through rain/snow or simply going through a car wash. Cause The speed sensor signal may have become corrupted. Possible openings in the speed sensor wire insulation (twisted pairs) can allow water intrusion. Also wire connections contaminated by water may result in short circuits and erroneous speed sensor readings. This most often occurs on the rear speed sensor circuit. Correction Inspect the wiring harness to the transfer case speed sensors. On Rainier, TrailBlazer, Envoy and 9-7X models, fabricate a replacement speed sensor harness between the C101 connector and the speed sensors. Completely inspect and test all wiring. Refer to Speed Signal Front Axle Actuator and Indicators schematic in SI. Replace the affected twisted pairs. Do not over-twist the two wires in the replacement harness. Wires should be twisted at a rate of 9 revolutions per foot. Use service connector pack, P/N 88987993 at the speed sensor end and terminal, P/N 15326267, at C101. Terminal testing tools and service terminals can be found in Terminal Repair Kit J 38125. Terminals are available from SPX/Kent-Moore. The smaller transfer case harness splices into the larger chassis harness a few inches in front of the crossmember. The chassis harness routes along the left side of the frame under the driver door area. Use nylon tie straps to secure the fabricated harness to the main chassis harness between the transfer case and C101. On the full-size pickup and full-size utility models, replace the 2.2 m (88 in) pigtail harness that runs from the C151 connector under the hood to the transfer case. Use either harness P/N 15832722 or 15224663 depending on vehicle equipment. Refer to Propshaft Speed Sensors Front Axle Actuator and Transfer Case Shift Control Switch schematic in SI. Important: Technicians should verify the integrity of the splice joints after the repair. All splice joints and connections should seal properly against water or a repeat condition can occur. Page 15494 Outside Temperature Display Sensor: Service and Repair AMBIENT AIR TEMPERATURE SENSOR REPLACEMENT REMOVAL PROCEDURE 1. Remove the radiator grille from the vehicle. 2. Remove the push pin retainer from the sensor mounted on the radiator support brace. 3. Disconnect the electrical connector from the sensor. INSTALLATION PROCEDURE 1. Connect the electrical connector to the sensor. 2. Install the sensor to the radiator support brace and install the push pin retainer. 3. Install the radiator grille to the vehicle. Page 10239 Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA and/or the secondary locks. Micro .64 Connectors MICRO .64 CONNECTORS TOOLS REQUIRED J 38125-D Terminal Repair Kit REMOVAL PROCEDURE Follow the steps below in order to remove terminals from Micro 64 connectors. 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. 2. Disconnect the connector from the component. Page 13235 The module uses a default value for the missing parameter. Conditions for Clearing the DTC A current DTC clears when the malfunction is no longer present. A history DTC clears when the module ignition cycle counter reaches the reset threshold, without a repeat of the malfunction. Diagnostic Aids When multiple Loss of Communication DTCs are set concurrently, the cause is likely to be 2 opens in the ring portion of the class 2 serial data circuit. Use the Control Modules and Devices ‐ Description and Identification Number table in order to determine which modules are not communicating. Use the class 2 serial data circuit schematic in order to determine the location of the opens. Test Description Page 7050 Drive/Propeller Shaft: Service and Repair Propeller Shaft Replacement - Two Piece Propeller Shaft Replacement - Two Piece ^ Tools Required J 43218 Clamp Pliers - Narrow Jaw Removal Procedure Important: Observe and accurately reference mark all driveline components relative to the propeller shaft and axles before disassembly. These components include the propeller shafts, the drive axles, the pinion flanges, the output shafts, etc. All components must be reassembled in the exact relationship to each other as they were when removed. In addition, published specifications and torque values, as well as any measurements made prior to disassembly must be followed. 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Reference mark the rear propeller shaft (3) to the rear axle pinion yoke (4). 3. Reference mark the front propeller shaft to the transmission or transfer case (slip yoke type) or to the transmission pinion yoke (universal joint type). 4. Remove the clamp (2) securing the boot (3) to the front propeller shaft stub shaft (4) and the rear propeller shaft slip yoke (1) by prying up the exposed end of the clamp (2) using a flat bladed tool (if applicable). 5. Remove the bolts (1) and the yoke retainers (2) from the rear axle pinion yoke (4). Page 16106 Control Module References Part 7 Page 14074 Electrical Symbols Part 14 Page 9119 Remove all rust from the ground terminal, the cylinder head and the retaining nut or bolt. Position the main engine wiring harness ground terminal and install the nut or bolt. Tighten: Tighten the retaining nut or bolt to 16 N.m (12 lb ft). Apply some type of electrical moisture sealant to protect the harness terminal from further corrosion. Disclaimer Page 12483 For vehicles repaired under warranty use, the table. Disclaimer Page 2457 For vehicles repaired under warranty, use the table. Disclaimer Page 8919 Cigar Lighter/Auxiliary Outlets Diagram 3 Cooling System, A/C - Aluminum Heater Cores/Radiators Heater Core: Technical Service Bulletins Cooling System, A/C - Aluminum Heater Cores/Radiators INFORMATION Bulletin No.: 05-06-02-001A Date: July 16, 2008 Subject: Information On Aluminum Heater Core and/or Radiator Replacement Models: 2005 and Prior GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2005 HUMMER H2 Supercede: This bulletin is being revised to update the Warranty Information. Please discard Corporate Bulletin Number 05-06-02-001 (Section 06 - Engine/Propulsion System). Important: 2004-05 Chevrolet Aveo (Pontiac Wave, Canada Only) does not use DEX-COOL(R). Refer to the flushing procedure explained later in this bulletin. The following information should be utilized when servicing aluminum heater core and/or radiators on repeat visits. A replacement may be necessary because erosion, corrosion, or insufficient inhibitor levels may cause damage to the heater core, radiator or water pump. A coolant check should be performed whenever a heater core, radiator, or water pump is replaced. The following procedures/ inspections should be done to verify proper coolant effectiveness. Caution: To avoid being burned, do not remove the radiator cap or surge tank cap while the engine is hot. The cooling system will release scalding fluid and steam under pressure if the radiator cap or surge tank cap is removed while the engine and radiator are still hot. Important: If the vehicle's coolant is low, drained out, or the customer has repeatedly added coolant or water to the system, then the system should be completely flushed using the procedure explained later in this bulletin. Technician Diagnosis ^ Verify coolant concentration. A 50% coolant/water solution ensures proper freeze and corrosion protection. Inhibitor levels cannot be easily measured in the field, but can be indirectly done by the measurement of coolant concentration. This must be done by using a Refractometer J 23688 (Fahrenheit scale) or J 26568 (centigrade scale), or equivalent, coolant tester. The Refractometer uses a minimal amount of coolant that can be taken from the coolant recovery reservoir, radiator or the engine block. Inexpensive gravity float testers (floating balls) will not completely analyze the coolant concentration fully and should not be used. The concentration levels should be between 50% and 65% coolant concentrate. This mixture will have a freeze point protection of -34 degrees Fahrenheit (-37 degrees Celsius). If the concentration is below 50%, the cooling system must be flushed. ^ Inspect the coolant flow restrictor if the vehicle is equipped with one. Refer to Service Information (SI) and/or the appropriate Service Manual for component location and condition for operation. ^ Verify that no electrolysis is present in the cooling system. This electrolysis test can be performed before or after the system has been repaired. Use a digital voltmeter set to 12 volts. Attach one test lead to the negative battery post and insert the other test lead into the radiator coolant, making sure the lead does not touch the filler neck or core. Any voltage reading over 0.3 volts indicates that stray current is finding its way into the coolant. Electrolysis is often an intermittent condition that occurs when a device or accessory that is mounted to the radiator is energized. This type of current could be caused from a poorly grounded cooling fan or some other accessory and can be verified by watching the volt meter and turning on and off various accessories or engage the starter motor. Before using one of the following flush procedures, the coolant recovery reservoir must be removed, drained, cleaned and reinstalled before refilling the system. Notice: ^ Using coolant other than DEX‐COOL(R) may cause premature engine, heater core or radiator corrosion. In addition, the engine coolant may require changing sooner, at 30,000 miles (50,000 km) or 24 months, whichever occurs first. Any repairs would not be covered by your warranty. Always use DEX‐COOL(R) (silicate free) coolant in your vehicle. ^ If you use an improper coolant mixture, your engine could overheat and be badly damaged. The repair cost would not be covered by your warranty. Too much water in the mixture can freeze and crack the engine, radiator, heater core and other parts. Service and Repair Suspension Mode Switch: Service and Repair Electronic Suspension Ride Control Switch Replacement Removal Procedure 1. Remove the instrument panel trim bezel. 2. Remove the switch from the lower opening of the switch plate panel. 3. Disconnect the electrical connector. Installation Procedure 1. Connect the electrical connector. 2. Install the switch into the lower opening of the switch plate panel. 3. Install the instrument panel trim bezel. Keyless Entry - Inoperative Keyless Entry Module: All Technical Service Bulletins Keyless Entry - Inoperative Bulletin No.: 04-08-52-005 Date: June 15, 2004 TECHNICAL Subject: Remote Keyless Entry (RKE) System Inoperative (Reprogram Passenger Door Module (PDM)) Models: 2004 Cadillac Escalade, Escalade ESV, Escalade EXT 2004 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2004 GMC Sierra, Yukon, Yukon XL Condition Some customers may comment on any of the following conditions: ^ The RKE key fob does not function. ^ The "Service Tire Pressure Monitoring System" message is displayed, if equipped. ^ The passenger door will not unlock from the passenger's or driver's door switches. ^ The passenger door window is inoperative. Correction Reprogram the PDM with the Tech 2(R). Currently the Tech 2(R) software is not available for the 2004 model year. Engineering is aware of this and are working to release a new service calibration. In the meantime, build the Tech 2(R) as a 2003 model year and perform the reprogram using the procedure listed below. 1. Turn the ignition switch to the ON position. 2. Connect the Tech 2(R) to the vehicle's diagnostic link connector (DLC), power it up and press enter. ^ Select: Diagnostics. ^ Select model year: 2003. ^ Select: Light truck. ^ Select: Body. ^ Select the proper Product line. ^ Select the proper HVAC Type. ^ Select the proper Radio System type. ^ Select: Passenger Door Module. ^ Select: Special Functions. ^ Select: Refresh. Important: You must remove the described fuse in the next step for the "Refresh" program to be performed. If you do not remove the fuse for five seconds, the Tech 2 will continue to display "Test in Progress" and the program will not complete. ^ Remove the PDM fuse for 5 seconds from the fuse center located behind the panel on the left end of the instrument panel. Page 5184 Mass Air Flow (MAF) Sensor: Service and Repair MASS AIR FLOW (MAF)/INTAKE AIR TEMPERATURE (IAT) SENSOR REPLACEMENT REMOVAL PROCEDURE IMPORTANT: Use care when handling the mass air flow/intake air temperature (MAF/IAT) sensor. Do not dent, puncture, or otherwise damage the honeycell located at the air inlet end of the MAF/IAT. Do not touch the sensing elements or allow anything including cleaning solvents and lubricants to come in contact with them. Use a small amount of a non-silicone based lubricant, on the air duct only, to aid in installation. 1. Remove the air cleaner outlet duct. 2. Pull out the gray connector position assurance (CPA) retainer. 3. Push down on the black clip in order to disconnect the MAF/IAT sensor electrical connector (4). 4. Loosen the MAF/IAT clamp. 5. Remove the MAF/IAT sensor from the air cleaner assembly. INSTALLATION PROCEDURE IMPORTANT: The embossed arrow on the MAF/IAT sensor indicates the proper air flow direction. The arrow must point toward the engine. Page 15023 1. Loosen the bolt (1) that attaches the opposite end of the support cable to the latch assembly (2). - If the toothed nut is present, you will only be able to loosen the bolt partily from the latch. If this condition is encountered, proceed to the next step. - If the toothed nut is not present, proceed to Step 6. 3. Important: DO NOT loosen the other bolt completely in the next step. Leave two or three threads of the bolt engaged in the tailgate. Removing this bolt completely may allow the linkage inside the tailgate to separate from the latch. 4. If the toothed nut is present, loosen the other bolt (3) attaching the latch to the tailgate. DO NOT remove this bolt. 5. Finish loosening the bolt that attaches the support cable. The bolt will NOT be removable even though the threads are completely out. 6. Place an interior trim removal type tool (2), or equivalent, between the support cable end (3) and the latch (1), and pry the two apart. As the two spread apart, the toothed nut on the other side of the latch will begin to move towards the end of the bolt. 7. Once the toothed nut has moved away from the backside of the latch, use long nose pliers to grasp and twist it off of the bolt. Discard the toothed nut. 8. Remove the bolt and support cable. Notice: Due to manufacturing variation in the thickness of the latch, support cable end, and the shoulder on the bolt, a spacer (flat washer) must be used when installing the new cable. The washer will act as an extension to the shoulder on the bolt, and the outside diameter of the washer will allow it to fit inside of the opening in the cable end. This will allow the cable end to rotate freely on the bolt/latch when the tailgate is closed and prevent the support cable from getting pinched between the tailgate and the pickup box. The washer does part number listed in this bulletin MUST BE used when installing the new support cables. Its dimensions are critical for correct cable positioning when closing the tailgate and it has the corrosion protection specified by GM. DO NOT use any other washer in place of the one listed in this recall. Important: The washer does NOT replace the toothed nut removed earlier and is NOT to be installed between the latch and the tailgate. Page 14382 Control Module References Part 1 Page 8077 The 1999 though early 2003 wiring harness jumper that plugs into the relay block will have a reddish/brown 6-way connector and a tag with the last four digits of the wiring harness part number. Second design 2003-05 may have a white plastic connector with part number 5418 as well. ^ The 1999 jumper is/was P/N 12171982 with a pink/purple tag identifier of 1982. This number has been superseded to 15366255, with a pink/purple tag identifier of 6255. ^ The 2000 jumper harness is P/N 15366255. The pink/purple tag identifier is 6255. ^ The 2001-2002 jumper is P/N 15086884. The orange tag identifier is 6884. ^ The 2003-05 jumper is P/N 15085418. The orange tag identifier is 5418. When transferring the brake controller with the wiring jumper attached from a 2001-2002 vehicle to a 2003-05 vehicle, a change to the jumper harness connector must be performed. Page 7072 Page 5500 Accelerator Pedal Position (APP) Sensor Part 2 Page 12824 Page 11986 DTC B2483: Global Positioning System (GPS) Antenna Malfunction Short to Ground DTC B2484: Global Positioning System (GPS) Antenna Malfunction Open Circuit Conditions for Running the DTCs The ignition is in RUN or ACC position System voltage is between 9.5 - 15.5 volts. The above conditions are met for more than 1 second. Conditions for Setting the DTCs B2462 02: The CIM detects a short to ground on the navigation antenna signal circuit. B2462 04: The CIM detects an open/high resistance on the navigation antenna signal circuit. B2483: The CIM detects a short to ground on the navigation antenna signal circuit. B2484: The CIM detects an open/high resistance on the navigation antenna signal circuit. Action Taken When the DTCs Set The OnStar(R) status LED turns red. The OnStar(R) Call Center cannot locate the vehicle. Conditions for Clearing the DTCs The condition responsible for setting the DTC no longer exists. A history DTC will clear once 50 consecutive malfunction-free ignition cycles have occurred. Circuit/System Testing Turn OFF the ignition. 1. Disconnect the navigation antenna coax cable from the VCIM. 2. Ignition ON, test for 4.5-5.5 volts between the VCIM coax cable center conductor terminal at the VCIM and ground. ^ If not within the specified range, replace the VCIM. Refer to the appropriate vehicle in SI. 3. Reconnect the coax cable to the VCIM. 4. Disconnect the coax cable from the navigation antenna. 5. Test for 4.55.5 volts between the coax cable center conductor and the outer shield. ^ If not within the specified range, replace the coax cable. 6. If all circuits test normal, replace the navigation antenna. Refer to the appropriate vehicle in SI. DTC B2470 DTC Descriptor DTC B2470 04: Cellular Phone Antenna Circuit Malfunction Open Circuit Circuit/System Description The cellular antenna is connected to the vehicle communication interface module (VCIM) with an RG-58 coax cable. The VCIM collects the data from the cellular antenna once every second. Page 9792 Junction Block - I/P Wire Entry Part 3 Page 12978 2. Disconnect the electrical connector (3) to the speaker. 3. Remove the speaker (1) by press until it is out of the molding. INSTALLATION PROCEDURE 1. Press in the speaker (1) until it is fully seated. 2. Connect the electrical connector (3). 3. Install the windshield garnish molding (2). Page 12340 9. Use J 38125-12A to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. REPAIR PROCEDURE The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. 1. Cut the wire as close to the terminal as possible. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. Page 6456 7. Important: DO NOT hold the transmission end (1) during this operation, this will result in a mis-adjusted cable. Release the transmission end (3) and allow the spring (2) to tension/adjust the cable system. 8. Pull the white cover (5) on the shifter end (1) back. 9. Push the natural colored lock button (4) down to engage the locking teeth on the transmission end (3). 10. Release the white cover (1). 11. Verify the white cover (1) conceals the natural colored lock (2). 12. If the white cover (1) does not conceal the natural colored lock (2), the shift cable must be re-adjusted. 13. Lower the vehicle. 14. Test the transmission for proper shift operation. 15. If all of the gear positions cannot be achieved, the shift cable must be re-adjusted. Cable Re-Adjustment Page 4220 Fuel Pressure Release: Service and Repair Fuel Pressure Relief Procedure FUEL PRESSURE RELIEF PROCEDURE TOOLS REQUIRED J 34730-1A Fuel Pressure Gage CAUTION: Relieve the fuel system pressure before servicing fuel system components in order to reduce the risk of fire and personal injury. After relieving the system pressure, a small amount of fuel may be released when servicing the fuel lines or connections. In order to reduce the chance of personal injury, cover the regulator and the fuel line fittings with a shop towel before disconnecting. This will catch any fuel that may leak out. Place the towel in an approved container when the disconnection is complete. 1. Disconnect the negative battery cable. 2. Install the J 34730-1A. 3. Loosen the fuel fill cap in order to relieve fuel tank vapor pressure. 4. Open the valve on J 34730-1A in order to bleed the system pressure. The fuel connections are now safe for servicing. 5. Drain any fuel remaining in the gage into an approved container. 6. Once the system pressure is completely relieved, remove the J 34730-1A. Page 9181 C106 Engine Harness To I/P Harness (With RPO Code PTO) Page 5794 Page 9416 Auxiliary Power Outlet: Diagnostic Aids Basic Knowledge Required BASIC KNOWLEDGE REQUIRED Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the Service Data. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories CHECKING AFTERMARKET ACCESSORIES Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: - Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions INDUCING INTERMITTENT FAULT CONDITIONS In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: - Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. Page 3010 *This product is currently available from 3M. To obtain information for your local retail location please call 3M at 1-888-364-3577. **This product is currently available from Meguiars (Canada). To obtain information for your local retail location please call Meguiars at 1-800-347-5700 or at www.meguiarscanada.com. ^ This product is currently available from Tri-Peek International. To obtain information for your local retail location please call Tri-Peek at 1-877-615-4272 or at www.tripeek.com. Disclaimer Page 7277 Steps 7-8 The number below refers to the step number on the diagnostic table. 5. This step tests the ground circuit. Page 11989 Circuit/System Testing Component Testing Page 12566 Models The service procedure in this bulletin has been revised. Step 11 in the procedure for the 2004-2005 Saab 9-3 (9440) Convertible has been revised. Discard all copies of bulletin 08089B, issued September 2008. Condition In November 2002, the U.S. Federal Commissions (FCC) ruled that wireless carriers would no longer be required to support the analog wireless network beginning in 2008. As a result, On Star(R) is unable to continue analog service. OnStar(R) has deactivated most of the systems operating in the analog mode; however, there are some vehicles that OnStar(R) could not deactivate. Although the analog OnStar(R) hardware in these vehicles can no longer communicate with OnStar(R), the hardware in the vehicle is still active. If the OnStar(R) emergency button is pressed, or in the case of an airbag deployment, or near deployment, the customer may hear a recording that OnStar(R) is being contacted. However, since analog service is no longer available, the call will not connect to OnStar(R). To end the call, the customer must press the white phone or white dot button. If the call is not ended, the system will continue to try to connect to OnStar(R) until the vehicle battery is drained. Special Policy Adjustment At the customer's request, dealers/retailers are to deactivate the OnStar(R) system. The service will be made at no charge to the customer. This special coverage covers the condition described above until December 31, 2008 for all non-Saab vehicles; April 30, 2009 for all Saab vehicles. Vehicles Involved Page 9331 Relay Box: Service and Repair I/P Electrical Center or Junction Block Replacement - Right INSTRUMENT PANEL ELECTRICAL CENTER OR JUNCTION BLOCK REPLACEMENT - RIGHT REMOVAL PROCEDURE 1. Remove the right side end panel. 2. Push in the tabs in order to remove the fuse block. 3. Pull out the fuse block out of the I/P in order to remove the retaining bolt. 4. Loosen the bolt. 5. Insert a screw driver between the wire harness block and fuse block in order to separate. 6. Separate the fuse block from the I/P harness block. 7. Remove the I/P wiring harness block from the vehicle. INSTALLATION PROCEDURE 1. Install the fuse block to the I/P wire harness block. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the retaining bolt. Tighten Tighten the bolt to 6 N.m (53 lb in) 3. Install the fuse block to the I/P until it clicks in place. Page 10843 AIR TEMPERATURE ACTUATOR REPLACEMENT - LEFT REMOVAL PROCEDURE 1. Remove the I/P insulator panel. 2. Disconnect the electrical connector (1) from the left air temperature actuator (2). 3. Remove the screws from the left air temperature actuator (2). 4. Remove the left air temperature actuator (2) from the HVAC module assembly (3). INSTALLATION PROCEDURE 1. Install the left air temperature actuator (2) to the HVAC module assembly (3). NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the screws to the left air temperature actuator (2). Tighten Tighten the screws to 2 N.m (18 lb ft). 3. Install the electrical connector (1) to the left air temperature actuator (2). 4. Install the I/P insulator panel. 5. Reprogram the air temperature actuator. Refer to Re-Calibrating Actuators. See: Testing and Inspection/Component Tests and General Diagnostics Air Temperature Actuator Replacement - Right AIR TEMPERATURE ACTUATOR REPLACEMENT - RIGHT REMOVAL PROCEDURE 1. Remove the I/P carrier. Page 6912 17. Inspect the inboard stroke position. ^ Use measurement A for the 1500 models (except 1500 HD). ^ Use measurement B for the 1500 HD, 2500, 3500, and Hummer H2 models. Page 11006 Cabin Temperature Sensor / Switch: Description and Operation AIR TEMPERATURE SENSORS The air temperature sensors are a 2-wire negative temperature co-efficient thermistor. The vehicle uses the following air temperature sensors: Ambient Air Temperature Sensor - Inside Air Temperature Sensor Assembly - Upper Left Air Temperature Sensor - Upper Right Air Temperature Sensor - Lower Left Air Temperature Sensor - Lower Right Air Temperature Sensor A signal and a low-reference circuit enables the sensor to operate. As the air temperature surrounding the sensor increases, the sensor resistance decreases. The sensor signal voltage decreases as the resistance decreases. The sensor operates within a temperature range between -40°C (-40°F) to 101°C (215°F). The sensor signal varies between 0.5 volts. The input of the duct air temperature sensors are different from the ambient and inside sensors. The HVAC control module converts the signal to a range between 0-255 counts. As the air temperature increases the count value will decrease. If the HVAC control module detects a malfunctioning sensor, then the control module software will use a defaulted air temperature value. The default value for the ambient and inside air temperature sensors will be displayed on the scan tool. The default value for the duct air temperature sensors will not be displayed on the scan tool. The scan tool parameter for the duct air temperature sensors are the actual state of the signal circuit. The default action ensures that the HVAC system can adjust the inside air temperature near the desired temperature until the condition is corrected. The ambient air temperature sensor mounts underhood and can be affected by city traffic, by idling, and by restarting a hot engine. Therefore, the HVAC control module filters the value of the ambient air temperature sensor for temperature display. The ambient air temperature value is updated under the above conditions. The scan tool has the ability to update the displayed ambient air temperature. To update the ambient air temperature display on the HVAC control module, perform the following procedure: Simultaneously press the MODE, FRONT DEFROST and REAR DEFROST switches. 1. Turn ON the ignition. 2. Simultaneously press the MODE, FRONT DEFROST and REAR DEFROST switches. Page 876 Electrical Symbols Part 13 Page 5579 Steps 4 - 5 Page 14305 WA8624/50 - WA8624/50 Page 3396 7. Important: Lightly coat the MAP sensor seal with clean engine oil before installing. Install the MAP sensor (1) to the intake manifold. 8. Install the PCV hose. Body - TPO Fascia Cleaning Prior to Painting Rear Bumper Cover / Fascia: Technical Service Bulletins Body - TPO Fascia Cleaning Prior to Painting INFORMATION Bulletin No.: 08-08-51-002 Date: March 12, 2008 Subject: New Primer For TPO Fascias and Affected Cleaning Process of Painting Operation Models: 2009 and Prior Passenger Cars and Trucks 2009 and Prior HUMMER H2, H3 The purpose of this bulletin is to inform the technician that General Motors has made a change in the primer it uses for TPO plastic for service parts. This new primer comes in several different colors from five different suppliers. This change affects the cleaning process of the painting operation. The new process is as follows. 1. Wash with soap and water. 2. Clean with a 50% mix of isopropyl alcohol and water (or a waterborne cleaner). Check with your paint supplier for product recommendations. 3. Scuff sand per your paint suppliers recommendations. Note: The use of a solvent-type cleaner will soften, or begin to dissolve the primer. Base coats do not have any affect on this primer. 4. Reclean with a 50% mix of isopropyl alcohol and water (or a waterborne cleaner). All fascias, with the exception of the Corvette, Camaro, and Cadillac XLR, are made of TPO. You may find other TPO parts with this primer. If the technician has a question as to the type of plastic they are painting, inspect the back of the part for the plastic symbol (TPO). Disclaimer Diagrams Page 7257 Control Module References Part 7 Page 14123 Front Passenger Door Module (FPDM) - C3 (With RPO Code YE9) Part 2 Page 8682 Electronic Brake Control Module: Diagrams ABS Connector End Views Electronic Brake Control Module (ECBCM) - C1 Page 13128 Page 14887 Front Passenger Seat (1 Of 2) (With RPO Code AN3) Page 13034 Page 2706 Fuse Block: Application and ID Fuse Block - Underhood Location View Page 4945 1. If necessary, install the oxygen sensors. 1. Apply anti-seize compound GM P/N 12377953 or equivalent to the threads of the old oxygen sensors. 2. Install the oxygen sensors. Tighten the sensors to 42 Nm (31 ft. lbs.). 2. Install the catalytic convertor. 3. Install NEW exhaust manifold pipe seals to the exhaust manifolds. 4. Install the right exhaust manifold pipe nuts until snug. 5. Install the left exhaust manifold pipe nuts until snug. 6. Tighten the exhaust manifold pipe nuts. Tighten the nuts to 50 Nm (39 ft. lbs.). 7. Install the exhaust muffler nuts. Tighten the nuts to 40 Nm (30 ft. lbs.). Drivetrain - Service 4WD Light/DTC C0374 Set Speed Sensor: All Technical Service Bulletins Drivetrain - Service 4WD Light/DTC C0374 Set TECHNICAL Bulletin No.: 05-04-21-003C Date: April 15, 2008 Subject: Service 4WD Light Illuminated, DTC C0374 Set (Inspect Wiring Harness to Transfer Case Speed Sensors,, Replace Wiring Harness) Models: 2004-2007 Buick Rainier 2003-2006 Chevrolet Avalanche, Suburban, Tahoe 2003-2007 Chevrolet Silverado Classic, TrailBlazer, TrailBlazer EXT 2003-2006 GMC Yukon, Yukon XL 2003-2007 GMC Envoy, Envoy XL, Sierra Classic 2003-2004 Oldsmobile Bravada 2005-2007 Saab 9-7X With Four Wheel Drive or All-Wheel Drive and Active All-Wheel Drive (RPO NP4) or Active Two-Speed (RPO NP8) Transfer Case Supercede: This bulletin is being revised to update the Model and Warranty Information. Please discard Corporate Bulletin Number 05-04-21-003B (Section 04 - Driveline/Axle). Condition Some customers may comment on intermittent illumination of the Service 4WD light. Upon investigation, the technician may find DTC C0374 set. The customer may also comment on intermittent erratic operation of the 4WD or AWD system after driving through rain/snow or simply going through a car wash. Cause The speed sensor signal may have become corrupted. Possible openings in the speed sensor wire insulation (twisted pairs) can allow water intrusion. Also wire connections contaminated by water may result in short circuits and erroneous speed sensor readings. This most often occurs on the rear speed sensor circuit. Correction Inspect the wiring harness to the transfer case speed sensors. On Rainier, TrailBlazer, Envoy and 9-7X models, fabricate a replacement speed sensor harness between the C101 connector and the speed sensors. Completely inspect and test all wiring. Refer to Speed Signal Front Axle Actuator and Indicators schematic in SI. Replace the affected twisted pairs. Do not over-twist the two wires in the replacement harness. Wires should be twisted at a rate of 9 revolutions per foot. Use service connector pack, P/N 88987993 at the speed sensor end and terminal, P/N 15326267, at C101. Terminal testing tools and service terminals can be found in Terminal Repair Kit J 38125. Terminals are available from SPX/Kent-Moore. The smaller transfer case harness splices into the larger chassis harness a few inches in front of the crossmember. The chassis harness routes along the left side of the frame under the driver door area. Use nylon tie straps to secure the fabricated harness to the main chassis harness between the transfer case and C101. On the full-size pickup and full-size utility models, replace the 2.2 m (88 in) pigtail harness that runs from the C151 connector under the hood to the transfer case. Use either harness P/N 15832722 or 15224663 depending on vehicle equipment. Refer to Propshaft Speed Sensors Front Axle Actuator and Transfer Case Shift Control Switch schematic in SI. Important: Technicians should verify the integrity of the splice joints after the repair. All splice joints and connections should seal properly against water or a repeat condition can occur. Page 5203 Fuel: Technical Service Bulletins Fuel System - E85 Fuel Usage Precautions Bulletin No.: 05-06-04-035C Date: July 30, 2007 INFORMATION Subject: Usage of E85 Fuels in GM Vehicles Models: 1997-2008 GM Passenger Cars and Trucks (including Saturn) 2003-2008 HUMMER H2 2006-2008 HUMMER H3 1997-2008 Isuzu NPR Commercial Medium Duty Trucks 2005-2008 Saab 9-7X Supercede: This bulletin is being revised to add the 2008 model year and additional engines with E85 capability. Please discard Corporate Bulletin Number 05-06-04-035B (Section 06 Engine/Propulsion System). Customer Interest in E85 Fuel As the retail price of gasoline increases, some locations in the country are seeing price differentials between regular gasoline and E85 where E85 is selling for substantially less than regular grade gasoline. One result of this is that some customers have inquired if they are able to use E85 fuel in non-E85 compatible vehicles. Only vehicles designated for use with E85 should use E85 blended fuel. E85 compatibility is designated for vehicles that are certified to run on up to 85% ethanol and 15% gasoline. All other gasoline engines are designed to run on fuel that contains no more than 10% ethanol. Use of fuel containing greater than 10% ethanol in non-E85 designated vehicles can cause driveability issues, service engine soon indicators as well as increased fuel system corrosion. Using E85 Fuels in Non-Compatible Vehicles General Motors is aware of an increased number of cases where customers have fueled non-FlexFuel designated vehicles with E85. Fueling non-FlexFuel designated vehicles with E85, or with fuels where the concentration of ethanol exceeds the ASTM specification of 10%, will result in one or more of the following conditions: Lean Driveability concerns such as hesitations, sags and/or possible stalling. SES lights due to OBD codes. Fuel Trim codes P0171 and/or P0174. Misfire codes (P0300). Various 02 sensor codes. Disabled traction control or Stability System disabled messages. Harsh/Firm transmission shifts. Fuel system and/or engine mechanical component degradation. Use of fuel containing greater than 10% ethanol in non-E85 designated vehicles can cause driveability issues, service engine soon indicators as well as increased fuel system corrosion. If the dealer suspects that a non-FlexFuel designated vehicle brought in for service has been fueled with E85, the fuel in the vehicle's tank should be checked for alcohol content with tool J 44175. If the alcohol content exceeds 10% the fuel should be drained and the vehicle refilled with gasoline - preferably one of the Top Tier brands. Page 7921 7. Use the modified screw extractor in order to remove the plug. 8. Remove the parking pawl shaft retainer, shaft and pawl. 9. Important: If the manual shaft binds in the case during removal, file or sand the shaft in the area adjacent to the detent lever. Remove the manual shaft. 10. Remove the manual shaft seal. Installation Procedure 1. Install the pawl shaft. 2. Install the parking pawl. 3. Install the plug using a 8 mm or (5/16 inch) rod with Loctite® or equivalent. 4. Install the retainer. 5. Install the pawl return spring. 6. Install the detent lever to the actuator. 7. Install the actuator over the parking pawl. 8. Install the manual shaft seal. 9. Lubricate the manual shaft with transmission oil and install the manual shaft into the case. 10. Install the nut on the shaft. 11. Install the roll pin. 12. Notice: Refer to Fastener Notice in Service Precautions. Page 12524 ^ Audio amplifier ^ Driver door module (DDM) ^ Driver door switch assembly (DDSA) ^ Front passenger door module (FPDM) ^ Left rear door module (LRDM) ^ Memory seat module (MSM) ^ Radio antenna module (listed as remote function actuation in scan tool display) ^ Rear integration module (RIM) ^ Right rear door module (RRDM) ^ Theft deterrent module (TDM) ^ TV antenna module ^ Vehicle communication interface module (VCIM) The star has 4 splice packs: ^ SP200 located in the left side of the instrument panel, near the steering column , taped to the instrument panel harness ^ SP201 located in the center of the instrument panel, near the radio ^ SP300 located in the left side middle of the passenger compartment, taped to the body harness, near the carpet seam ^ SP303 located in the right rear of the passenger compartment, taped to the body harness, approximately 24 cm (9.5 in) from the fuse block - right rear. Refer to Data Communication Schematics in SI. The following modules, components, and splice packs are connected to the ring portion of the class 2 serial data circuit: ^ Dash integration module (DIM) ^ Electronic brake control module (EBCM) ^ Engine control module (ECM) ^ Inflatable restraint sensing and diagnostic module (SDM) ^ Instrument panel cluster (IPC) ^ HVAC control module ^ Radio ^ Rear integration module (RIM) ^ Vehicle communication interface module (VCIM) OR ^ Communication interface module (CIM) ^ SP200 ^ SP201 ^ SP300 Page 13047 Important: The optic cable must not be bent with a radius less than 25 mm (1 in). 6.12. Place the optic cable in the wiring harness channels on the right-hand side. Thread through the existing cable ties (C) if possible, otherwise, secure with a cable tie to the existing one. Close the cover on the channels. Ensure the catches lock. 6.13. Secure the optic cable along the right-hand rear wheel housing, next to the ordinary wiring harness securing points and by the SRS unit (D). 6.14. Thread the optic cable up next to the safety belt by the old optic cable and place on the parcel shelf. 6.15. Unplug the connectors (E) from the OnStar(R) control modules. 6.16. Remove the console (F) together with the OnStar(R) control modules. Page 6247 Fluid - A/T: Service and Repair Automatic Transmission - 4L80-E/4L85-E Automatic Transmission Fluid/Filter Replacement Removal Procedure 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. Place a drain pan under the transmission oil pan. 3. Remove the oil pan drain plug, if equipped. 4. Allow the transmission fluid to drain completely. 5. Apply a small amount of sealant GM P/N 12346004 (Canadian P/N 10953480), or equivalent to the treads of the drain plug, if equipped. Notice: Refer to Fastener Notice in Service Precautions. 6. Install the oil pan drain plug. ^ Tighten the oil pan drain plug to 18 Nm (13 ft. lbs.). 7. Remove the drain pan from under the transmission oil pan. 8. Support the transmission with a transmission jack. 9. Remove the transmission mount nuts. 10. Remove the transmission support bolts and nuts. 11. Remove the transmission support side bracket bolts and bracket. 12. Remove the transmission support. 13. Disconnect the range selector cable end (2) from the transmission range selector lever ball stud (1). Page 2418 Page 9031 Fuse Block- I/P C1 Part 5 Page 11366 Air Temperature Sensor - Lower Left Page 4693 Door Control Module Diagram 3 Part 1 Page 4973 Left Side Of The Engine Page 6463 7. Lower the vehicle. 8. Install the cable grommet to the floor panel. 9. Important: Avoid unnecessary twisting/bending of the range selector cable when installing the cable to the support. Install the range selector cable to the support. 10. Notice: Refer to Fastener Notice in Service Precautions. Install the bolt securing the cable support to the brace. ^ Tighten the bolt to 10 Nm (89 inch lbs.). Interior - Seat Memory Feature Appears Inoperative Memory Positioning Module: All Technical Service Bulletins Interior - Seat Memory Feature Appears Inoperative Bulletin No.: 04-08-50-003 Date: February 26, 2004 INFORMATION Subject: Enabling Memory Seat Feature via DIC If Feature Appears Inoperative Models: 2003-2004 Cadillac Escalade, Escalade ESV, Escalade EXT 2003-2004 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2003-2004 GMC Sierra, Yukon, Yukon Denali, Yukon Denali XL 2003-2004 HUMMER H2 with Steering Wheel Controls (RPO UK3) (standard on H2) If the memory seat feature appears inoperative, check the Driver Information Center (DIC). Many of the memory seat modules that were returned through the Warranty Parts Center for a condition of inoperative have shown No Trouble Found. The Driver Information Center (DIC), programmed for Seat Entry and Exit, is set to the default "Off" mode at the assembly plant. DO NOT REPLACE THE MEMORY SEAT MODULE. Perform the following procedure. Important: The following procedure will need to be completed for each Remote/Key selection. Using the DIC menu, do the following steps: 1. Set the "Seat Recall" to either "At Key In" or "On Remote" based on the customer's preference. 2. Set the "Exit Seat" to "On". 3. Adjust the following items: Memory Seat: 3.1. Driver's Seat (including the seat back, recliner, lumbar, and side wings) 3.2. Throttle and Brake Pedals (not available on H2 or Silverado and Sierra Trucks) 3.3. Outside Mirrors 3.4. Radio Station Presets 3.5. Last Chosen Climate Control System Settings (not available on Silverado or Sierra Trucks) 3.6. Press and hold the "1" or "2" (for driver 1 or 2) button of the memory control for three seconds. A double chime will sound to let you know that the position has been stored. Easy Exit Seat: 3.1. Press and release the 1 or 2 button or press the unlock button on the desired remote keyless entry transmitter. The seat will move to the stored memory position. 3.2. Adjust the seat to the desired exit position. 3.3. Press and hold the exit button of the memory control (located on the door) for three seconds. A double chime will sound to let you know that the position has been stored for the identified driver (1 or 2). Page 2514 2. Fill the transfer case to the bottom of the fill plug hole with DEXRON® III, GM P/N 12346143 (Canadian P/N 10952622). 3. Install the fill plug. ^ Tighten the plug to 20 Nm (15 ft. lbs.). 4. Install the transfer case shield, if equipped. 5. Lower the vehicle. Page 13149 7.1. Remove the console (A) together with the OnStar(R) control modules. 7.2. Remove the connectors (B). Important: The optic cable must not be bent with a radius less than 25 mm (1 in). Important: Secure the wiring harness so that there is no risk of chafing and rattling. 7.3. Fold back the wiring harness and tape over the connectors (C). Fold back the wiring harness once more and secure with cable ties (D). 7.4. Fit the parcel shelf trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 8. CV: Removing the OnStar(R) control modules and securing the wiring: Adjustment/Replacement. 8.1. Open the luggage compartment floor. Page 8627 Tighten Tighten the nuts to 50 N.m (37 lb-ft). 3. Install the booster pump rod to the lever. 4. Install the stop lamp switch to the lever. 5. Install the booster pump rod retainer. 6. Connect the power brake booster outlet hose, the steering gear inlet hose, and the power brake booster inlet hose. Tighten ^ Tighten the power brake booster inlet hose to 28 N.m (20 lb-ft). ^ Tighten the steering gear inlet hose to 28 N.m (20 lb-ft). 7. Install the master cylinder. 8. Install the mounting nuts. Tighten Tighten the mounting bolts to 50 Nm (37 lb-ft). 9. Install the electrical connectors to the electrohydraulic pump and the flow switch. 10. Fill the hydraulic pump reservoir. Important: Maintain the fluid level throughout the bleed procedure. 11. Remove the pump reservoir cap. Important: Page 15019 4. Important: DO NOT loosen the other bolt completely in the next step. Leave two or three threads of the bolt engaged in the tailgate. Removing this bolt completely may allow the linkage inside the tailgate to separate from the latch. 5. If the toothed or plastic nut is present, loosen the other two bolts (1) attaching the latch (2) to the tailgate. DO NOT remove these bolts. 6. Finish loosening the bolt that attaches the support cable. The bolt will NOT be removable even though the threads are completely out. 7. Place an interior trim removal type tool (2) between the support cable end (3) and the latch (1), and pry the two apart. As the two spread apart, the toothed or plastic nut on the other side of the latch will begin to move towards the end of the bolt. 8. Once the toothed or plastic nut has moved away from the backside of the latch, use long nose pliers to grasp and twist it off of the bolt. Discard the toothed nut. 9. Remove the bolt and support cable. Important: Do not reinstall the toothed or plastic nut when installing the new support cable. Also, the support cables used on these vehicles are interchangeable from side to side, and no washers are to be installed like those used on the new style trucks (GMT800). 10. Install the new support cable to the latch and reinstall the original bolt. Tighten Tighten the bolt to 30 Nm (22 lb-ft). 11. If the other bolts were loosened earlier, Tighten Tighten the other loose bolts to 30 Nm (22 lb-ft). 12. Attach the opposite end of the support cable to the pickup box. 13. Repeat this procedure on the other support cable. Important: Depending on the condition of the tailgate and related parts, one of the two new support cables (either left or right) may NOT be tight (taut) when the tailgate is fully open. This condition may be caused by several factors including a damaged hinge, pickup box, or the tailgate itself may be slightly bent due to overloading at some previous time. Replacing either or both support cables a second time will NOT correct this condition. Replacement of any additional parts to correct this condition will NOT be covered under this recall. 14. Remove the tailgate support, close, open and re-close the tailgate. Verify that the support cables fold properly. Escalade EXT, Avalanche, New Style Silverado and Sierra (GMT800), Kodiak, TopKick The following procedures provides instructions for inspecting, and if necessary, replacing the rear endgate (tailgate) support cables and inspecting the right side tailgate hinge for damage, and replacing if necessary. Service and Repair Glove Box Lamp Switch: Service and Repair INSTRUMENT PANEL (I/P) COMPARTMENT LAMP SWITCH REPLACEMENT REMOVAL PROCEDURE 1. Lower the instrument panel storage compartment door by pressing in the tab. 2. With one hand holding the plunger of the switch, use a small screw driver to push in the tabs on each side while pulling outwards. 3. Pull the switch assembly from the I/P. 4. Disconnect the electrical connector. 5. Remove the bulb (1). INSTALLATION PROCEDURE Page 10867 Air Register: Service and Repair Deflector Replacement - Instrument Panel Air - Right DEFLECTOR REPLACEMENT - INSTRUMENT PANEL AIR - RIGHT REMOVAL PROCEDURE 1. Use a flat blade tool in order to remove the deflector from the instrument panel. 2. Remove the deflector. INSTALLATION PROCEDURE 1. Align the deflector into the opening in the instrument panel. 2. Push the deflector into the instrument panel until the deflector snaps into place. Powertrain Control Module (PCM) C1 Engine Control Module: Diagrams Powertrain Control Module (PCM) C1 Page 15229 - Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-D in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-D if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Page 1505 Headlamp Switch Part 2 Page 4880 8. Connect the PNP switch electrical connector (2). 9. If equipped with 4WD, install the front propeller shaft. 10. Lower the vehicle. 11. Check the switch for proper operation. The engine must start in the park (P) or neutral (N) positions only. If proper operation of the switch can not be obtained, replace the switch. Page 3931 Intake Air Temperature (IAT)/Mass Air Flow (MAF) Sensor Page 8994 Junction Block - I/P Wire Entry Part 1 Input Shaft Speed Sensor Replacement Transmission Speed Sensor: Service and Repair Input Shaft Speed Sensor Replacement Input Shaft Speed Sensor Replacement Removal Procedure 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. Disconnect the input speed sensor electrical connector (1). 3. Remove the input speed sensor bolt. 4. Remove the input speed sensor (1). 5. Inspect the input speed sensor (1) for any evidence of damage. Installation Procedure Page 11870 In summary, whenever a vehicle subject to this program enters your vehicle inventory, or is in your dealership/facility for service through April 30, 2011, you must take the steps necessary to be sure the program correction has been made before selling or releasing the vehicle. Disclaimer Service Procedure Service Procedure Note Do NOT replace the inside rear view mirror in tandem with this concern. The mirror has no bearing on this specific issue. 1. Remove the OnStar(R) module (referred to as the Communication Interface Module (CIM) or Vehicle Communication Interface Module (VCIM) in SI). Refer to SI for module removal instructions. Note Inform customer that all Bluetooth devices must be paired with the new VCIM. Bluetooth devices that have not been paired to the new VCIM will not function properly. 2. Install the new OnStar(R) module (referred to as the Communication Interface Module (CIM) or Vehicle Communication Interface Module (VCIM) in SI). Refer to SI for module installation instructions. Page 1391 Extended Cab Short Box Shown Below, Other Configurations Similar 6. Install the new canister vent valve solenoid to the fuel tank clip or mounting bracket as shown above. The valve port closest to the electrical connector must point towards the canister. 7. Cut bulk 5/8" heater hose to a length of approximately 76 mm (3 in). Install the hose between the solenoid and the canister pipe and secure using clamps. 8. Attach bulk 5/8" heater hose to the vent port and secure using a clamp. Run a length as needed along the frame rail routing to the area above the transmission. 9. Cut the hose to determined length and install the supplied filter box. Secure using a clamp. 10. Remove the transmission support and lower the transmission assembly as necessary to allow for access to the new filter box location. 11. Secure the filter box to the transmission vent hose just forward of the hose tee-section using a tie strap. DO NOT pinch or restrict the transmission vent hose. The filter box opening should be pointing downward. 12. Raise the transmission and reinstall the transmission support. 13. Connect the EVAP canister vent valve electrical connector. 14. Tie strap the hose as needed along the frame rail in order to keep the hose away from pinch-points and heat sources. 15. Lower the vehicle. Correction (2007-2010 New Style Models) After following the published SI diagnostics and determining that the EVAP canister vent valve is the cause of the MIL light, replace the EVAP canister vent valve assembly and relocate the remote filter box. To ensure correct installation, follow the procedures below. Important DO NOT replace the EVAP canister assembly for this concern unless it fails the leak test. Use Service Kit P/N 19207763 1. Raise the vehicle. Suitably support the vehicle. 2. Disconnect the EVAP canister vent valve electrical connector. Page 3998 Manifold Pressure/Vacuum Sensor: Service and Repair MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR REPLACEMENT REMOVAL PROCEDURE 1. Remove the engine sight shield. 2. Disconnect the manifold absolute pressure (MAP) sensor electrical connector (1). 3. Remove the MAP sensor (1). INSTALLATION PROCEDURE IMPORTANT: Lightly coat the MAP sensor seal with clean engine oil before installing the sensor. 1. Install the MAP sensor (1). Page 7067 10. Place the J 9522-3 on the open horizontal bearing cups. Press the lower bearing cup out of the yoke ear. 11. If you do not completely remove the bearing cup, lift the cross and insert the J 9522-5 between the seal and the bearing cup you are removing. Continue pressing the bearing cup out of the yoke. 12. Rotate the propeller shaft. Press the opposite bearing cup out of the drive shaft yoke. 13. Remove the old slip yoke and universal joint. 14. Inspect the retaining ring grooves for dirt, corrosion, or pieces of the old ring. 15. Inspect the bearing cup bores for burrs or imperfections. 16. Clean the retaining ring grooves. Corrosion, dirt, rust, or pieces of the old retaining ring may prevent the bearing cups from pressing into place or prevent the bearing retainers from properly seating. 17. Install the new nickel-plated slip yoke and universal joint. See parts table below for parts information. 18. Remove the bearing cups from the universal joint. 19. Assemble one bearing cup part way into one side of the yoke. Turn the yoke ear toward the bottom. 20. Assemble the cross into the yoke so that the trunnion seats freely into the bearing cup. Page 7650 Seals and Gaskets: Service and Repair Transfer Case - NVG 246-NP8 Transfer Case Output Shaft Seal Replacement - Front Transfer Case Output Shaft Seal Replacement - Front ^ Tools Required J 8092 Driver Handle - J 43484 Output Shaft Seal Installer Removal Procedure 1. Remove the transfer case shield, if equipped. 2. Remove the front propeller shaft. 3. Insert a flat-tipped screwdriver into the inner race. 4. Pry the inner race back. 5. Insert a small pry bar into the inner race. 6. Remove the inner part of the seal. Fuel Level Sensor Replacement - 1 Fuel Level Sensor: Service and Repair Fuel Level Sensor Replacement - 1 FUEL LEVEL SENSOR REPLACEMENT REMOVAL PROCEDURE 1. Remove the sending unit. 2. Disconnect the fuel pump electrical connector. 3. Remove the fuel lever sensor electrical connector retaining clip. 4. Disconnect the fuel level sensor electrical connector. 5. Remove the fuel level sensor retaining clip. 6. Remove the fuel level sensor (1). INSTALLATION PROCEDURE 1. Install the fuel level sensor (1). 2. Install the fuel level sensor retaining clip. 3. Connect the fuel level sensor electrical connector. 4. Install the fuel lever sensor electrical connector retaining clip. 5. Connect the fuel pump electrical connector. 6. Install the sending unit. Page 4659 6. Use fingers to squeeze the 2 locking legs of the cover. 7. Apply pressure and gently rock the cover until one locking leg is unseated. 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. Brakes/Wheels - Excessive Debris Build Up Brake Caliper: Customer Interest Brakes/Wheels - Excessive Debris Build Up Bulletin No.: 04-05-23-005 Date: June 22, 2004 INFORMATION Subject: Availability of Rear Wheel Mud Flaps to Reduce Debris Build-up on Rear Brake Calipers and/or Rear Wheels Models: 1999-2004 Chevrolet Silverado Pickup Models 1999-2004 GMC Sierra Pickup Models This bulletin is to inform dealers of the release of rear wheel mud flaps. The above models that are exposed to extensive off-paved roads may benefit from the mud flaps. The mud flaps have been developed to minimize the amount of stones and/or mud that can impact and collect on the rear caliper and/or wheel rim. Please advise customers that the installation of these mud flaps and following the recommended off-road driving information provided in their Owner's Manual should greatly reduce the possibility of accelerated rear brake component wear and/or rim damage. Install the mud flap forward of each rear wheel using the following procedure. Important: Always work from outboard to inboard, drilling one hole at a time and securing with a fastener. Follow the sequence of the procedure. This will prevent distortion of the mud flap. 1. Raise the vehicle. Support the vehicle. 2. Locate the pickup box side panel rear brace. 3. Remove the existing outboard upper fastener on the brace. 4. Install the mud flap through the "V" of the brace. Install the previously removed fastener in the hole (2) of the mud flap to the brace. Do not tighten the fastener at this time. 5. Using the mud flap as a template, locate and mark the location of the hole (1) in the pickup box wheel house. Page 11357 2. Install the inside air temperature sensor to the headliner and sensor grille. 3. Connect the electrical connector to the inside air temperature sensor. 4. Install the left sunshade. 5. Install the left center pillar garnish molding. 6. Install the left center assist handle. 7. Install the left windshield garnish molding. Page 8164 1. Install the anti-rattle clips to the brake caliper mounting bracket. 2. Install the disc brake pads to the brake caliper mounting bracket. 3. Perform the following procedure before installing the 2 brake caliper mounting bracket bolts. 1. Remove all traces of the original adhesive patch. 2. Clean the threads of the bolts with brake parts cleaner or the equivalent and allow to dry. 3. Apply Threadlocker GM P/N 2345493 (Canadian P/N 10953488) to the threads of the bolts. 4. Notice: Refer to Fastener Notice in Service Precautions. Install the brake caliper mounting bracket and the 2 brake caliper mounting bracket bolts. ^ Tighten the 2 brake caliper mounting bracket bolts to 200 Nm (148 ft. lbs.). 5. Perform the following procedure before installing the 2 brake caliper mounting bolts. Page 15788 Fog Lamp Switch Rear (With RPO Code T79) Page 1514 Horn Switch: Service and Repair Horn Switch Replacement Removal Procedure 1. Caution: Refer to Servicing the SIR System Caution in Cautions and Notices. Disable the SIR system. 2. Remove the inflatable restraint steering wheel module. 3. Remove the horn plunger from the steering column by pressing inward to the stop and rotating the horn plunger 90 degrees. 4. Disconnect the captured screws (1,4) to the horn contact plate (2) from the steering wheel (3). 5. Remove the horn switch (2) from the steering wheel (3). Installation Procedure 1. Install the horn switch (2) to the steering wheel (3). 2. Notice: Refer to Fastener Notice in Service Precautions. Connect the captured screws (1,4) from the horn contact plate (2) to the steering wheel (3). ^ Tighten the screws to 5.5 Nm (50 inch lbs.). Page 15973 Control Module References Part 4 Page 10150 24. From the technicians point of view, the FRONT of the sensor will have: ^ A flush rotor flange cuff (4) ^ A pin hole (2) for the centering pin. Note the location of the pin hole. ^ An alignment mark (3) on the flush rotor flange cuff (4) for installation ^ A foam ring (1) 25. Remove the connector from the sensor. 26. Remove the sensor from the adapter and bearing assembly. 27. To install the sensor, proceed to step 21 in the installation procedure. Installation Procedure 1. Important: If reusing the existing sensor, no centering of the sensor is required. If installing a new sensor, it will come with a pin installed in the sensor. Do not remove the pin until the sensor is seated. 2. From the technicians point of view, the FRONT of the sensor (1) connector will be on your right.From the technicians point of view, the BACK of the sensor (2) connector will be on your left. 3. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install into the adapter and bearing assembly. 4. Install the connector to the sensor. 5. From the technicians point of view, the FRONT of the sensor will have: ^ A foam ring (4) ^ A pin hole (7) for the centering pin. Note the location of the pin hole. ^ A flushed rotor flange cuff (6) ^ An alignment mark (5) for installation 6. From the technicians point of view, the BACK of the sensor will have: ^ Double D flats (1) Page 4684 Body Control Module (BCM) - C3 Part 2 Page 10866 Air Register: Service and Repair Deflector Replacement - Instrument Panel Air - Left DEFLECTOR REPLACEMENT - INSTRUMENT PANEL AIR - LEFT REMOVAL PROCEDURE 1. Remove the instrument panel (I/P) bezel. 2. Remove the knee bolster. 3. Remove the air deflector housing from the I/P by prying it out. 4. Disconnect the electrical connectors. 5. Remove the air deflector screws. 6. Remove the air deflector from the housing. INSTALLATION PROCEDURE 1. Install the air deflector to the housing. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the retaining screws. Tighten Tighten the screws to 1.6 N.m (14 lb in). 3. Connect the electrical connectors. 4. Install the air deflector assembly to the I/P. 5. Remove the knee bolster. 6. Install the I/P bezel. A/C - New PAG Oil Refrigerant Oil: Technical Service Bulletins A/C - New PAG Oil Bulletin No.: 02-01-39-004B Date: November 16, 2005 INFORMATION Subject: New PAG Oil Released Models: 2006 and Prior GM Passenger Cars and Trucks (Including Saturn) 2003-2006 HUMMER H2 2006 HUMMER H3 2005-2006 Saab 9-7X Built With R-134a Refrigeration System All Air Conditioning Compressor Types (Excluding R4 and A6 Type Compressors) Supercede: This bulletin is being revised to change the PAG oil part number used for R4 and A6 compressors with R-134a refrigerant systems. Please discard Corporate Bulletin Number 02-01-39-004A (Section 01 - HVAC). All General Motors vehicles built with R-134a refrigerant systems shall now be serviced with GM Universal PAG Oil (excluding vehicles equipped with an R4 or A6 compressor). R4 and A6 compressors with R-134a refrigerant systems shall use PAG OIL, GM P/N 12356151 (A/C Delco part number 15-118) (in Canada, use P/N 10953486). Important: The PAG oil referenced in this bulletin is formulated with specific additive packages that meet General Motors specifications and use of another oil may void the A/C systems warranty. Use this new PAG oil when servicing the A/C system on the vehicles listed above. Oil packaged in an 8 oz tube should be installed using A/C Oil Injector, J 45037. Refer to the HVAC Section of Service Information for detailed information on Oil Balancing and Capacities. Disclaimer Page 2989 Refer to the Model Application Chart shown to verify usage. Supercede: This bulletin is being revised to include 2007 model year and calibration information. Please discard Corporate Bulletin Number 03-03-10-006E (Section 03 - Suspension). Tires GM has designed 20" wheels based on the Goodyear Eagle LS and LS2 P275/55R20 tire. The Goodyear Eagle LS tire has a Tire Performance Criteria spec # 1235 and the LS2 has a Tire Performance Criteria spec # 1245. These tires have been designed to GM's specific Tire Performance Criteria. GM's Tire Performance Criteria specifications meet or exceed all Federal safety guidelines. When mounting the tires, rubber lubricant, P/N 12345884 (in Canada, P/N 5728223), MUST be used. The vehicle should not be driven aggressively (hard acceleration or braking) for at least 6-8 hours after tire mounting to allow the lube to dry. Failure to do so may cause the tire to slip on the rim. This condition will affect wheel balance which could result in a vibration. Spare Tire A P265/75R16 or P265/70R17 tire should be used as a spare. Re-use the vehicle's original spare wheel to mount the spare tire. The spare tire should be used to drive the vehicle to a tire repair/replacement facility and is not intended for extended driving conditions. Tire Changers Dealers must have the correct level of tire changing equipment to perform tire changing services. GM requirements and recommendations for servicing glamour wheels are as follows: ^ Rim Clamp design ^ Runflat capable (preferred) ^ Side mounted bead breaking to reduce stress on the wheel and tire ^ No metal contact to the wheel at the clamping jaws Protective devices to prevent damage during mounting and dismounting operations Regulated air pressure to protect user and wheel assembly. Approved lubricant (P/N 12345884 [in Canada, P/N 5728223]) to avoid wheel slip and damage to the wheel For further information regarding equipment meeting the requirements for this program, call 1-800-GM-TOOLS. Balancing MC style coated weights are recommended and will provide the best balancing of the tire-wheel assembly. If stick-on weights are used, be sure to follow the manufacturers recommended installation procedure (SI Document ID # 664222) making sure the surface is clean and dry. Using the incorrect type of weights will result in improper fit, and such weights may fall off the wheel. Page 5362 3. If vehicle is a regular cab, install the fuel and EVAP bundle nuts. Tighten Tighten the nuts to 12 N.m (106 lb in). 4. Connect the quick connect fittings to the EVAP canister. 5. Install the EVAP line to the clips (2) on the fuel tank. 6. Remove the caps from the fuel and EVAP lines. 7. Connect the fuel and EVAP quick connect fittings. Page 7335 Steps 1-9 Test Description The numbers below refer to the step numbers on the diagnostic table. 2. This step tests for a faulty tow/haul switch. 3. This step tests for voltage input from the BCM to the tow/haul switch. 6. This step tests for ground integrity. Page 8949 For vehicles repaired under warranty, use the table. Disclaimer Service and Repair Vacuum Brake Booster Check Valve: Service and Repair Vacuum Brake Booster Check Valve and/or Hose Replacement Removal Procedure 1. Remove the vacuum brake booster check valve from the vacuum brake booster. 2. Remove the vacuum brake booster hose clamp at the check valve. 3. Remove the vacuum brake booster check valve from the hose. 4. Remove the manifold sight shield (4.8L, 5.3L, 6.0L). 5. Disconnect the vacuum brake booster hose at the engine (4.8L, 5.3L, 6.0L). 6. Disconnect the vacuum brake booster hose at the engine (4.3L). 7. Remove the vacuum brake booster hose from the vehicle. Installation Procedure 1. Connect the vacuum brake booster hose at the engine (4.8L, 5.3L, 6.0L). Page 11161 Heater Core: Service and Repair Heater Core Replacement - Visteon HEATER CORE REPLACEMENT (VISTEON) REMOVAL PROCEDURE 1. Remove the HVAC module assembly. See: Housing Assembly HVAC/Service and Repair 2. Remove the screws from the heater core cover. 3. Remove the heater core cover (1) from the HVAC module assembly (2). 4. Remove the heater core cowl gasket (1) from the heater core (2). 5. Remove the heater core (1) from the HVAC module assembly (2). Page 8916 Auxiliary Power Outlet 120-Volt AC - Interior (With RPO Code HP2) Page 8891 6. Use fingers to squeeze the 2 locking legs of the cover. 7. Apply pressure and gently rock the cover until one locking leg is unseated. 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. Page 14129 Door Control Module Diagram 2 Part 2 Page 9797 Location View Location View OnStar(R) - System Inoperative/No LED Lamp ON Fuse: Customer Interest OnStar(R) - System Inoperative/No LED Lamp ON Bulletin No.: 04-08-46-005 Date: December 21, 2004 TECHNICAL Subject: OnStar(R) Generation 6 (Digital) System Inoperative/Has No Power, LED Light Not On (Remove/Reinstall OnStar(R) Fuse and Replace VCIM or Follow SI Diagnostics) Models: 2004-2005 Buick Rainier, Rendezvous 2005 Buick Allure (Canada), LaCrosse, LeSabre, Terrazza 2004-2005 Cadillac Escalade, Escalade ESV, Escalade EXT 2005 Cadillac CTS, DeVille 2004-2005 Chevrolet Avalanche, Silverado, Suburban, Tahoe, TrailBlazer, TrailBlazer EXT 2005 Chevrolet Colorado, Express, Impala, Monte Carlo, Uplander 2004-2005 GMC Denali, Denali XL, Envoy, Envoy XL, Envoy XUV, Sierra, Yukon, Yukon XL 2005 GMC Canyon, Savana 2004-2005 Pontiac Aztek 2005 Pontiac Bonneville, Grand Prix, Montana SV6, Vibe with Digital Gen 6 OnStar(R) (RPO UE1) Condition Some customers may comment any or all of the following conditions: ^ The OnStar(R) system may be inoperative. ^ The OnStar(R) system may have no power. ^ The OnStar(R) LED light may not be on. The technician may also not be able to communicate with the OnStar(R) Vehicle Communication Interface Module VCIM) with a Tech 2(R). Correction Remove the OnStar(R) fuse from the fuse box, wait five minutes and reinstall the fuse. If the OnStar(R) system DOES NOT return to normal functionality, then follow the diagnostics in SI for this condition. If the OnStar(R) system DOES return to normal functionality, you will need to replace the VCIM. If the VCIM is not replaced, there is the possibility that the customer will return to the dealership with the same conditions at a later date. Please contact the GM Technical Assistance Center (TAC), to obtain a new VCIM. The TAC consultant will verify your diagnosis and, if appropriate, order a replacement part. Replacement parts are usually shipped out within 24 hours, and a pre-paid return package label will be included for returning the faulty part. By returning the faulty part, you will avoid a significant non-return core charge. After the VCIM has been replaced, press the blue OnStar(R) button and request a full reconfiguration. When contacting TAC regarding this concern, the availability of certain information from the vehicle will streamline the process for the dealership technician as well as minimize the time necessary for TAC to provide the correct diagnosis. Please refer to Corporate Bulletin Number 01-00-89-011B for further information concerning the information necessary before contacting TAC. Dealers in Canada should refer to GM Service Policies & Procedures Section 5.3.1 "DEALER REQUIREMENTS FOR ASSISTANCE". Warranty Information Page 9075 Application Table Part 2 Service and Repair Air Bag(s) Arming and Disarming: Service and Repair SIR Disabling and Enabling The SIR Identification Views shown below illustrate the approximate location of all SIR components available for the vehicle. This will assist in determining the appropriate SIR Disabling and Enabling for a given service procedure. Refer to See: Air Bag Systems/Locations/SIR Zone Identification Views There are several reasons for disabling the SIR system, such as repairs to the SIR system or servicing a component near or attached to an SIR component. There are several ways to disable the SIR system depending on what type of service is being performed. The following information covers the proper procedures for disabling/enabling the SIR system. SIR Service Precautions Caution: When performing service on or near the SIR components or the SIR wiring, the SIR system must be disabled. Failure to observe the correct procedure could cause deployment of the SIR components. Serious injury can occur. Failure to observe the correct procedure could also result in unnecessary SIR system repairs. The inflatable restraint sensing and diagnostic module (SDM) maintains a reserved energy supply. The reserved energy supply provides deployment power for the air bags if the SDM loses battery power during a collision. Deployment power is available for as much as 1 minute after disconnecting the vehicle power. Waiting 1 minute before working on the system after disabling the SIR system prevents deployment of the air bags from the reserved energy supply. General Service Instructions The following are general service instructions which must be followed in order to properly repair the vehicle and return it to its original integrity: - Do not expose inflator modules to temperatures above 65°C (150°F). - Verify the correct replacement part number. Do not substitute a component from a different vehicle. - Use only original GM replacement parts available from your authorized GM dealer. Do not use salvaged parts for repairs to the SIR system. Discard any of the following components if it has been dropped from a height of 91 cm (3 feet) or greater: - Inflatable restraint sensing and diagnostic module (SDM) - Any Inflatable restraint air bag module - Inflatable restraint steering wheel module coil - Any Inflatable restraint sensor - Inflatable restraint seat belt pretensioners - Inflatable restraint Passenger Presence System (PPS) module or sensor Disabling Procedure - Air Bag Fuse 1. Turn the steering wheel so that the vehicles wheels are pointing straight ahead. 2. Place the ignition in the OFF position. Important: The SDM may have more than one fused power input. To ensure there is no unwanted SIR deployment, personal injury, or unnecessary SIR system repairs, remove all fuses supplying power to the SDM. With all SDM fuses removed and the ignition switch in the ON position, the AIR BAG warning indicator illuminates. This is normal operation, and does not indicate a SIR system malfunction. 3. Locate and remove the fuse(s) supplying power to the SDM. Page 13455 The information shown is for the 1999-2002 wiring harnesses and for the 2003-05 wiring harness. To modify a 12171982, 15366255 or 15086884 harness for use in a 2003-05 vehicle, switch the wires in cavities "A" and "D". To modify a 15085418 harness for use in a 1999-2002 vehicle (see model list at the front of this bulletin for applicable models), switch the wires in cavities "A" and "D". Warranty Information When the correct wiring harness P/N is matched to the specific model year of the vehicle, everything works properly. Therefore, conversion of an incorrect wiring jumper to match the vehicle would not be considered a warrantable repair. Disclaimer Page 6522 of transmission fluid (ATF), (DEXRON(R)VI) (fluid) that is to be charged for the flush portion of the repair should not exceed the allowable charge for 7.5 L (2 gal) of fluid. This expense should be shown in the Parts Section of the warranty claim document. The Seven digit Alpha/Numeric flow code, i.e. A10DFB2, "MUST" be written on the job card and placed in the comments section of the warranty claim. Any repair that requires the technician to contact the Product Quality Center (PQC) must also include the seven digit flow code. The agent will request the seven digit flow code and add the information to the PQC case prior to providing authorization for the warranty claim. The Seven digit Alpha/Numeric flow code, i.e. A10DFB2, "MUST" be written on the job card, entered in the warranty claim labor operation Flush Code additional field (when available) and placed in the comments section of the warranty claim. Any repair that requires the technician to contact the Product Quality Center (PQC) must also include the seven digit flow code. The agent will request the seven digit flow code and add the information to the PQC case prior to providing authorization for the warranty claim. Disclaimer Page 1978 Electrical Symbols Part 4 Page 8013 4. Install the ground, then the washer and then the bolt to the frame. Important: It is important to use the bolts, washers and nuts specified in this bulletin. These parts have been identified due to their conductive finish. 5. Install a washer and nut to the back side of the frame. Tighten Tighten the nut to 9 Nm (79 lb in). 6. Cover the front and back side of the repair area using Rubberized Undercoating. An additional check can be made to ensure a good connection for the battery cable to frame ground. It is possible for this ground to cause similar symptoms with the ABS as described above. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Parts Information Warranty Information Disclaimer A/C - Blower Motor Inop. or Works On Low Speed Only Blower Motor Resistor: Customer Interest A/C - Blower Motor Inop. or Works On Low Speed Only Bulletin No.: 05-01-38-012C Date: November 02, 2006 TECHNICAL Subject: EI05082 - Loss of Blower Motor Speeds Except for Low Speed or Inoperative (Replace Blower Motor Resistor and Resistor Module Connector) Models: 2004-2006 Chevrolet Avalanche, Silverado, Suburban, Tahoe, TrailBlazer, TrailBlazer EXT 2007 Chevrolet Silverado (Classic) Built Prior to September 1, 2006 2004-2006 GMC Envoy, Envoy XL, Sierra, Yukon, Yukon Denali, Yukon XL 2007 GMC Sierra (Classic) Built Prior to September 1, 2006 with HVAC System AC Front, Manual Temp Control (RPO CJ3) or Heater Only (RPO C42) Supercede: This bulletin is being revised to clarify the Warranty Information. Please discard Corporate Bulletin Number 05-01-38-012B (Section 01 - HVAC). Condition Some customers may comment that the blower will only work on low speeds or has become inoperative. Correction REPLACE THE BLOWER MOTOR RESISTOR AND RESISTOR MODULE CONNECTOR. Replace the blower motor resistor and module connector using the following procedure: Remove the blower fuse. Fullsize Trucks and Utility Vehicles - Htr A/C & HVAC 1 fuses Midsize Utility Vehicles - Blower Fuse 35 located in the Underhood Fuse Block Lower the hush panel or close-out panel enough to gain access to the resistor module connector. Disconnect the connector from the resistor module. Remove the tape from the wiring harness to expose the wiring. Page 9433 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. REPLACEMENT PROCEDURE After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Insure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the Terminal Removal Procedure. Repairing Connector Terminals REPAIRING CONNECTOR TERMINALS TOOLS REQUIRED J 38125-D Terminal Repair Kit Use the following repair procedures in order to repair the following: - Push to Seat terminals - Pull to Seat terminals - Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-D contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100 World terminals. Soldering Micro-Pack 100 World terminals may damage the terminal. Circuit Protection - Circuit Breakers CIRCUIT PROTECTION - CIRCUIT BREAKERS A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Page 5703 Transfer Case Actuator: Service and Repair Transfer Case Encoder Motor Replacement Removal Procedure 1. Remove the transfer case shield, if equipped. 2. Remove the front propeller shaft. 3. Disconnect the encoder motor electrical connector. 4. Remove the encoder motor bolts. 5. Remove the encoder motor. 6. Remove the actuator insulator gasket. 7. If replacing the encoder motor, remove the locating pins from the old motor. Installation Procedure Important: ^ If the encoder motor is being replaced because it is defective, ensure that the transfer case is in the neutral position. Manually shift the unit at the shift shaft. Use a crescent wrench, if necessary. ^ If the encoder motor is being replaced, a new gasket will come with the encoder motor. DO NOT reuse the old gasket. ^ A NEW encoder motor does NOT come with locating pins. Page 12117 ^ Pay the dealer the regular retail price (no discounts are available) for one of the following 1-year, non-refundable OnStar(R) Analog-to-Digital Transition (ADT) Service Subscription Plans: ^ 1-year Safe & Sound Subscription: $199 ($289 in Canada) ^ 1-year Directions & Connections Subscription: $399 ($579 in Canada) ^ Pay the dealer the applicable state and local sales taxes on the subscription: ^ U.S. Dealers: Taxes only apply in these states: CT, DC, FL, HI, ND, NJ, NM, NY, SC, SD, TX, and WV ^ Canadian Dealers: All applicable taxes ^ Pay the dealer a one-time charge of $15 for the upgrade: ^ U.S. Dealers: Do not collect taxes on the $15 ^ Canadian Dealers: Collect all applicable taxes on the $15 Note: Dealers should NOT remit OnStar(R) ADT-related taxes to their taxing authority as OnStar(R) is responsible for tax remittance. Please Be Sure To Read these Important Points: ^ The 1-year OnStar(R) subscription is not refundable or transferable to another person. Upgraders can apply unused subscription months to a new or Certified Pre-Owned digital OnStar-equipped GM vehicle purchase or lease. As noted above, the digital upgrade program requires the subscriber to purchase a one-year prepaid OnStar(R) subscription. Assuming the subscriber intends to keep their vehicle, but subsequently purchases or leases a 2006 model year or newer OnStar(R)-equipped new or certified used GM vehicle, in the interest of subscriber satisfaction, they may apply remaining unused whole months of the subscription to the new vehicle. The subscription may not be applied to another person's vehicle. Important: This is a customer satisfaction measure that would usually occur several months after an upgrade. It is not intended to be leveraged as part of a new/used vehicle purchase or lease transaction. ^ The $15 charge is not refundable. ^ Dealer ADT kit orders are VIN specific. Dealer kit orders require a VIN and must be exchanged with the OnStar(R) unit in the vehicle with that VIN. Proper activation and enrollment depends on this step. ^ You must put the actual miles on the Repair Order. Do not estimate. ^ Customers will receive a Hands-Free Calling number once the digital hardware is installed and configured. ^ Any nametags that were stored in the old system will need to be re-set by the subscriber once the new hardware is installed. ^ Customers are responsible for the charges described above regardless of whether their vehicle is in or out of the New Vehicle Warranty period. In addition, customers should not be charged labor costs. Dealers can charge GM the labor for the upgrade as specified at the end of this bulletin using the listed labor operation. ^ Vehicles eligible for an OnStar(R) hardware upgrade are listed in this bulletin. Vehicle upgradeability can also be determined by typing the VIN into the field entitled "Determine VIN Hardware Functionality" on the OnStar(R) Online Enrollment website, located in the sales or service workbench tab of GM GlobalConnect. Canadian Dealers can use a similar tool that is available within InfoNET. ^ Access to the sales and/or service workbench in the GM GlobalConnect website can be granted by the dealership's Partner Security Coordinator (PSC). If you are unsure who the PSC is, check with the Sales Manager. Ordering the Upgrade Kit/Upgrade kit Installation Ordering the Upgrade Kit 1. To order a kit, you will need to access the OnStar(R) Online Enrollment webpage, located under the sales or service workbench of GM GlobalConnect (infoNET for Canadian upgrade orders). These kits cannot be ordered from GMSPO. Page 13696 Tighten the hinge nuts (4) to 25 N.m (18 lb ft). 17. Clean and prepare all of the surfaces as necessary for refinishing. 18. Apply the sealers. Refinish the surfaces as necessary. 19. Install and align all of the related panels and the components. Page 3246 Steps 1 - 13 Locations Full Engine View Left Side Page 10279 7. From inside the vehicle remove the upper bolt from the upper intermediate steering shaft (1) to the steering column connection. 8. Remove the upper intermediate steering shaft assembly. 1. From inside the vehicle slide the shaft down and off the steering column. 2. From inside the vehicle slide the upper intermediate shaft through the dash boot seal and remove the shaft from the vehicle. 9. Replace the upper intermediate shaft. 10. Install the upper intermediate steering shaft through the dash boot seal and slide the lower end into the steering gear coupling shaft. 11. Raise the upper end of the intermediate steering shaft and install into the steering column shaft. 12. Install the upper bolt and nut. Tighten Tighten the bolt to 47 N.m (35 lb ft). 13. Install the lower bolt and nut. Tighten Tighten the bolt to 50 N.m (37 lb ft). 14. For vehicles equipped with adjustable foot pedals perform the following steps: 1. Reposition the accelerator pedals into position on the bulkhead. 2. Install the two retaining nuts. Tighten Tighten the nuts to 20 N.m (15 lb ft). 3. Reposition the carpet into place. Parts Information Warranty Information For vehicles repaired under warranty use, the table. A/C - Ticking Noise From Instrument Panel/DTC's Set Control Module HVAC: All Technical Service Bulletins A/C - Ticking Noise From Instrument Panel/DTC's Set Bulletin No.: 06-01-38-003 Date: April 27, 2006 TECHNICAL Subject: Intermittent Ticking Noise from I/P, Poor A/C Performance, HVAC DTCs B0229, B0414, B0424, B3770 (Reprogram HVAC Control Module) Models: 2004-2006 Cadillac Escalade Models 2004-2006 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2004-2006 GMC Sierra Models, Yukon Models with Air Conditioning (RPOs CJ2, CJ3) Condition Some customers may comment on one or more of the following concerns: ^ Intermittent ticking/clicking noise from the instrument panel. ^ Recirculation mode does not work or Air Conditioning (A/C) system performance is poor during high ambient temperatures. ^ Unable to control the driver side temperature. ^ Unable to control the passenger side temperature. ^ Unable to change the front system modes. Cause This condition may be caused by the Heating, Ventilation and Air Conditioning (HVAC) actuators that may hunt for the correct commanded position. This cycling may cause a clicking or ticking noise. An overtravel of the HVAC system control doors may cause one or more of the concerns listed above. If an overtravel occurs, a Diagnostic Trouble Code (DTC) will be set, and the door will go to a preset default position. When a system door defaults, that door will stay at the default position until the DTC is cleared. After the DTC is cleared, the door will operate properly until the overtravel condition re-occurs. The table lists the HVAC system doors and the DTC associated with it. Correction Technicians are to perform the normal diagnostic procedures in SI for these concerns. If diagnostics show that the HVAC system door(s) travel below 5 counts (out of the lower range) or above 250 counts (out of the upper range), then update the software calibrations in the HVAC control module. The new calibrations were made available to dealerships as part of TIS2000 incremental satellite update version 2.5, which was broadcast to dealers in February 2006. Page 5828 6. With the output gear encoder assembly in hand, carefully align the casting and output gear timing marks (1). 7. At the same time, be sure to align the encoder phasing post (1) with the phasing slot (2) in the casting and insert the shaft into the bushing. 8. Verify that the output gear and idler are engaged properly. 9. Seat the harness wires on the casting channel. 10. Place the shim on the output shaft gear. 11. Press a NEW seal into the cover. Page 4553 This table identifies which serial data link that a particular module uses for in-vehicle data transmission. Some modules may use more than one data link to communicate. This table is used to assist in correcting a communication malfunction between the control module and the scan tool. For the description and operation of these serial data communication circuits refer to Data Link Communications Description and Operation. Page 8561 Tighten Tighten the nuts to 50 N.m (37 lb-ft). 3. Install the booster pump rod to the lever. 4. Install the stop lamp switch to the lever. 5. Install the booster pump rod retainer. 6. Connect the power brake booster outlet hose, the steering gear inlet hose, and the power brake booster inlet hose. Tighten ^ Tighten the power brake booster inlet hose to 28 N.m (20 lb-ft). ^ Tighten the steering gear inlet hose to 28 N.m (20 lb-ft). 7. Install the master cylinder. 8. Install the mounting nuts. Tighten Tighten the mounting bolts to 50 Nm (37 lb-ft). 9. Install the electrical connectors to the electrohydraulic pump and the flow switch. 10. Fill the hydraulic pump reservoir. Important: Maintain the fluid level throughout the bleed procedure. 11. Remove the pump reservoir cap. Important: Page 13051 8.5. Close the luggage compartment floor. 9. Fold down the left-hand rear side hatch in the luggage compartment. 10. M03: Replace the optic cable on the left-hand rear side: 10.1. Place the optic cable so that it is positioned behind the terminal housing on top of REC (A). 10.2. Remove the locking strip (B) on the 2-pin connector (H2-9) for the optic cable. 10.3. Open the terminal housing (C) with a screwdriver. Remove the secondary catch (D) on the connector and disconnect the optic cable coming from the OnStar(R) control modules. Page 2058 Memory Steer Description Memory steer is when the vehicle wants to lead or pull in the direction the driver previously turned the vehicle. Additionally, after turning in the opposite direction, the vehicle will want to lead or pull in that direction. Wander Description Wander is the undesired drifting or deviation of a vehicle to either side from a straight path with hand pressure on the steering wheel. Wander is a symptom of the vehicle's sensitivity to external disturbances, such as road crown and crosswind, and accentuated by poor on-center steering feel. Scrub Radius Description Ideally, the scrub radius is as small as possible. Normally, the SAI angle and the centerline of the tire and the wheel intersect below the road surface, causing a positive scrub radius. With struts, the SAI angle is much larger than the long arm/short arm type of suspension. This allows the SAI angle to intersect the camber angle above the road surface, forming a negative scrub radius. The smaller the scrub radius, the better the directional stability. Installing aftermarket wheels that have additional offset will dramatically increase the scrub radius. The newly installed wheels may cause the centerline of the tires to move further away from the spindle. This will increase the scrub radius. A large amount of scrub radius can cause severe shimmy after hitting a bump. Four-wheel drive vehicles with large tires use a steering damper to compensate for an increased scrub radius. Scrub radius is not directly measurable by the conventional methods. Scrub radius is projected geometrically by engineers during the design phase of the suspension. Page 16136 Electrical Symbols Part 12 Page 2503 1. Install a new gasket and the rear axle housing cover (2). 2. Notice: Refer to Fastener Notice in Service Precautions. Important: Do not reuse the rear axle housing cover bolts. Install the new rear axle housing cover bolts (1). ^ Tighten the bolts to 40 Nm (30 ft. lbs.). 3. Fill the rear axle. Use the proper fluid. 4. Install the rear axle fill plug. ^ Tighten the rear axle fill plug to 33 Nm (24 ft. lbs.). 5. Lower the vehicle. 9.75 Inch Axle Lubricant Replacement - Rear Drive Axle (9.75 Inch Axle) Removal Procedure 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Remove the rear axle fill plug. Page 3823 Body Control Module (BCM) - C2 Part 1 Page 2914 Refer to the appropriate section of SI for specifications and repair procedures that are related to the vibration concern. Disclaimer Automatic Transmission - 4L60-E/4L65-E Pressure Regulating Solenoid: Service and Repair Automatic Transmission - 4L60-E/4L65-E Pressure Regulator Replacement Removal Procedure 1. Remove the transmission filter. 2. Compress the reverse boost valve sleeve into the bore of the oil pump to release tension on the reverse boost valve retaining ring. 3. Remove the reverse boost valve retaining ring, then slowly release tension on the reverse boost valve sleeve. 4. Remove the reverse boost valve sleeve (5) and the reverse boost valve (4). 5. Remove the pressure regulator isolator spring (3) and the pressure regulator valve spring (2). 6. Remove the pressure regulator valve (1). Installation Procedure 1. Install the pressure regulator valve (1). 2. Install the pressure regulator isolator spring (3) and the pressure regulator valve spring (2). 3. Install the reverse boost valve (4) in the reverse boost valve sleeve (5). 4. Install the reverse boost valve (4) and sleeve (5) in the oil pump cover. Page 4975 G302 (With RPO Code HVY) Page 15224 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. REPLACEMENT PROCEDURE After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Insure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the Terminal Removal Procedure. Repairing Connector Terminals REPAIRING CONNECTOR TERMINALS TOOLS REQUIRED J 38125-D Terminal Repair Kit Use the following repair procedures in order to repair the following: - Push to Seat terminals - Pull to Seat terminals - Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-D contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100 World terminals. Soldering Micro-Pack 100 World terminals may damage the terminal. Circuit Protection - Circuit Breakers CIRCUIT PROTECTION - CIRCUIT BREAKERS A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Underhood Electrical Center or Junction Block Replacement Fuse Block: Service and Repair Underhood Electrical Center or Junction Block Replacement UNDERHOOD ELECTRICAL CENTER OR JUNCTION BLOCK REPLACEMENT REMOVAL PROCEDURE 1. Disconnect the negative battery cable. 2. Remove the left fender upper brace. 3. Remove the electrical center brace cover assemble by lifting the cover (3) outwards to clear the tabs. 4. Remove all fuses and relays. Page 12686 A current DTC clears when the condition for setting the DTC is no longer present. A history DTC clears after 50 malfunction-free ignition cycles. Circuit/System Testing Without RPO UAV 1. Turn OFF the ignition and all electrical components, including the scan tool. 2. Disconnect the harness connector at the cellular microphone. 3. Test for less than 5 Ohms between the low reference circuit terminal A and ground. ^ If greater than the specified range, test the low reference circuit for an open/high resistance. If the circuit tests normal, replace the VCIM. 4. Ignition ON, test for 9 - 11 volts between the signal circuit terminal B and ground. ^ If greater than the specified range, test the signal circuit for a short to voltage. If the circuit tests normal, replace the VCIM. ^ If less than the specified range, test the signal circuit for a short to ground or an open/high resistance. If the circuit tests normal, replace the VCIM. Refer to the appropriate vehicle in SI. 5. If all circuits test normal, test or replace the cellular microphone. Circuit/System Testing With RPO UAV 1. Turn OFF the ignition and all electrical components, including the scan tool. 2. Disconnect the X4 harness connector at the navigation radio and the harness connector at the cellular microphone. 3. Test for less than 5 Ohms between the low reference circuit terminal A and ground. ^ If greater than the specified range, test the low reference circuit for an open/high resistance. If the circuit tests normal, replace the VCIM. Refer to the appropriate vehicle in SI. 4. Ignition ON, test for 9 - 11 volts between the signal circuit terminal B and ground. ^ If greater than the specified range, test the signal circuit for a short to voltage. If the circuit tests normal, replace the VCIM. ^ If less than the specified range, test the signal circuit for a short to ground or an open/high resistance. If the circuit tests normal, replace the VCIM. 5. If all circuits test normal, test or replace the cellular microphone. 6. Connect the X4 harness connector at the navigation radio. 7. With a scan tool, verify that DTC B2455 is not set as current in the navigation radio. ^ If DTC B2455 is set as current, replace the navigation radio. Refer to the appropriate vehicle in SI. DTC B2462, B2483, or B2484 Circuit/System Description The vehicle communication interface module (VCIM) receives information from a specific navigation antenna located on the outside of the vehicle. The navigation antenna is connected to the VCIM via a shielded coaxial cable. The antenna cable also provides a path for DC current for powering the antenna. DTC Descriptors DTC B2462 02: Global Positioning System (GPS) Antenna Malfunction Short to Ground DTC B2462 04: Global Positioning System (GPS) Antenna Malfunction Open Circuit Page 10114 3. Connect the electrical connectors to the module. 4. Program the control module. Refer to Service Programming System (SPS) in Programming. 5. Install the spare tire to the vehicle. 6. Lower the vehicle. 7. Perform a learn alignment. See: Testing and Inspection/Programming and Relearning Page 819 Application Table Page 14404 Front Passenger Door Module (FPDM) - C4 (With RPO Code YE9) Part 2 Front Passenger Door Module (FPDM) - C5 (With RPO Code AN3) Part 1 Page 1161 Disclaimer Page 5321 Fuel Pump Relay: Locations Fuel Pump Relay Secondary - With Dual Tanks FUEL PUMP RELAY - SECONDARY (Vehicles with Dual Tanks Only) Fuel Pump Relay-Secondary-With Dual Tanks The Fuel Pump Relay - Secondary is attached to the Underhood Fuse Block Bracket. The Underhood Fuse Block is located at the left side of the engine compartment, to the rear of the battery. Electrical - Aftermarket Fuse Warning Fuse: All Technical Service Bulletins Electrical - Aftermarket Fuse Warning Bulletin No.: 07-08-45-002 Date: September 05, 2007 ADVANCED SERVICE INFORMATION Subject: Service Alert: Concerns With Aftermarket Fuses in GM Vehicles Models: 2008 and Prior GM Passenger Cars and Light Duty Trucks (including Saturn) 2008 and Prior HUMMER H2, H3 2008 and Prior Saab 9-7X Concerns with Harbor Freight Tools "Storehouse" Branded Blade Type Fuses General Motors has become aware of a fuse recall by Harbor Freight Tools/Storehouse for a variety of aftermarket fuses. In two cases, these fuses have not provided protection for the wiring system of the vehicles they were customer installed in. Upon testing the 15 amp version, it was found that the fuse still would not "open" when shorted directly across the battery terminals. How to Identify These Fuses Packed in a 120 piece set, the fuse has a translucent, hard plastic, blue body with the amperage stamped into the top. There are no white painted numbers on the fuse to indicate amperage. There are no identifying marks on the fuse to tell who is making it. The fuses are known to be distributed by Harbor Freight Tools but there may be other marketers, and packaging of this style of fuse. It would be prudent to replace these fuses if found in a customers vehicle. Likewise, if wiring overheating is found you should check the fuse panel for the presence of this style of fuse. All GM dealers should use genuine GM fuses on the vehicles they service. You should also encourage the use of GM fuses to your customers to assure they are getting the required electrical system protection. GM has no knowledge of any concerns with other aftermarket fuses. If additional information becomes available, this bulletin will be updated. Disclaimer Interior - Erratic Memory Seat Operation Memory Positioning Module: Customer Interest Interior - Erratic Memory Seat Operation Bulletin No.: 04-08-50-016C Date: August 12, 2005 TECHNICAL Subject: Memory Seat May Not Return to Requested Position (Reprogram Driver Seat Module) Models: 2003-2005 Cadillac Escalade, Escalade ESV, Escalade EXT 2003-2005 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2003-2005 GMC Sierra, Yukon, Yukon XL, Yukon Denali All with Seat FRT, Individual (Non BKT) (RPO AN3) 2003-2005 HUMMER H2 with Seat, Front Bucket Deluxe (RPO AR9) Supercede: This bulletin is being revised to update the correction information. Please discard Corporate Bulletin Number 04-08-50-016B (Section 08 - Body and Accessories). Condition Some customers may comment that with repeated cycling of the memory seat between the "exit" and one of the "presets", the position of the seat may "creep" forward or rearward out of expected adjustment. Cause There is a coding deficiency in the software for the memory seat module. Correction Technicians are to reprogram the driver seat module with an updated software calibration. The previous bulletin stated to use a service calibration that was released with TIS satellite data update version 4.5. Feedback has proved that calibration to be ineffective in eliminating the memory seat creep condition. An updated service calibration was released with TIS satellite data update version 6.5 available June 13, 2005. This new calibration has additional memory seat creep protection. As always, make sure your Tech 2(R) is updated with the latest software version. Important: After programming is complete, move the seat all the way rearward and down, then bump the seat slightly forward and up. This position will be just off the end of travel hard stops. Reset both memory seat exit positions at this position. Having the seat set at just off the hard stops will aid in reducing the creep condition. Warranty Information Underhood Electrical Center or Junction Block Replacement Relay Box: Service and Repair Underhood Electrical Center or Junction Block Replacement UNDERHOOD ELECTRICAL CENTER OR JUNCTION BLOCK REPLACEMENT REMOVAL PROCEDURE 1. Disconnect the negative battery cable. 2. Remove the left fender upper brace. 3. Remove the electrical center brace cover assemble by lifting the cover (3) outwards to clear the tabs. 4. Remove all fuses and relays. Page 9283 Application Table Wheels - Correct Hub Cap Installation Procedure Wheel Cover: Technical Service Bulletins Wheels - Correct Hub Cap Installation Procedure Bulletin No.: 03-03-10-002B Date: November 02, 2005 INFORMATION Subject: Use of Correct Installation Procedure for Loose Hubcap Assembly Models: 1998-2006 Chevrolet Express Van 1999-2006 Chevrolet Silverado Models 2000-2006 Chevrolet Suburban, Tahoe Models 2002-2006 Chevrolet Avalanche 1998-2006 GMC Savana Van 1999-2006 GMC Sierra Models 2000-2006 GMC Yukon, Yukon XL Models Supercede: This bulletin is being revised to add the 2006 model year. Please discard Corporate Bulletin Number 03-03-10-002A (Section 03 - Suspension). Some hubcap assemblies on the above-listed vehicles are being returned to the Warranty Parts Center (WPC) for loose and/or rattle conditions. Some returned hubcaps have the stand-off insulators removed. Analyses of these parts show no out of specification condition. Hubcap assemblies are placed in the vehicle by the assembly plant for dealer installation. Installation is done by threading the six or eight plastic nut caps, which are part of the hubcap assembly, to the external threads of the wheel (lug) nuts. If over-tightened, these plastic nut caps will jump threads, as designed, causing a loose or rattle condition. Important: ^ DO NOT over-tighten the plastic nut caps. ^ DO NOT use an impact wrench on the plastic nut caps. ^ DO NOT modify or remove the stand-off insulators from the plastic hubcap assembly. The nut cap system is designed to skip a thread if over-tightened. DO NOT replace the hubcap assembly if this happens. Hold hubcap (2) firmly in place on wheel with the plastic wheel nut caps (3) aligned with the steel wheel nuts (1). Hand snug each nut cap (3) (using a hand held deep socket or torque stick) until fully seated against the hubcap (2). You should feel the nut cap (3) ratchet against the hubcap (2) a couple times as the nut cap (3) seats. After all nut caps (3) have been seated, check tightness of each nut cap (3) using the socket or torque stick and tighten any nut cap (3) that may have loosened. If a nut cap (3) jumps thread (a design feature to prevent damage) and becomes loose during tightening, continue to tighten and stop short of thread jump. Follow the installation instruction sheet that is included in each hubcap package. Trim Height Specifications Alignment: Specifications Trim Height Specifications Trim Height Specifications Page 9272 Junction Block - Rear Lamps - C2 Page 9175 C100 I/P Harness To Engine Harness Part 2 Page 13014 THIS PROGRAM IS IN EFFECT UNTIL APRIL 30, 2011. Condition Certain 2002-2009 model year vehicles equipped with OnStar(R) may have a condition in which the vehicle's OnStar(R) system repeatedly makes incomplete calls to OnStar(R) without the vehicle's occupant(s) input or knowledge. Customer initiated Blue Button call, Emergency calls, and Automatic Crash Notification calls will also fail to establish a data connection with the OnStar(R) Call Center. Eventually, the customer's call will connect as a voice only line and the customer will be able to talk with an OnStar(R) advisor; however, the advisor will not get crucial customer data such as vehicle identification and location. Correction Dealers/retailers are to replace the OnStar(R) module (VCIM). Vehicles Involved Involved are certain 2002-2009 model year vehicles equipped with OnStar(R), and built within these VIN breakpoints: Note: Some model years/models have only one vehicle involved. Important Dealers/retailers are to confirm vehicle eligibility prior to beginning repairs by using GMVIS (dealers/retailers using WINS) or the Investigate Vehicle History link (dealers/retailers using GWM). Not all vehicles within the above breakpoints may be involved. For dealers/retailers with involved vehicles, a listing with involved vehicles containing the complete vehicle identification number, customer name, and address information has been prepared and will be provided to dealers/retailers through the GM GlobalConnect Recall Reports. Dealers/retailers will not have a report available if they have no involved vehicles currently assigned. The listing may contain customer names and addresses obtained from Motor Vehicle Registration Records. The use of such motor vehicle registration data for any purpose other than follow-up necessary to complete this program is a violation of law in several states/provinces/countries. Accordingly, you are urged to limit the use of this report to the follow-up necessary to complete this program. Parts Information US: OnStar(R) modules required for this program are to be obtained by contacting Autocraft Electronics via the web at www.autocraft.com, and selecting the catalog item that contains bulletin number 10037 (or PIC 4893B), or by calling 1-800-336-3998. Dealer must provide the VIN, R.O. number, and the current vehicle mileage. Canada: OnStar(R) modules required for this program are to be obtained by contacting MASS Electronics at 1-877-410-6277. Dealer must provide the VIN, R.O. number, and the current vehicle mileage. DO NOT ORDER ONSTAR(R) MODULES FROM GENERAL MOTORS CUSTOMER CARE AND AFTERSALES (GMCC&A;), SATURN SERVICE PARTS OPERATION (SSPO), OR THE TECHNICAL ASSISTANCE CENTER (TAC). Courtesy Transportation The General Motors Courtesy Transportation program is intended to minimize customer inconvenience when a vehicle requires a repair that is covered by the New Vehicle Limited Warranties. The availability of courtesy transportation to customers whose vehicles are within the warranty coverage period and involved in a product program is very important in maintaining customer satisfaction. Dealers/retailers are to ensure that these customers understand that shuttle service or some other form of courtesy transportation is available and will be provided at no charge. Dealers should refer to the General Motors Service Policies and Procedures Manual for Courtesy Transportation guidelines. Claim Information 1. Submit a claim using the table below. 2. Courtesy Transportation - For dealers/retailers using WINS, submit using normal labor code; for dealers/retailers using GWM - submit as Net Item under the repair labor code. Page 3734 For vehicles repaired under warranty, use the table. Disclaimer Page 7547 Fluid - Transfer Case: Service and Repair Transfer Case - NVG 263-NP1 Transfer Case Fluid Replacement Removal Procedure Important: When performing the following procedure, use only hand tools to remove and install the drain and fill plugs. 1. Remove the transfer case shield, if equipped. 2. Remove the fill plug. 3. Remove the drain plug. Installation Procedure Notice: Refer to Fastener Notice in Service Precautions. Important: Use only drain and fill plugs that are made from aluminum. Steel or brass plugs are not compatible with the magnesium case. 1. Install the drain plug. ^ Tighten the plug to 20 Nm (15 ft. lbs.). 2. Fill the transfer case to the bottom of the fill plug hole with the approved fluid. Page 1219 Traction Control Switch: Diagrams ABS Connector End Views Traction Control Switch (NW7) Page 11868 THIS PROGRAM IS IN EFFECT UNTIL APRIL 30, 2011. Condition Certain 2002-2009 model year vehicles equipped with OnStar(R) may have a condition in which the vehicle's OnStar(R) system repeatedly makes incomplete calls to OnStar(R) without the vehicle's occupant(s) input or knowledge. Customer initiated Blue Button call, Emergency calls, and Automatic Crash Notification calls will also fail to establish a data connection with the OnStar(R) Call Center. Eventually, the customer's call will connect as a voice only line and the customer will be able to talk with an OnStar(R) advisor; however, the advisor will not get crucial customer data such as vehicle identification and location. Correction Dealers/retailers are to replace the OnStar(R) module (VCIM). Vehicles Involved Involved are certain 2002-2009 model year vehicles equipped with OnStar(R), and built within these VIN breakpoints: Note: Some model years/models have only one vehicle involved. Important Dealers/retailers are to confirm vehicle eligibility prior to beginning repairs by using GMVIS (dealers/retailers using WINS) or the Investigate Vehicle History link (dealers/retailers using GWM). Not all vehicles within the above breakpoints may be involved. For dealers/retailers with involved vehicles, a listing with involved vehicles containing the complete vehicle identification number, customer name, and address information has been prepared and will be provided to dealers/retailers through the GM GlobalConnect Recall Reports. Dealers/retailers will not have a report available if they have no involved vehicles currently assigned. The listing may contain customer names and addresses obtained from Motor Vehicle Registration Records. The use of such motor vehicle registration data for any purpose other than follow-up necessary to complete this program is a violation of law in several states/provinces/countries. Accordingly, you are urged to limit the use of this report to the follow-up necessary to complete this program. Parts Information US: OnStar(R) modules required for this program are to be obtained by contacting Autocraft Electronics via the web at www.autocraft.com, and selecting the catalog item that contains bulletin number 10037 (or PIC 4893B), or by calling 1-800-336-3998. Dealer must provide the VIN, R.O. number, and the current vehicle mileage. Canada: OnStar(R) modules required for this program are to be obtained by contacting MASS Electronics at 1-877-410-6277. Dealer must provide the VIN, R.O. number, and the current vehicle mileage. DO NOT ORDER ONSTAR(R) MODULES FROM GENERAL MOTORS CUSTOMER CARE AND AFTERSALES (GMCC&A;), SATURN SERVICE PARTS OPERATION (SSPO), OR THE TECHNICAL ASSISTANCE CENTER (TAC). Courtesy Transportation The General Motors Courtesy Transportation program is intended to minimize customer inconvenience when a vehicle requires a repair that is covered by the New Vehicle Limited Warranties. The availability of courtesy transportation to customers whose vehicles are within the warranty coverage period and involved in a product program is very important in maintaining customer satisfaction. Dealers/retailers are to ensure that these customers understand that shuttle service or some other form of courtesy transportation is available and will be provided at no charge. Dealers should refer to the General Motors Service Policies and Procedures Manual for Courtesy Transportation guidelines. Claim Information 1. Submit a claim using the table below. 2. Courtesy Transportation - For dealers/retailers using WINS, submit using normal labor code; for dealers/retailers using GWM - submit as Net Item under the repair labor code. Transfer Case - NVG 149-NP3 Speed Sensor: Service and Repair Transfer Case - NVG 149-NP3 Transfer Case Speed Sensor Replacement Removal Procedure 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. Disconnect the speed sensor electrical connector (4). 3. Remove the speed sensor. Installation Procedure 1. Install the speed sensor. ^ Tighten the sensor to 15 Nm (11 ft. lbs.). Notice: Refer to Fastener Notice in Service Precautions. Page 5386 1. Relieve the fuel system pressure. Refer to Fuel Pressure Relief Procedure. 2. Disconnect the fuel feed and pressure balance lines from the front tank. 3. Cap the fuel and balance lines at the fuel tank in order to avoid possible system contamination. 4. Disconnect the fuel feed and pressure balance lines from the rear tank. 5. Cap the fuel and balance lines at the fuel tank in order to avoid possible system contamination. 6. Remove the rear fuel line bundle clip nuts. 7. Remove the rear fuel line bundle. INSTALLATION PROCEDURE Page 11242 1. Coat the O-rings (2) with 525 viscosity refrigerant oil. 2. Install the O-rings (2) to the evaporator tube. 3. Install the A/C refrigerant filter (3) to the evaporator tube (2) with the flow arrow pointing towards the evaporator. NOTE: Refer to Fastener Notice in Service Precautions. 4. Install the nuts (4) to the A/C refrigerant filter (1). Tighten Tighten the nuts to 15 N.m (11 lb ft). 5. Recharge the A/C system. Refer to Refrigerant Recovery and Recharging. Page 2564 Brake Bleeding: Service and Repair Master Cylinder Bench Bleeding Master Cylinder Bench Bleeding Caution: Refer to Brake Fluid Irritant Caution in Service Precautions. Notice: When adding fluid to the brake master cylinder reservoir, use only Delco Supreme 11, GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. The use of any type of fluid other than the recommended type of brake fluid, may cause contamination which could result in damage to the internal rubber seals and/or rubber linings of hydraulic brake system components. 1. Secure the mounting flange of the brake master cylinder in a bench vise so that the rear of the primary piston is accessible. 2. Remove the master cylinder reservoir cap and diaphragm. 3. Install suitable fittings to the master cylinder ports that match the type of flare seat required and also provide for hose attachment. 4. Install transparent hoses to the fittings installed to the master cylinder ports, then route the hoses into the master cylinder reservoir. 5. Fill the master cylinder reservoir to at least the half-way point with Delco Supreme 11® (GM P/N 12377967) or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. 6. Ensure that the ends of the transparent hoses running into the master cylinder reservoir are fully submerged in the brake fluid. 7. Using a smooth, round-ended tool, depress and release the primary piston as far as it will travel, a depth of about 25 mm (1 inch), several times. Observe the flow of fluid coming from the ports.As air is bled from the primary and secondary pistons, the effort required to depress the primary piston will increase and the amount of travel will decrease. 8. Continue to depress and release the primary piston until fluid flows freely from the ports with no evidence of air bubbles. 9. Remove the transparent hoses from the master cylinder reservoir. 10. Install the master cylinder reservoir cap and diaphragm. 11. Remove the fittings with the transparent hoses from the master cylinder ports. Wrap the master cylinder with a clean shop cloth to prevent brake fluid spills. 12. Remove the master cylinder from the vise. Entertainment System - DVD Monitor Display Inoperative DVD Player: Customer Interest Entertainment System - DVD Monitor Display Inoperative Bulletin No.: 07-08-44-016A Date: August 28, 2007 TECHNICAL Subject: GM Accessories Headrest DVD System Display Monitor Inoperative (Install Cable Connector Clamps) Models Supercede: This bulletin is being revised to update the models affected list. Please discard Corporate Bulletin Number 07-08-44-016 (Section 08 - Body & Accessories). Condition Some customers may comment on an inoperative display monitor or monitors in the GM Accessories Headrest DVD System. Cause This condition may be caused by a loose connection at the display monitor cable connectors. These connectors are located at the lower rear part of both front seats. Two cables are routed to the display monitor in each seat. Correction A number of headrest monitors have been replaced under warranty and in many cases, no trouble was found by the supplier when these units were Page 8680 For vehicles repaired under warranty, use the table. Disclaimer Page 3828 Body Control Module (BCM) - C4 Part 1 Fuel System Description Fuel Injector: Description and Operation Fuel System Description FUEL INJECTORS The fuel injector assembly is a solenoid device controlled by the PCM that meters pressurized fuel to a single engine cylinder. The PCM energizes the injector solenoid to open a normally closed ball valve. This allows the fuel to flow into the top of the injector, past the ball valve, and through a director plate at the injector outlet. The director plate has machined holes that control the fuel flow, generating a spray of finely atomized fuel at the injector tip. Fuel from the injector tip is directed at the intake valve, causing the fuel to become further atomized and vaporized before entering the combustion chamber. This fine atomization improves fuel economy and emissions. Page 2148 Steps 1 - 13 Page 5972 Vehicle Speed Sensor (VSS) Tow/Haul Switch Location Service and Repair Cabin Ventilation Duct: Service and Repair Pressure Relief Valve Replacement Removal Procedure Use a flat-bladed tool to pry the pressure release valve from the cab back panel. Remove the pressure relief valve from the vehicle. Installation Procedure Align the pressure relief valve into the opening of the rear cab. Press the Pressure Relief Valve into the Cab Back Panel until the locking tabs are fully seated. Page 11130 Parts Information Important The Cooling Coil Coating listed below is the only GM approved product for use under warranty as an evaporator core disinfectant and for the long term control of evaporator core microbial growth. Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Page 14381 IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. Splicing Twisted or Shielded Cable SPLICING TWISTED OR SHIELDED CABLE Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. - Rewrap the conductors with the mylar tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with mylar tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Control Module References Interior - Seat Memory Feature Appears Inoperative Memory Positioning Module: All Technical Service Bulletins Interior - Seat Memory Feature Appears Inoperative Bulletin No.: 04-08-50-003 Date: February 26, 2004 INFORMATION Subject: Enabling Memory Seat Feature via DIC If Feature Appears Inoperative Models: 2003-2004 Cadillac Escalade, Escalade ESV, Escalade EXT 2003-2004 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2003-2004 GMC Sierra, Yukon, Yukon Denali, Yukon Denali XL 2003-2004 HUMMER H2 with Steering Wheel Controls (RPO UK3) (standard on H2) If the memory seat feature appears inoperative, check the Driver Information Center (DIC). Many of the memory seat modules that were returned through the Warranty Parts Center for a condition of inoperative have shown No Trouble Found. The Driver Information Center (DIC), programmed for Seat Entry and Exit, is set to the default "Off" mode at the assembly plant. DO NOT REPLACE THE MEMORY SEAT MODULE. Perform the following procedure. Important: The following procedure will need to be completed for each Remote/Key selection. Using the DIC menu, do the following steps: 1. Set the "Seat Recall" to either "At Key In" or "On Remote" based on the customer's preference. 2. Set the "Exit Seat" to "On". 3. Adjust the following items: Memory Seat: 3.1. Driver's Seat (including the seat back, recliner, lumbar, and side wings) 3.2. Throttle and Brake Pedals (not available on H2 or Silverado and Sierra Trucks) 3.3. Outside Mirrors 3.4. Radio Station Presets 3.5. Last Chosen Climate Control System Settings (not available on Silverado or Sierra Trucks) 3.6. Press and hold the "1" or "2" (for driver 1 or 2) button of the memory control for three seconds. A double chime will sound to let you know that the position has been stored. Easy Exit Seat: 3.1. Press and release the 1 or 2 button or press the unlock button on the desired remote keyless entry transmitter. The seat will move to the stored memory position. 3.2. Adjust the seat to the desired exit position. 3.3. Press and hold the exit button of the memory control (located on the door) for three seconds. A double chime will sound to let you know that the position has been stored for the identified driver (1 or 2). TPMS System - Service And Re-Learning Sensor IDs Tire Pressure Module: Technical Service Bulletins TPMS System - Service And Re-Learning Sensor IDs INFORMATION Bulletin No.: 10-03-16-001 Date: July 19, 2010 Subject: TPMS System Service and Re-Learning Sensor IDs Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks 2010 and Prior HUMMER H2 2009 and Prior HUMMER H3 2010 and Prior Saturn Models 2009 and Prior Saab 9-7X with Wheel-Mounted Tire Pressure Sensors In the event that the spare tire, which is normally not equipped with a tire pressure monitor (TPM) sensor, is installed in place of one of the road tires and the vehicle is driven above 40 km/h (25 mph) for 20 minutes or more, the TPM indicator icon on the instrument panel cluster (IPC) will flash for approximately one minute and then remain on steady each time the ignition is turned ON, indicating a diagnostic trouble code (DTC) has been set. The driver information center (DIC), if equipped, will also display a SERVICE TIRE MONITOR type message. When the road tire is repaired and reinstalled in the original location, the TPM indicator icon illumination and DIC message may remain displayed until the DTC is cleared. To ensure that the TPM indicator and the DIC message are cleared after service, it is necessary to clear any TPM DTCs using a scan tool. If a scan tool is unavailable, performing the TPM relearn procedure using a TPM diagnostic tool will provide the same results. It is advised to perform the relearn procedure away from other vehicles to prevent picking up a stray sensor signal. If one or more of the TPM sensors are missing or damaged and have been replaced, then the relearn procedure must be performed. Disclaimer Page 10132 Steering Control Module: Service and Repair Rear Wheel Steering Control Module Replacement Rear Wheel Steering Control Module Replacement Removal Procedure 1. Notice: Refer vehicle Lifting. Raise the vehicle. Refer to Vehicle Lifting. 2. Remove the spare tire from the vehicle to gain access to the control module. 3. Disconnect the electrical connectors from the control module. 4. Remove the bolts (1) retaining the control module (2) to the bracket. 5. Remove the control module from the vehicle. Installation Procedure 1. Install the control module to the vehicle. 2. Notice: Refer to Fastener Notice in Service Precautions. Install the control module (2) retaining bolts (1). ^ Tighten the bolts to 24 Nm (18 ft. lbs.). A/C - Ticking Noise From Instrument Panel/DTC's Set Control Module HVAC: All Technical Service Bulletins A/C - Ticking Noise From Instrument Panel/DTC's Set Bulletin No.: 06-01-38-003 Date: April 27, 2006 TECHNICAL Subject: Intermittent Ticking Noise from I/P, Poor A/C Performance, HVAC DTCs B0229, B0414, B0424, B3770 (Reprogram HVAC Control Module) Models: 2004-2006 Cadillac Escalade Models 2004-2006 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2004-2006 GMC Sierra Models, Yukon Models with Air Conditioning (RPOs CJ2, CJ3) Condition Some customers may comment on one or more of the following concerns: ^ Intermittent ticking/clicking noise from the instrument panel. ^ Recirculation mode does not work or Air Conditioning (A/C) system performance is poor during high ambient temperatures. ^ Unable to control the driver side temperature. ^ Unable to control the passenger side temperature. ^ Unable to change the front system modes. Cause This condition may be caused by the Heating, Ventilation and Air Conditioning (HVAC) actuators that may hunt for the correct commanded position. This cycling may cause a clicking or ticking noise. An overtravel of the HVAC system control doors may cause one or more of the concerns listed above. If an overtravel occurs, a Diagnostic Trouble Code (DTC) will be set, and the door will go to a preset default position. When a system door defaults, that door will stay at the default position until the DTC is cleared. After the DTC is cleared, the door will operate properly until the overtravel condition re-occurs. The table lists the HVAC system doors and the DTC associated with it. Correction Technicians are to perform the normal diagnostic procedures in SI for these concerns. If diagnostics show that the HVAC system door(s) travel below 5 counts (out of the lower range) or above 250 counts (out of the upper range), then update the software calibrations in the HVAC control module. The new calibrations were made available to dealerships as part of TIS2000 incremental satellite update version 2.5, which was broadcast to dealers in February 2006. Page 7238 6. Use fingers to squeeze the 2 locking legs of the cover. 7. Apply pressure and gently rock the cover until one locking leg is unseated. 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. Page 13360 For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to refer to the table above. Disclaimer Page 13016 In summary, whenever a vehicle subject to this program enters your vehicle inventory, or is in your dealership/facility for service through April 30, 2011, you must take the steps necessary to be sure the program correction has been made before selling or releasing the vehicle. Disclaimer Service Procedure Service Procedure Note Do NOT replace the inside rear view mirror in tandem with this concern. The mirror has no bearing on this specific issue. 1. Remove the OnStar(R) module (referred to as the Communication Interface Module (CIM) or Vehicle Communication Interface Module (VCIM) in SI). Refer to SI for module removal instructions. Note Inform customer that all Bluetooth devices must be paired with the new VCIM. Bluetooth devices that have not been paired to the new VCIM will not function properly. 2. Install the new OnStar(R) module (referred to as the Communication Interface Module (CIM) or Vehicle Communication Interface Module (VCIM) in SI). Refer to SI for module installation instructions. Page 16105 Control Module References Part 6 Page 8318 1. Important: Install 2 new copper brake hose gaskets. Assemble the 2 new copper brake hose gaskets, and the brake hose bolt to the brake hose. 2. Notice: Refer to Fastener Notice in Service Precautions. Install the brake hose to caliper bolt and 2 new washers to the brake caliper. ^ Tighten the bolt to 40 Nm (30 ft. lbs.). 3. Important: The hose must not be twisted. Make sure the hose is not in contact with any suspension component. With the weight of the vehicle on the suspension, install the brake hose into the bracket. 4. Install the brake hose bolt and the bracket to the steering knuckle. ^ Tighten the bolt to 9 Nm (80 inch lbs.). 5. Install the brake hose bolt and the bracket to the upper control arm. ^ Tighten the bolt to 9 Nm (80 inch lbs.). 6. Install the brake hose retaining clip. 7. Remove the rubber cap or plug from the exposed brake pipe fitting end. 8. Connect the brake pipe fitting nut to the brake hose: ^ Use a backup wrench on the hose fitting. ^ Do not bend the bracket or the pipe. ^ Tighten the bolt to 25 Nm (18 ft. lbs.). 9. Bleed the hydraulic brake system. 10. Install the tire and wheel assembly. 11. Ensure that the hose does not make contact with any part of the suspension or the wheel. Check the hose in extreme right and left turn conditions. If the hose makes contact, remove the hose and correct the condition. 12. Lower the vehicle. Page 12704 Page 14992 The following procedure should only be performed if the right side of the tailgate could be disengaged for the pickup truck and the hinge was damaged or bent. 1. Release (unhook) the left side tailgate support cable from the pickup box. 2. Remove the tailgate from the vehicle. 3. Remove the bolt (1) attaching the right side hinge (2) to the side of the tailgate. 4. Locate and drill out the large weld (2) attaching the hinge (1) to the backside of the tailgate bracket (3). Remove the hinge. Important: Because the new hinge must be welded to the bracket on the tailgate in the next steps, do not paint the hinge until after installation. After welding is complete, the new hinge must be primed and painted in the body color. 5. Install a new hinge to the tailgate and install the bolt. Tighten Tighten the bolt to 27 Nm (20 lb-ft). 6. Weld the backside of the new hinge to the original bracket on the tailgate. 7. Tape off the area around the hinge and prime and paint the hinge as required. 8. Reinstall the tailgate on the vehicle and proceed to the section titled, "Support Cable Replacement". Support Cable Replacement - Classic CK and Sierra The following procedure provides instruction for replacing the rear endgate (tailgate) support cables. Page 5630 Knock Sensor: Service and Repair KNOCK SENSOR (KS) REPLACEMENT REMOVAL PROCEDURE 1. Remove the intake manifold. 2. Gently pry up the rubber covers. 3. Disconnect the knock sensor electrical connectors. 4. Remove the knock sensors. INSTALLATION PROCEDURE NOTE: Refer to Fastener Notice in Service Precautions. Fuse Block - I/P Fuse Block: Application and ID Fuse Block - I/P Location View Page 5348 Fuel Supply Line: Service and Repair Fuel Hose/Pipes Replacement - Chassis 2 FUEL HOSE/PIPES REPLACEMENT - CHASSIS REMOVAL PROCEDURE IMPORTANT: Clean all fuel pipe connections and surrounding areas before disconnecting the pipes in order to avoid possible fuel system contamination. 1. Relieve the fuel system pressure. Refer to the Fuel Pressure Relief Procedure. 2. Disconnect the fuel feed and return pipes (1) at the fuel rail. 3. Disconnect the evaporative emission (EVAP) canister purge tube (3). 4. Cap the fuel rail and EVAP pipes. 5. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 6. Remove the fuel pipe bracket nut (2). 7. Remove the fuel pipe bracket from the bellhousing stud. 8. Remove the heated oxygen sensor (HO2S) sensor connector from the bracket. 9. Remove the fuel hose/pipe clip from the bracket on the automatic transmission. 10. If equipped with 4-wheel drive (4WD), remove the fuel hose/pipe clip from the bracket on the transfer case. 11. Remove the clip from the bracket on the frame. 12. Remove the transfer case harness from the clip bracket. 13. Remove the EVAP canister. IMPORTANT: The area around the electro-hydraulic control unit (EHCU) MUST be free from loose dirt to prevent contamination of disassembled anti-lock brake components (ABS) components. Service and Repair Suspension Mode Switch: Service and Repair Electronic Suspension Ride Control Switch Replacement Removal Procedure 1. Remove the instrument panel trim bezel. 2. Remove the switch from the lower opening of the switch plate panel. 3. Disconnect the electrical connector. Installation Procedure 1. Connect the electrical connector. 2. Install the switch into the lower opening of the switch plate panel. 3. Install the instrument panel trim bezel. OnStar(R) - No Power/Inoperative/No LED Emergency Contact Module: All Technical Service Bulletins OnStar(R) - No Power/Inoperative/No LED TECHNICAL Bulletin No.: 05-08-46-001D Date: May 02, 2008 Subject: OnStar(R) Generation 5 or 6 (Digital) System Inoperative/Has No Power, LED Light Not On (Remove/Reinstall OnStar(R) Fuse and Replace VCIM or Follow SI Diagnostics) Models Supercede: This bulletin is being revised to update the information on VCIM ordering instructions in step 3 of the Correction statement. Please discard Corporate Bulletin Number 05-08-46-001C (Section 08 - Body & Accessories). Condition Some customers may comment any or all of the following conditions: ^ The OnStar(R) system may be inoperative. ^ The OnStar(R) system may have no power. ^ The OnStar(R) LED light may not be on. The technician may also not be able to communicate with the OnStar(R) Vehicle Communication Interface Module (VCIM) with a Tech 2(R). Correction Notice: On 2006 Chevrolet Impala and Monte Carlo models, make sure the ignition is OFF and the vehicle has "RAP"ed out prior to removing the OnStar(R) fuse. Disconnecting power to the OnStar(R) module while the ignition is ON may discharge and permanently damage the OnStar(R) back-up battery. Page 8474 Involved are certain 2003 and 2004 model year Cadillac Escalade, Escalade EXT and Escalade ESV; Chevrolet Silverado, Avalanche, Suburban, and Express; GMC Sierra, Yukon, Yukon XL, and Savana; and 2004 model year Chevrolet Tahoe vehicles built within the VIN breakpoints shown. IMPORTANT: Dealers should confirm vehicle eligibility through GMVIS (GM Vehicle Inquiry System) prior to beginning recall repairs. [Not all vehicles within the above breakpoints may be involved.] For U.S.: For dealers with involved vehicles, a Campaign Initiation Detail Report containing the complete Vehicle Identification Number, customer name and address data has been prepared and will be loaded to the GM DealerWorld, Recall Information website. The customer name and address data furnished will enable dealers to follow up with customers involved in this recall. For Canada & IPC: Computer listings containing the complete Vehicle Identification Number, customer name and address data of involved vehicles have Page 14354 Door Module: Diagnostic Aids Basic Knowledge Required BASIC KNOWLEDGE REQUIRED Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the Service Data. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories CHECKING AFTERMARKET ACCESSORIES Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: - Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions INDUCING INTERMITTENT FAULT CONDITIONS In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: - Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. Page 6813 6. For the 9.5 inch and 11.5 inch axles, press the bearing off of the pinion using the J 22912-01. 7. Remove the shim. 8. Remove the outer pinion bearing cup from the axle housing using a hammer and a brass drift in the slots provided. Move the drift back and forth between one side of the cup and the other in order to work the cups out of the housing evenly. 9. Remove the inner pinion bearing cup from the axle housing using a hammer and a brass drift in the slots provided. Move the drift back and forth between one side of the cup and the other in order to work the cups out of the housing evenly. Installation Procedure Page 14934 Seat Memory Switch: Service and Repair MEMORY SEAT SWITCH REPLACEMENT REMOVAL PROCEDURE 1. Remove the front door trim panel. 2. Disconnect the electrical connector. 3. Release the front seat memory switch assembly retaining clips in order to remove the switch. 4. Remove the front seat memory switch assembly. INSTALLATION PROCEDURE 1. Install the front seat memory switch assembly to the front trim panel by pressing into place until fully seated. 2. Connect the electrical connector to the front seat memory switch assembly. 3. Install the front trim panel. Page 12793 Page 13373 Passlock Sensor Page 6572 Park Neutral Position (PNP) Switch C175 Page 9559 Fuse Block - Underhood C3 Part 2 Page 6938 5. Slide the boot (5) down the halfshaft bar (4) and away from the CV joint outer race (1). 6. Wipe all grease away from the face of the CV joint. 7. Find the halfshaft bar retaining snap ring (3), which is located in the inner race (2). 8. Spread the snap ring ears apart using J 8059 (or equivalent). 9. Pull the CV joint (1) and the CV joint boot (5) from the halfshaft bar (4). 10. Discard the oil CV joint boot (5). 11. Place a brass drift against the CV joint cage (1). 12. Tap gently on the brass drift with a hammer in order to tilt the cage (1). 13. Remove the first chrome alloy ball (2) when the CV joint cage (1) tilts. 14. Tilt the CV joint cage (1) in the opposite direction to remove the opposing chrome alloy ball (2). 15. Repeat this process to remove all six of the balls. Locations Brake Light Switch: Locations ABS Component Views Stoplamp Switch OnStar(R) - Analog/Digital System Information Navigation System: All Technical Service Bulletins OnStar(R) - Analog/Digital System Information INFORMATION Bulletin No.: 06-08-46-008C Date: September 18, 2008 Subject: Information on OnStar(R) Dual-Mode (Analog/Digital) Systems Models Supercede: This bulletin is being revised to correct the model year range for the Chevrolet Impala and Monte Carlo and update the reference to GM Dealerworld. Please discard Corporate Bulletin Number 06-08-46-008B (Section 08 - Body and Accessories). All 2000-2003 model year vehicles equipped with OnStar® from the list above were built with Analog/Digital-Ready OnStar(R) Hardware. Some of these vehicles may have been upgraded to Dual-Mode (Analog/Digital). Certain 2004-2005 model year vehicles equipped with OnStar(R) from the list above may have been either: ^ Originally built at the factory with Dual-Mode (Analog/Digital) OnStar(R) Hardware with Dual-Mode (Analog/Digital) OnStar(R) Hardware OR ^ Upgraded to Dual-Mode (Analog/Digital) Hardware All 2006 model year and newer vehicles equipped with OnStar(R) were built at the factory with Dual-Mode (Analog/Digital) OnStar(R) Hardware. If a vehicle has Dual-Mode (Analog/Digital) OnStar(R) Hardware, then the system is capable of operating on both the analog and digital cellular Page 6932 9. Assemble the tripot housing and the tripot seal using the following procedure: 1. Pinch the swage ring (2) slightly by hand in order to distort it into an oval shape. 2. Slide the distorted swage ring (2) over the large diameter of the seal. 3. Place the tripot housing over the spider assembly. 4. Install the seal onto the tripot housing. 5. Align the tripot seal (1), with the swage ring (2) in place, over the flat area on the tripot housing (3). Fuse Block - Underhood - Secondary Fuse: Application and ID Fuse Block - Underhood - Secondary Location View Page 12666 Page 13422 If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Sir/SRS Wiring Repairs SIR/SRS WIRING REPAIRS TOOLS REQUIRED J 38125-D Terminal Repair Kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-D contains the following items: - Special sealed splices - in order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping tool - A heat torch - An instruction manual The sealed splices have the following 2 critical features: - A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-D also serves as a generic terminal repair kit. The kit contains the following items: - A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors Page 6507 Park Neutral Position (PNP) Switch C175 Page 6564 4. Position the J 41364-A onto the PNP switch. Ensure that the two slots on the switch where the manual shaft is inserted are lined up with the lower two tabs on the tool. 5. Notice: Refer to Fastener Notice in Service Precautions. Rotate J 41364-A until the upper locator pin on the tool is lined up with the slot on the top of the switch. ^ Tighten the bolts to 25 Nm (18 ft. lbs.). 6. Remove J 41364-A from the PNP switch. If installing a new switch, remove the positive assurance bracket at this time. 7. Install the control lever to the manual shaft with the nut. 8. Install the manual shaft nut. ^ Tighten the nut to 25 Nm (18 ft. lbs.). 9. Install the range selector cable end (2) to the range selector lever ball stud (1). Page 9597 Relay Block - I/P C3 Part 1 Page 11659 1. Install the buckle assembly. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the bolt (13) that retains the buckle assembly (14) to the seat frame. Tighten Tighten the bolts to 53 N.m (39 lb ft). 3. Install the rear seat cushion and cover. Page 1792 For vehicles repaired under warranty, use the table. Disclaimer Automatic Transmission Input Shaft Speed (AT ISS) Sensor Connector Page 14600 Passenger Presence Components - Side of Front Passenger Seat Page 15738 Ambient Light Sensor: Diagrams Ambient Light Sensor Page 7219 Electrical Symbols Part 11 Page 9436 If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Sir/SRS Wiring Repairs SIR/SRS WIRING REPAIRS TOOLS REQUIRED J 38125-D Terminal Repair Kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-D contains the following items: - Special sealed splices - in order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping tool - A heat torch - An instruction manual The sealed splices have the following 2 critical features: - A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-D also serves as a generic terminal repair kit. The kit contains the following items: - A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors Page 2641 Fuse Block - Underhood C1 Part 2 Junction Block - I/P Relay Box: Locations Junction Block - I/P Location View Location View Page 7270 Steps 3-9 Page 11109 Air Temperature Sensors - Lower Right Page 8176 Brake Pad: Service and Repair Burnishing Pads and Rotors Burnishing Pads and Rotors Caution: Refer to Road Test Caution in Service Precautions. Burnishing the brake pads and brake rotors is necessary in order to ensure that the braking surfaces are properly prepared after service has been performed on the disc brake system. This procedure should be performed whenever the disc brake rotors have been refinished or replaced, and/or whenever the disc brake pads have been replaced. 1. Select a smooth road with little or no traffic. 2. Accelerate the vehicle to 48 km/h (30 mph). Important: Use care to avoid overheating the brakes while performing this step. 3. Using moderate to firm pressure, apply the brakes to bring the vehicle to a stop. Do not allow the brakes to lock. 4. Repeat steps 2 and 3 until approximately 20 stops have been completed. Allow sufficient cooling periods between stops in order to properly burnish the brake pads and rotors. Page 15230 Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips SPLICING COPPER WIRE USING SPLICE CLIPS IMPORTANT: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. TOOLS REQUIRED J 38125-D Terminal Repair Kit 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-D in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. Page 6821 3. Install the outer pinion bearing cup into the pinion gear bearing retainer using the J 8608 (2) and the J 8092 (1). 4. Install the inner pinion bearing using the J 24433. Press the bearing on until the cone seats on the pinion. 5. Install a new collapsible spacer. 6. Lubricate the pinion bearings with axle lubricant. Use the proper fluid. 7. Install the outer pinion bearing into the pinion bearing retainer. 8. Install a new pinion oil seal using the J 22388. 9. Install the pinion into the pinion gear bearing retainer. 10. Apply sealant, GM P/N 12346004 (Canadian P/N 10953480) or equivalent, to the splines of the pinion yoke. 11. Install the pinion yoke. Align the marks made during removal. 12. Notice: Refer to Pinion Flange/Yoke Installation Notice in Service Precautions. Page 917 Body Control Module (BCM) - C3 Part 1 Page 8291 11. Remove the 2 brake caliper mounting bolts. 12. Caution: Do not depress the brake pedal with the brake rotors/calipers and/or the brake drums removed. Damage to the brake system may result. If brake system damage occurs and is not repaired, vehicle damage and/or personal injury or death may result. Remove the brake caliper from the brake caliper mounting bracket. Installation Procedure 1. Notice: Refer to Fastener Notice in Service Precautions. Install the brake caliper to the brake caliper mounting bracket. 2. Install the 2 brake caliper mounting bolts. ^ Tighten the 2 brake caliper mounting bolts to 108 Nm (80 ft. lbs.). 3. Remove the rubber cap or plug from the exposed brake hose fitting end. 4. Important: Install 2 New copper brake hose gaskets. Assemble the 2 New copper brake hose gaskets and the brake hose to caliper bolt to the brake hose. 5. Install the brake hose to caliper bolt to the brake caliper. ^ Tighten the brake hose to caliper bolt to 40 Nm (30 ft. lbs.). 6. Bleed the hydraulic brake system. 7. Install the tire and wheel assembly. 8. Lower the vehicle. 9. Fill the master cylinder reservoir to the proper level with clean brake fluid. Refer to Master Cylinder Reservoir Filling in Hydraulic Brakes. Page 15969 IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. Splicing Twisted or Shielded Cable SPLICING TWISTED OR SHIELDED CABLE Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. - Rewrap the conductors with the mylar tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with mylar tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Control Module References Page 12788 Check - Vehicle. The Diagnostic System Check will provide the following information: ^ The identification of the control modules which command the system ^ The ability of the control modules to communicate through the serial data circuit ^ The identification of any stored diagnostic trouble codes (DTCs) and their status The use of the Diagnostic System Check will identify the correct procedure for diagnosing the system and where the procedure is located. Visual/Physical Inspection Perform the following visual inspections; ^ Inspect for aftermarket devices which could affect the operation of the Radio/Audio System. Refer to Checking Aftermarket Accessories in SI. ^ Inspect the easily accessible and visible system components for obvious damage or conditions which could cause the symptom. Intermittent Conditions Faulty electrical connections or wiring may be the cause of intermittent conditions. Refer to Testing for Intermittent Conditions and Poor Connections in SI. Symptom List Page 697 supported, only J2534. 1. BEFORE the original IPC is disconnected from the vehicle, record the odometer and engine hour values. 2. Replace the IPC with a replacement part obtained from the ESC. Refer to Instrument Cluster Replacement in SI. 3. Using the TIS2WEB SPS application, select either: J2534 Tech 2 or J2534 MDI, when available and build the vehicle. 4. Select: IPC Setup J2534. 5. After selecting IPC Setup J2534, the user will be prompted to: install the new controller. Ignore this prompt if the new IPC was already installed. This prompt is just to remind the user that this application is only for a new IPC. Important FOR 2003 FULLSIZE TRUCKS, UTILITIES AND H2, THE ENGINE MUST BE STARTED AND RUNNING PRIOR TO ENTERING THE MILEAGE AND ENGINE HOURS. After the odometer value is programmed, the engine must remain running for 6 minutes 15 seconds before the ignition can be turned off. Failure to do so will result in engine hours not being programmed and a new IPC will have to be ordered. 6. Enter the odometer and engine hour values, when applicable. By default the application will be set to miles. For metric units, click the button on the left next to: Kilometers. The IPC odometer and engine hour meter setup procedure is now complete. 7. The IPC calibration files can now be programmed into the IPC. Refer to SPS in SI. Disclaimer Page 10493 ^ Dry or brittle ^ Compression set Installation Procedure 1. Clean all corrosion or contaminates from the steering knuckle bore and the hub and bearing assembly. 2. Lubricate the steering knuckle bore with wheel bearing grease or the equivalent. 3. Install the O-ring (7) to the steering knuckle, the 25/35 series. 4. Notice: Refer to Fastener Notice in Service Precautions. Install the wheel speed sensor mounting bolt to the wheel hub and bearing. ^ Tighten the sensor mounting bolt to 18 Nm (13 ft. lbs.). 5. Install the wheel hub and bearing and splash shield to the vehicle, 25/35 series. 6. Install the wheel hub and bearing (5) and splash shield (6) to the vehicle, 15 series. 7. Install the wheel hub and bearing mounting bolts, the 15 series. 8. Install the wheel hub and bearing mounting bolts, 25/35 series. ^ Tighten the wheel hub to knuckle bolts to 180 Nm (133 ft. lbs.). Diagrams Windshield Washer Fluid Pump Page 14087 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Weather Pack Connectors WEATHER PACK CONNECTORS The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. Page 13425 Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips SPLICING COPPER WIRE USING SPLICE CLIPS IMPORTANT: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. TOOLS REQUIRED J 38125-D Terminal Repair Kit 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-D in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. Page 2289 5. Install the air cleaner outlet duct. 6. Install the radiator inlet hose clip to the outlet duct. NOTE: Refer to Fastener Notice in Service Precautions. 7. Tighten the air cleaner outlet duct clamps at the following locations: - Throttle body - MAF/IAT sensor Tighten Tighten the screws to 7 N.m (62 lb in). 8. Fill the cooling system. Refer to Draining and Filling Cooling System (with HP2)Draining and Filling Cooling System (without HP2) in Cooling System. Page 7501 Pay particular attention to the terminal connections at the module. Spread or open terminal connections may create an intermittent contact. Do a pin drag test. Refer to the terminal testing information in the table shown. ^ After repairs are complete, ALWAYS clear DTCs from the module prior to a system function test. If codes are not cleared first, the system will not function after repair. The technician may erroneously think that the system is still down and that further repairs are needed. Warranty Dealers who unnecessarily replace the TCCM that are found to have No Trouble Found (NTF) at the WPC will be returned to the AVM (Area Service Manager), or the DSM (District Service Manager) in Canada, through the Regional Feedback Process and may be charged back for the repair through the WINS system. Disclaimer Page 8428 Parking Brake Shoe: Adjustments Park Brake Adjustment Park Brake Shoe Adjustment ^ Tools Required J 21177-A Drum-to-Brake Shoe Clearance Gage Caution: Refer to Brake Dust Caution in Service Precautions. Important: The park brake shoes must be adjusted before the park brake pedal is adjusted. 1. Set the J 21177-A so that it contacts the inside diameter of the rotor. 2. Position the J 21177-A over the shoe and the lining at the widest point. 3. Turn the adjuster nut until the lining just contacts the J 21177-A. 4. Repeat steps 1-3 for the opposite side. 5. The clearance between the park brake shoe and the rotor is 0.6604 mm (0.026 inch). Park Brake Pedal Adjustment Important: Before you adjust the park brake, verify that the park brake shoes are adjusted to provide a clearance of 0.6604 mm (0.026 inch). 1. Verify that the self adjuster lock-out pin has be removed. 2. Fully apply and release the park brake pedal 3 times. Restraints - SRS Lamp ON/Multiple DTC's are Set Air Bag Harness: All Technical Service Bulletins Restraints - SRS Lamp ON/Multiple DTC's are Set TECHNICAL Bulletin No.: 05-09-41-001B Date: June 02, 2008 Subject: Supplemental Inflatable Restraint (SIR) Light ON, Diagnostic Trouble Codes (DTC) B0013, B0014, B0017, B0018, B0024, B0026, B0043, B0044 (Inspect and/or Replace IP Harness to Inflatable Restraint Module (Air Bag) Yellow 4-Way Connector C221 and/or C222) Models: 2003 - 2006 Cadillac Escalade Models 2003 - 2006 Chevrolet Avalanche, Suburban, Tahoe 2003 - 2007 Chevrolet Silverado (Classic Only) 2003 - 2006 GMC Yukon, Yukon XL, Yukon Denali, Yukon Denali XL 2003 - 2007 GMC Sierra (Classic Only) Supercede: This bulletin is being revised to add the 2007 model year for pickups and change a part number. Please discard Corporate Bulletin Number 05-09-41-001A (Section 09 - Restraints). Condition Some customers may comment that the Service Supplemental Inflatable Restraint Light is on. Diagnosis with a scan tool may indicate a DTC B0013, B0014, B0017, B0018, B0024, B0026, B0043, B0044. Cause The most likely cause of any one of the following DTCs: B0013, B0014, B0017, B0018, B0024, B0026, B0043, B0044 is improper connection/high resistance in the IP harness to inflatable restraint module connector C221 and/or C222. Diagnostic Information DTC B0013, B0014, B0017, B0018, B0024, B0026, B0043, B0044 will set when one of the following conditions occur: ^ The SDM detects the air bag module deployment loop resistance is greater than 4.8 ohms for 500 milliseconds. ^ The SDM detects that the voltage at the air bag module high control is less than 2.4 volts and deployment loop resistance is 6 ohms or greater for 500 milliseconds. ^ For additional diagnostic information, refer to DTC B0013, B0014, B0017, B0018, B0024, B0026, B0043, B0044 in the appropriate SI Document. Correction Caution: When performing service on or near the SIR components or the SIR wiring, the SIR system must be disabled. Refer to SIR Disabling and Enabling Zones. Failure to observe the correct procedure could cause deployment of the SIR components, personal injury, or unnecessary SIR system repairs. Important: The IP harness to inflatable restraint module connectors C221 or C222 is NOT located at the base of the steering column. ^ C221 (4 Cavities) - I/P Harness to Body Harness, behind the left kick panel ^ C222 (4 Cavities) (w/o HP2) - I/P harness to body harness, behind the right kick panel Page 7349 7. Remove the control lever to the manual shaft nut. 8. Remove the control lever from the manual shaft. 9. Remove the PNP switch bolts. 10. Remove the PNP switch from the manual shaft. If the PNP switch does not slide off the manual shaft, file the outer edge of the manual shaft in order to remove any burrs. Installation Procedure 1. Install the PNP switch to the manual shaft by aligning the switch hub flats with the manual shaft flats. 2. Slide the PNP switch onto the manual shaft until the switch mounting bracket contacts the mounting bosses on the transmission. 3. Important: If a new PNP switch is being installed, the switch will come with a positive assurance bracket. The positive assurance bracket aligns the new switch in its proper position for installation and the use of the park neutral switch aligner will not be necessary. Install the PNP switch bolts finger tight. Page 12997 Accessory Delay Module: Scan Tool Testing and Procedures Scan Tool Data Definitions SCAN TOOL DATA DEFINITIONS Courtesy Lamp Switch: Input showing state of the courtesy lamp as commanded by the BCM. Cargo Door Ajar Switch: Input from the liftgate and liftglass indicating their status. Driver Door Ajar Switch (w/o DDM): Input from the driver door indicating door status. Left Rear/Rear Cargo Door Ajar Switch: Input from the left rear door indicating its status. Passenger Door Ajar Switch (w/o PDM): Input from the front passenger door indicating door status. RAP Relay: Output indicates the RAP Relay state that the control module has commanded. Right Rear Door Ajar Sw.: Input from the right rear door indicating door status. BCM Data List DDM Data List PDM Data List Page 3271 1. Remove the engine mount. 2. Remove the engine mount bracket bolts. 3. Remove the engine mount bracket. Installation Procedure 1. Install the engine mount bracket. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the engine mount bracket bolts. ^ Tighten the engine mount bracket bolts to 75 Nm (55 ft. lbs.). 3. Install the engine mount. Page 7764 2. Connect the speed sensor electrical connector (4). 3. Lower the vehicle. Page 372 12.2. Cars with brackets for e.g. an amplifier: Remove the pin strap (A) from the bracket and remove the tape (B) holding the optic cables. 12.3. Remove the locking strip (C) on the 2-pin connector (H2-9). Open the terminal housing with a screwdriver. Remove the secondary catch (E) on the connector and remove the optic cables coming from the OnStar(R) control modules. 12.4. Loosen one of the optic cables remaining in H2-9 (F), connect it to the connector and fit the secondary catch (E). Connect the connector so that the optic cables are opposite each other (G). Connect the terminal housing (D) and refit the locking strip (C). Page 16241 Rear Door Window Glass Weatherstrip: Service and Repair Door Window Sealing Strip Sealing Strip Replacement - Rear Door Window Belt Outer Removal Procedure Important: The outer belt sealing strip seals between the inner and outer door panels and the window at the belt line. The outer sealing strip is replaceable. Do not remove the inner sealing strip, because the strip is attached to the glass run channel. 1. Lower the window. 2. Remove the outer sealing strip from the door. Installation Procedure 1. Align the sealing strip in place. Lower and press the strip into place. 2. Raise the window. Page 8206 Lateral Runout (LRO) Correction. 7. Install the rotor by slowly turning the rotor while pushing the rotor towards the axle. 8. Install the caliper and the bracket as an assembly to the vehicle. 9. Perform the following procedure before installing the caliper bracket mounting bolts. 1. Remove all traces of the original adhesive patch. 2. Clean the threads of the bolt with brake parts cleaner or the equivalent and allow to dry. 3. Apply Threadlocker GM P/N 12345493 (Canadian P/N 10953488) to the threads of the bolt. 10. Notice: Refer to Fastener Notice in Service Precautions. Install the caliper bracket mounting bolts. For the 15 series, tighten the brake caliper bracket mounting bolts to 200 Nm (148 ft. lbs.). For the 25/35 series, tighten the brake caliper bracket mounting bolts to 165 Nm (122 ft. lbs.). 11. Install the tire and wheel assembly. 12. Lower the vehicle. 13. With the engine OFF, gradually apply the brake pedal to approximately 2/3 of it's travel distance. 14. Slowly release the brake pedal. 15. Wait 15 seconds, then repeat steps 13-14 until a firm pedal is obtained. This will properly seat the brake caliper pistons and brake pads. 16. Fill the master cylinder reservoir to the proper level with clean brake fluid. Refer to Master Cylinder Reservoir Filling in Hydraulic Brakes. (W/Dual Wheels) Brake Rotor Replacement - Rear (W/Dual Wheels) Caution: Refer to Brake Dust Caution in Service Precautions. Locations Ambient Light Sensor Page 8390 3. Roll the carpet back to access cable grommet. 4. Raise and support the vehicle. Refer Vehicle Lifting 5. Disengage the grommet and the cable from the floor pan. 6. Disconnect the front cable from the intermediate cable. 7. Remove the cable from the body mount by depressing the retaining tabs. 8. Remove the cable. Installation Procedure Page 16020 High Temperature Conditions Tools Required J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency MEASURING FREQUENCY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage MEASURING VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop MEASURING VOLTAGE DROP NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Page 12078 Disclaimer Page 8297 ^ Replace all the components included in the repair kits used to service this brake caliper. ^ Lubricate the rubber parts with clean brake fluid to make assembly easier. ^ The torque values specified are for dry, non lubricated fasteners. ^ Perform the service operations on a clean bench free from all mineral oil materials. 1. Remove the brake caliper from the vehicle. 2. Caution: Do not place your fingers in front of the piston in order to catch or protect the piston while applying compressed air. This could result in serious injury. Place a thin piece wood in front of the piston in order to prevent damage. Remove the piston by directing compressed air into the brake hose inlet fitting port of the brake caliper housing. 3. Remove the piston boot. 4. Remove the piston seal. 5. Remove the brake caliper bleed screw cap. 6. Remove the brake caliper bleed screw. 7. Inspect the brake caliper bore and the piston seal groove for scoring and corrosion. If you find excessive scoring or corrosion around the piston seal area, replace the brake caliper housing. 8. Inspect the brake caliper mounting bracket guide surfaces for corrosion and wear. Remove and replace the brake caliper mounting bracket if needed. 9. Clean all of the residue from the brake pad guiding surfaces on the brake caliper housing and the brake caliper mounting bracket. 10. Clean all of the parts not included in the repair kit with denatured alcohol. 11. Dry all the parts with non lubricated filtered compressed air. 12. Blow out all passages in the brake caliper housing and the brake caliper bleeder valve. Page 357 Claim Information - GM, Saturn Canada and Saab Canada Only Claim Information - Saturn US Only Customer Reimbursement Claims - Special Attention Required Customer reimbursement claims must have entered into the "technician comments" field the CSO # (if repair was completed at a Saturn Retail Facility) date, mileage, customer name, and any deductibles and taxes paid by the customer. Claim Information - Saab US Only Page 5594 1. Install the knock sensors. Tighten Tighten the sensor to 20 N.m (15 lb ft). 2. Connect the knock sensor electrical connectors. 3. Push down on the rubber covers. 4. Install the intake manifold. Page 1723 Flexible Fuel Sensor: Description and Operation FUEL COMPOSITION SENSOR DESCRIPTION The fuel composition sensor (FCS), or flex fuel sensor (service parts term), measures the ethanol-gasoline ratio of the fuel being used in a flexible fuel vehicle. Flexible fuel vehicles can be operated with a blend of ethanol and gasoline, up to 85 percent ethanol. In order to adjust the ignition timing and the fuel quantity to be injected, the engine management system requires information about the percentage of ethanol in the fuel. The FCS uses quick-connect style fuel connections, an incoming fuel connection, and an outgoing fuel connection. The two connections have different diameters, to prevent incorrect attachment of the fuel lines. All fuel passes through the fuel composition sensor before continuing on to the fuel rail. The fuel composition sensor measures two different fuel related parameters, and sends an electrical signal to the powertrain control module (PCM) to indicate ethanol percentage, and fuel temperature. The fuel composition sensor has a three-wire electrical harness connector. The three wires provide a ground circuit, a power source, and a signal output to the PCM. The power source is vehicle system voltage, +12 volts), and the ground circuit connects to chassis ground. The signal circuit carries both the ethanol percentage and fuel temperature within the same signal, on the same wire. The FCS uses a microprocessor inside the sensor to measure the ethanol percentage and fuel temp, and change an output signal accordingly. The electrical characteristic of the FCS signal is a square-wave digital signal. The signal is both variable frequency and variable pulse width. The frequency of the signal indicates the ethanol percentage, and the pulse width indicates the fuel temperature. The PCM provides an internal pull-up to five volts on the signal circuit, and the FCS pulls the 5 volts to ground in pulses. The output frequency is linear to the percentage of ethanol content in the fuel. The normal range of operating frequency is between 50 and 150 Hertz, with 50 Hertz representing 0 percent ethanol, and 150 Hertz representing 100 percent ethanol. The normal pulse width range of the digital pulses is between 1 and 5 milliseconds, with 1 millisecond representing -40°C (-40°F), and 5 milliseconds representing 125°C (257°F). The microprocessor inside the sensor is capable of a certain amount of self-diagnosis. An output frequency of 170 Hertz indicates either that the fuel is contaminated or contains methanol (it should not), or that an internal sensor electrical fault has been detected. Certain substances dissolved in the fuel can cause the fuel to be contaminated, raising the output frequency to be higher than the actual ethanol percentage should indicate. Examples of these substances include water, sodium chloride (salt), and methanol. It should be noted that it is likely that the FCS will indicate a slightly lower ethanol percentage than what is advertised at the fueling station. This is not a fault of the sensor. The reason has to do with government requirements for alcohol-based motor fuels. Government regulations require that alcohol intended for use as motor fuel be DENATURED. This means that 100 percent pure ethanol is first denatured with approximately 41/2 percent gasoline, before being mixed with anything else. When an ethanol gasoline mixture is advertised as E85, the 85 percent ethanol was denatured before being blended with gasoline, meaning an advertised E85 fuel contains only about 81 percent ethanol. The FCS measures the actual percentage of ethanol in the fuel. Page 9034 Fuse Block- I/P C3 Part 1 Page 5143 Steps 7 - 9 Locations Mass Air Flow (MAF) Sensor: Locations Right Side Of The Engine Compartment Page 11642 3. Fold the rear seat down. 4. Pull the seat belt buckles through the seat cushion. Page 6697 3. Push in and rotate the clutch master cylinder 45 degrees counterclockwise to the locked position. 4. If equipped with a ZF S6-650 transmission, disconnect the clutch actuator cylinder to clutch master cylinder quick connect fitting. 5. If equipped with a NV 3500 or NV 4500 transmission, disconnect the clutch actuator cylinder to clutch master cylinder quick connect fitting. 6. Install the clutch master cylinder clip to the brake pressure module valve pipe. 7. Apply light pressure to the clutch pedal to couple the pushrod socket to the clutch pedal. 8. Connect the clutch pedal position switch electrical connector (1). 9. Pump the clutch pedal 3 time prior to starting the vehicle to ensure connection is complete. Page 16080 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly, Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Pull to Seat Connectors PULL TO SEAT CONNECTORS TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Page 9421 IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections TESTING FOR INTERMITTENT AND POOR CONNECTIONS TOOLS REQUIRED - J 35616-C GM-Approved Terminal Test Kit - J 38125-D Terminal Repair Kit - J 42675 Flat-Wire Probe Adapter Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector. - Poor terminal to wire connection - Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. - Wire insulation which is rubbed through - This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. - Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. Testing For Proper Terminal Contact It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-D or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-D, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 120 Volt Receptacle Replacement Auxiliary Power Outlet: Service and Repair 120 Volt Receptacle Replacement 120 VOLT RECEPTACLE REPLACEMENT REMOVAL PROCEDURE 1. Remove the receptacle outlet screws (2). 2. Remove the receptacle outlet (3) from the receptacle box (1). 3. Disconnect the receptacle electrical connections. INSTALLATION PROCEDURE 1. Connect the receptacle electrical connections. 2. Install the receptacle outlet (3) to the receptacle box (1). NOTE: Refer to Fastener Notice in Service Precautions. 3. Install the receptacle outlet screws (2). Tighten Tighten the screws to 2 N.m (18 lb in). Page 14102 IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. Splicing Twisted or Shielded Cable SPLICING TWISTED OR SHIELDED CABLE Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. - Rewrap the conductors with the mylar tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with mylar tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Control Module References Page 15175 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Page 2313 Hose/Line HVAC: Service and Repair Suction Hose Replacement (W/ Denso) SUCTION HOSE REPLACEMENT (W/DENSO) TOOLS REQUIRED J 39400-A Halogen Leak Detector REMOVAL PROCEDURE 1. Recover the refrigerant. Refer to Refrigerant Recovery and Recharging. 2. Remove the suction hose mounting bolt from the A/C compressor. 3. Remove the suction hose (2) from the A/C compressor. 4. Remove the suction hose nut from the accumulator. 5. Remove the suction hose from the accumulator. 6. Remove the suction hose assembly from the vehicle. 7. Discard all of the used sealing washers. Cap the system openings. INSTALLATION PROCEDURE 1. Install the suction hose to the vehicle. Page 16165 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-8 (12085115) crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-8 (12085115) until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes SPLICING INLINE HARNESS DIODES Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate Service Data wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. 9. Tape the diode to the harness or connector using electrical tape. Page 9552 Fuse Block - Underhood C2 Part 1 Page 4682 Body Control Module (BCM) - C2 Part 3 Diagrams Headlamp Leveling Switch (Export) Door Hinge Pin and Bushing Replacement - Front Door Front Door Hinge: Service and Repair Door Hinge Pin and Bushing Replacement - Front Door Door Hinge Pin and Bushing Replacement - Front Door The door hinge pins and bushings are not replaceable. If the hinge pins or bushings are damaged, replace the door hinge as an assembly. Refer to Hinge Replacement - Front Door - Door Side and Hinge Replacement - Front Door - Body Side. Page 4718 Remove all rust from the ground terminal, the cylinder head and the retaining nut or bolt. Position the main engine wiring harness ground terminal and install the nut or bolt. Tighten: Tighten the retaining nut or bolt to 16 N.m (12 lb ft). Apply some type of electrical moisture sealant to protect the harness terminal from further corrosion. Disclaimer Page 11924 1. Remove the ground cable from the battery's negative cable. 2. Remove the center console, see WIS - Body - Interior. 3. Loosen the gear shift housing (A). AUT: Disconnect the 6-pin connector (B) to improve access to the gear shift housing screws. 4. Disconnect the signal cable from the SRS control module to the OnStar(R) control module and secure the cable. 4.1. Disconnect the connector (A) from the SRS control module and cut the cable tie (B). Page 9265 Junction Block - I/P Wire Entry Part 3 Page 14962 Page 6464 11. Install the cable to the steering column bracket. 12. Ensure the tangs fully seat (snap) into the steering column bracket. 13. Install the cable end to the steering column ball stud. 14. Install the retainer securing the cable to the steering column. 15. Position the carpet and insulation around the driver's area. 16. Install the driver's seat. 17. Install the instrument panel knee bolster. 18. Test the transmission for proper shift operation. 19. If all of the gear positions cannot be achieved, adjust the cable. Range Selector Cable Bracket Replacement Automatic Transmission Range Selector Cable Bracket Replacement Removal Procedure 1. Apply the park brake. 2. Shift the transmission into neutral. 3. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 4. Remove the retainer that secures the cable to the bracket. 5. Depress the tangs and remove the cable from the bracket. 6. Remove the bolts (1) securing the transmission range selector cable bracket (2) to the transmission. 7. Remove the transmission range selector cable bracket. Installation Procedure Page 13752 Important: Clean the fuel filler cap and surrounding areas prior to removing the fuel filler housing in order to avoid possible contamination. 1. Remove the fuel fill cap. 2. Remove the fuel tank filler housing to fuel tank fill pipe screws. 3. Remove the fuel tank filler housing to body TORX® screws (1) and retainer (2). Important: It is NOT necessary to raise the vehicle in order to remove and/or install the fuel filler housing. 4. Remove the fuel filler housing from under the vehicle. 5. Install the new fuel filler housing, P/N 15289921, from under the vehicle. 6. Install the fuel tank filler housing to fuel tank fill pipe screws. Tighten Tighten the screws to 2.3 N.m (20 lb in). 7. Install the fuel tank filler housing to body TORX(R) screws and retainer. Tighten Tighten the screws to 2.3 N.m (20 lb in). Important: The new fuel cap, P/N 15225005 "tether strap" installs in the elongated hole in the fuel filler housing. DO NOT install the new fuel cap tether in the round hole in the fuel filler housing. Locations Full Engine View Left Side Page 8790 IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections TESTING FOR INTERMITTENT AND POOR CONNECTIONS TOOLS REQUIRED - J 35616-C GM-Approved Terminal Test Kit - J 38125-D Terminal Repair Kit - J 42675 Flat-Wire Probe Adapter Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector. - Poor terminal to wire connection - Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. - Wire insulation which is rubbed through - This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. - Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. Testing For Proper Terminal Contact It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-D or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-D, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. Page 5985 Transfer Case Actuator: Service and Repair Transfer Case Encoder Motor Replacement Removal Procedure 1. Remove the transfer case shield, if equipped. 2. Remove the front propeller shaft. 3. Disconnect the encoder motor electrical connector. 4. Remove the encoder motor bolts. 5. Remove the encoder motor. 6. Remove the actuator insulator gasket. 7. If replacing the encoder motor, remove the locating pins from the old motor. Installation Procedure Important: ^ If the encoder motor is being replaced because it is defective, ensure that the transfer case is in the neutral position. Manually shift the unit at the shift shaft. Use a crescent wrench, if necessary. ^ If the encoder motor is being replaced, a new gasket will come with the encoder motor. DO NOT reuse the old gasket. ^ A NEW encoder motor does NOT come with locating pins. Heated Seat Switch Replacement - Front Seat Heater Switch: Service and Repair Heated Seat Switch Replacement - Front HEATED SEAT SWITCH REPLACEMENT - FRONT REMOVAL PROCEDURE 1. Remove the front door trim panel. 2. Disconnect the electrical connector. 3. Release the retaining clips for the front seat heater switch assembly in order to remove the switch. 4. Remove the front seat heater switch assembly. INSTALLATION PROCEDURE 1. Install the front seat heater switch assembly to the front trim panel by pressing the switch into place until the switch is completely seated. 2. Connect the electrical connector to the front seat heater switch assembly. 3. Install the front trim panel. Page 14315 WA9417/88 - WA9539/47 Locations Vehicle Speed Sensor (VSS) - 4 Wheel Drive Manual Transmission Wheels/Tires - Refinishing Aluminum Wheels Wheels: All Technical Service Bulletins Wheels/Tires - Refinishing Aluminum Wheels INFORMATION Bulletin No.: 99-08-51-007E Date: March 17, 2011 Subject: Refinishing Aluminum Wheels Models: 2012 and Prior GM Passenger Cars and Trucks Supercede: This bulletin is being revised to add additional model years. Please discard Corporate Bulletin Number 99-08-51-007D (Section 08 - Body and Accessories). This bulletin updates General Motor's position on refinishing aluminum wheels. GM does not endorse any repairs that involve welding, bending, straightening or re-machining. Only cosmetic refinishing of the wheel's coatings, using recommended procedures, is allowed. Evaluating Damage In evaluating damage, it is the GM Dealer's responsibility to inspect the wheel for corrosion, scrapes, gouges, etc. The Dealer must insure that such damage is not deeper than what can be sanded or polished off. The wheel must be inspected for cracks. If cracks are found, discard the wheel. Any wheels with bent rim flanges must not be repaired or refinished. Wheels that have been refinished by an outside company must be returned to the same vehicle. The Dealer must record the wheel ID stamp or the cast date on the wheel in order to assure this requirement. Refer to Refinisher's Responsibility - Outside Company later in this bulletin. Aluminum Wheel Refinishing Recommendations - Chrome-plated aluminum wheels Re-plating these wheels is not recommended. - Polished aluminum wheels These wheels have a polyester or acrylic clearcoat on them. If the clearcoat is damaged, refinishing is possible. However, the required refinishing process cannot be performed in the dealer environment. Refer to Refinisher's Responsibility - Outside Company later in this bulletin. - Painted aluminum wheels These wheels are painted using a primer, color coat, and clearcoat procedure. If the paint is damaged, refinishing is possible. As with polished wheels, all original coatings must be removed first. Media blasting is recommended. Refer to GM Aluminum Refinishing Bulletin #53-17-03A for the re-painting of this type of wheel. - Bright, machined aluminum wheels These wheels have a polyester or acrylic clearcoat on them. In some cases, the recessed "pocket" areas of the wheel may be painted. Surface refinishing is possible. The wheel must be totally stripped by media blasting or other suitable means. The wheel should be resurfaced by using a sanding process rather than a machining process. This allows the least amount of material to be removed. Important Do not use any re-machining process that removes aluminum. This could affect the dimensions and function of the wheel. Painting is an option to re-clearcoating polished and bright machined aluminum wheels. Paint will better mask any surface imperfections and is somewhat more durable than clearcoat alone. GM recommends using Corsican SILVER WAEQ9283 for a fine "aluminum-like" look or Sparkle SILVER WA9967 for a very bright look. As an option, the body color may also be used. When using any of the painting options, it is recommended that all four wheels be refinished in order to maintain color uniformity. Refer to GM Aluminum Refinishing Bulletin #53-17-03A for specific procedures and product recommendations. Refinisher's Responsibility - Outside Company Important Some outside companies are offering wheel refinishing services. Such refinished wheels will be permanently marked by the refinisher and are warranted by the refinisher. Any process that re-machines or otherwise re-manufactures the wheel should not be used. A refinisher's responsibility includes inspecting for cracks using the Zyglo system or the equivalent. Any cracked wheels must not be refinished. No welding, hammering or reforming of any kind is allowed. The wheel ID must be recorded and follow the wheel throughout the process in order to assure that the same wheel is returned. A plastic media blast may be used for clean up of the wheel. Hand and/or lathe sanding of the machined surface and the wheel window is allowed. Material removal, though, must be kept to a minimum. Re-machining of the wheel is not allowed. Paint and/or clear coat must not be present on the following surfaces: the nut chamfers, the wheel mounting surfaces and the wheel pilot hole. The refinisher must permanently ID stamp the wheel and warrant the painted/clearcoated surfaces for a minimum of one year or the remainder of the new vehicle warranty, whichever is Page 14128 Door Control Module Diagram 2 Part 1 Page 11975 ^ SP303 The following modules, components, and splice pack are connected to the star portion of the class 2 serial data circuit: ^ SP300 ^ Audio amplifier ^ Driver door module (DDM) ^ Driver door switch assembly (DDSA) ^ Memory seat module (MSM) ^ Left rear door module (LRDM) AND ^ SP303 ^ Antenna module ^ Front passenger door module (FPDM) ^ Rear integration module (RIM) ^ Right rear door module (RRDM) ^ Theft deterrent module (TDM) ^ Vehicle communication interface module (VCIM). Refer to Data Communication Schematics and Data Link Communications Description and Operation in SI. Part 2 Conditions for Running the DTC Voltage supplied to the module is in the normal operating voltage range of 9 - 16 volts. DTCs B1327, B1328, U1300, U1301, U1305 are not set as current. The vehicle power mode requires serial data communication to occur. Conditions for Setting the DTC A message containing a critical operating parameter has not been received within the last 5 seconds after establishing class 2 serial data communication. Action Taken When the DTC Sets The module uses a default value for the missing parameter. Conditions for Clearing the DTC A current DTC clears when the malfunction is no longer present. A history DTC clears when the module ignition cycle counter reaches the reset threshold, without a repeat of the malfunction. Diagnostic Aids When a malfunction such as an open fuse to a module occurs while modules are communicating, a DTC U1001-1254 Loss of XXX Communications is set current. When the modules stop communicating the current DTC U1001-1254 Loss of XXX Communications is cleared but the history DTC remains. When the modules begin to communicate again, the module with the open fuse will not be learned by the other modules so U1000 or U1255 is set current by the other modules. If the malfunction occurs when the modules are not communicating, only U1000 or U1255 is set. Page 7352 7. Use the modified screw extractor in order to remove the plug. 8. Remove the parking pawl shaft retainer, shaft and pawl. 9. Important: If the manual shaft binds in the case during removal, file or sand the shaft in the area adjacent to the detent lever. Remove the manual shaft. 10. Remove the manual shaft seal. Installation Procedure 1. Install the pawl shaft. 2. Install the parking pawl. 3. Install the plug using a 8 mm or (5/16 inch) rod with Loctite® or equivalent. 4. Install the retainer. 5. Install the pawl return spring. 6. Install the detent lever to the actuator. 7. Install the actuator over the parking pawl. 8. Install the manual shaft seal. 9. Lubricate the manual shaft with transmission oil and install the manual shaft into the case. 10. Install the nut on the shaft. 11. Install the roll pin. 12. Notice: Refer to Fastener Notice in Service Precautions. Page 9612 Location View Page 6702 Clutch Slave Cylinder: Service and Repair ZF S6-650 Transmission Clutch Actuator Cylinder Replacement (ZF S6-650 Transmission) Removal Procedure 1. Remove the manual transmission. 2. Remove the clutch actuator cylinder bolts. 3. Remove the clutch actuator cylinder. If required, the clutch release bearing can be removed from the clutch actuator cylinder for replacement. Installation Procedure 1. Install the clutch actuator cylinder. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the clutch actuator cylinder bolts. ^ Tighten the bolts to 8 Nm (71 inch lbs.). 3. Install the manual transmission. Page 8971 Fuse: Locations I/P Fuse Block Body Control Module (BCM) Page 2218 3. Disconnect the vent valve pipe quick connect from the canister. 4. Either cut the existing valve vent pipe and leave the remaining section of pipe in the vehicle or remove along with the valve. 5. Push in the retainer and remove the existing canister vent valve from the fuel tank clip or mounting bracket. 6. Cut back the existing canister pipe approximately 51 mm (2 in) and retain the pipe for use with new valve. 7. Connect the canister pipe quick connect to the canister. 2500 Crew Cab Short Box Shown Below, Other Configurations Similar 1500 Extended Cab Short Box Shown Below, Other Configurations Similar 8. Install the new canister vent valve solenoid to the fuel tank clip or mounting bracket as shown above. The valve port closest to the electrical connector must point towards the canister. 9. Cut bulk 5/8" heater hose to a length of approximately 76 mm (3 in). Install the hose between the solenoid and the canister pipe and secure using clamps. 10. Attach bulk 5/8" heater hose to the vent port and secure using a clamp. Run a length as needed along the frame rail routing to the passenger side area above the transmission. 11. Cut the hose to determined length and install the supplied filter box. Secure using a clamp. 12. Remove the transmission heat shield, if necessary. 13. Remove the transmission support and lower the transmission assembly as necessary to allow for access to the new filter box location. 14. Secure the filter box to the transmission vent hose just forward of the hose tee-section using a tie strap. DO NOT pinch or restrict the transmission vent hose. The filter box opening should be pointing downward. 15. Raise the transmission and reinstall the transmission support. 16. Reinstall the transmission heat shield. 17. Connect the EVAP canister vent valve electrical connector. 18. Tie strap the hose as needed along the frame rail in order to keep the hose away from pinch-points and heat sources. 19. Lower the vehicle. Parts Information Page 9706 C104 I/P Harness To Forward Lamp Harness (With RPO Code YE9) Page 8182 Important When using any one of the brake labor operations listed in this bulletin (except for H9709 - Brake Burnish), the following two rotor measurements (1. Original Rotor Thickness, 2. Refinished Rotor Thickness are required and MUST be written/documented on the repair order, or for your convenience, complete the form (GM Brake Service Repair Order Documentation for Required Measurements) shown above and attach it to the repair order. If the Warranty Parts Center generates a request, this Documentation/Form must be attached to the repair order that is sent back. Important Documentation of brake lathe maintenance and calibration as recommended by the lathe manufacturer must be available for review upon request. Repair Order Documentation - Rotor Original And Refinished Thickness - REQUIRED When resurfacing a brake rotor or drum, the ORIGINAL thickness (measured thickness before refinish) and REFINISHED thickness (measured thickness after refinish) MUST be written/documented on the repair order hard copy for each rotor serviced. If a rotor replacement is necessary, only the original thickness measurement needs to be recorded. Repair Order Documentation - Explanation of Part Replacement - REQUIRED If replacement of a brake component is necessary, proper documentation on the repair order is required. See the following examples: ^ Brake rotor replacement - Customer comment was brake pulsation. Rotor was refinished on a prior brake service. After rotor measurement, it was determined that refinishing the rotor again would take it under the Minimum Thickness specification. ^ Brake pad replacement - Customer comment was brake squeak noise. On inspection, found pads contaminated by fluid leak at caliper. Page 1352 Solar Sensor: Diagrams Sunload Sensor Page 1705 1. Install the accelerator pedal assembly. NOTE: Refer to the Fastener Notice in Service Precautions. 2. Install the accelerator pedal nuts. Tighten Tighten the nuts to 20 N.m (15 lb ft). 3. Connect the APP sensor electrical connector. 4. Reposition the carpet. 5. Connect a scan tool in order to test for proper throttle-opening and throttle-closing range. 6. Operate the accelerator pedal and monitor the throttle angles. The accelerator pedal should operate freely, without binding, between a closed throttle, and a wide open throttle (WOT). 7. Verify that the vehicle meets the following conditions: - The vehicle is not in a reduced engine power mode. - The ignition is ON. - The engine is OFF. 8. Inspect the carpet fit under the accelerator pedal. Page 14298 WA822K/97 - WA8554/40 Page 4882 7. Remove the control lever to the manual shaft nut. 8. Remove the control lever from the manual shaft. 9. Remove the PNP switch bolts. 10. Remove the PNP switch from the manual shaft. If the PNP switch does not slide off the manual shaft, file the outer edge of the manual shaft in order to remove any burrs. Installation Procedure 1. Install the PNP switch to the manual shaft by aligning the switch hub flats with the manual shaft flats. 2. Slide the PNP switch onto the manual shaft until the switch mounting bracket contacts the mounting bosses on the transmission. 3. Important: If a new PNP switch is being installed, the switch will come with a positive assurance bracket. The positive assurance bracket aligns the new switch in its proper position for installation and the use of the park neutral switch aligner will not be necessary. Install the PNP switch bolts finger tight. Page 1117 1. Install the door module into the switch panel bezel until it snaps into place. 2. Install the switch panel bezel and module to the door panel. Notice: Refer to Fastener Notice in Service Precautions. 3. Install the screw that retains the switch panel bezel (1) to the front door panel. Tighten the screw to 2 N.m (18 lb in). 4. Connect the electrical connectors. 5. Install the front door trim panel. 6. If equipped with camper mirrors program the door module. Refer to Service Programming System (SPS). See: Testing and Inspection/Programming and Relearning Page 1642 ^ Reinstall the fuse and fuse panel cover. ^ Press the "Enter" button to perform the "Refresh" function. ^ "Test in Progress" will be displayed and the right front passenger door lock will cycle once. ^ The screen will display "Procedure Completed". ^ Press the "Exit" button as necessary to return to the main menu screen. 3. Using the switches in the right front passenger door, verify that the power window and power door lock located in that door function properly. Important: The calibrations required for performing SPS reprogram in the next step are based on the type of exterior rearview mirror the vehicle has. To determine the correct calibration, check the Service Parts Identification Label on the vehicle for the RPO code for exterior mirrors. 4. Follow normal Service Programming System (SPS) to reprogram the passenger door module with the current calibration available in TIS 2000. 5. After reprogramming is complete, using the switches in the right front passenger door, verify that the power window and power door lock located in that door function properly. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 15225 Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses CIRCUIT PROTECTION - FUSES The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the Page 1675 Transmission Position Switch/Sensor: Service and Repair Automatic Transmission 4L80-E/4L85-E Park/Neutral Position Switch Replacement Park/Neutral Position Switch Replacement ^ Tools Required J 41364-A Park Neutral Switch Aligner Removal Procedure 1. Apply the park brake. 2. Shift the transmission into neutral. 3. If equipped with 4-wheel drive (4WD), remove the front propeller shaft. 4. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 5. Disconnect the park/neutral position (PNP) switch electrical connector (2). 6. Remove the range selector cable end (2) from the range selector lever ball stud (1). Page 9836 Junction Block - Rear Lamps - C2 Page 12210 Claim Information - GM, Saturn Canada and Saab Canada Only Claim Information - Saturn US Only Customer Reimbursement Claims - Special Attention Required Customer reimbursement claims must have entered into the "technician comments" field the CSO # (if repair was completed at a Saturn Retail Facility) date, mileage, customer name, and any deductibles and taxes paid by the customer. Claim Information - Saab US Only Page 15145 Electrical Symbols Part 9 Page 8986 Fuse: Application and ID Fuse Block - Underhood Location View Page 1326 Air Temperature Sensor - Lower Right Locations Turn Signal Switch: Locations Upper Steering Column Page 13980 Disclaimer Page 10697 Wheels: Service and Repair Aluminum Wheel Refinishing Aluminum Wheel Refinishing A protective clear coating covers the surface of original equipment cast aluminum wheels. A surface degradation may develop if frequent automatic car wash cleaning wears off the factory applied protective clear coating. This can happen at some automatic car wash facilities that use aggressive brushes to clean whitewalls and tires. Once you damage the protective clear coating, exposure to caustic cleaners and road salt can cause further surface deterioration. Damage to the protective clear coating is corrected by replacing the damaged wheel. Refinishing is no longer recommended. Page 5683 2. Install the 2-3 shift solenoid (367A) and the 2-3 shift solenoid retainer (395). 3. Install the 1-2 shift solenoid (267A) and the 1-2 shift solenoid retainer (395). 4. Important: When installing the pressure control solenoid, the electrical connector (2) must be in the position shown. Install the pressure control solenoid (377). 5. Notice: Refer to Fastener Notice in Service Precautions. Install the pressure control solenoid retainer (378) and retainer bolt (364A). ^ Tighten the bolt to 11 Nm (97 inch lbs.). Page 1450 Stop Lamp Switch Part 2 Page 12204 Page 8312 Brake Fluid: Fluid Type Specifications HYDRAULIC BRAKE SYSTEM Delco Supreme II Brake Fluid or equivalent DOT-3 brake fluid. Page 7241 Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses CIRCUIT PROTECTION - FUSES The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the Component Locations Fluid Pressure Sensor/Switch: Component Locations Automatic Transmission - 4L60-E/4L65-E Automatic Transmission Electronic Component Views (M30/M32) Electronic Components Page 11786 Disclaimer Page 11343 Control Module HVAC: Service and Repair HVAC System - Manual HVAC CONTROL MODULE REPLACEMENT REMOVAL PROCEDURE 1. Remove the instrument cluster trim plate bezel. 2. Remove the instrument panel storage tray. 3. Remove the accessory switch assembly from the instrument panel. 4. Remove the screws from the HVAC control assembly. 5. Remove the HVAC control assembly, with the following procedure: 5.1. Release the retaining tabs. 5.2. Pull the control head out of the instrument panel carrier. 6. Disconnect the electrical connectors from the HVAC control assembly. INSTALLATION PROCEDURE IMPORTANT: The Key should be in the off position when connecting the electrical connectors to ensure proper calibration. 1. Connect the electrical connectors to the HVAC control assembly. 2. Install the HVAC control assembly. 3. Install the accessory switch assembly to the instrument panel. NOTE: Refer to Fastener Notice in Service Precautions. 4. Install the screws from the HVAC control assembly. Tighten Tighten the screws to 1.9 N.m (17 lb in). Page 10665 Do not use cleaning solutions that contain hydrofluoric, oxalic and most other acids on chrome wheels (or any wheels). If the customer is unsure of the chemical make-up of a particular wheel cleaner, it should be avoided. For wheels showing signs of milky staining from acidic cleaners, refer to Customer Assistance and Instructions below. Warranty of Stained Chrome Wheels Stained wheels are not warrantable. Most acid based cleaners will permanently stain chrome wheels. Follow-up with dealers has confirmed that such cleaners were used on wheels that were returned to the Warranty Parts Center (WPC). Any stained wheels received by the WPC will be charged back to the dealership. To assist the customer, refer to Customer Assistance and Instructions below. Pitting or Spotted Appearance of Chrome Wheels Figure 2 A second type or staining or finish disturbance may result from road chemicals, such as calcium chloride used for dust control of unpaved roads. The staining will look like small pitting (refer to Figure 2). This staining will usually be on the leading edges of each wheel spoke, but may be uniformly distributed. If a vehicle must be operated under such conditions, the chrome wheels should be washed with mild soap and water and thoroughly rinsed as soon as conveniently possible. Important Road chemicals, such as calcium chloride used for dust control of unpaved roads, can also stain chrome wheels. The staining will look like small pitting. This staining will usually be on the leading edges of each wheel spoke. This is explained by the vehicle traveling in the forward direction while being splashed by the road chemical. If a vehicle must be operated under such conditions, the chrome wheels should be washed with mild soap and water and thoroughly rinsed as soon as conveniently possible. Warranty of Pitted or Spotted Chrome Wheels Wheels returned with pitting or spotting as a result of road chemicals may be replaced one time. Damage resulting from contact with these applied road chemicals is corrosive to the wheels finish and may cause damage if the wheels are not kept clean. Important Notify the customer that this is a one time replacement. Please stress to the customer the vital importance of keeping the wheels clean if they are operating the vehicle in an area that applies calcium chloride or other dust controlling chemicals! "GM of Canada" dealers require prior approval by the District Manager - Customer Care and Service Process (DM-CCSP). "Stardust" Corrosion of Chrome Wheels Figure 3 A third type of finish disturbance results from prolonged exposure to brake dust and resultant penetration of brake dust through the chrome. As brakes are applied hot particles of brake material are thrown off and tend to be forced through the leading edge of the wheel spoke windows by airflow. These Page 7553 Diagrams Page 7169 1. Remove transfer case. 2. Using J 36825 and J 23907 remove the output shaft seal. Installation Procedure 1. Position the J 36502-2A over the output shaft. 2. Using J 36502 install the NEW output shaft seal. 3. Remove the J 36502-2A from the output shaft. NVG 246-NP8 Control Module: Service and Repair NVG 246-NP8 Transfer Case Control Module Reprogramming Transfer Case Control Module Reprogramming Set-up for Module Programming/Reprogramming Important: Ensure that the vehicle battery is fully charged and that a battery charger is no longer connected. If performing this procedure for module replacement, install new module before proceeding. Before reprogramming close the doors and wait two minutes to allow other modules to stop communicating via the class 2 data line. Failure to do so could result in a failed reprogramming procedure. ^ Turn OFF all accessories. ^ Turn ON the ignition, with the engine OFF. Remote Programming Feature 1. Connect the scan tool to the vehicle. 2. Power-up the scan tool and select the Service Programming feature. 3. Select the appropriate vehicle. 4. Press the Request Info button on the scan tool. 5. Disconnect the scan tool from the vehicle and connect the scan tool to the computer station. 6. Follow the menu select items for reprogramming and provide information as to what type of device you are programming and whether you are reprogramming or replacing the electronic control unit (ECU). 7. Select "vehicle" from the selection menu. 8. Select the module you wish to Program. 9. Select "Normal" for Programming Type. 10. Select the applicable software calibrations. 11. Transfer data file to the scan tool. 12. Reconnect the scan tool to the vehicle. 13. Turn ON the ignition, with the engine OFF. 14. Select the Service Programming feature on the scan tool. 15. Press the Program button on the scan tool. Programming Using Scan Tool Pass-Through Connection 1. Connect the scan tool to vehicle and power it up. 2. Connect the computer station to the scan tool. 3. Select "PC Using Scan Tool Connection" from the programming menu on the computer station. 4. Follow the menu select items for reprogramming and provide information as to what type of device you are programming and whether you are reprogramming or replacing the electronic control unit (ECU). 5. Select "vehicle" from the selection menu. 6. Select the module you wish to program. 7. Select "Normal" for Programming Type. 8. Select the applicable software calibrations. 9. Transfer data file to the scan tool. Transfer Case Shift Control Module Replacement Transfer Case Shift Control Module Replacement Removal Procedure Page 4790 Crankshaft Position (CKP) Sensor Page 8634 1. Lubricate all of the seals and the metal friction points with power steering fluid. 2. Install the accumulator (2) and the O-ring seal (3). 3. Place the J 26889 over the end of the accumulator. 4. Install the nut on the stud. 5. Depress the accumulator with a C-clamp. 6. Install the accumulator retainer ring (1). Description and Operation Shift Indicator: Description and Operation PRNDL DISPLAY The IPC displays the selected gear position as determined by the PCM. The IPC receives a class 2 message from the PCM indicating the gear position. The PRNDL display blanks if: - The IPC receives a class 2 message indicating the park position and the column park switch indicates a position other than park, open input. - The IPC detects a loss of class 2 communications with the PCM. Page 16231 4. Close the side access door. Page 1888 7. Use the modified screw extractor in order to remove the plug. 8. Remove the parking pawl shaft retainer, shaft and pawl. 9. Important: If the manual shaft binds in the case during removal, file or sand the shaft in the area adjacent to the detent lever. Remove the manual shaft. 10. Remove the manual shaft seal. Installation Procedure 1. Install the pawl shaft. 2. Install the parking pawl. 3. Install the plug using a 8 mm or (5/16 inch) rod with Loctite® or equivalent. 4. Install the retainer. 5. Install the pawl return spring. 6. Install the detent lever to the actuator. 7. Install the actuator over the parking pawl. 8. Install the manual shaft seal. 9. Lubricate the manual shaft with transmission oil and install the manual shaft into the case. 10. Install the nut on the shaft. 11. Install the roll pin. 12. Notice: Refer to Fastener Notice in Service Precautions. Page 436 For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to refer to the table above. Disclaimer Page 15181 Control Module References Part 3 Page 16112 Power Window Switch: Service and Repair Switch Replacement - Door Lock and Side Window Driver SWITCH REPLACEMENT - DOOR LOCK AND SIDE WINDOW - DRIVER REMOVAL PROCEDURE 1. Remove the front door trim panel. 2. Disconnect the electrical connectors. 3. Remove the screw that retains the switch panel bezel (1) from the front door panel. 4. Remove the switch panel bezel from the door panel using a flat-bladed tool. 5. Using a wide plastic flat-bladed tool, release the retaining clips on both sides of the door module. 6. Remove the door module from the switch panel bezel. Page 12467 12.2. Cars with brackets for e.g. an amplifier: Remove the pin strap (A) from the bracket and remove the tape (B) holding the optic cables. 12.3. Remove the locking strip (C) on the 2-pin connector (H2-9). Open the terminal housing with a screwdriver. Remove the secondary catch (E) on the connector and remove the optic cables coming from the OnStar(R) control modules. 12.4. Loosen one of the optic cables remaining in H2-9 (F), connect it to the connector and fit the secondary catch (E). Connect the connector so that the optic cables are opposite each other (G). Connect the terminal housing (D) and refit the locking strip (C). Page 10847 Tighten Tighten the screws to 1.6 N.m (14 lb in). 6. Install the center console. 7. Install the floor air outlet duct extension (1) to the floor air duct (2). Mode Actuator (Without RPO Code D07) MODE ACTUATOR REPLACEMENT (W/O D07) REMOVAL PROCEDURE 1. Remove the floor air outlet duct extension (1) from the floor duct (2). 2. Disconnect the electrical connection at the mode actuator (10). Description and Operation Tachometer: Description and Operation TACHOMETER The IPC displays the engine speed on the analog tachometer based on the engine speed signal from the PCM. The IPC uses the engine speed signal circuit - 2 pulses/engine revolution - from the PCM in order to calculate the engine speed. The tachometer defaults to 0 RPM if a malfunction in the engine speed signal circuit exists. Page 9451 Auxiliary Power Outlet: Connector Views Auxiliary Power Outlet - Bin (With RPO Code Y91) Automatic Transmission - 4L60-E/4L65-E Transmission Speed Sensor: Locations Automatic Transmission - 4L60-E/4L65-E Automatic Transmission Electronic Component Views (M30/M32) Electronic Components Page 15783 Door Switch: Description and Operation DOOR LATCH (DOOR JAMB) SWITCHES The theft deterrent system uses the door key switch as one method in order to activate the alarm. If the BCM detects any door opening before the BCM receives a disarm input, the alarm mode activates. DOOR KEY SWITCH The BCM monitors the door key switches in order to disarm the CTD system. When the lock cylinder turns in order to unlock the door, the switch grounds the disarm input to the BCM. Page 3020 Some customers may use penetrating oils, grease or other lubricants on wheel studs to aid in removal or installation. Always use a suitable cleaner/solvent to remove these lubricants prior to installing the wheel and tire assemblies. Lubricants left on the wheel studs may cause improper readings of wheel nut torque. Always install wheels to clean, dry wheel studs ONLY. Notice Lubricants left on the wheel studs or vertical mounting surfaces between the wheel and the rotor or drum may cause the wheel to work itself loose after the vehicle is driven. Always install wheels to clean, dry wheel studs and surfaces ONLY. Beginning with 2011 model year vehicles, put a light coating of grease, GM P/N 1051344 (in Canada, P/N 9930370), on the inner surface of the wheel pilot hole to prevent wheel seizure to the axle or bearing hub. Wheel Stud and Lug Nut Damage Always inspect the wheel studs and lug nuts for signs of damage from crossthreading or abuse. You should never have to force wheel nuts down the stud. Lug nuts that are damaged may not retain properly, yet give the impression of fully tightening. Always inspect and replace any component suspected of damage. Tip Always start wheel nuts by hand! Be certain that all wheel nut threads have been engaged BEFORE tightening the nut. Important If the vehicle has directional tread tires, verify the directional arrow on the outboard side of the tire is pointing in the direction of forward rotation. Wheel Nut Tightening and Torque Improper wheel nut tightening can lead to brake pulsation and rotor damage. In order to avoid additional brake repairs, evenly tighten the wheel nuts to the proper torque specification as shown for each vehicle in SI. Always observe the proper wheel nut tightening sequence as shown below in order to avoid trapping the wheel on the wheel stud threads or clamping the wheel slightly off center resulting in vibration. The Most Important Service You Provide While the above information is well known, and wheel removal so common, technicians run the risk of becoming complacent on this very important Page 13341 For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to refer to the table above. Disclaimer Page 14998 1. Loosen the bolt (1) that attaches the opposite end of the support cable to the latch assembly (2). - If the toothed nut is present, you will only be able to loosen the bolt partily from the latch. If this condition is encountered, proceed to the next step. - If the toothed nut is not present, proceed to Step 6. 3. Important: DO NOT loosen the other bolt completely in the next step. Leave two or three threads of the bolt engaged in the tailgate. Removing this bolt completely may allow the linkage inside the tailgate to separate from the latch. 4. If the toothed nut is present, loosen the other bolt (3) attaching the latch to the tailgate. DO NOT remove this bolt. 5. Finish loosening the bolt that attaches the support cable. The bolt will NOT be removable even though the threads are completely out. 6. Place an interior trim removal type tool (2), or equivalent, between the support cable end (3) and the latch (1), and pry the two apart. As the two spread apart, the toothed nut on the other side of the latch will begin to move towards the end of the bolt. 7. Once the toothed nut has moved away from the backside of the latch, use long nose pliers to grasp and twist it off of the bolt. Discard the toothed nut. 8. Remove the bolt and support cable. Notice: Due to manufacturing variation in the thickness of the latch, support cable end, and the shoulder on the bolt, a spacer (flat washer) must be used when installing the new cable. The washer will act as an extension to the shoulder on the bolt, and the outside diameter of the washer will allow it to fit inside of the opening in the cable end. This will allow the cable end to rotate freely on the bolt/latch when the tailgate is closed and prevent the support cable from getting pinched between the tailgate and the pickup box. The washer does part number listed in this bulletin MUST BE used when installing the new support cables. Its dimensions are critical for correct cable positioning when closing the tailgate and it has the corrosion protection specified by GM. DO NOT use any other washer in place of the one listed in this recall. Important: The washer does NOT replace the toothed nut removed earlier and is NOT to be installed between the latch and the tailgate. Page 11096 5. Install the instrument panel storage tray. 6. Install the instrument cluster trim plate bezel. IMPORTANT: Do not adjust any controls on the HVAC control module while the HVAC control module is calibrating. If interrupted improper HVAC performance will result. 7. Start the vehicle and let run for one minute. Page 9575 Fuse Block- I/P C3 Part 2 Engine, A/T - Shift/Driveability Concerns/MIL ON Air Filter Element: Customer Interest Engine, A/T - Shift/Driveability Concerns/MIL ON Bulletin No.: 04-07-30-013B Date: February 01, 2007 INFORMATION Subject: Automatic Transmission Shift, Engine Driveability Concerns or Service Engine Soon (SES) Light On as a Result of the Use of an Excessively/Over-Oiled Aftermarket, Reusable Air Filter Models: 2007 and Prior GM Cars and Light Duty Trucks 2007 and Prior Saturn Models 2003-2007 HUMMER H2 2006-2007 HUMMER H3 2005-2007 Saab 9-7X Supercede: This bulletin is being revised to add models and model years. Please discard Corporate Bulletin Number 04-07-30-013A (Section 07 - Transmission/Transaxle). The use of an excessively/over-oiled aftermarket, reusable air filter may result in: Service Engine Soon (SES) light on Transmission shift concerns, slipping and damaged clutch(es) or band(s) Engine driveability concerns, poor acceleration from a stop, limited engine RPM range The oil that is used on these air filter elements may be transferred onto the Mass Air Flow (MAF) sensor causing contamination of the sensor. As a result, the Grams per Second (GPS) signal from the MAF may be low and any or all of the concerns listed above may occur. When servicing a vehicle with any of these concerns, be sure to check for the presence of an aftermarket reusable, excessively/over-oiled air filter. The MAF, GPS reading should be compared to a like vehicle with an OEM air box and filter under the same driving conditions to verify the concern. The use of an aftermarket reusable air filter DOES NOT void the vehicle's warranty. If an aftermarket reusable air filter is used, technicians should inspect the MAF sensor element and the air induction hose for contamination of oil prior to making warranty repairs. Transmission or engine driveability concerns (related to the MAF sensor being contaminated with oil) that are the result of the use of an aftermarket reusable, excessively/over-oiled air filter are not considered to be warrantable repair items. Page 11675 6. Install the rear seat. Page 3165 3. Connect the coolant heater electrical connector (2). 4. Lower the vehicle. Page 11428 Enabling Procedure - Air Bag Fuse 1. Place the ignition in the OFF position. 2. Install the fuse(s) supplying power to the SDM. 3. Turn the ignition switch to the ON position. The AIR BAG indicator will flash then turn OFF. 4. Perform the Diagnostic System Check - Vehicle if the AIR BAG warning indicator does not operate as described. Disabling Procedure - Negative Battery Cable 1. Turn the steering wheel so that the vehicles wheels are pointing straight ahead. 2. Place the ignition in the OFF position. 3. Disconnect the negative battery cable from the battery. 4. Wait 1 minute before working on system. Enabling Procedure - Negative Battery Cable 1. Place the ignition in the OFF position. 2. Connect the negative battery cable to the battery. 3. Turn the ignition switch to the ON position. The AIR BAG indicator will flash then turn OFF. 4. Perform the Diagnostic System Check - Vehicle if the AIR BAG warning indicator does not operate as described. Page 2519 Fluid - Transfer Case: Service and Repair Transfer Case - NVG 263-NP1 Transfer Case Fluid Replacement Removal Procedure Important: When performing the following procedure, use only hand tools to remove and install the drain and fill plugs. 1. Remove the transfer case shield, if equipped. 2. Remove the fill plug. 3. Remove the drain plug. Installation Procedure Notice: Refer to Fastener Notice in Service Precautions. Important: Use only drain and fill plugs that are made from aluminum. Steel or brass plugs are not compatible with the magnesium case. 1. Install the drain plug. ^ Tighten the plug to 20 Nm (15 ft. lbs.). 2. Fill the transfer case to the bottom of the fill plug hole with the approved fluid. Page 7973 Parts Information Warranty Information (excluding Saab U.S. Models) Warranty Information (Saab U.S. Models) Page 13435 Control Module References Part 6 Page 5900 Disclaimer Page 1834 11. From the technicians point of view, the FRONT of the sensor will have: ^ A raised rotor flange cuff (3) ^ An alignment mark (2) on the rotor flange cuff (3) for installation ^ A pin hole (1) for the centering pin. Note the location of the pin hole. 12. Remove the connector from the sensor. 13. Remove the sensor from the adapter and bearing assembly. 14. To install the sensor, proceed to step 9 in the installation procedure. 15. From the technicians point of view, the FRONT of the sensor will have: ^ A raised rotor flange cuff (3) ^ An alignment mark (2) on the rotor flange cuff (3) for installation ^ A pin hole (1) for the centering pin. Note location of the pin hole. ^ A sensor clip in FRONT of the sensor 16. Remove the connector from the sensor. 17. Remove the sensor clip from the sensor. 18. Remove the sensor from the adapter and bearing assembly. 19. To install the sensor, proceed to step 13 in the installation procedure. 20. From the technicians point of view, the FRONT of the sensor will have: ^ A flush rotor flange cuff (3) ^ A pin hole (1) for the centering pin. Note the location of the pin hole. ^ An alignment mark (2) on the flush rotor flange cuff (3) for installation 21. Remove the connector from the sensor. 22. Remove the sensor from the adapter and bearing assembly. 23. To install the sensor, proceed to step 17 in the installation procedure. Page 7244 SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-D. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: - The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair Tools Required J 38125-D Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-D. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Page 5564 Ignition Coil 4 Page 3080 Page 10710 8. Remove the wheel hub and the 15-series bearing mounting bolts (4). 9. Remove the wheel hub and bearing (4) mounting bolts, 25/35 series. 10. Remove the wheel hub and bearing and splash shield from the vehicle. 11. Remove the O-ring seal from the steering knuckle bore, 25/35 series. 12. Remove the wheel speed sensor mounting bolt (5). 13. Clean and inspect the O-ring seal, 25/35 series. 14. Replace the seal if the following conditions exist: ^ Nicks ^ Cuts ^ Dry or brittle ^ Compression set Installation Procedure 1. Clean all corrosion or contaminates from the steering knuckle bore and the hub and bearing assembly. 2. Lubricate the steering knuckle bore with wheel bearing grease or the equivalent. 3. Install the O-ring (7) to the steering knuckle, the 25/35 series. 4. Notice: Refer to Fastener Notice in Service Precautions. Install the wheel speed sensor mounting bolt to the wheel hub and bearing. ^ Tighten the sensor mounting bolt to 18 Nm (13 ft. lbs.). 5. Install the wheel hub and bearing and splash shield to the vehicle, 25/35 series. Page 5429 Fuel Gauge Sender: Diagrams Fuel Pump/Sender Assembly - Primary Page 10897 IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections TESTING FOR INTERMITTENT AND POOR CONNECTIONS TOOLS REQUIRED - J 35616-C GM-Approved Terminal Test Kit - J 38125-D Terminal Repair Kit - J 42675 Flat-Wire Probe Adapter Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector. - Poor terminal to wire connection - Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. - Wire insulation which is rubbed through - This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. - Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. Testing For Proper Terminal Contact It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-D or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-D, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. Page 9725 C198 I/P Harness To Chassis Harness Page 11119 Discharge Air Temperature Sensor / Switch: Service and Repair Air Temperature Sensor Replacement - Lower Left AIR TEMPERATURE SENSOR REPLACEMENT - LOWER LEFT REMOVAL PROCEDURE 1. Disconnect the electrical connector from the lower left air temperature sensor (1). 2. Remove the lower left air temperature sensor (1) from the HVAC module (2). INSTALLATION PROCEDURE 1. Install the lower left air temperature sensor (1) to the HVAC module (2). 2. Connect the electrical connector to the lower left air temperature sensor (1). Page 2142 Drive Belt: Testing and Inspection Drive Belt Excessive Wear Drive Belt Excessive Wear Diagnosis Diagnostic Aids Excessive wear on a drive belt(s) is usually caused by incorrect installation or the incorrect drive belt(s) for the application. Minor misalignment of the accessory drive pulley(s) will not cause excessive wear, but will probably cause the drive belt(s) to make a noise or fall off. Excessive misalignment of the accessory drive pulley(s) will cause excessive wear and may also make the drive belt(s) fall off. Test Description Steps 1 - 6 The number(s) below refer to the step(s) in the diagnostic table. 2. This inspection is to verify that the drive belt(s) is correctly installed on all of the accessory drive pulleys. Wear on the drive belt(s) may be caused by mis-positioning the drive belt(s) by one or more grooves on a pulley(s). 3. The installation of a drive belt(s) that is too wide or too narrow will cause wear on the drive belt(s). The drive belt(s) ribs should match all of the grooves on the pulleys. 4. This inspection is to verify that the drive belt(s) is not contacting any part of the engine or body while the engine is operating. There should be sufficient clearance when the accessory drive components load varies. The drive belt(s) should not come in contact with an engine or a body component when snapping the throttle. Page 10329 Control Arm: Specifications Lower Control Arm to Frame Nuts ...................................................................................................................................................... 175 Nm (129 ft. lbs.) Page 7363 Page 15711 Parking Lamp: Service and Repair PARK/TURN SIGNAL LAMP REPLACEMENT (OLD STYLE) REMOVAL PROCEDURE 1. Ensure the headlamp switch is in the OFF position. 2. Remove the headlamp. 3. Remove the park/turn signal lamp assembly by pushing on the inboard retainer clip. 4. Disconnect the electrical connector from the assembly. INSTALLATION PROCEDURE 1. Install the electrical connector to the park/turn signal lamp assembly. 2. Install the lamp assembly. 3. Install the headlamp. Page 14655 1. Remove the power seat switch bezel from the seat. 2. Remove the power seat switch to bezel screws. 3. Remove the power seat switch. INSTALLATION PROCEDURE NOTE: Refer to Fastener Notice in Service Precautions. 1. Install the power seat switch to bezel screws. Tighten Tighten the screws to 2 N.m (18 lb in). Page 14375 SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-D. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: - The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair Tools Required J 38125-D Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-D. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Page 9617 Application Table Part 4 Page 4631 Electrical Symbols ELECTRICAL SYMBOLS Electrical Symbols Part 1 Page 13395 Electrical Symbols Part 8 Page 12554 Page 15826 Upper Steering Column Body - Dimple In Body Side Molding(s) Lower Side Moulding / Trim: All Technical Service Bulletins Body - Dimple In Body Side Molding(s) Bulletin No.: 04-08-111-002B Date: October 26, 2006 TECHNICAL Subject: Dimple in Body Side Molding (Replace Moldings) Models: 2004 Chevrolet Avalanche without Body Hardware (RPO WBH) 2004 Chevrolet Silverado, Suburban, Tahoe with Body/Side Exterior-Molding-in-Color (RPO B85) Supercede: This bulletin is being revised to change the Warranty and add a revised parts information statement. Please discard Corporate Bulletin Number 04-08-111-002A (Section 08 - Body and Accessories). Condition Some customers may comment on a raised surface or a dimple in the exterior molded-in-color body side door moldings. This condition may be more pronounced in warmer climates. This does not apply to standard colored keyed black body side moldings. Cause Engineering has determined that this condition may be caused by a bar code label on the backside of the molding that dimples the molding. Correction Replace ALL of the exterior body side door moldings. Refer to Molding Replacement-Body Side procedure in SI. Dealer Action Please contact all customers that were told they would be called when a repair became available. Parts Information Page 12008 1. To receive credit, submit a claim with the information above. Disclaimer 2001 and Older Model Year Vehicles (Except Saab Vehicles) 2001 and Older Model Year Vehicles (Except Saab Vehicles) Important: 2001 and older model year vehicles require the removal of the battery power from the OnStar(R) vehicle interface unit (VIU) to eliminate the possibility of an inadvertent OnStar(R) or emergency/airbag call. 1. Locate and gain access to the OnStar® VIU. Refer to OnStar Vehicle Interface Unit Replacement in SI. Important: Complete removal of the VIU is usually not required. Perform only the steps required to gain access to the C2 32-way blue connector. Residing in the C2 connector are the battery positive (+) circuits. Removal of the C2 connector will deactivate the unit and eliminate the possibility of an inadvertent OnStar(R) or emergency/airbag call. Page 2241 Notice: Refer to Fastener Notice in Service Precautions. 2. Install the oil filter to the engine block. ^ Tighten the oil filter to 30 Nm (22 ft. lbs.). 3. Install the oil drain plug to the engine block. ^ Tighten the oil pan drain plug to 25 Nm (18 ft. lbs.). 4. Lower the vehicle. 5. Fill the crankcase with the proper quantity and grade of engine oil. Refer to Capacities - Approximate Fluid and Fluid and Lubricant Recommendations. 6. Remove the oil level indicator. 7. Wipe the indicator with a clean cloth. 8. Install the oil level indicator. 9. Remove the oil level indicator in order to check the level. 10. Add oil if necessary. 11. Close the hood. Page 5071 Put unused material on the shelf for future use. Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Page 15986 Steps 1-2 Page 7255 Control Module References Part 5 Component Locations Pressure Regulating Solenoid: Component Locations Automatic Transmission - 4L60-E/4L65-E Automatic Transmission Electronic Component Views (M30/M32) Electronic Components Propshaft Speed Sensor - Front Page 4678 Control Module References Part 7 Page 1680 Install the parking lock bracket bolts. ^ Tighten the bolts to 24 Nm (18 ft. lbs.). 13. Install the PNP switch. 14. Install the transmission filter. 15. Fill the transmission to the proper level with Dexron® III transmission fluid. Page 12224 10.4. Remove the end cap from the new optic cable, connect to the connector and refit the secondary catch (D). Fit the terminal housing (C) to the connector and refit the locking strip (B). 10.5. Secure the old optic cable together with the new one (E). Important: The optic cable must not be bent with a radius less than 25 mm (1 in). Important: Secure the wiring harness so that there is no risk of chafing and rattling. 11. CV: Remove the rear seat in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. The O-bus connector H2-9 is located behind the left speaker. 12. M04-05: Disconnect the optic cables on the OnStar(R) control modules and join the cables: 12.1. Cut off the cable tie holding the connector (H2-9) against REC. Specifications Crankshaft: Specifications Crankshaft End Play ........................................................................................................................................................ 0.04-0.2 mm (0.0015-0.0078 inch) Crankshaft Main Journal Diameter - Production ....................................................................................................... 64.992-65.008 mm (2.558-2.559 inch) Crankshaft Main Journal Diameter - Service ................................................................................................................................... 64.992 mm (2.558 inch) Crankshaft Main Journal Out-of-Round - Production .................................................................................................................. 0.003 mm (0.000118 inch) Crankshaft Main Journal Out-of-Round -Service ............................................................................................................................ 0.008 mm (0.0003 inch) Crankshaft Main Journal Taper - Production ..................................................................................................................................... 0.01 mm (0.0004 inch) Crankshaft Main Journal Taper - Service ........................................................................................................................................ 0.02 mm (0.00078 inch) Crankshaft Rear Flange Runout ........................................................................................................................................................... 0.05 mm (0.002 inch) Crankshaft Reluctor Ring Runout - Measured 1.0 mm (0.04 inch) Below Tooth Diameter .................................................................. 0.7 mm (0.028 inch) Crankshaft Thrust Surface - Production ...................................................................................................................... 26.14-26.22 mm (1.029-1.0315 inch) Crankshaft Thrust Surface - Service ................................................................................................................................................ 26.22 mm (1.0315 inch) Crankshaft Thrust Surface Runout ..................................................................................................................................................... 0.025 mm (0.001 inch) Page 5363 8. If equipped with 4WD, install the fuel line clip to the bracket on the transfer case. 9. Install the fuel line clips to the brackets on the transmission. 10. Install the fuel pipe bracket to the bellhousing stud. 11. Install the fuel pipe bracket nut. Tighten Tighten the nut to 10 N.m (89 lb in). 12. Lower the vehicle. 13. Remove the caps from the fuel rail. 14. Connect the EVAP canister purge tube line (2). 15. Connect the fuel feed line (1) at the engine. 16. Install the fuel fill cap. Rear Wheel Steering Control Module Bracket Replacement Steering Control Module: Service and Repair Rear Wheel Steering Control Module Bracket Replacement Rear Wheel Steering Control Module Bracket Replacement Removal Procedure 1. Remove the rear wheel steering control module from the bracket. 2. Remove the bolts retaining the bracket (2) to the frame. 3. Remove the bracket (2) from the vehicle. Installation Procedure 1. Install the bracket (2) to the vehicle. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the bolts retaining the bracket (2) to the frame. ^ Tighten the bracket retaining bolts to 10 Nm (81 inch lbs.). 3. Install the rear wheel steering control module to the vehicle. Page 7236 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Micro-Pack 100W Connectors MICRO-PACK 100W CONNECTORS TOOLS REQUIRED J 38125-D Terminal Repair Kit REMOVAL PROCEDURE There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2)has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. IMPORTANT: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Front Impact Sensor: Service and Repair Front INFLATABLE RESTRAINT FRONT END SENSOR REPLACEMENT REMOVAL PROCEDURE CAUTION: Do not strike or jolt the inflatable restraint front end sensor. Before applying power to the front end sensor make sure that it is securely fastened. Failure to observe the correct installation procedure could cause SIR deployment, personal injury, or unnecessary SIR system repairs. 1. Disable the SIR system. Refer to SIR Disabling and Enabling Zone 1. 2. Disconnect the electrical connector. 3. Remove the connector position assurance (CPA) from the connector. 4. Remove the sensor bolt. 5. Remove the sensor (2) from the vehicle. INSTALLATION PROCEDURE 1. Remove any dirt, grease, or other contaminants from the mounting surface (1). IMPORTANT: Refer to SIR Service Precautions. 2. Point the arrow on the sensor toward the front of the vehicle. NOTE: Refer to Fastener Notice in Service Precautions. 3. Install the sensor (2) horizontally to the radiator support. Page 3916 Steps 28 - 31 Page 14079 When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage TESTING FOR A SHORT TO VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity TESTING FOR CONTINUITY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents TESTING FOR ELECTRICAL INTERMITTENTS Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground - Testing for Continuity - Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 msRECORD and emits an audible tone (beep). Page 9848 Location View Location View Page 7159 5. Using J 36511 install the oil fill plug. ^ Tighten the plug to 30 Nm (22 ft. lbs.). 6. Lower the vehicle. Page 6581 Transmission Speed Sensor: Service and Repair Output Shaft Speed Sensor Replacement Output Shaft Speed Sensor Replacement Removal Procedure Important: This procedure is for 2-wheel drive (2WD) vehicles only. If the vehicle is equipped with 4-wheel drive (4WD), the output speed sensor is located on the transfer case. 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. Disconnect the output speed sensor (2) electrical connector. 3. Remove the output speed sensor bolt. 4. Remove the output speed sensor (2). 5. Inspect the output speed sensor (2) for any evidence of damage. Installation Procedure Aluminum Wheel Porosity Repair Wheels: Service and Repair Aluminum Wheel Porosity Repair Aluminum Wheel Porosity Repair 1. Remove the tire and wheel. 2. Inflate the tire to the manufactures specified pressure as stated on the tire. 3. Submerge the tire/wheel into a water bath in order to locate the leak. 4. Inscribe a mark on the wheel in order to indicate the leak areas. 5. Inscribe a mark on the tire at the valve stem in order to Indicate the orientation of the tire to the wheel. 6. Remove the tire from the wheel. 7. Use number 80 grit sandpaper to scuff the inside of the rim surface at the leak area. Important: Do not damage the exterior surface of the wheel. 8. Use general purpose cleaner such as 3M®, P/N 08984 or equivalent, to clean the leak area. 9. Apply 3 mm (0.12 inch) thick layer of adhesive/sealant, GM P/N 12378478 (Canadian P/N 88900041) or equivalent, to the leak area. 10. Allow for the adhesive/sealant to dry. 11. Align the inscribed mark on the tire with the valve stem on the wheel. 12. Install the tire to the wheel. 13. Inflate the tire to the manufactures specified pressure as stated on the tire. 14. Submerge the tire/wheel into a water bath in order ensure the leak is sealed. 15. Balance the tire and wheel. 16. Install the tire and wheel. 17. Lower the vehicle. Page 13728 Rear Door Weatherstrip: Service and Repair Weatherstrip Replacement - Side Door Opening Weatherstrip Replacement - Side Door Opening Removal Procedure 1. Open both doors. 2. Remove the sill plate. 3. Remove the hinge pillar trim pillar. 4. Remove the windshield pillar molding. 5. Remove the weather-strip from the rear side door pinch-weld flange. Installation Procedure 1. Install the weather-strip from the rear side door opening fully seating the weather-strip into the pinch-weld flange. 2. Install the windshield pillar molding. 3. Install the hinge pillar trim pillar. 4. Install the sill plate. 5. Inspect the door closing effort and seal to door fit. Page 6237 All 2006 and future model transmissions that use DEXRON(R)-VI are to be serviced ONLY with DEXRON(R)-VI fluid. DEXRON(R)-VI is an improvement over DEXRON(R)-III in the following areas: * These ATF change intervals remain the same as DEXRON(R)-III for the time being. 2006-2008 Transmission Fill and Cooler Flushing Some new applications of the 6L80 six speed transmission will require the use of the J 45096 Flushing and Flow Tester to accomplish transmission fluid fill. The clean oil reservoir of the machine should be purged of DEXRON(R)-III and filled with DEXRON(R)-VI. Parts Information Disclaimer Page 7786 Page 3242 4. Misalignment of the accessory drive pulley(s) may be caused from improper mounting or incorrect installation of a accessory drive component, or the pulley may be bent inward or outward from a previous repair. Test for a misaligned pulley using a straight edge in the pulley grooves across two or three pulleys. If a misaligned pulley is found, refer to that accessory drive component for the proper removal and installation procedure of that pulley. 5. Inspection of the accessory drive pulley(s) should include inspecting for bends, dents, or other damage that would prevent the drive belt from seating properly in the pulley grooves or on the smooth surface of a pulley when the back side of the drive belt(s) is used to drive the pulley. 6. Accessory drive component brackets that are bent or cracked will also cause the drive belt(s) to fall off. 7. Inspection of the fasteners can eliminate the possibility that a incorrect bolt, nut, spacer, or washer was installed. Missing, loose, or incorrect fasteners may cause pulley misalignment from the accessory drive bracket(s) moving under load. Over tightening the fasteners may cause misalignment of the accessory component bracket(s). OnStar(R) - Negative Impact of Cloth/Vinyl Roofs Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Negative Impact of Cloth/Vinyl Roofs INFORMATION Bulletin No.: 02-08-44-007D Date: May 12, 2009 Subject: Negative Impact of Dealer-Installed Cloth/Vinyl Roofs on XM Radio and/or OnStar(R) Systems Models: 2002-2009 Passenger Cars and Trucks (Including Saturn) 2003-2009 HUMMER H2 2006-2009 HUMMER H3 2005-2009 Saab 9-7X with XM Radio (RPO U2K) and/or OnStar(R) (RPO UE1) .............................................................................................................................................................. .................................................................................. Supercede: This bulletin is being revised to include the 2009 model year. Please discard Corporate Bulletin Number 02-08-44-007C (Section 08 - Body and Accessories). .............................................................................................................................................................. .................................................................................. Dealers should not install a cloth or vinyl roof on vehicles that have been ordered with the XM radio option (RPO U2K) and/or OnStar(R) (RPO UE1). The performance of these systems may be negatively impacted by the installation of the cloth/vinyl roof. Additionally, water leaks may result from installing a cloth or vinyl roof on vehicles with roof-mounted antenna systems. Relocating the antenna to another spot on the vehicle exterior, in order to install a cloth or vinyl roof, is not advised either. The performance of the OnStar(R) and XM Radio antennas has been optimized for their current locations. Relocating the antennas may result in a performance degradation. Disclaimer Locks - Key Code Security Rules and Information Key: Technical Service Bulletins Locks - Key Code Security Rules and Information INFORMATION Bulletin No.: 10-00-89-010 Date: May 27, 2010 Subject: Key Code Security Rules and Information on GM KeyCode Look-Up Application (Canada Only) Models: 2011 and Prior GM Passenger Cars and Trucks 2010 and Prior HUMMER H2, H3 2009 and Prior Saturn and Saab 2002 and Prior Isuzu Attention: This bulletin has been created to address potential issues and questions regarding KeyCode security. This bulletin should be read by all parties involved in KeyCode activity, including dealer operator, partner security coordinator, sales, service and parts departments. A copy of this bulletin should be printed and maintained in the parts department for use as a reference. Important U.S. dealers should refer to Corporate Bulletin Number 10-00-89-009. Where Are Key Codes Located? General Motors provides access to KeyCodes through three sources when a vehicle is delivered to a dealer. Vehicle KeyCodes are located on the original vehicle invoice to the dealership. There is a small white bar coded tag sent with most new vehicles that also has the key code printed on it. Dealerships should make a practice of comparing the tag's keycode numbers to the keycode listed on the invoice. Any discrepancy should be reported immediately to the GM of Canada Key Code Inquiry Desk. Remember to remove the key tag prior to showing vehicles to potential customers. The third source for Key codes is through the GM KeyCode Look-Up feature within the OEConnection D2DLink application. KeyCode Look-Up currently goes back 17 previous model years from the current model year. When a vehicle is received by the dealership, care should be taken to safeguard the original vehicle invoice and KeyCode tag provided with the vehicle. Potential customers should not have access to the invoice or this KeyCode tag prior to the sale being completed. After a sale has been completed, the KeyCode information belongs to the customer and General Motors. Tip Only the original invoice contains key code information, a re-printed invoice does not. GM KeyCode Look-Up Application for GM of Canada Dealers All dealers should review the General Motors of Canada KeyCode Look-Up Policies and Procedures (Service Policy & Procedures Manual Section 3.1.6 "Replacement of VIN plates & keys"). Please note that the KeyCode Access site is restricted. Only authorized users should be using this application. Please see your Parts Manager for site authorized users. KeyCode Look-Up currently goes back 17 years from current model year. Important notes about security: - Users may not access the system from multiple computers simultaneously. - Users may only request one KeyCode at a time. - KeyCode information will only be available on the screen for 2 minutes. - Each user is personally responsible for maintaining and protecting their password. - Never share your password with others. - User Id's are suspended after 6 consecutive failed attempts. - User Id's are disabled if not used for 90 days. - Processes must be in place for regular dealership reviews. - The Parts Manager (or assigned management) must have processes in place for employee termination or life change events. Upon termination individuals access must be turned off immediately and access should be re-evaluated upon any position changes within the dealership. - If you think your password or ID security has been breached, contact Dealer Systems Support at 1-800-265-0573. Automatic Transmission - 4L60-E/4L65-E Transmission Position Switch/Sensor: Adjustments Automatic Transmission - 4L60-E/4L65-E Park/Neutral Position Switch Adjustment Important: ^ The following procedure is for vehicles that have not had the park/neutral position (PNP) switch removed or replaced. If the PNP switch has been removed or replaced, refer to Park/Neutral Position Switch Replacement for the proper adjustment procedure. ^ Apply the park brake. ^ The engine must start in the park (P) or neutral (N) positions only. ^ Check the PNP switch for proper operation. If adjustment is required, proceed as follows: 1. Place the transmission range selector in the neutral (N) position. 2. With an assistant in the drivers seat, raise and suitably support the vehicle. Refer to Vehicle Lifting. 3. Loosen the park/neutral position (PNP) switch bolts. 4. With the vehicle in the neutral (N) position, rotate the switch while the assistant attempts to start the engine. 5. Following a successful start, turn the engine off. 6. Notice: Refer to Fastener Notice in Service Precautions. ^ Tighten the PNP switch bolts. ^ Tighten the bolts to 25 Nm (18 ft. lbs.). 7. Lower the vehicle. 8. Check the PNP switch for proper operation. The engine must start in the park (P) or neutral (N) positions only. 9. Replace the PNP switch if proper operation can not be achieved. Page 797 For vehicles repaired under warranty, use the table. Disclaimer Recall 05V163000: 2nd Row Seat Belt Modification Seat Belt: All Technical Service Bulletins Recall 05V163000: 2nd Row Seat Belt Modification MAKE/MODELS: MODEL/BUILD YEARS: CADILLAC / ESCALADE 2003-2005 CHEVROLET / AVALANCHE 2003-2005 CHEVROLET / SILVERADO 2003-2005 CHEVROLET / SUBURBAN 2003-2005 CHEVROLET / TAHOE 2003-2005 GMC / SIERRA 2003-2005 GMC / YUKON 2003-2005 HUMMER / H2 2004-2005 MANUFACTURER: General Motors Corp. NHTSA CAMPAIGN ID NUMBER: 05V163000 RECALL DATE: April 22, 2005 COMPONENT: Seat Belts: Rear POTENTIAL NUMBER OF UNITS AFFECTED: 1359824 SUMMARY: On certain crew cab pickup trucks and sport utility vehicles, the 2nd row center occupant seat belt routing may make it difficult to position the lap portion of the safety belt low around the hips of occupants, especially smaller occupants, seated in this position. Appropriate use of a child seat or booster seat, as recommended for small children, does improve the fit condition for this user group. In addition to instructions on proper infant and young child restraint (with child seats or boosters), special verbiage for restraining older child is included in the owner's manual text. CONSEQUENCE: A lap portion of the seat belt routing that is not low and snug on the hips can allow the lap belt to ride up on an occupant's abdomen instead of fitting low around their hipbones, and therefore, can expose them to more risk of abdominal and internal organ injury. REMEDY: Dealers will cut open the guide loop, remove a portion of the loop, and then the remaining two sides should be folded over and secured with a retainer. The manufacturer has not yet provided an owner notification schedule for this campaign. Owners should contact Cadillac at 1-866-982-2339, Chevrolet at 1-800-630-2438, GMC at 1-866-996-9463, or Hummer at 1-800-732-5493. NOTES: GM recall No. 05037. Customers can also contact The National Highway Traffic Safety Administration's Auto Safety Hotline at 1-888-327-4236. Page 11475 Inflatable Restraint Front End Sensor - Right Page 1652 3. If equipped with a 6.0L engine, connect the HO2S electrical connector (1). 4. If equipped with a 4.8L or 5.3L engine, connect the HO2S electrical connector (1). 5. Install the HO2S electrical connector to the fuel line clip. 6. Disconnect the CPA retainer. 7. If necessary, bolt the front propeller shaft to the front differential. Refer to Propeller Shaft Replacement - Front in Propeller Shaft. 8. Lower the vehicle. Page 6542 Steps 1-9 Test Description The numbers below refer to the step numbers on the diagnostic table. 2. This step tests for a faulty tow/haul switch. 3. This step tests for voltage input from the BCM to the tow/haul switch. 6. This step tests for ground integrity. Page 15945 Refer to the table as a guide in selecting the correct test adapter for frontprobing connectors: Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure SCAN TOOL SNAPSHOT PROCEDURE Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: - Snapshot - taken from the Snapshot menu choice - Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information Page 351 Service and Repair Wheel Seal: Service and Repair Wheel Hub, Bearing, and Seal Replacement (4WD) ^ Tools Required J 45859 Axle Remover Removal Procedure 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Remove the tire and wheel. 3. Remove the rotor. Refer to Brake Rotor Replacement - Front in Disc Brakes. 4. Remove the wheel speed sensor and brake hose mounting bracket bolt from the steering knuckle. 5. Remove the wheel drive shaft nut retaining cover. 6. Important: Fuel System - Cranks But No Start/Inaccurate Fuel Gauge Fuel Gauge Sender: All Technical Service Bulletins Fuel System - Cranks But No Start/Inaccurate Fuel Gauge Bulletin No.: 04-08-49-018E Date: January 05, 2005 TECHNICAL Subject: Cranks But No Start, Stall, Inaccurate/Incorrect Fuel Gauge Reading, No Fuel, Vehicle is Out of Fuel and Fuel Gauge Reads Above Empty (Replace Fuel Level Sensor) Models: 2001-2004 Cadillac Trucks 1999-2004 Chevrolet and GMC Trucks with Gasoline Engine (VINs Z, X, V, T, U, N, G, 6, 8 - RPOs LU3, LR4, LM7, LQ4, LQ9, L59, L18,LK5 L52) Attention: Parts are currently available for vehicles with Variable Fuel (VIN Z - RPO L59) vehicles. Please refer to Corporate Bulletin Number 04-06-04-01 2B or newer for Variable Fuel (VIN Z - RPO L59) vehicles. Supercede: This bulletin is being revised to include information on the Chevrolet Colorado and the GMC Canyon. Please discard Corporate Bulletin Number 04-08-49-018D (Section 08 - Body and Accessories). Condition Some customers may comment on the vehicle stalling and will not restart, vehicle ran out of fuel, vehicle appears to be out of fuel but the fuel gauge reads above empty. The fuel gauge may read 1/4 tank. Cause Contamination on the fuel sending card may cause inaccurate/incorrect fuel gauge readings. Correction Follow the service procedure below for diagnosis and repair of this concern. 1. Confirm that the vehicle is actually out of fuel. ^ If the vehicle is not out of fuel but Engine Cranks but Does Not Run, refer to the appropriate Service Information. ^ If the vehicle is out of fuel and the gauge does not read empty, test the fuel gauge. Refer to the following information: - Fuel Gage Inaccurate or Inoperative Single Tank - Fuel Gage Inaccurate or Inoperative Dual Tanks - Fuel Gage Inaccurate or Inoperative Colorado and Canyon 2. If testing reveals that the fuel gauge is operating correctly, replace the fuel sensor assembly and auxiliary tank fuel level sensor if equipped. 3. Replace the fuel level sensor. Refer to the following appropriate service information: ^ Fuel Level Sensor Replacement 4.8L and 5.3L Engines ^ Fuel Level Sensor Replacement 6.0L Engine - Front Tank ^ Fuel Level Sensor Replacement 6.0L Engine - Rear Tank ^ Fuel Level Sensor Replacement 8.1L vehicles with Front Tank ^ Fuel Level Sensor Replacement 8.1 L vehicles with Rear Tank Page 12916 Audio Amplifier C1 - With RPO Code UQ7, Without RPO Code Y91 - Part 3 Brakes - ABS Lamp ON/DTC's C0265/C0201/U1041 Set Electronic Brake Control Module: All Technical Service Bulletins Brakes - ABS Lamp ON/DTC's C0265/C0201/U1041 Set TECHNICAL Bulletin No.: 04-05-25-002E Date: March 11, 2009 Subject: ABS Light On, DTCs C0265, C0201, U1041 Set and/or Loss of Communication with Brake Module (Reground EBCM Ground) Models Supercede: This bulletin is being revised to add step 2 to the procedure and update the Parts and Warranty Information. Please discard Corporate Bulletin Number 04-05-25-002D (Section 05 - Brakes). Condition Some customers may comment that the ABS light is on. Upon further inspection, DTCs C0265 and C0201 may be set in the brake module. It is also possible for DTC U1041 to set in other modules. There may also be a loss of communication with the brake module. Cause A poor connection at the EBCM ground is causing unnecessary replacement of brake modules. Important: The EBCM ground is different for each application. Refer to the list below for the proper ground reference: ^ Midsize Utilities = Ground 304 ^ SSR = Ground 400 ^ Fullsize Trucks and Utilities = Ground 110 Correction Important: Do not replace the brake module to correct this condition. Perform the following repair before further diagnosis of the EBCM. Perform the following steps to improve the connection of the EBCM Ground: 1. Remove the EBCM Ground. The EBCM Ground is located on the frame beneath the driver's side door. If multiple grounds are found in this location, the EBCM ground can be identified as the heavy (12-gauge) wire. 2. If the original fastener has a welded on nut, remove the nut from the frame, and if required, enlarge the bolt hole to accommodate the new bolt and nut. 3. Clean the area, front and back, using a tool such as a *3M(TM) Scotch-Brite Roloc disc or equivalent. Page 14282 WA382E/11 - WA408G/44 Page 11706 Tighten Tighten the bolt to 9 N.m (79 lb in). 4. Connect the electrical connector to the sensor (2). 5. Install the CPA. 6. Enable the SIR system. Refer to SIR Disabling and Enabling Zone 1. Page 8798 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Micro-Pack 100W Connectors MICRO-PACK 100W CONNECTORS TOOLS REQUIRED J 38125-D Terminal Repair Kit REMOVAL PROCEDURE There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2)has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. IMPORTANT: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Page 1353 Sunload Sensor (With RPO Code CJ2) Page 8143 Brake Caliper: Service and Repair Brake Caliper Overhaul - Front Brake Caliper Overhaul - Front ^ Tools Required J 45515 Brake Caliper Piston Boot Seal Installer Caution: Refer to Brake Dust Caution in Service Precautions. Caution: Refer to Brake Fluid Irritant Caution in Service Precautions. Notice: Refer to Brake Fluid Effects on Paint and Electrical Components Notice in Service Precautions. 1. Replace all the components included in the repair kits used to service this brake caliper. 2. Lubricate the rubber parts with new Delco Supreme 11®, GM P/N 12377967 (Canadian P/N 992667) or equivalent DOT-3 brake fluid to make assembly easier. 3. If any hydraulic component is removed or disconnected, it may be necessary to bleed all or part of the brake system. 4. The torque values specified are for dry, non-lubricated fasteners. 5. Perform the service operations on a clean bench, free from all mineral oil materials. 6. Remove the brake caliper from vehicle. Refer to Brake Caliper Replacement - Front. 7. Drain the brake fluid from the brake caliper. 8. Caution: Do not place your fingers in front of the piston in order to catch or protect the piston while applying compressed air. This could result in serious injury. Notice: Use clean cloths to pad interior of caliper housing during piston removal. Use just enough air to ease the pistons out of the bores. If the pistons are blown out, even with the padding provided, it may be damaged. Place a 25 mm (1 inch) block of wood between the caliper and the piston. 9. Install a large C-clamp over the body of the brake caliper with the C-clamp ends against the rear of the caliper body and against the block of wood. 10. Carefully remove the brake caliper piston by directing low pressure compressed air into the brake caliper inlet hole. 11. Remove the C-clamp form the caliper. 12. Remove the block of wood from the caliper. 13. Install clean cloths to pad the interior of the caliper housing between the remaining caliper piston and the caliper body. 14. To cover the open caliper bore place a 25 mm (1 inch) block of wood between the caliper body and the brake caliper dust boot seal. 15. Install a large C-clamp over the body of the brake caliper with the C-clamp ends against the rear of the caliper body and against the block of wood. 16. Carefully remove the brake caliper piston by directing low pressure compressed air into the brake caliper inlet hole. 17. Remove the C-clamp form the caliper. 18. Remove the block of wood from the caliper. Steering/Suspension - Pitman Arm Shaft Seal Service Kit Steering Gear Seal: Technical Service Bulletins Steering/Suspension - Pitman Arm Shaft Seal Service Kit INFORMATION Bulletin No.: 10-02-33-001A Date: October 13, 2010 Subject: Information on Pitman Arm Shaft Seal Service Kit Models: 2004-2005 Buick Rainier 2000-2006 Cadillac Escalade, Escalade ESV, Escalade EXT 2000-2005 Chevrolet Blazer, S-10 2000-2011 Chevrolet Avalanche, Express, Silverado, Suburban, Tahoe 2000-2005 GMC Jimmy, Sonoma 2000-2011 GMC Savana, Sierra, Yukon, Yukon Denali, Yukon XL, Yukon Denali XL 2000-2004 Oldsmobile Bravada 2003-2009 HUMMER H2 with Recirculating Ball Steering Gears Supercede: This bulletin is being revised to update the model years and models involved. Please discard Corporate Bulletin Number 10-02-33-001 (Section 02 - Steering). Note Do not replace the entire steering gear for a pitman seal leak. Technicians have been replacing entire steering gears due to not being able to service just the leaking pitman shaft seal. The seal is serviced as a kit and is not called out separately in the catalog illustration. The seal package is cataloged in Group 06.855 as Seal Kit - GM Part Number 26002516 - Steering Gear Pitman Shaft, which includes the seal, washer, retaining ring and dust seal or G/M P/N 19256667, which includes the seal and retainer. Refer to Steering Gear Pitman Shaft Seal in SI. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 8086 Wheel Speed Sensor: Locations ABS Component Views Wheel Speed Sensor (WSS) - RF and LF Page 2659 Fuse Block - Underhood C9 Fuse Block- I/P C1 Page 10465 Wheel Bearing: Service and Repair With Full Floating 10.5" or 11.5" Ring Gear Rear Axle Hub, Bearing, Cup, and/or Seal Replacement ^ Tools Required J 8092 Universal Driver Handle - 3/4 inch - 10 - J 2222-C Wheel Bearing Nut Wrench - J 24426 Wheel Bearing Race Installer - Outer - J 24427 Wheel Bearing Race Installer - Inner - J 44419 Hub Outer Bearing Race Installer - J 44420 Differential Bearing and Hub Seal Installer Removal Procedure 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Remove the tire and wheel assembly. 3. Remove the brake caliper. 4. Remove the axle shaft. 5. Remove the axle nut retaining ring. 6. Remove the key. 7. Remove the adjusting nut using the J 2222-C. Page 9616 Application Table Part 3 Page 16052 Control Module References Part 6 Page 12121 ^ On 2002 Sevilles and DeVilles, the GPS jumper cable MUST be unclipped from the back seat cross brace, or unplugged from the VCIM first. DO NOT pull back on the mounting bracket until the GPS antenna jumper cable is unclipped from the back seat cross brace or unplugged from the VCIM. The short length of jumper cable does not allow the VCIM mounting bracket to be pulled back very far, and could lead to a break at the VCIM connector. ^ On 2000-2002 Bonnevilles and LeSabres and 2001-2002 Auroras you will need to follow these steps: 1. Remove the 4 nuts that secure the VCU/VIU bracket assembly to the rear seat back brace. Note: Save these nuts for later use. 2. Remove and discard the plastic VCU/VIU bracket assembly from the vehicle. 3. Remove the upper right stud (1) from the rear seat back brace and re-install in the middle lower slot (2) on the brace. Tighten the fastener to 4 Nm (36 lb in). 4. Position the new VCIM in the vehicle over the studs on the rear seat back brace. 5. Install two of the nuts saved from step (1). Tighten the nuts to 4 Nm (36 lb in). 6. Connect the new OnStar jumper harness supplied in the kit to the VCIM (two white connectors) and the body wiring harness (C345 connector). 7. Connect the small coaxial jumper cable supplied in the kit, to the VCIM, with the end that has a blue plastic housing connector. Plug the other end of this coaxial jumper cable to the OnStar Global Positioning Satellite (GPS) antenna coaxial cable at the right angle connector. Note: The GPS cable in the new OnStar jumper harness is not utilized. 8. Connect the cellular coaxial cable to the OnStar VCIM. On 2001 Impala and Monte Carlos you will need to follow these steps: 9. Remove the Vehicle Communications Unit (VCU) and Vehicle Interface Unit (VIU) following the procedures listed in SI. Save the bracket nuts for later use. Heated Oxygen Sensor (HO2S) Replacement Bank 1 Sensor 1 Oxygen Sensor: Service and Repair Heated Oxygen Sensor (HO2S) Replacement Bank 1 Sensor 1 HEATED OXYGEN SENSOR (HO2S) REPLACEMENT BANK 1 SENSOR 1 REMOVAL PROCEDURE 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. If necessary, unbolt the front propeller shaft from the front differential. Refer to Propeller Shaft Replacement - Front in Propeller Shaft. 3. Disconnect the connector position assurance (CPA) retainer. NOTE: Refer to Heated Oxygen and Oxygen Sensor Notice in Service Precautions. 4. Remove the heated oxygen sensor (HO2S) electrical connector from the fuel line clip. 5. If equipped with a 4.8L or 5.3L engine, disconnect the HO2S electrical connector (1). 6. If equipped with a 6.0L engine, disconnect the HO2S electrical connector (1). Instruments - Unable to Reset Oil Life Monitor Oil Change Reminder Lamp: Customer Interest Instruments - Unable to Reset Oil Life Monitor Bulletin No.: 04-06-04-043 Date: June 17, 2004 TECHNICAL Subject: Unable to Reset Engine Oil Life Monitor (Reprogram PCM) Models: 2004 Buick Rainier 2004 Cadillac Escalade, Escalade ESV, Escalade EXT 2004 Chevrolet Avalanche, Express, SSR, Silverado, Suburban, Tahoe, Trailblazer 2004 GMC Envoy, Savana, Sierra, Yukon, Yukon XL with V8 Engine (VINs G, N, P, T, U, V, Z - RPOs L18, LQ9, LM4, LM7, LQ4, LR4, L59) and Electronic Throttle Control Condition Some owners may comment that they are unable to reset the Engine Oil Life Monitor. Correction Reprogram the PCM with calibration operating system P/N 12587603 or later. The new calibration was released beginning with TIS satellite data update version 8.0 for 2003, available August 2003. As always, make sure your TECH2(R) is updated with the latest software version. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 11795 Global Positioning System Antenna: Service and Repair Antenna Assembly Replacement - Cellular and Navigation ANTENNA ASSEMBLY REPLACEMENT - CELLULAR AND NAVIGATION REMOVAL PROCEDURE 1. Lower the headliner. Refer to Headliner Replacement in Interior Trim 2. Disconnect the cables from the antenna. 3. Loosen the retaining nut until the antenna assembly can be pulled from the top of the roof. INSTALLATION PROCEDURE 1. Place the antenna assembly on the roof opening. NOTE: Refer to Fastener Notice in Service Precautions. 2. Tighten the retaining nut. Tighten Tighten the nut to 6 N.m (53 lb in). 3. Connect the antenna cables. 4. Install the headliner. Page 6089 9. Remove the servo cover and O-ring seal. If the cover is hung up on the seal, use a pick (2) in order to pull and stretch the seal (1) out of the groove. Cut and remove the O-ring seal before removing the cover. 10. Remove the 2-4 servo. 11. Inspect the 4th apply piston, 2-4 servo converter, 2nd apply piston, and the servo piston inner housing for the following defects: ^ Cracks ^ Scoring ^ Burrs and nicks Installation Procedure 1. Install NEW seals onto the servo pistons and the servo cover. 2. Install the 2-4 servo. 3. Install the J 29714-A. Page 4458 5. Remove the fuel level sensor retaining clip. 6. Remove the fuel level sensor. INSTALLATION PROCEDURE 1. Install the fuel level sensor. Page 12321 Electrical Symbols Part 12 Page 16060 Electrical Symbols Part 2 Page 15465 For vehicles repaired under warranty, use the table. Disclaimer Page 14306 WA8624/50 - WA8624/50 Page 9581 Junction Block - I/P - C5 Page 6433 Vehicle Speed Sensor (VSS) Tow/Haul Switch Location Automatic Transmission Electronic Component Views (M33 Only) Automatic Transmission Electronic Component Views (M33 Only) Page 14588 Disclaimer Page 6847 4. Remove the thrust washer. 5. Install the J 22536 as shown. Ensure that the J 22536 is firmly seated on the pinion. 6. Drive the pinion out using the J 22536 and a hammer. Strike the J 22536 slowly. Do not let the pinion fall out of the rear axle housing. 7. Remove the pinion preload shims from the drive pinion and set aside. 8. Remove the inner pinion bearing and the pinion position shim. 9. Important: The ring gear bolts have right-hand threads. Remove the ring gear bolts. Discard the bolts. 10. Notice: Refer to Ring Gear Removal Notice in Service Precautions. Page 9051 Relay Block - I/P C1 Part 2 Page 10691 Provide all information required on the form. Make a copy of the completed form for the customer to keep in the vehicle along with their Owner's Manual. File the original completed form in the Dealership's Vehicle Service History folder. Because this is not a warranty repair, dealers will incur a charge to obtain a VCI number. A VCI number will only be available for the following models: 1999-2007 Chevrolet Silverado and GMC Sierra (1500 Series Only) EXCLUDES 1999-2000 vehicles equipped with 4.3L engine (RPO L35) EXCLUDES vehicles equipped with Quadrasteer (RPO NYS) EXCLUDES Parallel Hybrid Truck (RPO HP2) EXCLUDES 2001-2004 vehicles equipped with Traction Control (RPO NW7) combined with 3.42 Axle Ratio (RPO GU6) Refer to the Model Application Chart to in the beginning of this bulletin to verify usage. Calibrations are not available for 1999 and 2000 model year vehicles with 3.08 axle. Calibrations are not available for 1999 and 2000 model year vehicles equipped with 4.3L engine (RPO L35). If original equipment tires/wheels are reinstalled, it will be necessary to reset the programming of the PCM and the ABS module to the original specifications. Labels After installing the recommended P275/55R20 tires, place the provided label on the vehicle. The label should be located on the doorjamb, near the original tire label, and should not cover up the original tire label. Be sure that the surface is clean and dry. The surface temperature should not be less than 21°C (70°F). The label is provided as a guide for tire inflation pressures and information relevant to occupant/cargo capacities. Page 13055 1. Remove the ground cable from the battery's negative cable. 2. Remove the center console, see WIS - Body - Interior. 3. Loosen the gear shift housing (A). AUT: Disconnect the 6-pin connector (B) to improve access to the gear shift housing screws. 4. Disconnect the signal cable from the SRS control module to the OnStar(R) control module and secure the cable. 4.1. Disconnect the connector (A) from the SRS control module and cut the cable tie (B). Page 9246 C326 Heated Seat Jumper Harness To Passenger Seat Harness (With RPO Code KA1) Page 4883 4. Position the J 41364-A onto the PNP switch. Ensure that the two slots on the switch where the manual shaft is inserted are lined up with the lower two tabs on the tool. 5. Notice: Refer to Fastener Notice in Service Precautions. Rotate J 41364-A until the upper locator pin on the tool is lined up with the slot on the top of the switch. ^ Tighten the bolts to 25 Nm (18 ft. lbs.). 6. Remove J 41364-A from the PNP switch. If installing a new switch, remove the positive assurance bracket at this time. 7. Install the control lever to the manual shaft with the nut. 8. Install the manual shaft nut. ^ Tighten the nut to 25 Nm (18 ft. lbs.). 9. Install the range selector cable end (2) to the range selector lever ball stud (1). Page 12358 Control Module References Part 7 Service and Repair Pilot Bearing: Service and Repair Pilot Bearing Replacement ^ Tools Required J 43276 Clutch Pilot Bearing Remover - J 38836 Bushing Installer/Clutch Arbor Removal Procedure Notice: When using the J 43276 Clutch Pilot Bearing Remover, always secure the J 43276-1 Clutch Pilot Bearing Remover tool body using a wrench. Do not allow the J 43276-1 tool body to rotate. Failing to do so causes damage to the J 43276-1 tool body. Important: The flywheel spacer (if applicable) must be removed prior to clutch pilot bearing removal. 1. Remove the clutch assembly. 2. Using J 43276 perform the following in order to remove the clutch pilot bearing: 1. Install the J 43276-1 into the clutch pilot bearing. 2. Using a wrench, secure the J 43276-1. 3. Insert the J 43276-2 into the J 43276-1. 4. Rotate the J 43276-2 clockwise into the J 43276-1 until the clutch pilot bearing is completely removed from the crankshaft. 5. Rotate the J 43276-2 counterclockwise to remove the J 43276-2 from the J 43276-1. 6. Remove the J 43276-1 from the tool body. Page 9138 Tighten Tighten to 8 Nm (71 lb in). Note The repair area MUST BE properly refinished to maintain a secure, stable and corrosion-free electrical ground. 12. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 13. Verify proper system operation. M8 Weld Nut Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M8 weld nut electrical ground location is accessible from both sides of the panel, a M8 conductive bolt and a M8 conductive nut may be used to secure the electrical ground wire terminal. Refer to the Parts Information section of this bulletin. 2. Select a location adjacent the M8 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the new electrical ground site. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the ground location and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 10 mm (0.40 in) diameter hole through the panel. 5. Remove paint and primer from the area surrounding the 10 mm (0.40 in) hole until bare metal is visible. 6. Select a M8 conductive bolt. Refer to the Parts Information section of this bulletin. 7. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M8 conductive bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 8. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 9. Install the electrical ground wire terminal and the M8 conductive bolt to the ground location. 10. Select a M8 conductive nut. Refer to the Parts Information section of this bulletin. 11. Install the M8 conductive nut to the bolt and: Tighten Tighten to 22 Nm (16 lb ft). Note The repair area MUST BE properly refinished to maintain a secure, stable and corrosion-free electrical ground. 12. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 13. Verify proper system operation. M8 Weld Nut Alternative Repair Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M8 weld nut electrical ground location is not accessible from both sides of the panel, a M6 conductive rivet stud and a M6 conductive nut may be used to secure the electrical ground wire terminal. 2. Select a location adjacent the damaged M8 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the M6 conductive rivet stud flange. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the repair site and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 10 mm (0.40 in) diameter hole through the panel. Page 12959 Speaker: Diagrams Speaker - LF Door - With RPO Code UQ5 Page 3218 11. If equipped with RPO HP2, position the cable (w/bracket) and install the 3-phase cable bracket to the studs. 12. Install the 3-phase cable bracket nuts (2). ^ Tighten the nuts to 15 Nm (11 ft. lbs.). 13. If equipped with RPO HP2, install the 3-phase cable to the SGCM. 14. Install the 3-phase cable nuts to the SGCM. ^ Tighten the nuts to 9 Nm (80 inch lbs.). 15. Install the SGCM cover and bolts. ^ Tighten the bolts to 9 Nm (80 inch lbs.). Page 884 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground TESTING FOR SHORT TO GROUND NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting With A Digital Multimeter TROUBLESHOOTING WITH A DIGITAL MULTIMETER NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TROUBLESHOOTING WITH A TEST LAMP Page 9620 Fuse Block: Application and ID Fuse Block - Underhood - Secondary Location View Lighting - Exterior Lamp Condensation and Replacement Brake Lamp: Technical Service Bulletins Lighting - Exterior Lamp Condensation and Replacement INFORMATION Bulletin No.: 01-08-42-001H Date: January 05, 2011 Subject: Exterior Lamp Condensation and Replacement Guidelines Models: 2011 and Prior GM Passenger Cars and Trucks (including Saturn) Supercede: This bulletin is being revised to add the 2011 model year. Please discard Corporate Bulletin Number 01-08-42-001G (Section 08 - Body and Accessories). The following information is being provided to better define the causes of condensation in exterior lamps and includes guidelines for determining the difference between a lamp with a normal atmospheric condition (condensation) and a lamp with a water leak. Some exterior lamps, such as cornering, turn signal, backup, headlamps or tail lamps may exhibit very small droplets of water, a fine mist or white fog (condensation) on the inside of the lamp lens. This may be more noticeable on lamps with "multi-lens" designs and may be normal during certain weather conditions. Condensation occurs when the air inside the lamp assembly, through atmospheric changes, reaches the "dew point". When this takes place, the moisture in the air within the lamp assembly condenses, creating a fine mist or white fog on the inside surface of the lamp lens. Most exterior lamps on General Motors vehicles use a vented design and feature a replaceable bulb assembly. They are designed to remove any accumulated moisture vapor by expelling it through a vent system. The vent system operates at all times, however, it is most effective when the lamps are ON or when the vehicle is in motion. Depending on the size, shape and location of the lamp on the vehicle, and the atmospheric conditions occurring, the amount of time required to clear the lamp may vary from 2 to 6 hours. Completely sealed headlamp assemblies (sealed beams) are still used on a limited number of models being manufactured today. These lamps require the replacement of the complete lamp assembly if a bulb filament burns out. Condensation 2006 TrailBlazer Shown A Fine Mist or White Fog on the Inside Surface of the Lamp Lens Occurring After a Period of High Humidity - May be located primarily in the lens corners (near the vents) and SHOULD NOT cover more than half the lens surface. - The condition should clear of moisture when the vehicle is parked in a dry environment, or when the vehicle is driven with the lights ON. - A comparison of the equivalent lamp on the opposing side of the vehicle indicates a SIMILAR performance. If the above conditions are noted, the customer should be advised that replacement of a lamp assembly may not correct this condition. Water Leak New Style Pickup Shown Locations Engine Oil Pressure (EOP) Sensor And CMP Sensor HVAC System - Automatic Control Module HVAC: Service and Repair HVAC System - Automatic Blower Motor Control Processor Replacement BLOWER MOTOR CONTROL PROCESSOR REPLACEMENT REMOVAL PROCEDURE 1. If equipped, remove the sound insulator panel. 2. Disconnect the electrical connector at the blower motor. 3. Disconnect the electrical connector (4) from the blower motor control processor (2). 4. Remove the blower motor control processor retaining screws (3) from the HVAC module (1). 5. Remove the blower motor control processor (2) from the HVAC module (1). INSTALLATION PROCEDURE Page 5769 Steps 1-9 Test Description The numbers below refer to the step numbers on the diagnostic table. 2. This step tests for a faulty tow/haul switch. 3. This step tests for voltage input from the BCM to the tow/haul switch. 6. This step tests for ground integrity. Page 6391 Tow/Haul Switch: Testing and Inspection 4L80-E/4L85-E Transmission Tow/Haul Switch/Indicator Always On or Inoperative Circuit Description Tow/haul mode enables the operator to achieve enhanced shift performance when towing or hauling a load. When tow/haul mode is selected, the tow/haul switch input signal to the body control module (BCM) is momentarily toggled to zero volts. This signals the powertrain control module (PCM) to extend the length of time between up shifts and increase transmission line pressure. Cycling the tow/haul switch again disables tow/haul mode and returns the transmission to a normal shift pattern. Diagnostic Aids If the electrical circuit checks are OK and the tow/haul shift pattern is not occurring, there may be a mechanical/hydraulic condition that prevents tow/haul operation. Refer to Symptoms - Automatic Transmission. Page 12011 5.2 Cut off the cable tie (B), detach the connector's rear end face (C) and pull out the connecting rail (D). 5.3. Remove pin 39, cut off the cable terminal and insulate the end with tape (E). Fold back the cable and secure it with tape (F). 5.4. Fit the connecting rail and end face. 5.5. Plug in the connector (A) and secure the cables with cable ties (B). 6. Install the floor console over the handbrake. Do not press the console down into place, but instead allow it to fit loosely. 7. Install the switch: 7.1. Install the switch for the roof lighting (B) and plug in its connector. 7.2. Guide the connectors for the window lift module and rear seat heater, if equipped, through the hole for each respective unit. Plug in the window lift module's connector and install the module (A). Page 15766 Upper Steering Column Page 10966 - Proof of ownership at time of repair. - Original paid receipt confirming the amount of unreimbursed repair expense(s) (including Service Contract deductibles), a description of the repair, and the person or entity performing the repair. If the work was done by someone other than a GM dealership, the amount of reimbursement will be limited to the amount that the repair would have cost GM to have it completed by a GM dealership. Courtesy Transportation The General Motors Courtesy Transportation program is intended to minimize customer inconvenience when a vehicle requires a repair that is covered by the New Vehicle Limited Warranties. The availability of courtesy transportation to customers whose vehicles are within the warranty coverage period and involved in a product program is very important in maintaining customer satisfaction. Dealers are to ensure that these customers understand that shuttle service or some other form of courtesy transportation is available and will be provided at no charge. Dealers should refer to the General Motors Service Policies and Procedures Manual for Courtesy Transportation guidelines. Warranty Transaction Information Submit a transaction using the table below. * The amount identified in "Net Item" should represent the dollar amount reimbursed to the customer. Disclaimer Page 2919 10. Align the inscribed mark on the tire with the valve stem on the wheel. 11. Reinstall the Tire Pressure Sensor. Refer to Tire Pressure Sensor installation procedure in SI. 12. Mount the tire on the wheel. Refer to Tire Mounting and Dismounting. 13. Pressurize the tire to 276 kPa (40 psi) and inspect for leaks. 14. Adjust tire pressure to meet the placard specification. 15. Balance the tire/wheel assembly. Refer to Tire and Wheel Assembly Balancing - Off-Vehicle. 16. Install the tire and wheel assembly onto the vehicle. Refer to the appropriate service procedure in SI. Parts Information Warranty Information (excluding Saab U.S. Models) Important The Silicone - Adhesive/Sealant comes in a case quantity of six. ONLY charge warranty one tube of adhesive/sealant per wheel repair. For vehicles repaired under warranty, use: One leak repair per wheel. Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table above. Disclaimer Drivetrain - Transfer Case Control Module Replacement Control Module: All Technical Service Bulletins Drivetrain - Transfer Case Control Module Replacement Bulletin No.: 05-04-21-002 Date: March 10, 2005 INFORMATION Subject: Guidelines for Replacement of Transfer Case Control Module (TCCM) Models: 2005 and Prior Light Duty Trucks with New Venture Gear (NVG) Transfer Case (RPOs NP1, NP4, NP8) Dealers are replacing the TCCM unnecessarily. Dealers are replacing the TCCM with codes stored in HISTORY only. The TCCM does not have a current fault condition when tested. Parts reviewed at the Warranty Parts Center (WPC) have a 75% No Trouble Found (NTF) rate. The only two legitimate reasons to replace the TCCM are: ^ Diagnostic Trouble Code (DTC) C0550 ^ NO Communication with a scan tool. DTC C0550 This DTC indicates that the module has an internal fault and should be replaced. No Communication ^ The no communication conditions referenced here are also caused by a module internal fault to a point where the module physically will not talk. A technician cannot pull DTCs from the module because it will not communicate. The module is electrically dead. ^ No communication is not to be confused with a U1026 code. This code tells the technician that the module may still be functioning but is temporarily off line. This code may be set by the Instrument Panel (IP) or the Powertrain Control Module (PCM) against the TCCM. The technician needs to figure out why the module went off line. These are typically caused by connection concerns. There is no need to replace a TCCM for a U1026 DTC. Diagnostic Aids ^ When diagnosing a transfer case electrical control system, ALWAYS check power and ground wiring first. ^ Test the connections for intermittent or poor connections, complete plug insertion, bent pins, pushed out terminals and water contamination. Page 1994 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground TESTING FOR SHORT TO GROUND NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting With A Digital Multimeter TROUBLESHOOTING WITH A DIGITAL MULTIMETER NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TROUBLESHOOTING WITH A TEST LAMP Page 8348 1. Important: Do not use abrasives to clean the brake master cylinder bore. Clean the interior and exterior of the master cylinder, the secondary piston (1), and the return spring in denatured alcohol, or equivalent. 2. Inspect the master cylinder bore, inlet and outlet ports, the secondary piston (1), and the return spring for cracks, scoring, pitting, and/or corrosion. Replace the master cylinder if any of these conditions exist. 3. Dry the master cylinder and the individual components with non-lubricated, filtered air. 4. Lubricate the master cylinder bore, the secondary piston (1), the return spring, and all of the individual overhaul components with Delco Supreme 11® (GM P/N 12377967) or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. 5. Assemble the lubricated, new primary seal (6) and retainer, and new secondary seal (5) onto the secondary piston. 6. Install the lubricated return spring and secondary piston assembly (1) into the cylinder bore. 7. Install the lubricated, new primary piston assembly (2) into the cylinder bore. 8. Using a smooth, round-ended tool, depress the primary piston (2) and install the new piston retainer. 9. Install the master cylinder reservoir to the master cylinder. 10. Install the reservoir cap and diaphragm to the reservoir. 11. Install the master cylinder to the vehicle. Master Cylinder Reservoir Replacement Master Cylinder Reservoir Replacement Removal Procedure Caution: Refer to Brake Fluid Irritant Caution in Service Precautions. Notice: Refer to Brake Fluid Effects on Paint and Electrical Components Notice in Service Precautions. 1. Apply the park brake and block the wheels. 2. Remove the master cylinder. 3. Drain the master cylinder reservoir. 4. Secure the master cylinder in a vise. Do not clamp the master cylinder body, secure only at the flange. 5. Remove the brake fluid level sensor by carefully depressing the retaining tabs and pushing the sensor through the reservoir. Carefully remove the reservoir retaining pins. Page 9528 Application Table Part 2 Page 2774 4. Connect the wiring connectors to the fuse block. Refer to Electrical Center Identification Views to ensure the right connections are made. 5. Install the right side end panel. Page 8972 Body Harness SRS - Air Bag Lamp ON/DTC B0092 Set Seat Occupant Sensor: All Technical Service Bulletins SRS - Air Bag Lamp ON/DTC B0092 Set Bulletin No.: 02-09-41-002A Date: March 24, 2004 TECHNICAL Subject: Air Bag Lamp On, Passenger Air Bag Indicator Always Reads OFF, DTC B0092 Set (Repair Passenger Presence System (PPS) Sensor Harness) Models: 2003-2004 Cadillac Escalade, Escalade EXT 2003-2004 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2003-2004 GMC Sierra, Yukon, Yukon XL with Sensor Indicator Inflatable Restraint Front Passenger/Child Presence Detector (RPO ALO) Supercede: This bulletin is being revised to add the 2004 model year. Please discard Corporate Bulletin Number 02-09-41-002 (Section 09 - Restraints). Condition Some customers may comment that the Air Bag Lamp is on and the Passenger Air Bag indicator always reads OFF. Upon investigation, the technician may find DTC B0092 set. Cause The cause of this condition may be a shorted Passenger Presence System (PPS) sensor wire. The PPS sensor harness is located under the front passenger seat. This harness may be pinched between the seat frame and the track/riser. Correction Locate the PPS sensor (1) and inspect the harness for proper routing. If the harness is pinched between the seat frame and the track/riser, use the procedure listed below to repair wire(s). 1. Move the front passenger seat to the full rearward and full tilt up position. 2. Loosen the seat frame to track/riser nut and remove the harness. 3. Tighten the seat frame to track/riser nut. 4. Repair any damaged wires. Refer to Wiring Repairs in the Wiring Systems sub-section of the Service Manual. Warranty Information Center Rear Seat Belt: Service and Repair Center Rear SEAT BELT REPLACEMENT - CENTER REAR CAUTION: To avoid personal injury to the occupants of the vehicle, observe the following precautions: - More than one supplier's seat belts are used, therefore, install ONLY the seat belt components specified in the GM parts catalog. - To verify that the correct seat belt components were installed, insert the seat belt latch in the seat belt buckle. The latch must be fully seated and be retained in the buckle until purposely released. REMOVAL PROCEDURE 1. Remove the seat belt guide cover (1). 2. Remove the rear seat armrest. 3. Release the J-Clip from under the center armrest. 4. Remove the nut from the seat belt retractor. Page 3911 Steps 10 - 14 Page 13643 Front Door Hinge: Service and Repair Door Hinge Replacement Door Hinge Replacement Body Side REMOVE OR DISCONNECT 1. Remove door from body. 2. Visually inspect and restore as much of the damage as possible to factory specifications. 3. Lightly hand-sand existing hinge with 100 grit or finer sandpaper to locate the four welds attaching hinge to the pillar (Fig.1.12). 4. Center punch each of the four weld marks on the original hinge. It is critical to punch the center of the weld so that as much of the weld is removed during drilling as possible. NOTE: Do not drill into the hinge pillar -drill through hinge ONLY (Fig.1.13). If necessary, use a chisel to separate the hinge from the pillar. 5. At each punch location, drill through hinge ONLY, using a 13 mm (1/2 inch) rotabroach hole saw or equivalent. (Fig.1.13). 6. Remove all remaining weld material from pillar surface to ensure a flush fit of the service hinge. INSTALL OR CONNECT 1. Repair any damage done to the pillar during drilling or removal. 2. Position the service template on the hinge pillar using 3M's Repositionable Adhesive (Part #6091), or equivalent. 3. Center punch each stud location on the hinge pillar according to the template. OnStar(R) - Analog/Digital Ready System Digital Upgrade Technical Service Bulletin # 05-08-46-006Q Date: 081028 OnStar(R) - Analog/Digital Ready System Digital Upgrade INFORMATION Bulletin No.: 05-08-46-006Q Date: October 28, 2008 Subject: Information on Upgrading Certain OnStar(R) Analog/Digital-Ready Systems to OnStar(R) Generation 6 Digital-Capable System Models Supercede: This bulletin is being revised to update the upgrade kit installation information for the 2001 Chevrolet Impala and Monte Carlo. Please discard Corporate Bulletin Number 05-08-46-006P (Section 08 - Body and Accessories). This bulletin is being issued to provide dealer personnel with information and procedures to follow should an owner wish to upgrade their OnStar(R) Analog/Digital-Ready system to an OnStar(R) Generation 6 Digital-Capable system. Disclaimer Program Overview Program Overview To upgrade their vehicle to an OnStar(R) Generation 6 Digital-Capable system, all that a customer must do is: ^ Take their vehicle to their dealer for the system upgrade. Page 12969 Speaker - RR - Except Crew Cab Page 1833 Steering Column Position Sensor: Service and Repair Steering Wheel Position Sensor Centering Steering Wheel Position Sensor Centering Removal Procedure 1. Important: Identify the type of steering wheel position sensor from the illustrations shown BEFORE removing the sensor from the steering column. Once you have identified the steering wheel position sensor, follow the instructions listed in the removal procedure. Verify the type of steering wheel position sensor. 2. From the technicians point of view, the FRONT of the sensor (1) connector will be on the right. 3. Important: If reusing the existing sensor, you do not have to align the sensor before removal. Centering is not required when it is time to reinstall. Remove the connector from the sensor. 4. Remove the sensor (1) from the adapter and bearing assembly. 5. To install the sensor, proceed to step 1 in the installation section. 6. From the technicians point of view, the FRONT of the sensor will have: ^ A foam ring (2) ^ A pin hole (1) for centering the pin. Note the location of the pin hole. ^ A flush rotor flange cuff (4) 7. Important: If reusing the existing sensor, you must make an alignment mark on the rotor flange cuff (3) before removing the sensor. Failure to do so will cause misalignment when installing the sensor. A new sensor will be required if misaligned. Make an alignment mark on the flush rotor flange cuff (3). 8. Remove the connector from the sensor. 9. Remove the sensor from the adapter and bearing assembly. 10. To install the sensor, proceed to step 5 in the installation procedure. Page 14130 Door Control Module Diagram 3 Part 1 Page 4965 Important The new canister vent valve will be installed in a new location, outside of the frame. 7. Position and secure the new valve assembly to the frame bracket on the outside of the frame using the existing hole and mounting bolt. Tighten Tighten the bracket mounting bolt to 12 Nm (106 lb in). 8. Connect the vent valve pipe to the EVAP canister. 9. Install the two vent valve pipe clips into the existing underbody holes. 10. Connect the EVAP canister vent valve electrical connector, if equipped. 11. Attach bulk 5/8" heater hose to the vent valve port and secure using a clamp. Run a length as needed along the frame rail routing to the area above the transmission. 12. Cut the hose to determined length and install the supplied filter box. Secure using a clamp. 13. Remove the transmission support and lower the transmission assembly as necessary to allow for access to the new filter box location. 14. Secure the filter box to the transmission vent hose just forward of the hose tee-section using a tie strap. DO NOT pinch or restrict the transmission vent hose. The filter box opening should be pointing downward. 15. Raise the transmission and reinstall the transmission support. 16. Tie strap the hose as needed along the frame rail in order to keep the hose away from pinch-points and heat sources. 17. Lower the vehicle. 2004-2007 Model Year (Use Service Kit P/N 19152349) 1. Raise the vehicle. Suitably support the vehicle. 2. Disconnect the EVAP canister vent valve electrical connector. 3. Disconnect the canister pipe from the vent valve. 4. Push in the retainer and remove the existing canister vent valve from the fuel tank clip or mounting bracket. Discard the old valve. 5. Cut back the existing canister pipe approximately 51 mm (2 in) to remove the quick connect end. Crew Cab Short Box Shown Below, Other Configurations Similar Page 15947 IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections TESTING FOR INTERMITTENT AND POOR CONNECTIONS TOOLS REQUIRED - J 35616-C GM-Approved Terminal Test Kit - J 38125-D Terminal Repair Kit - J 42675 Flat-Wire Probe Adapter Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector. - Poor terminal to wire connection - Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. - Wire insulation which is rubbed through - This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. - Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. Testing For Proper Terminal Contact It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-D or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-D, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. Page 10429 Do Not Replace coil-over shock absorbers displaying condition 1 or 2 levels of seepage. 1. Oil or fluid residue only on the bottom of the lower shock absorber tube or the coil-over shock absorber components and not originating from the shaft seal (located at the top of the coil-over shock tube). 2. Light film/residue on the shock absorber tube, but not on the spring seat and originating from the shaft seal. Replace coil-over shock absorbers displaying conditions 3 and 4 levels of leaks. 3. Oil drip or trail down the lower shock tube and originating from the shaft seal. 4. An extreme, wet film of oil covering the shock absorber tube and pooling in the spring seat and originating from the shaft seal. Struts Do Not Replace Struts displaying condition 1 or 2 levels of seepage. 1. Oil or fluid residue only on the bottom of the strut tube or on other strut components and not originating from the shaft seal. 2. Light film/residue on the strut tube, but not on the spring seat and originating from the shaft seal. Replace Struts displaying conditions 3 and 4 levels of leaks. 3. Oil drip or trail down the strut tube and originating from the shaft seal (located at the top of the strut tube). 4. Extreme wet film of oil covering the strut tube and pooling in the spring seat and originating from the shaft seal. Correction Use the information published in SI for diagnosis and repair. Use the applicable published labor operation. Disclaimer Page 7173 8. Install the clutch actuator cylinder and bolts. ^ Tighten the bolts to 8 Nm (71 inch lbs.) 9. Install the transmission. 10. Lower the vehicle. Page 12521 ^ An OnStar(R) Call Center button press WILL NOT connect the vehicle with OnStar(R). The vehicle must be upgraded to reactivate the account. The customer will hear a demo message stating that there is not a current OnStar(R) subscription for the vehicle. The message will also instruct the customer how to upgrade and reactivate services. ^ OnStar(R) personal calling (OPC) will not be available, as this feature requires the customer to have a current OnStar(R) account. Attempts to use this feature will result in cellular connection failure messages and the inability to connect to the number dialed. Note For deactivated vehicles, a no connect response should be considered normal system operation. Further diagnosis and subsequent repair is only necessary should the customer elect to become an active OnStar(R) subscriber and upgrade the account subscription. OnStar(R) Cellular, GPS, and Diagnostic Limitations The proper operation of the OnStar(R) System is dependent on several elements outside the components integrated into the vehicle. These include the National Cellular Network Infrastructure, the cellular telephone carriers within the network, and the GPS. The cellular operation of the OnStar(R) system may be inhibited by factors such as the users range from a digital cellular tower, the state of the cellular carrier's equipment, and the location where the call is placed. Making an OnStar(R) key press in areas that lack sufficient cellular coverage or have a temporary equipment failure will result in either the inability of a call to complete with a data transfer or the complete inability to connect to the OnStar(R) Call Center. The OnStar(R) system may also experience connection issues if the identification numbers for the module, station identification number (STID), electronic serial number (ESN) or manufacturers electronic ID (MEID), are not recognized by the cellular carriers local signal receiving towers. The satellites that orbit earth providing the OnStar system with GPS data have almost no failures associated with them. In the event of a no GPS concern, the failure will likely lie with the inability of the system to gain GPS signals because of its location, i.e. in a parking structure, hardware failure, or being mistaken with an OnStar(R) call which has reached the Call Center without vehicle data. During diagnostic testing of the OnStar(R) system, the technician should ensure the vehicle is located in an area that has a clear unobstructed view of the open sky, and preferably, an area where digital cellular calls have been successfully placed. These areas can be found by successfully making an OnStar(R) keypress in a known good OnStar(R) equipped vehicle and confirming success with the OnStar(R) Call Center advisor. Such places can be used as a permanent reference for future OnStar(R) testing. Mobile Identification Number and Mobile Directory Number The vehicle communication interface module (VCIM) utilizes 2 numbers for cellular device identification, call routing and connection. They are: ^ A mobile identification number (MIN) ^ A mobile directory number (MDN) Note The MIN represents the number used by the cellular carrier for call routing purposes. The MDN represents the number dialed to reach the cellular device. Diagnostic Information Symptoms - Cellular Communication The following steps must be completed before using the symptom table. 1. Perform the Diagnostic System Check - Vehicle, before using the Symptom Tables in order to verify that the following are true: ^ There are no DTCs set. ^ The control modules can communicate via the serial data link. 2. Review the system operation in order to familiarize yourself with the system functions. Refer to Radio/Audio System Description and Operation in SI. Diagnostic Starting Point - Displays and Gages Begin the displays and gages system diagnosis with Diagnostic System Check - Vehicle or the audible warning system diagnosis with Diagnostic System Page 10278 1. Set the front wheels in the straight ahead position. Notice: On the 2002 and later model year vehicles the steering column LOCK was removed from the steering column. It is critical that the J 42640 - Steering column Anti-Rotation Pin is used when servicing steering columns on 2002 and later model year vehicles. Failure to use the J 42640 may result in damage to the SIR coil. 2. Set the steering wheel in the LOCK position on 2001 and prior model year vehicles. 3. For 2002 and later vehicles install the J 42640 in the steering column lower access hole. 4. From under the hood remove the lower bolt that connects the upper intermediate shaft to the steering gear coupling shaft. 5. Slide the shaft towards the dash in order to disengage the shaft from the steering gear coupling shaft. 6. For vehicles equipped with adjustable foot pedals perform the following steps: 1. Reposition the carpet away from the accelerator pedal position (APP) sensor. 2. Remove the two nuts retaining the accelerator pedal to the bulkhead. 3. Reposition the accelerator pedal out of the way so the intermediate shaft can be removed. Page 6068 3. Clean the area around and below the cover. 4. Inspect the transmission fluid level. Refer to Transmission Fluid Checking Procedure in the appropriate Service Manual. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 5519 6. Connect the fuel composition sensor electrical connector. 7. Lower the vehicle. 8. Use the following procedure in order to inspect for leaks: 8.1. Turn the ignition ON, with the engine OFF, for 2 seconds. 8.2. Turn the ignition OFF for 10 seconds. 8.3. Turn the ignition ON, with the engine OFF. 8.4. Inspect for fuel leaks. Locations Traction Control Switch: Locations ABS Component Views Traction Control Switch Page 4144 Air Induction Components Specifications Fuel Pressure: Specifications Fuel Pressure (Key ON Engine OFF) .............................................................................................................................................. 385-425 kPa (55-62 psi) Page 8389 Parking Brake Cable: Service and Repair Park Brake Cable Guide Replacement Park Brake Cable Guide Replacement Removal Procedure 1. Release the parking brake. 2. Raise and support the vehicle. Refer Vehicle Lifting 3. Remove the park brake cable guide bolt from the frame. 4. Remove the park brake cable guide. 5. Remove the park brake guide from the park brake cable. Installation Procedure 1. Install the park brake cable guide to the park brake cable. 2. Install the park brake cable guide. 3. Notice: Refer to Fastener Notice in Service Precautions. Install the park brake cable guide bolt to the frame. ^ Tighten the bolt to 12 Nm (106 inch lbs.). 4. Remove the safety stands. 5. Lower the vehicle. Park Brake Cable Replacement - Front Park Brake Cable Replacement - Front Removal Procedure 1. Release the park brake. 2. Remove the park brake pedal. Refer to Park Brake Pedal Assembly Replacement. Page 14922 Memory/Heated Seat Switch - Driver (DDM C5) Part 1 Page 10312 7. Pry between the lower control arm (2) and the outer bearing race (1) while reading the dial indicator. This shows vertical looseness in the lower ball joints. The lower ball joint may show some looseness. 8. If the dial indicator reading is more than 3.18 mm (0.125 inch), replace the lower ball joint. 9. If the lower ball joint is within specifications, and there is too much horizontal looseness, check the upper ball joint for wear. 0. Disconnect the upper ball joint from the steering knuckle. 1. If you find any looseness or can twist the upper ball joint stud with your fingers, replace the upper control arm. Page 15237 Control Module References Part 3 Page 15206 Electrical Symbols Part 14 Page 3061 Wheel Bearing: Service and Repair With Rear Wheel Steering Wheel Hub and Bearing Replacement ^ Tools Required J 45859 Axle Remover Removal Procedure 1. Notice: Refer vehicle Lifting. Raise the vehicle. Refer to Vehicle Lifting. 2. Remove the tire and wheel. 3. Remove the brake rotor. 4. Remove the axle nut dust cover (4). 5. Remove the cotter pin (2) and retainer (3) from the wheel drive shaft nut. 6. Remove the wheel drive shaft retaining nut. 7. Remove the wheel hub and bearing retaining bolts. Page 12786 these systems will then completely power OFF. OnStar(R) Module Expected Current Draw The expected current draw of the OnStar(R) module in various ignition modes are as follows: ^ Ignition ON ‐ 240 to 400 mA ^ Ignition OFF ‐ 3 to 20 mA for 48 hours ^ Ignition OFF ‐ 0.2 to 0.8 mA after 48 hours (120 hours on specified vehicle communication platforms (VCPs)). Note During extended voltage testing for battery parasitic draw, it is possible to observe a voltage spike caused by the following: ^ A cellular registration call that was triggered by the local cellular system. ^ The OnStar(R) system has set a monthly trigger for a vehicle data upload call for the OnStar(R) Vehicle Diagnostic E‐mail upload. OnStar(R) System States of Readiness The OnStar(R) system will use the following 4 states of readiness, depending upon the type of cellular market the vehicle is in when the ignition is turned OFF. ^ High power ^ Low power ^ Sleep ^ Digital standby The high power state is in effect whenever the ignition is in the ON or RUN position, retained accessory power (RAP) is enabled, and/or the OnStar(R) system is sending or receiving calls or when the system is performing a remote function. The low power state is in effect when the OnStar(R) system is idle with the ignition in the ON or RUN position, or with RAP enabled. The sleep state is entered after the vehicle has been shut OFF and the RAP has timed out. At a predetermined time recorded within the VCIM, the system re-enters the low power state to listen for a call from the OnStar(R) Call Center for 1 minute. After this interval, the system will again return to the sleep state for 9 minutes. If a call is sent during the 1 minute interval, the OnStar(R) system will receive the call and immediately go into the high power mode to perform any requested functions. If a call is not received during the 1 minute interval, the system will go back into the sleep mode for another 9 minutes. This process will continue for up to 48 hours, after which the OnStar(R) system will turn OFF until the ignition is turned to the ON or RUN position. The digital standby power state is entered after the vehicle has been shut off and the RAP has timed out while in a digital cellular area. When in digital standby mode, the OnStar(R) module is able to perform all remote functions as commanded by an OnStar(R) advisor at any time, for a continuous 48 hours. After 48 hours, the OnStar(R) module will go into sleep mode until a wake up signal from the vehicle is seen by the CIM. If the OnStar module loses the digital cellular signal it will revert to analog mode and follow the standard sleep state (9 minutes OFF, 1 minute standby) based on the time of the GPS signals, this will continue until a digital cellular signal is again received. If the OnStar(R) system loses battery power while the system is in a standby or sleep mode, the system will remain OFF until battery power is restored and the ignition is turned to the ON or RUN position. Deactivated OnStar(R) Accounts In the event that a customer has not upgraded their vehicle to a digital system, the account has been deactivated. The customers have been previously notified of the steps required to upgrade their vehicles. After the OnStar(R) account has been deactivated, customers will experience the following: ^ The OnStar(R) status LED will not illuminate ^ The OnStar(R) system will NOT attempt to connect to the OnStar(R) Call Center in the event of a collision or if the vehicle's front air bags deploy for any other reason. ^ An emergency button press will result in a demo message being played, indicating the service has been deactivated and needs to be upgraded. Page 6747 Important The new canister vent valve will be installed in a new location, outside of the frame. 7. Position and secure the new valve assembly to the frame bracket on the outside of the frame using the existing hole and mounting bolt. Tighten Tighten the bracket mounting bolt to 12 Nm (106 lb in). 8. Connect the vent valve pipe to the EVAP canister. 9. Install the two vent valve pipe clips into the existing underbody holes. 10. Connect the EVAP canister vent valve electrical connector, if equipped. 11. Attach bulk 5/8" heater hose to the vent valve port and secure using a clamp. Run a length as needed along the frame rail routing to the area above the transmission. 12. Cut the hose to determined length and install the supplied filter box. Secure using a clamp. 13. Remove the transmission support and lower the transmission assembly as necessary to allow for access to the new filter box location. 14. Secure the filter box to the transmission vent hose just forward of the hose tee-section using a tie strap. DO NOT pinch or restrict the transmission vent hose. The filter box opening should be pointing downward. 15. Raise the transmission and reinstall the transmission support. 16. Tie strap the hose as needed along the frame rail in order to keep the hose away from pinch-points and heat sources. 17. Lower the vehicle. 2004-2007 Model Year (Use Service Kit P/N 19152349) 1. Raise the vehicle. Suitably support the vehicle. 2. Disconnect the EVAP canister vent valve electrical connector. 3. Disconnect the canister pipe from the vent valve. 4. Push in the retainer and remove the existing canister vent valve from the fuel tank clip or mounting bracket. Discard the old valve. 5. Cut back the existing canister pipe approximately 51 mm (2 in) to remove the quick connect end. Crew Cab Short Box Shown Below, Other Configurations Similar Lighting - Exterior Lamp Condensation and Replacement Parking Lamp: Technical Service Bulletins Lighting - Exterior Lamp Condensation and Replacement INFORMATION Bulletin No.: 01-08-42-001H Date: January 05, 2011 Subject: Exterior Lamp Condensation and Replacement Guidelines Models: 2011 and Prior GM Passenger Cars and Trucks (including Saturn) Supercede: This bulletin is being revised to add the 2011 model year. Please discard Corporate Bulletin Number 01-08-42-001G (Section 08 - Body and Accessories). The following information is being provided to better define the causes of condensation in exterior lamps and includes guidelines for determining the difference between a lamp with a normal atmospheric condition (condensation) and a lamp with a water leak. Some exterior lamps, such as cornering, turn signal, backup, headlamps or tail lamps may exhibit very small droplets of water, a fine mist or white fog (condensation) on the inside of the lamp lens. This may be more noticeable on lamps with "multi-lens" designs and may be normal during certain weather conditions. Condensation occurs when the air inside the lamp assembly, through atmospheric changes, reaches the "dew point". When this takes place, the moisture in the air within the lamp assembly condenses, creating a fine mist or white fog on the inside surface of the lamp lens. Most exterior lamps on General Motors vehicles use a vented design and feature a replaceable bulb assembly. They are designed to remove any accumulated moisture vapor by expelling it through a vent system. The vent system operates at all times, however, it is most effective when the lamps are ON or when the vehicle is in motion. Depending on the size, shape and location of the lamp on the vehicle, and the atmospheric conditions occurring, the amount of time required to clear the lamp may vary from 2 to 6 hours. Completely sealed headlamp assemblies (sealed beams) are still used on a limited number of models being manufactured today. These lamps require the replacement of the complete lamp assembly if a bulb filament burns out. Condensation 2006 TrailBlazer Shown A Fine Mist or White Fog on the Inside Surface of the Lamp Lens Occurring After a Period of High Humidity - May be located primarily in the lens corners (near the vents) and SHOULD NOT cover more than half the lens surface. - The condition should clear of moisture when the vehicle is parked in a dry environment, or when the vehicle is driven with the lights ON. - A comparison of the equivalent lamp on the opposing side of the vehicle indicates a SIMILAR performance. If the above conditions are noted, the customer should be advised that replacement of a lamp assembly may not correct this condition. Water Leak New Style Pickup Shown Page 6444 6. Remove the 1-2 shift solenoid retainer (395) and the 1-2 shift solenoid (267A). 7. Remove the 2-3 shift solenoid retainer (395) and the 2-3 shift solenoid (367A). 8. Remove the 3-2 control solenoid retainer (395) and the 3-2 control solenoid (394). Installation Procedure 1. Install the 3-2 control solenoid (394) and the 3-2 control solenoid retainer (395). Service and Repair Air Bag(s) Arming and Disarming: Service and Repair SIR Disabling and Enabling The SIR Identification Views shown below illustrate the approximate location of all SIR components available for the vehicle. This will assist in determining the appropriate SIR Disabling and Enabling for a given service procedure. Refer to See: Restraint Systems/Air Bag Systems/Locations/SIR Zone Identification Views There are several reasons for disabling the SIR system, such as repairs to the SIR system or servicing a component near or attached to an SIR component. There are several ways to disable the SIR system depending on what type of service is being performed. The following information covers the proper procedures for disabling/enabling the SIR system. SIR Service Precautions Caution: When performing service on or near the SIR components or the SIR wiring, the SIR system must be disabled. Failure to observe the correct procedure could cause deployment of the SIR components. Serious injury can occur. Failure to observe the correct procedure could also result in unnecessary SIR system repairs. The inflatable restraint sensing and diagnostic module (SDM) maintains a reserved energy supply. The reserved energy supply provides deployment power for the air bags if the SDM loses battery power during a collision. Deployment power is available for as much as 1 minute after disconnecting the vehicle power. Waiting 1 minute before working on the system after disabling the SIR system prevents deployment of the air bags from the reserved energy supply. General Service Instructions The following are general service instructions which must be followed in order to properly repair the vehicle and return it to its original integrity: - Do not expose inflator modules to temperatures above 65°C (150°F). - Verify the correct replacement part number. Do not substitute a component from a different vehicle. - Use only original GM replacement parts available from your authorized GM dealer. Do not use salvaged parts for repairs to the SIR system. Discard any of the following components if it has been dropped from a height of 91 cm (3 feet) or greater: - Inflatable restraint sensing and diagnostic module (SDM) - Any Inflatable restraint air bag module - Inflatable restraint steering wheel module coil - Any Inflatable restraint sensor - Inflatable restraint seat belt pretensioners - Inflatable restraint Passenger Presence System (PPS) module or sensor Disabling Procedure - Air Bag Fuse 1. Turn the steering wheel so that the vehicles wheels are pointing straight ahead. 2. Place the ignition in the OFF position. Important: The SDM may have more than one fused power input. To ensure there is no unwanted SIR deployment, personal injury, or unnecessary SIR system repairs, remove all fuses supplying power to the SDM. With all SDM fuses removed and the ignition switch in the ON position, the AIR BAG warning indicator illuminates. This is normal operation, and does not indicate a SIR system malfunction. 3. Locate and remove the fuse(s) supplying power to the SDM. Page 2700 Relay Block I/P C7 (With RPO Codes Z82 Or T89) Page 4550 The scan tool will power up with the ignition OFF. Some modules however, will not communicate unless the ignition is ON and the power mode master (PMM) module sends the appropriate power mode message. TEST DESCRIPTION Steps 1 - 4 The number below refers to the step number on the diagnostic table. 4. If the battery positive voltage and ground circuits of the DLC are functioning properly. The malfunction must be due to the scan tool. Page 8829 6. Remove the generator bolts. 7. Remove the generator. INSTALLATION PROCEDURE 1. Install the generator. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the generator bolts. Tighten Tighten the bolts to 50 N.m (37 lb ft). Page 12880 Parts Information Campaign - Deactivation Of Analog OnStar(R) Technical Service Bulletin # 08089C Date: 081118 Campaign - Deactivation Of Analog OnStar(R) # 08089C: Special Coverage Adjustment - Analog OnStar Deactivation (Nov 18, 2008) Subject: 08089C -- SPECIAL COVERAGE ADJUSTMENT - ANALOG ONSTAR(R) DEACTIVATION Page 3580 1. Install the coolant air bleed hose (1) to the pipe (2). 2. Position the coolant air bleed hose clamp at the pipe. 3. Install the coolant air bleed hose to the throttle body. 4. Position the coolant air bleed hose clamp at the throttle body. 5. Add engine coolant, if necessary. Page 14590 Power Seat Control Module: Diagrams Memory Seat Module - C1 Diagrams Roof Beacon Relay (With RPO Code 5X7, 5G4, TRW, Or 5Y0) Page 8761 18. Install the positive cable (1) into the junction block. 19. Snap the junction block cover closed. 20. If necessary, install the engine sight shield. 21. Tighten the positive cable bolt at the UBEC. Tighten Tighten the bolt to 9 N.m (80 lb in). 22. Install the positive battery cable. 23. Tighten the positive battery cable. Tighten Page 12446 Page 335 A current DTC clears when the condition for setting the DTC is no longer present. A history DTC clears after 50 malfunction-free ignition cycles. Circuit/System Testing Without RPO UAV 1. Turn OFF the ignition and all electrical components, including the scan tool. 2. Disconnect the harness connector at the cellular microphone. 3. Test for less than 5 Ohms between the low reference circuit terminal A and ground. ^ If greater than the specified range, test the low reference circuit for an open/high resistance. If the circuit tests normal, replace the VCIM. 4. Ignition ON, test for 9 - 11 volts between the signal circuit terminal B and ground. ^ If greater than the specified range, test the signal circuit for a short to voltage. If the circuit tests normal, replace the VCIM. ^ If less than the specified range, test the signal circuit for a short to ground or an open/high resistance. If the circuit tests normal, replace the VCIM. Refer to the appropriate vehicle in SI. 5. If all circuits test normal, test or replace the cellular microphone. Circuit/System Testing With RPO UAV 1. Turn OFF the ignition and all electrical components, including the scan tool. 2. Disconnect the X4 harness connector at the navigation radio and the harness connector at the cellular microphone. 3. Test for less than 5 Ohms between the low reference circuit terminal A and ground. ^ If greater than the specified range, test the low reference circuit for an open/high resistance. If the circuit tests normal, replace the VCIM. Refer to the appropriate vehicle in SI. 4. Ignition ON, test for 9 - 11 volts between the signal circuit terminal B and ground. ^ If greater than the specified range, test the signal circuit for a short to voltage. If the circuit tests normal, replace the VCIM. ^ If less than the specified range, test the signal circuit for a short to ground or an open/high resistance. If the circuit tests normal, replace the VCIM. 5. If all circuits test normal, test or replace the cellular microphone. 6. Connect the X4 harness connector at the navigation radio. 7. With a scan tool, verify that DTC B2455 is not set as current in the navigation radio. ^ If DTC B2455 is set as current, replace the navigation radio. Refer to the appropriate vehicle in SI. DTC B2462, B2483, or B2484 Circuit/System Description The vehicle communication interface module (VCIM) receives information from a specific navigation antenna located on the outside of the vehicle. The navigation antenna is connected to the VCIM via a shielded coaxial cable. The antenna cable also provides a path for DC current for powering the antenna. DTC Descriptors DTC B2462 02: Global Positioning System (GPS) Antenna Malfunction Short to Ground DTC B2462 04: Global Positioning System (GPS) Antenna Malfunction Open Circuit Page 3796 Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA and/or the secondary locks. Micro .64 Connectors MICRO .64 CONNECTORS TOOLS REQUIRED J 38125-D Terminal Repair Kit REMOVAL PROCEDURE Follow the steps below in order to remove terminals from Micro 64 connectors. 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. 2. Disconnect the connector from the component. Page 4328 Control Module References Part 4 Locations Fuel Pump And Sender Assembly Components Locations Instrument Panel Switches-LH Instruments - IPC Odometer Programming Reference Guide Odometer: All Technical Service Bulletins Instruments - IPC Odometer Programming Reference Guide INFORMATION Bulletin No.: 07-08-49-020D Date: December 06, 2010 Subject: IPC Odometer Programming Method Quick Reference Guide Models: 2003-2011 GM Passenger Cars and Trucks (Including Saturn) 2003-2010 HUMMER H2, H3 2005-2009 Saab 9-7X Attention: This bulletin applies to vehicles sold in the U.S. and Canada Only. Supercede: This bulletin is being revised to add information for the 2011 model year and add new 2011 vehicles. Please discard Corporate Bulletin Number 07-08-49-020C (Section 08 - Body and Accessories). The purpose of this bulletin is to provide a reference guide to help identify which season odometer programming method to use after replacing the instrument panel cluster (IPC). The three season odometer programming methods in use today are listed below. In addition, this reference guide lists the component where the season odometer value is stored. The season odometer value may be stored in the IPC, the driver information center (DIC) or the integrated body control module (IBCM), also commonly called a body control module (BCM). Season Odometer Programming Methods in Use Today 1. IPC reprogramming and setup using the service programming system (SPS). 2. Odometer setup at the electronic service center (ESC) when using an exchange IPC/DIC. 3. Tech 2(R) - The Tech 2 is used to set up a replacement BCM, which includes loading the odometer value that is displayed and stored in the IPC. A replacement IPC will display the previously stored vehicle odometer value, communicated from the BCM, after cycling the ignition or driving the vehicle. *The odometer programming is integrated as part of the BCM programming procedure. It is not a stand-alone event. Diagrams Clutch Start Switch (M/T) Navigation System - Software/DVD Update Program Navigation System: All Technical Service Bulletins Navigation System - Software/DVD Update Program INFORMATION Bulletin No.: 06-08-44-012E Date: April 20, 2010 Subject: DVD Navigation Update Program, Navigation Disc Diagnostic Aid, AVN Software Update Discs and Ordering Information Models: 2002-2010 GM Passenger Cars and Trucks (including Saturn) 2004-2010 HUMMER H2, H3 2005-2009 Saab 9-7X Attention: Please direct this information to your Sales Consultants, Service Consultants, Parts Personnel and Used Car Department. This bulletin ONLY applies to North American dealers/retailers. Supercede: This bulletin is being revised to include the 2010 model year and update the usage table. Please discard Corporate Bulletin Number 06-08-44-012D (Section 08 - Body and Accessories). DVD Navigation Update Program The data on the DVD map disc ages at a rate of 15-20% per year. As the data ages, the functionality of the navigation system declines. Offering GM customers new navigation DVDs will ensure that the customers have the latest information for their system. General Motors offered a Navigation Disc Update Program for 2006 and 2007 model year vehicles. This program concluded on December 31, 2009. The DVD Navigation Update Program policy has changed and customers are no longer eligible for free annual updates, however, a navigation DVD update disc can be purchased for $199 (USD) + shipping. If the navigation disc is needed for a warranty situation, the disc can be purchased for $120 (USD). The dealer must provide a VIN and RO# to qualify for the reduced price. The dealer must call the GM Navigation Disc Center, as this option is not available on the website. The GM Navigation Disc Center launched on March 15, 2006. There are two ways to obtain an updated disc: - Via the web through gmnavdisc.com - GM Navigation Disc Center Navigation Disc Diagnostic Aid The following table can be used to identify acceptable discs for testing the navigation unit's map drive functionality. This should only be used to verify the map drive's ability to read the map disc properly and to determine if there is an issue with the unit's map drive or the disc. Some functions, such as voice recognition, may not work properly with some of the discs in the list. If the disc is found to be defective always contact the GM Navigation Disc Center to obtain the most recent disc for the vehicle. AVN Software Update Discs Technical Service Bulletins are sometimes generated to address specific navigation radio operational or performance issues. When a navigation radio bulletin is issued, it may contain instructions to utilize an advanced vehicle navigation (AVN) software update with a specific part number. GM dealers must order advanced vehicle navigation (AVN) software update discs as directed in the specific bulletin. AVN software update discs are for the dealer to update the navigation radio software only. They do NOT update or replace the navigation map disc that is supplied with the vehicle. Please order these parts only as needed. There is a limited supply of these discs available. Do not order these discs for stock. AVN software update discs can be used to reprogram more than one vehicle. The first update disc for each P/N is free. Subsequent copies of the same P/N for the same dealer will cost $50 (USD). To obtain an AVN software update disc, follow the specific ordering information provided in the bulletin. Page 13028 Page 12589 Important: The optic cable must not be bent with a radius less than 25 mm (1 in). 6.17. Fold back the wiring harness and tape over the connectors (G). Fold back the wiring harness once more and secure with cable ties (H). 6.18. Secure the new optic cable on the parcel shelf along the existing wiring harness by the ordinary securing points and by the speaker (I). 6.19. Thread the optic cable down next to the old cable from the parcel shelf to the left-hand wheel housing, next to REC. The cable is secured in the existing clips. 6.20. Fit the right-hand C-pillar trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.21. Fit the parcel shelf trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.22. Fit the passenger seat in accordance with WIS - 8. Body - Seats - Adjustment/Replacement. 6.23. Fit the right-hand side bolster in accordance with WIS - 8. Body - Seats Adjustment/Replacement. 6.24. Fold up the rear seat backrest. 6.25. Fit the right-hand B-pillar trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.26. Fit the A-pillar's lower side piece. 7. M04-05, 4D: Removing the OnStar® control modules and securing the wiring: Page 12928 9. Move both front seats to the fully forward. 10. Reposition the inboard seat track trim (1) in order to gain access to the rear console side panel screw (2). 11. Remove both rear console side panel screws. 12. Move both front seats to the fully rearward. 13. Remove both front console side panel screws (1). 14. Disconnect the floor console electrical connector. 15. Remove the console assembly from the vehicle. 16. Remove the audio amplifier screws (1). 17. Remove the audio amplifier from the vehicle. Page 837 5. Push on the tab (3) so that the electrical center can be rotated on the studs located at (2). 6. Remove all connectors by removing the bolt (1) for each connector. 7. Disconnect all connectors from the electrical center block. 8. Push on the tabs (2) in order to lift the electrical center (1) out of the housing. 9. To replace the engine electrical center bracket remove the 4 retaining bolts (1). 10. Remove the engine electrical center bracket assembly from the fender. INSTALLATION PROCEDURE Page 7830 7. Remove the pressure control solenoid retainer bolt (364A) and retainer (378). 8. Remove the pressure control solenoid (377). 9. Remove the TCC solenoid bolts and the valve body bolts which retain the internal wiring harness. 10. Using J 28458 , release the pass-through electrical connector from the transmission case. 1. Use the small end of the J 28458 over the top of the connector. 2. Twist in order to release the four tabs retaining the connector. 3. Pull the harness connector down through the transmission case. 11. Remove the TCC solenoid (with O-ring seal) and wiring harness. Entertainment System - DVD Monitor Display Inoperative DVD Player: All Technical Service Bulletins Entertainment System - DVD Monitor Display Inoperative Bulletin No.: 07-08-44-016A Date: August 28, 2007 TECHNICAL Subject: GM Accessories Headrest DVD System Display Monitor Inoperative (Install Cable Connector Clamps) Models Supercede: This bulletin is being revised to update the models affected list. Please discard Corporate Bulletin Number 07-08-44-016 (Section 08 - Body & Accessories). Condition Some customers may comment on an inoperative display monitor or monitors in the GM Accessories Headrest DVD System. Cause This condition may be caused by a loose connection at the display monitor cable connectors. These connectors are located at the lower rear part of both front seats. Two cables are routed to the display monitor in each seat. Correction A number of headrest monitors have been replaced under warranty and in many cases, no trouble was found by the supplier when these units were Page 7367 Transmission Speed Sensor: Service and Repair Output Shaft Speed Sensor Replacement Output Shaft Speed Sensor Replacement Removal Procedure Important: This procedure is for 2-wheel drive (2WD) vehicles only. If the vehicle is equipped with 4-wheel drive (4WD), the output speed sensor is located on the transfer case. 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. Disconnect the output speed sensor (2) electrical connector. 3. Remove the output speed sensor bolt. 4. Remove the output speed sensor (2). 5. Inspect the output speed sensor (2) for any evidence of damage. Installation Procedure Page 10237 TOOLS REQUIRED J 34142-B 12 V Unpowered Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. When testing for voltage: 1. Attach 1 lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach 1 lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Using Connector Test Adapters USING CONNECTOR TEST ADAPTERS NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-B Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires USING FUSED JUMPER WIRES TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Connector Position Assurance Locks CONNECTOR POSITION ASSURANCE LOCKS The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Terminal Position Assurance Locks TERMINAL POSITION ASSURANCE LOCKS The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Push to Seat Connectors PUSH TO SEAT CONNECTORS TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Page 10761 The 1999 though early 2003 wiring harness jumper that plugs into the relay block will have a reddish/brown 6-way connector and a tag with the last four digits of the wiring harness part number. Second design 2003-05 may have a white plastic connector with part number 5418 as well. ^ The 1999 jumper is/was P/N 12171982 with a pink/purple tag identifier of 1982. This number has been superseded to 15366255, with a pink/purple tag identifier of 6255. ^ The 2000 jumper harness is P/N 15366255. The pink/purple tag identifier is 6255. ^ The 2001-2002 jumper is P/N 15086884. The orange tag identifier is 6884. ^ The 2003-05 jumper is P/N 15085418. The orange tag identifier is 5418. When transferring the brake controller with the wiring jumper attached from a 2001-2002 vehicle to a 2003-05 vehicle, a change to the jumper harness connector must be performed. Page 13966 Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 15993 Ambient Air Temperature Sensor Resistance The table will be used to measure the resistance of the sensor and compare it with the actual ambient temperature. The mirror's temperature accuracy should be within 5 degrees of the actual temperature. The actual temperature should not be taken from a radio station, a sign displaying the temperature, etc. A temperature measuring tool such as a thermometer should be used. Some temperature measuring tools may be within 5 degrees of the actual temperature. Make sure to consult the manufacturer for the accuracy of the tool. This comparison can make the mirror seem off by 5-10 degrees of the actual temperature when it is not. TEST Page 6227 Disclaimer Page 9227 Multiple Junction Connector: Diagrams C305 - C399 C305 Body Harness To Drivers Seat Harness (With RPO Code AG1) Part 1 Page 13374 Lock Cylinder Switch: Description and Operation PASSLOCK(TM) SENSOR The Passlock(TM) sensor is inside the ignition cylinder lock housing. The Passlock(TM) sensor contains 2 hall effect sensors. The tamper hall effect sensor is on the top. The security hall effect sensor is under the tamper hall effect sensor. Both of the hall effect sensors monitor the magnet of the lock cylinder through an opening. The tamper hall effect sensor is physically placed on top of the security hall effect sensor. This arrangement enables the tamper hall effect sensor to engage first if an intruder attempts to bypass the Passlock(TM) sensor by placing a large magnet around that area of the steering column. There is a tamper resistor inside the Passlock(TM) sensor in order to help prevent tamper to the system. Passlock(TM) equipped vehicles have a selection of 10 different security resistors ranging from 0.5K ohms up to 13.6K ohms. Installing one of the security resistors inside the Passlock(TM) sensor will generate a unique Passlock(TM) code. All 10 combinations of the Passlock(TM) sensor have the same part number. However, you cannot simply replace the Passlock(TM) sensor and expect the system to operate properly. Always start by performing the Diagnostic System Check first and following the instructions. Page 12339 6. Use fingers to squeeze the 2 locking legs of the cover. 7. Apply pressure and gently rock the cover until one locking leg is unseated. 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. Page 5937 5. Compress the reverse boost valve sleeve into the bore of the oil pump to expose the retaining ring slot. 6. Install the reverse boost valve retaining ring, then slowly release tension on the reverse boost valve sleeve. 7. Install the transmission filter. Page 1393 Put unused material on the shelf for future use. Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Page 2994 Page 6917 16. Remove the inner race (1) from the cage (2) by rotating the inner race (1) upward. 17. Clean the following items thoroughly with cleaning solvent. Remove all traces of old grease and any contaminates. 1. The inner and outer race assemblies 2. The CV joint cage 3. The chrome alloy balls 18. Dry all the parts. 19. Check the CV joint assembly for unusual wear, cracks, or other damage. 20. Replace any damaged parts. 21. Clean the halfshaft bar. Use a wire brush to remove any rust in the seal mounting area (grooves). Assembly Procedure 1. Inspect all of the parts for unusual wear, cracks, or other damage. Replace the CV joint assembly if necessary. 2. Put a light coat of the recommended grease on the inner (6) and the outer race (8) grooves. Page 10612 Some customers may use penetrating oils, grease or other lubricants on wheel studs to aid in removal or installation. Always use a suitable cleaner/solvent to remove these lubricants prior to installing the wheel and tire assemblies. Lubricants left on the wheel studs may cause improper readings of wheel nut torque. Always install wheels to clean, dry wheel studs ONLY. Notice Lubricants left on the wheel studs or vertical mounting surfaces between the wheel and the rotor or drum may cause the wheel to work itself loose after the vehicle is driven. Always install wheels to clean, dry wheel studs and surfaces ONLY. Beginning with 2011 model year vehicles, put a light coating of grease, GM P/N 1051344 (in Canada, P/N 9930370), on the inner surface of the wheel pilot hole to prevent wheel seizure to the axle or bearing hub. Wheel Stud and Lug Nut Damage Always inspect the wheel studs and lug nuts for signs of damage from crossthreading or abuse. You should never have to force wheel nuts down the stud. Lug nuts that are damaged may not retain properly, yet give the impression of fully tightening. Always inspect and replace any component suspected of damage. Tip Always start wheel nuts by hand! Be certain that all wheel nut threads have been engaged BEFORE tightening the nut. Important If the vehicle has directional tread tires, verify the directional arrow on the outboard side of the tire is pointing in the direction of forward rotation. Wheel Nut Tightening and Torque Improper wheel nut tightening can lead to brake pulsation and rotor damage. In order to avoid additional brake repairs, evenly tighten the wheel nuts to the proper torque specification as shown for each vehicle in SI. Always observe the proper wheel nut tightening sequence as shown below in order to avoid trapping the wheel on the wheel stud threads or clamping the wheel slightly off center resulting in vibration. The Most Important Service You Provide While the above information is well known, and wheel removal so common, technicians run the risk of becoming complacent on this very important Page 9603 Relay Block - I/P C9 Part 1 Page 5086 Evaporative Emissions (EVAP) Canister Vent Solenoid (w/EVA) Page 6944 18. Pinch the new swage ring (2) slightly by hand to distort it into an oval shape. 19. Slide the distorted swage ring (2) over the large diameter of the boot (1). Important: Be sure that the retaining ring side of the CV joint inner race faces the halfshaft bar (3) before installation. 20. Slide the CV joint (4) onto the halfshaft bar (3) The retaining snap ring inside of the inner race engages in the halfshaft bar groove with a clock when the CV joint (4) is in the proper position. 21. Pull on the CV joint (4) to verify engagement. 22. Slide the large diameter of the CV joint boot (1), with the large swage ring (2) in place, over the outside edge of the CV joint outer race (4). 23. Clamp the CV joint boot (2) tightly to the CV joint outer race (1) with the large swage ring (4), using the following procedure: 24. For the 1500 models, assemble the bolts and the support plate to the base of the J 36652-1 and secure the base in a vise. For the 2500 and 3500 models, use the J36652-2. Interior - Seat Memory Feature Appears Inoperative Memory Positioning Module: Customer Interest Interior - Seat Memory Feature Appears Inoperative Bulletin No.: 04-08-50-003 Date: February 26, 2004 INFORMATION Subject: Enabling Memory Seat Feature via DIC If Feature Appears Inoperative Models: 2003-2004 Cadillac Escalade, Escalade ESV, Escalade EXT 2003-2004 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2003-2004 GMC Sierra, Yukon, Yukon Denali, Yukon Denali XL 2003-2004 HUMMER H2 with Steering Wheel Controls (RPO UK3) (standard on H2) If the memory seat feature appears inoperative, check the Driver Information Center (DIC). Many of the memory seat modules that were returned through the Warranty Parts Center for a condition of inoperative have shown No Trouble Found. The Driver Information Center (DIC), programmed for Seat Entry and Exit, is set to the default "Off" mode at the assembly plant. DO NOT REPLACE THE MEMORY SEAT MODULE. Perform the following procedure. Important: The following procedure will need to be completed for each Remote/Key selection. Using the DIC menu, do the following steps: 1. Set the "Seat Recall" to either "At Key In" or "On Remote" based on the customer's preference. 2. Set the "Exit Seat" to "On". 3. Adjust the following items: Memory Seat: 3.1. Driver's Seat (including the seat back, recliner, lumbar, and side wings) 3.2. Throttle and Brake Pedals (not available on H2 or Silverado and Sierra Trucks) 3.3. Outside Mirrors 3.4. Radio Station Presets 3.5. Last Chosen Climate Control System Settings (not available on Silverado or Sierra Trucks) 3.6. Press and hold the "1" or "2" (for driver 1 or 2) button of the memory control for three seconds. A double chime will sound to let you know that the position has been stored. Easy Exit Seat: 3.1. Press and release the 1 or 2 button or press the unlock button on the desired remote keyless entry transmitter. The seat will move to the stored memory position. 3.2. Adjust the seat to the desired exit position. 3.3. Press and hold the exit button of the memory control (located on the door) for three seconds. A double chime will sound to let you know that the position has been stored for the identified driver (1 or 2). Page 8163 8. Remove the 2 brake caliper mounting bolts. 9. Notice: Support the brake caliper with heavy mechanic's wire, or equivalent, whenever it is separated from its mount and the hydraulic flexible brake hose is still connected. Failure to support the caliper in this manner will cause the flexible brake hose to bear the weight of the caliper, which may cause damage to the brake hose and in turn may cause a brake fluid leak. Remove the brake caliper and support with heavy mechanic's wire or equivalent. DO NOT disconnect the hydraulic brake hose from the brake caliper. 10. Remove the 2 brake caliper mounting bracket bolts. 11. Remove the disc brake pads from the brake caliper mounting bracket. 12. Remove the anti-rattle clips from the brake caliper mounting bracket. Installation Procedure Page 344 Models The service procedure in this bulletin has been revised. Step 11 in the procedure for the 2004-2005 Saab 9-3 (9440) Convertible has been revised. Discard all copies of bulletin 08089B, issued September 2008. Condition In November 2002, the U.S. Federal Commissions (FCC) ruled that wireless carriers would no longer be required to support the analog wireless network beginning in 2008. As a result, On Star(R) is unable to continue analog service. OnStar(R) has deactivated most of the systems operating in the analog mode; however, there are some vehicles that OnStar(R) could not deactivate. Although the analog OnStar(R) hardware in these vehicles can no longer communicate with OnStar(R), the hardware in the vehicle is still active. If the OnStar(R) emergency button is pressed, or in the case of an airbag deployment, or near deployment, the customer may hear a recording that OnStar(R) is being contacted. However, since analog service is no longer available, the call will not connect to OnStar(R). To end the call, the customer must press the white phone or white dot button. If the call is not ended, the system will continue to try to connect to OnStar(R) until the vehicle battery is drained. Special Policy Adjustment At the customer's request, dealers/retailers are to deactivate the OnStar(R) system. The service will be made at no charge to the customer. This special coverage covers the condition described above until December 31, 2008 for all non-Saab vehicles; April 30, 2009 for all Saab vehicles. Vehicles Involved Page 4921 Install the parking lock bracket bolts. ^ Tighten the bolts to 24 Nm (18 ft. lbs.). 13. Install the PNP switch. 14. Install the transmission filter. 15. Fill the transmission to the proper level with Dexron® III transmission fluid. Page 14855 Installation Procedure 1. Install the door module into the switch panel bezel until it snaps into place. 2. Install the switch panel bezel and module to the door panel. Notice: Refer to Fastener Notice in Service Precautions. 3. Install the screw that retains the switch panel bezel (1) to the front door panel. Tighten the screw to 2 N.m (18 lb in). 4. Connect the electrical connectors. 5. Install the front door trim panel. 6. If equipped with camper mirrors program the door module. Refer to Service Programming System (SPS) in Programming. See: Testing and Inspection/Programming and Relearning Switch Replacement - Door Lock and Side Window - Passenger Page 1646 Heated Oxygen Sensor (HO2S) Bank 1 Sensor 2 Page 1279 Left Side Of Engine Page 8921 Cigar Lighter/Auxiliary Outlets Diagram 4 (2 Of 2) Page 14811 Heated Seat Switch - Front Passenger (FPDM C5) Page 2731 4. Connect the wire connectors to the lower portion of the electrical center block. 5. Connect the wire connectors with the bolts to the electrical center block. Tighten Tighten all connector bolts (1) to 9 N.m (80 lb in). 6. Ensure all wire connectors are securely connected. 7. Set the electrical center block in its resting position till the tabs (3) locks in place. 8. Install the lower part of the cover (1). 9. With the cover (2) off, use the fuse location information to install all fuses and relays. 10. Install the cover. 11. Install the fender upper brace. 12. Install the 4 fender upper brace bolts. Tighten Tighten the 4 retaining bolts to 25 N.m (18 lb ft). 13. Connect the negative battery cable. 14. Start vehicle and ensure all components function properly. Page 2277 9. Install the A/C refrigerant filter (3) to the evaporator tube (2) with the flow arrow pointing towards the evaporator. NOTE: Refer to Fastener Notice in Service Precautions. 10. While holding the evaporator tube in the A/C refrigerant filter (1), tighten the nuts (4) to the A/C refrigerant filter (1). Tighten Tighten the nuts to 15 N.m (11 lb ft). 11. Remove the nuts (4) from the A/C refrigerant filter (1). 12. Coat the O-rings (2) with 525 viscosity refrigerant oil. 13. Install the O-rings (2) to the evaporator tube halves. 14. Install the nuts (4) to the A/C refrigerant filter (1). Tighten Tighten the nuts to 15 N.m (11 lb ft). 15. Evacuate and recharge the system. Refer to Refrigerant Recovery and Recharging. 16. Leak test the fittings of the component using the J 39400-A. 17. Install the air cleaner. Page 9407 Electrical Symbols Part 5 Page 9040 Junction Block - I/P - C4 Part 2 Page 12316 Electrical Symbols Part 6 Capacity Specifications Fluid - A/T: Capacity Specifications Transmission Fluid 4L-60-E Pan Removal .......................................................................................... ........................................................................................................... 4.7L (5.0 Qt) Overhaul ............. .............................................................................................................................................................. ............................. 10.6L (11.0 Qt) 4L80-E Pan Removal ................................................................... .................................................................................................................................. 7.3L (7.7 Qt) Overhaul .............................................................................................................................................. .......................................................... 12.8L (13.5 Qt) Allison Pan Removal ....................................... .............................................................................................................................................................. 7.0L (7.4 Qt) Overhaul ......................................................................................................................... ............................................................................... 12.0L (12.7 Qt) Page 1410 Fuel Gauge Sender: Description and Operation Fuel System Description (Cab Chassis) FUEL LEVEL SENSOR The fuel level sensor is a part of the fuel sender assembly. The position of the float arm indicates the fuel level. The fuel level sensor contains a variable resistor which changes resistance in correspondence with the amount of fuel in the fuel tank. On models that are equipped with a single fuel tank, the fuel level sensor is wired directly to the instrument panel (IP) cluster. On models equipped with dual fuel tanks, both fuel level sensors are wired to the PCM. The PCM calculates the total fuel level in both tanks. The instrument panel (IP) fuel gage displays the total fuel level in both fuel tanks. Page 6286 Park Neutral Position (PNP) Switch C175 Page 5704 1. Install the locating pins to the NEW encoder motor. 2. Position a NEW actuator insulator gasket to the transfer case. 3. Install the encoder motor. Notice: Refer to Fastener Notice in Service Precautions. 4. Install encoder motor bolts. ^ Tighten the bolts, in the sequence shown, to 20 Nm (15 ft. lbs.). 5. Connect the encoder motor electrical connector. Ensure that the retention clips activate. 6. Install the front propeller shaft. 7. Install the transfer case shield, if equipped. Page 3771 Body Control Module (BCM) Page 3822 Body Control Module: Connector Views Body Control Module (BCM) - C1 Garage Door Opener Replacement Garage Door Opener Transmitter: Service and Repair Garage Door Opener Replacement GARAGE DOOR OPENER REPLACEMENT REMOVAL PROCEDURE 1. Remove the console roof screw. 2. Disconnect the electrical connectors. 3. Remove the console from vehicle. 4. Disconnect the electrical connector from the garage door opener. 5. Remove the garage door opener retaining screws. 6. Remove the garage door opener from the overhead console. INSTALLATION PROCEDURE 1. Install the garage door opener to the overhead console. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the garage door opener retaining screws. Tighten Tighten the retaining screws to 2 N.m (18 lb in). 3. Connect the electrical connector to the garage door opener. 4. Install the console to the roof. 5. Connect the electrical connectors. Locations Windshield Washer Reservoir Service and Repair Maintenance Indicator - A/T: Service and Repair This vehicle does not use a Trans Fluid Life index, and has no monitor to reset. Interior - Seat Memory Feature Appears Inoperative Memory Positioning Module: Customer Interest Interior - Seat Memory Feature Appears Inoperative Bulletin No.: 04-08-50-003 Date: February 26, 2004 INFORMATION Subject: Enabling Memory Seat Feature via DIC If Feature Appears Inoperative Models: 2003-2004 Cadillac Escalade, Escalade ESV, Escalade EXT 2003-2004 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2003-2004 GMC Sierra, Yukon, Yukon Denali, Yukon Denali XL 2003-2004 HUMMER H2 with Steering Wheel Controls (RPO UK3) (standard on H2) If the memory seat feature appears inoperative, check the Driver Information Center (DIC). Many of the memory seat modules that were returned through the Warranty Parts Center for a condition of inoperative have shown No Trouble Found. The Driver Information Center (DIC), programmed for Seat Entry and Exit, is set to the default "Off" mode at the assembly plant. DO NOT REPLACE THE MEMORY SEAT MODULE. Perform the following procedure. Important: The following procedure will need to be completed for each Remote/Key selection. Using the DIC menu, do the following steps: 1. Set the "Seat Recall" to either "At Key In" or "On Remote" based on the customer's preference. 2. Set the "Exit Seat" to "On". 3. Adjust the following items: Memory Seat: 3.1. Driver's Seat (including the seat back, recliner, lumbar, and side wings) 3.2. Throttle and Brake Pedals (not available on H2 or Silverado and Sierra Trucks) 3.3. Outside Mirrors 3.4. Radio Station Presets 3.5. Last Chosen Climate Control System Settings (not available on Silverado or Sierra Trucks) 3.6. Press and hold the "1" or "2" (for driver 1 or 2) button of the memory control for three seconds. A double chime will sound to let you know that the position has been stored. Easy Exit Seat: 3.1. Press and release the 1 or 2 button or press the unlock button on the desired remote keyless entry transmitter. The seat will move to the stored memory position. 3.2. Adjust the seat to the desired exit position. 3.3. Press and hold the exit button of the memory control (located on the door) for three seconds. A double chime will sound to let you know that the position has been stored for the identified driver (1 or 2). Page 6983 4. Drive the bearing cup into the wheel hub using the J 44419 (2) and the J 8092 (1). 5. Install the retaining ring into the groove. Make sure the retaining ring is fully and evenly seated in the groove. 6. Install the inner bearing cup. 7. Drive the inner bearing cup into the wheel hub using the J 24427 (2) and the J 8092 (1). Interior - Heated Seats Intermittently Inoperative Seat Heater: Customer Interest Interior - Heated Seats Intermittently Inoperative Bulletin No.: 05-08-05-008 Date: August 18, 2005 TECHNICAL Subject: Intermittent Heated Seats Inoperative, DTC B3941 Set (Reprogram Driver Seat Module) Models: 2003-2005 Cadillac Escalade, Escalade ESV, Escalade EXT 2003-2005 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2003-2005 GMC Sierra, Yukon, Yukon XL, Yukon Denali All with Seat FRT, Individual (Non BKT) (RPO AN3) 2003-2005 HUMMER H2 with Seat, Front Bucket Deluxe (RPO AR9) Condition Some customers may comment that occasionally the seat heater will not operate when activated. If the ignition key is cycled OFF and back ON again, the heated seat will operate correctly. Also, on some LB7 diesel engine vehicles, the seat heater may turn itself off during the first 10 minutes of operation. This occurs only with the first activation for the day and works correctly with subsequent activations immediately after the event. These conditions are intermiffent and DTC B3941 may be set. Correction Technicians are to reprogram the driver seat module with an updated software calibration. This new service calibration was released with TIS satellite data update version 6.5 available June 13, 2005. As always, make sure your Tech 2(R) is updated with the latest software version. Warranty Information Disclaimer Page 16194 You MUST use a silver-bearing solder to make the solder joint. DO NOT attempt this repair with conventional tin/lead alloy solders. Most suppliers have this type of solder available and it is available nationally at Radio Shack(R)*. It is sold in several diameters and either are acceptable for this repair. 5. For this step, it is permitted that two technicians be used if required. Heat the new connector on the surface of the buss bar that is to be soldered. Long nose pliers are suggested to hold the electrical connector and the defroster tab in place. Keep the solder ready and begin flowing out the solder as soon as the melting temperature has been reached. Tip If a single technician is attempting this repair, it is beneficial to wrap one turn of the solder around the new contacts base. In this manner, as the melting point of the solder is reached, a layer is deposited on the bottom side of the contact. Important Try to align the new contact so that it is positioned with the same orientation as the original contact. 6. The above illustrates an ideal finished solder joint. Additional stray solder will not harm the performance of the bond; however, while it is unlikely that customers may refer to the appearance of the rear window defroster and its components as a positive styling feature of the vehicle interior, it is easy to elicit the opposite reaction due to a poor cosmetic application. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Parts Information Acrysol(TM) can be ordered directly from Kent Automotive at 1-800-654-6333 (in Canada, 1-800-563-1717). Radio Shack(R) products can be found nationally at retail locations, www.radioshack.com, or at 1-800-843-7422. All other parts can be ordered through GMSPO or SSPO. Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use: Warranty Information (Saab U.S. Models) Page 8225 2. Install the splash shield (15 series). 3. Install the hub and bearing assembly. 4. Install the tire and wheel assembly. 5. Remove the safety stands. 6. Lower the vehicle. (15 Series W/O NYS) Disc Brake Backing Plate Replacement - Rear (15 Series w/o NYS) Caution: Refer to Brake Dust Caution in Service Precautions. Removal Procedure 1. Release the park brake. 2. Raise and support the vehicle. Refer Vehicle Lifting 3. Remove the tire and wheel assembly. 4. Relieve the tension from the park brake cables by loosening the nut at the equalizer. Page 3055 Wheel Bearing: Service and Repair With Full Floating 10.5" or 11.5" Ring Gear Rear Axle Hub, Bearing, Cup, and/or Seal Replacement ^ Tools Required J 8092 Universal Driver Handle - 3/4 inch - 10 - J 2222-C Wheel Bearing Nut Wrench - J 24426 Wheel Bearing Race Installer - Outer - J 24427 Wheel Bearing Race Installer - Inner - J 44419 Hub Outer Bearing Race Installer - J 44420 Differential Bearing and Hub Seal Installer Removal Procedure 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Remove the tire and wheel assembly. 3. Remove the brake caliper. 4. Remove the axle shaft. 5. Remove the axle nut retaining ring. 6. Remove the key. 7. Remove the adjusting nut using the J 2222-C. Procedures Seat Cushion: Procedures Seat Cushion Frame Replacement - Front SEAT CUSHION FRAME REPLACEMENT - FRONT REMOVAL PROCEDURE 1. Remove the seat trim panel. 2. Remove the seat cushion trim cover and pad. 3. Remove the following components from the seat cushion frame: - The frame springs (1) - The frame suspension (2) - The plastic retainers (3) 4. Remove the seat cushion frame from the vehicle. INSTALLATION PROCEDURE 1. Install the following components to the seat cushion frame: - The plastic retainers (3) - The frame suspension (2) - The frame springs (1) 2. Install the seat cushion trim cover and pad. 3. Install the seat trim panel. 4. Re-zero the inflatable restraint passenger presence system. Refer to Passenger Presence System Rezeroing Procedure in Restraint Systems. Seat Cushion Cover and Pad Replacement - Rear SEAT CUSHION COVER AND PAD REPLACEMENT - REAR REMOVAL PROCEDURE Specifications Engine Oil Pressure: Specifications Oil Pressure - Minimum - Hot 41 kPa (6 psig) at 1,000 engine RPM 124 kPa (18 psig) at 2,000 engine RPM 165 kPa (24 psig) at 4,000 engine RPM Electrical - Information For Electrical Ground Repair Wiring Harness: All Technical Service Bulletins Electrical - Information For Electrical Ground Repair INFORMATION Bulletin No.: 10-08-45-001B Date: October 25, 2010 Subject: Information for Electrical Ground Repair - Use New Replacement Fasteners with Conductive Finish Models: 2011 and Prior GM Passenger Cars and Trucks (including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X Supercede: This bulletin is being revised to add the 2011 model year and update the Warranty Information. Please discard Corporate Bulletin Number 10-08-45-001A (Section 08 - Body and Accessories). Electrical Ground Repair Overview Proper electrical system function relies on secure, stable and corrosion-free electrical ground connections. Loose, stripped, or corroded connections increase the possibility of improper system function and loss of module communication. These conditions may also lead to unnecessary repairs and component replacement. In general, electrical ground connections are accomplished using one, or a combination of the following attachment methods: - Welded M6 stud and nut - Welded M6 nut and bolt - Welded M8 nut and bolt Determine which attachment method is used and perform the appropriate or alternative repair as described in this bulletin. M6 Weld Stud Replacement Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. Select a location adjacent the damaged or missing M6 ground stud having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the M6 conductive rivet stud flange. 2. Using GM approved residue-free solvent or equivalent, remove any grease from the repair site and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 3. Drill a 10 mm (0.40 in) diameter hole through the panel. 4. Remove paint and primer from the area surrounding the 10 mm (0.40 in) hole until bare metal is visible. Page 11922 12.2. Cars with brackets for e.g. an amplifier: Remove the pin strap (A) from the bracket and remove the tape (B) holding the optic cables. 12.3. Remove the locking strip (C) on the 2-pin connector (H2-9). Open the terminal housing with a screwdriver. Remove the secondary catch (E) on the connector and remove the optic cables coming from the OnStar(R) control modules. 12.4. Loosen one of the optic cables remaining in H2-9 (F), connect it to the connector and fit the secondary catch (E). Connect the connector so that the optic cables are opposite each other (G). Connect the terminal housing (D) and refit the locking strip (C). Page 14915 4. Press the button a second time, 2 light bars will glow indicating the MEDIUM temperature setting for the entire seat. 5. Press the button a third time, 1 light bar will glow indicating the LOW temperature setting for the entire seat. 6. Press the button a fourth time to turn the entire heated seat OFF. 7. To heat ONLY the seat back, press the vertical (LH) button one time. ^ An ON/OFF indicator light over the heated seat back symbol will glow to designate that ONLY the seat back is being heated. ^ All 3 light bars over the horizontal (RH) button will glow indicating the HIGH temperature setting for ONLY the seat back. 8. Press the button a second time, 2 light bars will glow indicating the MEDIUM temperature setting for ONLY the seat back. 9. Press the button a third time, 1 light bar will glow indicating the LOW temperature setting for ONLY the seat back. 10. Press the button a fourth time to turn the heated seat back OFF. Switch Diagnostics Important: In order to eliminate unnecessary part replacement and comeback repairs, it is essential that the appropriate diagnostic tables and aids found in the applicable manuals are followed. 1. Verify the condition prior to making any repairs. Refer to Seats and Seat Controls in the applicable Owners Manual or this bulletin for proper heated seat switch operation information. 2. If an improperly operating front heated seat condition exists, refer to the Diagnostic Information and Procedures in the Seats sub-section of the applicable Service Manual in order to diagnose the system accurately. 3. When measuring the resistance of the seat heater elements, ensure the values are within the updated range of 1.5-5.5 ohms. Refer to DTC B2425 or B2430-Clearing the DTC in the Diagnostic Information and Procedures in the Seats sub-section of the applicable Service Manual. Customer Information Some heated seat components from the above listed vehicles have been returned to the Warranty Parts Center (WPC) for heat function not operating properly. Analyses of these parts show 'no out of specification condition' or No Trouble Found (NTF). 1. Provide customers with the knowledge that if bumped, either one of the heated seat switches can be activated/deactivated accidentally. 2. Ensure customers have a thorough understanding of how the heated seat switches function. Disclaimer Page 5404 Tighten Tighten the clamp to 2.5 N.m (22 lb in). 5. Install the rear axle vent hose to the clip on the fuel fill pipe bracket. 6. Close the axle vent hose clip. 7. Position the fuel tank fill pipe ground wire and chassis harness ground wire (2). 8. Install the fuel tank fill pipe ground wire (3) anti-rotation tab into the frame hole. 9. Install the fuel tank fill pipe ground wire bolt (1). Tighten Tighten the bolt to 9 N.m (80 lb in). 10. Lower the vehicle. Page 5777 Transmission Position Switch/Sensor: Adjustments Automatic Transmission - 4L80-E/4L85-E Park/Neutral Position Switch Adjustment Important: ^ The following procedure is for vehicles that have not had the park/neutral position (PNP) switch removed or replaced. If the switch has been removed or replaced, refer to Park/Neutral Position Switch Replacement for the proper adjustment procedure. ^ Apply the park brake. ^ The engine must start in the park (P) or neutral (N) positions only. ^ Check the PNP switch for proper operation. If adjustment is required, proceed as follows: 1. Place the shift lever in the neutral (N) position. 2. With an assistant in the drivers seat, raise and suitably support the vehicle. Refer to Vehicle Lifting. 3. Loosen the PNP switch bolts. 4. With the vehicle in neutral (N), rotate the PNP switch while the assistant attempts to start the engine. 5. Following a successful start, turn the engine off. 6. Notice: Refer to Fastener Notice in Service Precautions. Tighten the PNP switch bolts. ^ Tighten the bolts to 25 Nm (18 ft. lbs.). 7. Lower the vehicle. 8. Check the PNP switch for proper operation. The engine must start in the park (P) or neutral (N) positions only. 9. Replace the PNP switch if proper operation can not be achieved. Page 601 Memory Seat Module - C4 Part 2 Page 13140 2. Disconnect the C2 32-way blue connector from the VIU and tape the connector to a secure location. Refer to Cellular Communications Connector End Views and related schematics in SI, if required. Important: DO NOT perform the OnStar(R) reconfiguration and/or programming procedure. 3. Secure the VIU in its original brackets and/or mounting locations and reinstall the VIU and interior components that were removed to gain access to the VIU. Refer to OnStar Vehicle Interface Unit Replacement in SI. 2002 Through 2006 Model Year Vehicles (Except Saab Vehicles) 2002 through 2006 Model Year Vehicles (Except Saab Vehicles) Important: The Tech 2 diagnostic tool must be updated with version 28.002 or later in order to successfully perform the VCIM setup procedure and disable the analog system. 1. Connect the Tech 2 to the data link connector (DLC), which is located under the instrument panel of the vehicle. 2. Turn the Tech 2 ON by pressing the power button. Important: Tech 2 screen navigation to get to the setup procedure depends on the year and make of the vehicle. The actual name of the setup procedure (Setup New OnStar or VCIM Setup) depends on model year and vehicle make as well. Example Tech 2 navigation to the setup procedure Tech 2 screen is provided below. ^ Diagnostics >> (2) 2002 >> Passenger Car >> Body >> C >> OnStar >> Special Functions >> Setup New OnStar >> ^ Diagnostics >> (5) 2005 >> Passenger Car >> (4) Buick >> C >> Body >> Vehicle Comm. Interface Module >> Module Setup >> VCIM Setup >> 3. Setup VCIM using the Tech 2. Follow on-screen instructions when you have reached the setup Tech 2 screen. 2000-2002 Saab 9-3 (9400) 4D/5D; 2000-2003 Saab 9-3 (9400) CV 2000-2002 Saab 9-3 (9400) 4D/5D; 2000-2003 Saab 9-3 (9400) CV 1. Remove the ground cable from the battery's negative terminal. 2. Apply the handbrake brake. 3. Detach the floor console. 4. Remove the switch and the floor console: 3.1. Twist loose the immobilizer unit (A), bayonet fitting. Unplug the unit's connector. 3.2. Remove the ignition switch cover (B) by first undoing the rear edge of the cover and then unhooking the front edge. Unplug the ignition Page 907 Control Module References Part 2 Specifications Idle Speed: Specifications Information not supplied by manufacturer. NVG 246-NP8 Control Module: Locations NVG 246-NP8 Transfer Case Shift Control Module Transfer Case Shift Control Module 1 - I/P Harness 2 - Transfer Case Shift Control Module Connectors 3 - Transfer Case Shift Control Module 4 - Instrument Panel Page 11102 6. The O-ring seal must be fully seated. 7. Assemble the A/C components. Refer to the appropriate repair procedure. For compression style fittings use a back up wrench on the fitting (2) and tighten the fitting nut (1) to specification. - For banjo style fittings install the bolt retaining the banjo type fitting and tighten to specification. Page 16201 3. Prepare the surface of the used defroster tab (not required for new tabs on new-style full-size utility models) and the defroster buss bar with fine grain (500 grit) sandpaper or Emery cloth. It is not necessary to remove all of the original solder, but it should be scuffed sufficiently so that no oxidation is present. The photo above shows a close up of a properly prepared surface. Tip You may want to mask the glass around the contact area with tape. This is easy to do and will allow you to safely prepare the contact surface without the risk of scratching the glass or the black painted shading. Important Most rear glass has a black painted masking around the edge of the glass. When cleaning up the connection surface, be very careful not to damage the surface of the black shading or the surface of the glass. 4. Wipe the newly prepared contact area with Kent Automotive* Acrysol(TM) (or equivalent) to remove any residual oil or dirt. Important Page 10235 IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections TESTING FOR INTERMITTENT AND POOR CONNECTIONS TOOLS REQUIRED - J 35616-C GM-Approved Terminal Test Kit - J 38125-D Terminal Repair Kit - J 42675 Flat-Wire Probe Adapter Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector. - Poor terminal to wire connection - Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. - Wire insulation which is rubbed through - This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. - Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. Testing For Proper Terminal Contact It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-D or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-D, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. Page 14813 Memory/Heated Seat Switch - Driver (DDM C5) Part 2 Page 16079 TOOLS REQUIRED J 34142-B 12 V Unpowered Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. When testing for voltage: 1. Attach 1 lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach 1 lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Using Connector Test Adapters USING CONNECTOR TEST ADAPTERS NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-B Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires USING FUSED JUMPER WIRES TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Connector Position Assurance Locks CONNECTOR POSITION ASSURANCE LOCKS The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Terminal Position Assurance Locks TERMINAL POSITION ASSURANCE LOCKS The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Push to Seat Connectors PUSH TO SEAT CONNECTORS TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Page 3732 Install the new heat shield (see parts list below) onto the muffler as shown above. Install three straps, P/N 10391259, so that the strap screw head will be located on top of the muffler. Tighten Tighten the strap screw to 4 N.m (35 lb in). Cut off the excess strap material and bend the strap over the strap screw head as indicated above. Remove the exhaust pipe clamp. ONLY 6.0L and 8.1L equipped vehicles require a new exhaust pipe clamp, P/N 15103174. On 6.0L and 8.1L equipped vehicles only, install a new exhaust pipe clamp, P/N 15103174, on the exhaust pipe. Reposition the muffler in the correct position. Slide the muffler forward into position, aligning the studs with the rear of the catalytic converter. Install the nuts securing the muffler to the catalytic converter, but DO NOT tighten at this time. Apply a soapy solution to the following areas in order to ease the installation of the hangers. The inner diameter of the exhaust pipe hanger The exhaust pipe hanger rod Press the exhaust pipe hangers over the exhaust pipe hanger rods. Tighten Tighten the muffler nuts by hand until each contacts the metal flange. Tighten the muffler nuts to 45 N.m (33 lb ft). On 6.0L and 8.1L equipped vehicles only, tighten the exhaust clamp to 50 N.m (36 lb ft). Page 4290 Electrical Symbols Part 8 Page 464 Electrical Symbols ELECTRICAL SYMBOLS Electrical Symbols Part 1 Page 9945 Alignment: Service and Repair Front Wheel Alignment Front Caster and Camber Adjustment Front Caster and Camber Adjustment 1. Important: Caster measurements or valves must be compensated for the measured frame angle. Caster is relative to frame, the caster values must be compensated for the measured frame angle by using a digital protractor or equivalent on a flat portion of the frame in front of the rear tire. 2. Frame angle is positive when higher in the rear. Measure both sides of the frame and take an average from those measurements. Then add the average frame angle to the caster reading when making adjustments. 3. Frame angle is negative when lower in the rear. Measure both sides of the frame and take an average from the measurements. Then subtract the Page 5369 7. Install the EHCU (1). 8. Install the bolts (4) attaching the EHCU bracket to the frame (5). Tighten Tighten the bolts to 25 N.m (18 lb ft). 9. Connect the brake lines to the BPMV. Tighten Tighten the fittings to 25 N.m (18 lb ft). 10. Connect the chassis electrical harness connectors to the EBCM. 11. Install the transfer case harness to the clip bracket. 12. Install the clip to the bracket on the frame. 13. If equipped with 4WD, install the fuel line clip to the bracket on the transfer case. Page 5787 Install the parking lock bracket bolts. ^ Tighten the bolts to 24 Nm (18 ft. lbs.). 13. Install the PNP switch. 14. Install the transmission filter. 15. Fill the transmission to the proper level with Dexron® III transmission fluid. Page 4360 Camshaft Position (CMP) Sensor Page 10911 circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links CIRCUIT PROTECTION - FUSIBLE LINKS Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Flat Wire Repairs FLAT WIRE REPAIRS NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Heated Oxygen Sensor (HO2S) Wiring Repairs HEATED OXYGEN SENSOR (HO2S) WIRING REPAIRS TOOLS REQUIRED J 38125-D Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: - Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-D. Repairing Damaged Wire Insulation REPAIRING DAMAGED WIRE INSULATION Page 6384 Fluid Pressure Sensor/Switch: Connector Locations Service and Repair Oil Level Sensor: Service and Repair Engine Oil Level Sensor and/or Switch Replacement Removal Procedure 1. Drain the engine oil. 2. Disconnect the oil level sensor electrical connector (3). 3. Remove the oil level sensor from the oil pan. Installation Procedure 1. Notice: Refer to Fastener Notice in Service Precautions. Heated Seat Switch Replacement - Front Seat Heater Switch: Service and Repair Heated Seat Switch Replacement - Front HEATED SEAT SWITCH REPLACEMENT - FRONT REMOVAL PROCEDURE 1. Remove the front door trim panel. 2. Disconnect the electrical connector. 3. Release the retaining clips for the front seat heater switch assembly in order to remove the switch. 4. Remove the front seat heater switch assembly. INSTALLATION PROCEDURE 1. Install the front seat heater switch assembly to the front trim panel by pressing the switch into place until the switch is completely seated. 2. Connect the electrical connector to the front seat heater switch assembly. 3. Install the front trim panel. Page 10537 Tire Pressure Sensor: Technical Service Bulletins Tire Monitor System - TPM Sensor Information INFORMATION Bulletin No.: 08-03-16-003 Date: May 12, 2008 Subject: Warranty Reduction - Transfer of Tire Pressure Monitoring (TPM) Sensors to Replacement Wheels and Allowable TPM Sensor Replacements Models: 2000-2009 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2009 HUMMER H2 2006-2009 HUMMER H3 2005-2009 Saab 9-7x with On-Wheel TPM Sensors TPM Sensor / Wheel Warranty Reviews During the last warranty review period it was noted that wheels being returned under the GM New Vehicle Warranty were being shipped back to General Motors with the TPM sensor still attached to the wheel. Return rates ran as high as 60% with the TPM sensors still attached. Operational TPM sensors should not be returned to GM and are to be transferred to replacement wheels if they become necessary. Important: Operational TPM Sensors that are returned under warranty to General Motors will be charged back to the dealer.Sensors have a 10 year /150,000 mile (240,000 km) battery life, and should be transferred if one or more wheels are replaced. TPM Valve Stem / Grommet (0-ring) Replacement When the TPM sensors are transferred to new wheels you should replace the component used to seal the TPM sensor stem to the wheel. On sensors with an aluminum stem and visible nut on the outside of the wheel a replacement grommet (0-ring) should be used to assure a proper seal. The sensor retaining nut (except Aveo) should be tightened to 7 N.m (62 lb in) for all vehicles except Pontiac Vibe (4.0 N.m (35.4 lb in)). Important: ^ DO NOT overtorque the retaining nut. Notice: ^ Factory installed TPM Sensors come with plastic aluminum or nickel-plated brass stem caps. These caps should not be changed. Chrome plated steel caps may cause corrosion of aluminum valve stems due to incompatibility of the metals. On current style sensors the entire rubber stem is replaceable. The service interval on the revised TPM sensor with replaceable stem is the same as for any other traditional valve stem. Replace the stem at the time of tire replacement sensor transfer or whenever air seepage is suspected at the valve stem. When replacing the valve stem tighten the screw to 1.3 N.m (11.5 lb in). For either style of TPM sensor see the service parts guide for the correct GM part numbers to order and use. Disclaimer Page 8543 1. Lubricate the output speed sensor seal with automatic transmission fluid. 2. Install the output speed sensor (2). Notice: Refer to Fastener Notice in Service Precautions. 3. Install the output speed sensor bolt. ^ Tighten the bolt to 11 Nm (96 inch lbs.). 4. Connect the output speed sensor (2) electrical connector. 5. Lower the vehicle. Page 3508 Disclaimer Page 9400 Right Rear Corner of Bed (HP2) Page 14478 Memory Seat Module - C4 Part 2 Page 13515 Electrical Symbols Part 5 Page 11168 6. Remove the inlet heater hose. INSTALLATION PROCEDURE 1. Install the inlet heater hose. 2. Install the inlet heater hose to the engine. 3. Connect the heater and surge tank hose to the heater core. Firmly push the quick connect onto the heater core pipe until you hear an audible click. 4. Install the heater and surge tank hose to the mounting clip. 5. Install the air intake tube. 6. Fill the cooling system. Refer to Draining and Filling Cooling System (with HP2)Draining and Filling Cooling System (without HP2) in Cooling System. Page 8826 Alternator: Service and Repair Generator Cable Replacement GENERATOR CABLE REPLACEMENT REMOVAL PROCEDURE CAUTION: Refer to Battery Disconnect Caution in Service Precautions. 1. Disconnect the negative battery cable. 2. If necessary, remove the engine sight shield. 3. Remove the generator cable from the generator, perform the following: 3.1. Reposition the boot to expose the stud. 3.2. Remove the generator cable nut. 3.3. Remove the generator cable from the stud. 4. Open the positive cable junction block. 5. Remove the generator cable nut. 6. Remove the generator cable (2) from the junction block. INSTALLATION PROCEDURE NOTE: Refer to Fastener Notice in Service Precautions. Page 15890 Steering Wheel and Column Sub-System Components Page 10952 - Proof of ownership at time of repair. - Original paid receipt confirming the amount of unreimbursed repair expense(s) (including Service Contract deductibles), a description of the repair, and the person or entity performing the repair. If the work was done by someone other than a GM dealership, the amount of reimbursement will be limited to the amount that the repair would have cost GM to have it completed by a GM dealership. Courtesy Transportation The General Motors Courtesy Transportation program is intended to minimize customer inconvenience when a vehicle requires a repair that is covered by the New Vehicle Limited Warranties. The availability of courtesy transportation to customers whose vehicles are within the warranty coverage period and involved in a product program is very important in maintaining customer satisfaction. Dealers are to ensure that these customers understand that shuttle service or some other form of courtesy transportation is available and will be provided at no charge. Dealers should refer to the General Motors Service Policies and Procedures Manual for Courtesy Transportation guidelines. Warranty Transaction Information Submit a transaction using the table below. * The amount identified in "Net Item" should represent the dollar amount reimbursed to the customer. Disclaimer Wheels/Tires - Tire Radial Force Variation (RFV) Wheels: Customer Interest Wheels/Tires - Tire Radial Force Variation (RFV) INFORMATION Bulletin No.: 00-03-10-006F Date: May 04, 2010 Subject: Information on Tire Radial Force Variation (RFV) Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X 2000-2005 Saturn L Series 2003-2007 Saturn ION Supercede: This bulletin is being revised to considerably expand the available information on Radial Force Variation (RFV) and should be reviewed in whole. Please discard Corporate Bulletin Number 00-03-10-006E (Section 03 - Suspension). Important - Before measuring tires on equipment such as the Hunter GSP9700, the vehicle MUST be driven a minimum of 16 km (10 mi) to ensure removal of any flat-spotting. Refer to Corporate Bulletin Number 03-03-10-007E - Tire/Wheel Characteristics of GM Original Equipment Tires. - Equipment such as the Hunter GSP9700 MUST be calibrated prior to measuring tire/wheel assemblies for each vehicle. The purpose of this bulletin is to provide guidance to GM dealers when using tire force variation measurement equipment, such as the Hunter GSP9700. This type of equipment can be a valuable tool in diagnosing vehicle ride concerns. The most common ride concern involving tire radial force variation is highway speed shake on smooth roads. Tire related smooth road highway speed shake can be caused by three conditions: imbalance, out of round and tire force variation. These three conditions are not necessarily related. All three conditions must be addressed. Imbalance is normally addressed first, because it is the simpler of the three to correct. Off-vehicle, two plane dynamic wheel balancers are readily available and can accurately correct any imbalance. Balancer calibration and maintenance, proper attachment of the wheel to the balancer, and proper balance weights, are all factors required for a quality balance. However, a perfectly balanced tire/wheel assembly can still be "oval shaped" and cause a vibration. Before balancing, perform the following procedures. Tire and Wheel Diagnosis 1. Set the tire pressure to the placard values. 2. With the vehicle raised, ensure the wheels are centered on the hub by loosening all wheel nuts and hand-tightening all nuts first by hand while shaking the wheel, then torque to specifications using a torque wrench, NOT a torque stick. 3. Visually inspect the tires and the wheels. Inspect for evidence of the following conditions and correct as necessary: - Missing balance weights - Bent rim flange - Irregular tire wear - Incomplete bead seating - Tire irregularities (including pressure settings) - Mud/ice build-up in wheel - Stones in the tire tread - Remove any aftermarket wheels and/or tires and restore vehicle to original condition prior to diagnosing a smooth road shake condition. 4. Road test the vehicle using the Electronic Vibration Analyzer (EVA) essential tool. Drive for a sufficient distance on a known, smooth road surface to duplicate the condition. Determine if the vehicle is sensitive to brake apply. If the brakes are applied lightly and the pulsation felt in the steering wheel increases, refer to the Brakes section of the service manual that deals with brake-induced pulsation. If you can start to hear the vibration as a low boom noise (in addition to feeling it), but cannot see it, the vehicle likely has a first order (one pulse per propshaft revolution) driveline vibration. Driveline first order vibrations are high enough in frequency that most humans can start to hear them at highway speeds, but are too high to be able to be easily seen. These issues can be caused by driveline imbalance or misalignment. If the vehicle exhibits this low boom and the booming pulses in-and-out on a regular basis (like a throbbing), chances are good that the vehicle could have driveline vibration. This type Electrical - Aftermarket Fuse Warning Fuse: All Technical Service Bulletins Electrical - Aftermarket Fuse Warning Bulletin No.: 07-08-45-002 Date: September 05, 2007 ADVANCED SERVICE INFORMATION Subject: Service Alert: Concerns With Aftermarket Fuses in GM Vehicles Models: 2008 and Prior GM Passenger Cars and Light Duty Trucks (including Saturn) 2008 and Prior HUMMER H2, H3 2008 and Prior Saab 9-7X Concerns with Harbor Freight Tools "Storehouse" Branded Blade Type Fuses General Motors has become aware of a fuse recall by Harbor Freight Tools/Storehouse for a variety of aftermarket fuses. In two cases, these fuses have not provided protection for the wiring system of the vehicles they were customer installed in. Upon testing the 15 amp version, it was found that the fuse still would not "open" when shorted directly across the battery terminals. How to Identify These Fuses Packed in a 120 piece set, the fuse has a translucent, hard plastic, blue body with the amperage stamped into the top. There are no white painted numbers on the fuse to indicate amperage. There are no identifying marks on the fuse to tell who is making it. The fuses are known to be distributed by Harbor Freight Tools but there may be other marketers, and packaging of this style of fuse. It would be prudent to replace these fuses if found in a customers vehicle. Likewise, if wiring overheating is found you should check the fuse panel for the presence of this style of fuse. All GM dealers should use genuine GM fuses on the vehicles they service. You should also encourage the use of GM fuses to your customers to assure they are getting the required electrical system protection. GM has no knowledge of any concerns with other aftermarket fuses. If additional information becomes available, this bulletin will be updated. Disclaimer Page 2001 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Micro-Pack 100W Connectors MICRO-PACK 100W CONNECTORS TOOLS REQUIRED J 38125-D Terminal Repair Kit REMOVAL PROCEDURE There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2)has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. IMPORTANT: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Page 7256 Control Module References Part 6 Page 13782 Disclaimer Page 13574 Door Control Module Diagram 3 Part 2 Page 12182 The control module ID number list above provides a method for determining which module is not communicating. A module with a class 2 serial data circuit malfunction or which loses power during the current ignition cycle will have a Loss of Communication DTC set by other modules that depend on information from that failed module. The modules that can communicate will set a DTC indicating the module that cannot communicate. Diagnostic Order When more than one Loss of Communication DTC is set in either one module or in several modules, diagnose the DTCs in the following order: 1. Current DTCs before history DTCs unless told otherwise in the diagnostic table. 2. The DTC which is reported the most times. 3. From the lowest number DTC to the highest number DTC. Conditions for Running the DTC The following DTCs do not have a current status: ^ B1327 ^ B1328 ^ U1300 ^ U1301 ^ U1305 AND ^ The vehicle power mode requires serial data communication to occur. Conditions for Setting the DTC A node alive message has not been received from a module with a learned identification number within the last 5 seconds. Action Taken When the DTC Sets Page 16107 Power Window Switch: Connector Views Window Switch - LR (Crew Cab Only) Page 12930 6. Install the bolts (1) retaining the console to the I/P. Tighten Tighten the bolts to 4 N.m (35 lb in). 7. Install both front console side panel screws (1). Tighten Tighten the screws to 2 N.m (18 lb in). 8. Move both front seats to the fully forward. 9. Install both rear console side panel screws (2). Page 14325 Paint: Application and ID Paint Identification Paint Identification Caution: Exposure to isocyanates during paint preparation and application processes can cause severe breathing problems. Read and follow all of the instructions from the manufacturers of painting materials, equipment, and protective gear. Important: Always refer to the GM Approved Refinish Materials book GM P/N 4901M-D. This book identifies the paint systems you may use. The basecoat/clearcoat paint is factory applied in the following 4 layers in order to give the finish a high gloss look: * A cathodic immersion primer * A primer/surfacer * A basecoat * A clear top coat (clearcoat) Refer to Label - Service Parts ID in order to identify the type of top coat on the vehicle. This label contains all paint related information for the vehicle. This includes paint technology, paint codes, trim level, and any special order paint colors. Service and Repair Fan Clutch: Service and Repair Fan Clutch Replacement ^ Tools Required J 46406 Fan Clutch Remover and Installer Removal Procedure 1. Remove the upper fan shroud. 2. Install the J 46406 to the fan clutch. 3. Remove the fan hub nut from the water pump in a counterclockwise rotation. 4. Remove the fan clutch bolts from the rear of the fan blade. 5. Separate the fan clutch from the fan blade. Installation Procedure Page 11703 Impact Sensor: Description and Operation Side Impact Sensor (SIS) (Right) With RPO HP2 INFLATABLE RESTRAINT SIDE IMPACT SENSOR (SIS) (RIGHT) WITH RPO HP2 The right side impact sensor (SIS) contains a sensing device which monitors vehicle acceleration and velocity changes to detect side collisions that are severe enough to warrant disabling the 42-volt system. The SIS is not part of the deployment loop, but instead provides an input to the sensing and diagnostic module (SDM). When the SDM receives a signal from the SIS that a collision has occurred, the SDM communicates this over the vehicles communication bus. The module responsible for the 42-volt system receives this message and disables the 42-volt system. Page 11495 For vehicles repaired under warranty, use the table. Disclaimer Page 3188 1. Apply a 5 mm (0.20 inch) bead of sealant GM P/N 12378190, or equivalent 20 mm (0.80 inch) long to the oil pan to engine block junction. 2. Install the rear cover gasket and cover. 3. Install the rear cover bolts until snug. Do not overtighten. 4. Install the oil pan-to-rear cover bolts (1) until snug. Do not overtighten. 5. Rotate the crankshaft until two opposing flywheel bolt holes are parallel to the oil pan surface. Important: The tapered legs of the alignment tool must enter the rear cover oil seal bore. 6. Install the J 41476 and bolts onto the rear of the crankshaft. Page 9236 C310 Body Harness To Left Rear Door Harness (Crew Cab) Part 2 Page 2768 4. Connect the wire connectors to the lower portion of the electrical center block. 5. Connect the wire connectors with the bolts to the electrical center block. Tighten Tighten all connector bolts (1) to 9 N.m (80 lb in). 6. Ensure all wire connectors are securely connected. 7. Set the electrical center block in its resting position till the tabs (3) locks in place. 8. Install the lower part of the cover (1). 9. With the cover (2) off, use the fuse location information to install all fuses and relays. 10. Install the cover. 11. Install the fender upper brace. 12. Install the 4 fender upper brace bolts. Tighten Tighten the 4 retaining bolts to 25 N.m (18 lb ft). 13. Connect the negative battery cable. 14. Start vehicle and ensure all components function properly. Page 10353 Front Steering Knuckle: Service and Repair Front Steering Knuckle Replacement (4WD) ^ Tools Required ^ J 43631 Ball Joint Remover ^ J 45851 Ball Joint Separator Protector Adapters Removal Procedure 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Remove the tire and wheel. 3. Remove the wheel hub and bearing assembly. Refer to Wheel Hub, Bearing, and Seal Replacement (RWD) Wheel Hub, Bearing, and Seal Replacement (4WD). 4. Support the lower control arm with a suitable jack. 5. Disconnect the outer tie rod to the steering knuckle. Refer to Tie Rod Replacement in Steering Linkage (Non- Rack and Pinion). 6. Remove the brake hose bracket retaining bolt from the steering knuckle. 7. Remove the upper control arm retaining nut and separate the upper ball joint from the steering knuckle using the J 43631 and J 45851. 8. Remove the lower control arm retaining nut. Separate the lower ball joint from the steering knuckle using the J 43631 and J 45851. Page 15942 Heated Glass Element: Diagnostic Aids Basic Knowledge Required BASIC KNOWLEDGE REQUIRED Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the Service Data. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories CHECKING AFTERMARKET ACCESSORIES Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: - Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions INDUCING INTERMITTENT FAULT CONDITIONS In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: - Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. Page 1863 Vehicle Speed Sensor (VSS) Tow/Haul Switch Location Page 3602 Coolant Reservoir: Service and Repair Surge Tank Hose/Pipe Replacement Surge Tank Hose/Pipe Replacement - Inlet Removal Procedure 1. Drain the cooling system. 2. Reposition the surge tank inlet hose clamp from the radiator. 3. Remove the surge tank inlet hose from the radiator. 4. Reposition the surge tank inlet hose clamp from the surge tank. 5. Remove the surge tank inlet hose (1) from the surge tank. Installation Procedure 1. Install the surge tank inlet hose (1) to the surge tank. 2. Position the surge tank inlet hose clamp to the surge tank. Page 5283 Steps 3 - 4 Page 4336 Body Control Module (BCM) - C3 Part 1 Page 10965 Parts required to complete this special coverage are to be obtained from General Motors Customer Care and Aftersales (GMCC&A;). Service Procedure Note The resistor module connector and blower motor resistor will need to be replaced if one or more of the symptoms below is present. - The HVAC blower may not function on certain or all blower speed settings - A burning plastic smell or smoke may be present in the vehicle - The HVAC blower may run continually with the ignition in the OFF position Determine if one or more of the above symptoms is present. If required refer to HVAC diagnostic information in SI. Refer to Resistor Module Connector and Blower Motor Resistor Replacement in this bulletin if one or more of the symptoms is present. Other HVAC repairs are NOT covered in this product safety special coverage bulletin. Resistor Module Connector and Blower Motor Resistor Replacement 1. Remove the blower fuses (Htr A/C & HVAC 1 fuses). 2. Lower the close-out panel enough to gain access to the resistor module connector. 3. Disconnect the connector from the resistor module. Note Connector replacement is required even if the connector was replaced on a previous service repair. 4. Remove the tape from the wiring harness to expose the wiring. 5. Cut the wires back far enough from the connector to eliminate any melted insulation on the wire. Note Use the old connector as a map for splicing the wires for the new connector. Be sure to use the correct crimping tool from the terminal repair kit J 38125. Use only Duraseal splice sleeves. Other splice sleeves may not protect the splice from moisture or provide a good electrical connection. 6. Install the new connector. Use the yellow splice sleeves provided with the connector. 7. Install the new blower motor resistor. 8. Reinstall the fuses. Test the blower motor to make sure all speeds are functional. 9. Reinstall the hush panel/close-out panel. Customer Reimbursement Customer requests for reimbursement of previously paid repairs to correct the condition described in this bulletin are to be submitted to the dealer prior to or by December 31, 2012. Repairs must have occurred within the 10 years of the date the vehicle was originally placed in service, or 240,000 kilometres, whichever occurs first. When a customer requests reimbursement, they must provide the following: Page 15764 Upper Steering Column Page 9315 Junction Block - I/P Wire Entry Part 2 Page 13729 Rear Door Weatherstrip: Service and Repair Rear Door Weatherstrip Replacement Weatherstrip Replacement - Rear Door Removal Procedure 1. Open the rear door. 2. Remove the rear door sill plate. 3. Remove the center pillar molding. 4. Remove the rear quarter trim panel. 5. Remove the weatherstrip (1) from the door opening flange. Installation Procedure Brakes- Disc Brake Warranty Service And Procedures Technical Service Bulletin # 00-05-22-002L Date: 090326 Brakes- Disc Brake Warranty Service And Procedures INFORMATION Bulletin No.: 00-05-22-002L Date: March 26, 2009 Subject: Disc Brake Warranty Service and Procedures Models: 1999-2010 GM Passenger Cars and Light Duty Trucks 2003-2010 HUMMER H2 2006-2010 HUMMER H3 1999-2004 Isuzu Light Duty Trucks (Canada Only) 2005-2009 Saab 9-7X (Canada Only) 1999-2010 Saturn Vehicles (Canada Only) EXCLUDING 2009-2010 Chevrolet Corvette ZR1 Supercede: This bulletin is being revised to inform you that due to improvements in vehicle brake corner and wheel design, assembly plant build processes and dealership required tools like the On-Car Lathe, measuring for Lateral Run Out (LRO) is no longer a required step when performing base brake service. Due to this change, you are no longer required to enter the LRO measurement on the repair order or in the warranty system failure code section. The bulletin information below and the base brake labor operations have been updated accordingly. Due to this change it is more important than ever to properly maintain your brake lathe (per the Brake Lathe Calibration Procedure in this bulletin). Please discard Corporate Bulletin Number 00-05-22-002K (Section 05 Brakes). For your convenience, this bulletin updates and centralizes all GM's Standard Brake Service Procedures and Policy Guidelines for brake rotor and brake pad service and wear. For additional information, the Service Technical College lists a complete index of available Brake courses. This information can be accessed at www.gmtraining.com > resources > training materials > brakes courseware index. In Canada, refer to Service Know How course 55040.00V and Hydraulic Brake Certification program 15003.16H. Important PLEASE FAMILIARIZE YOURSELF WITH THESE UPDATES BEFORE PERFORMING YOUR NEXT GM BRAKE SERVICE. The following four (4) key steps are a summary of this bulletin and are REQUIRED in completing a successful brake service. 1. Measure and Document Pre-Service Rotor Thickness* (REQUIRED on Repair Order) determine rotor clean-up/refinish/replace 2. Properly clean ALL brake corner mating surfaces - hub, rotor and wheel 3. Properly clean-up/refinish rotor, measure and document post-service rotor thickness (REQUIRED on Repair Order) Important If it is determined the rotor needs to be refinished, verify lathe equipment is properly calibrated. 4. Properly reassemble the brake corner using proper torque tools, torque specification and torque sequence - wheel lug nuts. * The bulletin refers to Minimum Thickness specification as the minimum allowable thickness after refinish. Always refer to SI to verify the spec stamped on the rotor is the minimum thickness spec after refinish and not the discard spec. Page 7995 Speed Sensor: Service and Repair Transfer Case - NVG 246-NP8 Transfer Case Speed Sensor Replacement - Front Transfer Case Speed Sensor Replacement - Front Removal Procedure 1. Remove the transfer case shield, if equipped. 2. Disconnect the front speed sensor electrical connector (5). 3. Remove the front speed sensor. Installation Procedure 1. Notice: Refer to Fastener Notice in Service Precautions. Install the front speed sensor. ^ Tighten the speed sensor to 15 Nm (11 ft. lbs.). Page 14341 Electrical Symbols ELECTRICAL SYMBOLS Electrical Symbols Part 1 Page 10889 Electrical Symbols Part 12 Page 1331 Discharge Air Temperature Sensor / Switch: Service and Repair Air Temperature Sensor Replacement - Lower Left AIR TEMPERATURE SENSOR REPLACEMENT - LOWER LEFT REMOVAL PROCEDURE 1. Disconnect the electrical connector from the lower left air temperature sensor (1). 2. Remove the lower left air temperature sensor (1) from the HVAC module (2). INSTALLATION PROCEDURE 1. Install the lower left air temperature sensor (1) to the HVAC module (2). 2. Connect the electrical connector to the lower left air temperature sensor (1). OnStar(R) - Incorrect GPS Position Reported During Call Navigation System: All Technical Service Bulletins OnStar(R) - Incorrect GPS Position Reported During Call Bulletin No.: 02-08-46-006C Date: January 08, 2008 INFORMATION Subject: Incorrect OnStar(R) Global Positioning System (GPS) Location Reported During OnStar(R) Call Models: 2000-2008 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2008 HUMMER H2 2006-2008 HUMMER H3 2005-2008 Saab 9-7X with OnStar(R) Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 02-08-46-006B (Section 08 - Body and Accessories). A small number of the above-mentioned vehicles may exhibit a condition in which the vehicle reports an inaccurate location to the OnStar(R) Call Center. This condition can only be identified via a button press to the OnStar(R) Call Center by the customer. Call Center personnel will be able to identify this inaccurate location condition. Customers will then be notified through the mail by OnStar(R) if their vehicle exhibits this condition. Once this condition has been identified OnStar(R) will instruct the customer to return to the dealership to have this condition corrected. It is not necessary to reconfigure the vehicle after the following procedure. In order to correct this condition you must cycle power to the OnStar(R) system. This can be done by either removing the fuses powering the OnStar(R) system or disconnecting the OnStar(R) module (VCIM) from the vehicle. As a last resort you can disconnect the vehicle's battery. The power needs to be removed from the system for approximately 15 minutes. After completing this procedure the vehicle should be taken to an area with an unobstructed view of the sky. The vehicle should be kept running for approximately 10 minutes to allow the vehicle to reacquire the global positioning system (GPS). Then contact the OnStar(R) Call Center via the blue OnStar(R) button and ask the advisor to verify the GPS position. If the OnStar(R) advisor still has an inaccurate GPS location refer to the Navigation Systems and Cellular Communications sub-sections in the Service Manual in order to diagnose and repair the concern. If the normal diagnostics lead to module replacement you will need to contact Technical Assistance (TAC) and choose the OnStar(R) prompt. GM OnStar(R) TAC will assist in the diagnosis and if appropriate order a replacement part. Replacement parts are usually shipped out within 24 hours and a pre-paid return package label will be included for returning the faulty part. By returning the faulty part you will avoid a significant non-return core charge. Warranty Information (excluding Saab US Models) For vehicles repaired under warranty, use the table. Warranty Information (Saab US Models) Diagrams Inside Air Temperature Sensor Assembly Page 12530 The module uses a default value for the missing parameter. Conditions for Clearing the DTC A current DTC clears when the malfunction is no longer present. A history DTC clears when the module ignition cycle counter reaches the reset threshold, without a repeat of the malfunction. Diagnostic Aids When multiple Loss of Communication DTCs are set concurrently, the cause is likely to be 2 opens in the ring portion of the class 2 serial data circuit. Use the Control Modules and Devices ‐ Description and Identification Number table in order to determine which modules are not communicating. Use the class 2 serial data circuit schematic in order to determine the location of the opens. Test Description Page 7000 14. Remove the retaining ring from the wheel hub. 15. Remove the outer hub bearing and bearing cup using the J 24426 (2) and the J 8092 (1). Installation Procedure 1. Lubricate the following with a light coat of high melting point EP bearing lubricant: ^ The outer wheel bearing ^ The inner wheel bearing ^ The outer wheel bearing cup ^ The inner wheel bearing cup ^ The axle housing 2. Install the outer bearing into the wheel hub. 3. Install the outer bearing cup into the wheel hub. Page 7317 Control Module: Service and Repair NVG 263-NP1 Transfer Case Shift Control Module Replacement Transfer Case Shift Control Module Replacement Removal Procedure 1. Disconnect the shift control module electrical connectors. 2. Unsnap and remove the shift control module from the bracket. Installation Procedure NV 3500 Seals and Gaskets: Service and Repair NV 3500 Transmission Housing Oil Seal Replacement - Front Transmission Housing Oil Seal Replacement - Front Removal Procedure 1. Remove the transmission. 2. Remove the clutch actuator cylinder bolts. 3. Remove the clutch actuator cylinder. 4. Remove the input shaft bearing retainer bolts. Remove the input shaft bearing retainer. Screw 2 of the removed bolts into the threaded holes in the retainer in order to remove the retainer. Page 15174 Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips SPLICING COPPER WIRE USING SPLICE CLIPS IMPORTANT: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. TOOLS REQUIRED J 38125-D Terminal Repair Kit 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-D in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. Page 4394 Throttle Actuator Control (TAC) Module C2 Part 2 Page 12982 Verify the component's operation. Speaker Replacement - Rear Door (Crew Cab) SPEAKER REPLACEMENT - REAR DOOR (CREW CAB) REMOVAL PROCEDURE 1. Remove the door trim panel. 2. Remove the screws (1) retaining the speaker to the mounting bracket. 3. Disconnect the electrical connector from the speaker. 4. Remove the speaker from the mounting bracket. 5. Remove the bolts (2) retaining the speaker mounting bracket to the door, if required. 6. Remove the speaker mounting bracket. INSTALLATION PROCEDURE 1. Install the speaker mounting bracket. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the bolts (2) retaining the speaker mounting bracket to the door, if removed. Tighten Tighten the bolts to 6 N.m (53 lb in). 3. Install the speaker to the mounting bracket. 4. Connect the electrical connector to the speaker. 5. Install the screws (1) that retain the speaker to the mounting bracket. Tighten Page 11683 Seat Sensor/Switch: Service and Repair INFLATABLE RESTRAINT SEAT POSITION SENSOR REPLACEMENT REMOVAL PROCEDURE 1. Remove the passenger or driver's seat from the vehicle. 2. Disconnect the electrical connector from the seat position sensor. CAUTION: Eye protection must be worn when drilling rivets to reduce the chance of personal injury. 3. Drill out the rivets that retain the seat position sensor (1) to the seat adjuster track bracket. 4. Remove the seat position sensor from the seat adjuster track bracket. INSTALLATION PROCEDURE 1. Install the seat position sensor to the seat adjuster bracket. 2. Install the rivets that retain the seat position sensor (1) to the seat adjuster track bracket. 3. Connect the electrical connector to the seat position sensor. 4. Install the passenger or driver's seat to the vehicle. Page 8681 Electronic Brake Control Module: Locations ABS Component Views Electronic Brake Control Module (EBCM) Page 3133 5. Remove the valve lifters from the guide. 6. Organize or mark the components so that they can be installed in the same location from which they were removed. 7. Clean and inspect the valve lifters. Installation Procedure Important: When reusing valve lifters, install the lifters to their original locations. 1. Lubricate the valve lifters and engine block valve lifter bores with clean engine oil. 2. Insert the valve lifters into the lifter guides. Align the flat area on the top of the lifter with the flat area in the lifter guide bore. Push the lifter completely into the guide bore. 3. Install the valve lifters and guide to the engine block. Page 5403 6. Remove the fuel tank fill pipe ground wire (3) anti-rotation tab from the frame hole. 7. Reposition the fuel tank fill pipe ground wire and chassis harness ground wire (2). 8. Open the axle vent hose clip on the fuel fill pipe bracket. 9. Remove the rear axle vent hose from the clip. 10. Loosen the fuel tank fill pipe clamp (1) at the fuel tank. 11. Disconnect the recirculation line from the sending unit. 12. Remove the fuel tank fill pipe. 13. Cap the opening on the fuel tank in order to prevent possible system contamination. INSTALLATION PROCEDURE 1. Remove the cap from the opening on the fuel tank. 2. Install the fuel tank fill pipe. 3. Connect the recirculation line to the sending unit. NOTE: Refer to Fastener Notice in Service Precautions. 4. Tighten the fuel tank fill pipe clamp (1) at the fuel tank. Locations Horn Switch: Locations Upper Steering Column Page 8794 Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA and/or the secondary locks. Micro .64 Connectors MICRO .64 CONNECTORS TOOLS REQUIRED J 38125-D Terminal Repair Kit REMOVAL PROCEDURE Follow the steps below in order to remove terminals from Micro 64 connectors. 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. 2. Disconnect the connector from the component. 4L60/4L60-E/4L65-E Transmission Tow/Haul Switch: Testing and Inspection 4L60/4L60-E/4L65-E Transmission Tow/Haul Switch/Indicator Always On or Inoperative Circuit Description Tow/haul mode enables the operator to achieve enhanced shift performance when towing or hauling a load. When tow/haul mode is selected, the tow/haul switch input signal to the body control module (BCM) is momentarily toggled to zero volts. This signals the powertrain control module (PCM) to extend the length of time between upshifts and increase transmission line pressure. Cycling the tow/haul switch again disables tow/haul mode and returns the transmission to a normal shift pattern. Diagnostic Aids If the electrical circuit tests are OK and the tow/haul shift pattern is not occurring, there may be a mechanical/hydraulic condition that prevents tow/haul operation. Refer to Symptoms - Automatic Transmission. Page 3068 Disclaimer A/C - Blower Motor Runs After Vehicle Is Shut OFF Blower Motor Relay: Customer Interest A/C - Blower Motor Runs After Vehicle Is Shut OFF TECHNICAL Bulletin No.: 03-01-38-015A Date: October 27, 2008 Subject: HVAC Blower Motor May Run Continuously After Vehicle is Turned Off (Replace Blower Resistor Relay) Models: 2004 Chevrolet Avalanche, Silverado, Suburban, Tahoe, TrailBlazer, TrailBlazer EXT 2004 GMC Envoy, Envoy XL, Sierra, Yukon, Yukon XL with Manual Control HVAC (RPO CJ3) Built Prior to August, 2003 Supercede: This bulletin is being revised to update the parts information. Please discard Corporate Bulletin Number 03-01-38-015 (Section 01 - HVAC). Condition Some customers may comment on the HVAC blower motor running after the vehicle has been turned off. The blower may run for just a few minutes or continuously until the battery is discharged. Cause A new style HVAC blower relay/resistor may stick in the "on" position. When the HVAC fan blower relay has been energized, the contacts may "micro-weld" together. After this occurrence, the HVAC blower may not respond to the HVAC controller commands. Correction Replace the HVAC blower resistor/relay with the type used previous to the 2004 model year. The appropriate part numbers are listed in the table below. For specific repair procedures, refer to the 2004 Service Information (SI) under Blower Motor Resistor Assembly Replacement (SI Document ID # 526350 (C/K) or # 729996 (S/T). Parts Information Warranty Information Disclaimer Page 5408 7. Install the rear axle vent hose to the clip on the fuel fill pipe bracket. 8. Close the axle vent hose clip. 9. Install the fuel tank filler housing. 10. Install the fuel tank filler housing to fuel tank fill pipe bolts. Tighten Tighten the screws to 2.3 N.m (20 lb in). 11. Install the fuel tank filler housing to body TORX(R) screws (1) and pushpin retainer (2). Tighten Tighten the screws to 2.3 N.m (20 lb in). Page 16179 Power Window Switch: Service and Repair Switch Replacement - Door Lock and Side Window Driver SWITCH REPLACEMENT - DOOR LOCK AND SIDE WINDOW - DRIVER REMOVAL PROCEDURE 1. Remove the front door trim panel. 2. Disconnect the electrical connectors. 3. Remove the screw that retains the switch panel bezel (1) from the front door panel. 4. Remove the switch panel bezel from the door panel using a flat-bladed tool. 5. Using a wide plastic flat-bladed tool, release the retaining clips on both sides of the door module. 6. Remove the door module from the switch panel bezel. Page 6040 12. Inspect the TCC solenoid and wiring harness for the following defects: ^ Damage ^ Cracked connectors ^ Exposed wires ^ Loose pins Installation Procedure 1. Install the wiring harness and TCC solenoid with a new O-ring seal to the transmission. 2. Install the pass-through electrical connector to the transmission case. 3. Notice: Refer to Fastener Notice in Service Precautions. Install the valve body bolts which retain the internal wiring harness and install the TCC solenoid bolts. ^ Tighten the control valve body bolts to 11 Nm (97 inch lbs.). ^ Tighten the TCC solenoid bolts to 11 Nm (97 inch lbs.). Page 4817 Intake Air Temperature (IAT)/Mass Air Flow (MAF) Sensor Page 10325 2. Install the upper control arm bolts (4) for the 25/35 Series 4WD. Note: Refer to Fastener Notice in Cautions and Notices. 3. Install the upper control arm nuts and the adjustment cams (2) 25/35 Series 4WD. Tighten Tighten the nuts to 190 N.m (140 lb ft). 4. Install the upper control arm bolts (4) for the 15 Series 2WD, 4WD, and 25/35 Series 2WD. 5. Install the upper control arm nuts and the adjustment cams (2) for the 15 Series 2WD, 4WD, and 25/35 Series 2WD. Tighten Tighten the nuts to 190 N.m (140 lb ft). 6. Connect the upper control arm to the steering knuckle. Page 9605 Relay Block - I/P C10 Part 1 Page 13694 Rear Door Hinge: Service and Repair Hinge Replacement - Rear Door - Body Side Hinge Replacement - Rear Door - Body Side Removal Procedure 1. Remove all of the related panels and components. 2. Remove any excess sealer surrounding the existing hinge and scribe the location of the hinge on the hinge pillar. 3. Lightly hand-sand the existing hinge with 100 grit or finer sandpaper in order to locate the 4 welds that attach the hinge to the door. Important: Punch the center of the weld so that as much of the weld as possible is removed during the drilling. 4. Center punch each of the 4 weld marks on the original hinge. Important: Do not drill into the hinge pillar. 5. Drill through the hinge only at each punch location. Use a 13 mm (1/2 in) rotabroach hole saw or the equivalent. 6. Remove the hinge. If necessary, use a chisel in order to separate the hinge from the pillar. 7. Remove all of the remaining weld from the pillar surface in order to ensure a flush fit of the service hinge. Installation Procedure Page 9981 11. From the technicians point of view, the FRONT of the sensor will have: ^ A raised rotor flange cuff (3) ^ An alignment mark (2) on the rotor flange cuff (3) for installation ^ A pin hole (1) for the centering pin. Note the location of the pin hole. 12. Remove the connector from the sensor. 13. Remove the sensor from the adapter and bearing assembly. 14. To install the sensor, proceed to step 9 in the installation procedure. 15. From the technicians point of view, the FRONT of the sensor will have: ^ A raised rotor flange cuff (3) ^ An alignment mark (2) on the rotor flange cuff (3) for installation ^ A pin hole (1) for the centering pin. Note location of the pin hole. ^ A sensor clip in FRONT of the sensor 16. Remove the connector from the sensor. 17. Remove the sensor clip from the sensor. 18. Remove the sensor from the adapter and bearing assembly. 19. To install the sensor, proceed to step 13 in the installation procedure. 20. From the technicians point of view, the FRONT of the sensor will have: ^ A flush rotor flange cuff (3) ^ A pin hole (1) for the centering pin. Note the location of the pin hole. ^ An alignment mark (2) on the flush rotor flange cuff (3) for installation 21. Remove the connector from the sensor. 22. Remove the sensor from the adapter and bearing assembly. 23. To install the sensor, proceed to step 17 in the installation procedure. Page 8092 10. Install the brake rotor (2) shown on the 1500 series. Refer to Brake Rotor Replacement - Front in Disc Brakes. 11. Install the tire and wheel. 12. Perform the Diagnostic System Check - ABS. Page 1196 Front Passenger Door Module (FPDM) - C5 (Heated Seat Switch) Page 5345 1. Install the fuel and EVAP bundle. NOTE: Refer to Fastener Notice in Service Precautions. 2. If vehicle is a crew cab or extended cab, install the fuel and EVAP bundle clip nuts. Tighten Tighten the nuts to 12 N.m (106 lb in). 3. If vehicle is a regular cab, install the fuel and EVAP bundle clip nuts. Tighten Tighten the nuts to 12 N.m (106 lb in). 4. Remove the caps from the fuel and EVAP lines at the fuel tank. 5. Connect the fuel and EVAP quick connect fittings. 6. If equipped with 4WD, install the torsion bar bracket. Page 4660 9. Use J 38125-12A to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. REPAIR PROCEDURE The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. 1. Cut the wire as close to the terminal as possible. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. Service and Repair Keyless Entry Transmitter Battery: Service and Repair TRANSMITTER BATTERY REPLACEMENT REMOVAL PROCEDURE Under normal use, the battery in the transmitter will last about 2 years. For battery replacement, use a Panasonic(R) 3 volt, type CR2032, or equivalent. 1. Open the transmitter case and perform the following steps: 1.1. Insert a dime between the 2 halves of the transmitter near the key ring hole. 1.2. Twist the dime. 2. Remove the battery. INSTALLATION PROCEDURE 1. Install the battery with the (+) positive side down. 2. Close the transmitter case and perform the following steps: 2.1. Align the top and bottom covers. Engine Controls - MIL ON/Misfire/Misfire DTC's Set Engine Control Module: All Technical Service Bulletins Engine Controls - MIL ON/Misfire/Misfire DTC's Set Bulletin No.: 06-06-04-046 Date: September 12, 2006 INFORMATION Subject: Information on Engine Misfire MIL/SES Light Illuminated or Flashing DTC P0300, P0301, P0302, P0303, P0304, P0305, P0306, P0307, P0308, P0420 or P0430 Models: 1999-2007 Cadillac, Chevrolet, GMC Full-Size Pickup and/or Utility Trucks with 4.8L, 5.3L, 5.7L, 6.0L or 6.2L VORTEC GEN III, GEN IV, V-8 Engine (VINs V, C, T, Z, B, 3, M, 0, J, R, U, N, Y, K, 8 - RPOs LR4, LY2, LM7, L59, L33, LC9, LH6, LMG, LY5, L31, LQ4, LQ9, L76, LY6, L92) with Active Fuel Management(TM) and E85 Flex Fuel If you encounter vehicles that exhibit the above conditions, refer to SI for the appropriate DTC(s) set. If no trouble is found, the cause may be due to an ECM ground terminal that has corroded with rust over time. Inspect the main engine wiring harness ground terminal (G103) for this condition. The wire terminal (G103) attaches either to the front or to the rear of the right side cylinder head, depending on the model year of the Full Size Pickup and/or Utility Trucks. If the ECM ground terminal has been found to be corroded, then follow the service procedure outlined in this bulletin to correct the corrosion issue. Remove either the nut or bolt securing the main engine wiring harness ground terminal (G103) to the right cylinder head. Refer to the above illustration to determine where the ground is located on the vehicle (1). Page 8927 Auxiliary Power Outlet: Scan Tool Testing and Procedures Scan Tool Data Definitions SCAN TOOL DATA DEFINITIONS Ignition 1 Signal: The scan tool displays the current voltage at the battery. GEN L-Terminal Signal Command: The scan tool displays OK/No Output. The scan tool displays OK until malfunction is detected on the generator L terminal circuit, then it reads No Output. GEN F-Terminal Signal: The scan tool displays 0-100%. The scan tool displays 0-5% until the engine is running, then the percentage value varies depending on electrical loads. Powertrain Control Module (PCM) O-Ring Replacement A/C Coupler O-ring: Service and Repair O-Ring Replacement O-RING REPLACEMENT REMOVAL PROCEDURE 1. Disassemble the A/C refrigerant components. - For compression style fittings use a back up wrench on the fitting (2) and loosen the fitting nut (1). - For banjo style fittings remove the bolt retaining the banjo type fitting. 2. Remove the O-ring seal from the A/C refrigerant component. 3. Inspect the O-ring seal for signs of damage to help determine the root cause of the failure. 4. Inspect the A/C refrigerant components for damage or burrs. Repair if necessary. IMPORTANT: Cap or tape the open A/C refrigerant components immediately to prevent system contamination. 5. Cap or tape the A/C refrigerant components. 6. Discard the O-ring seal. INSTALLATION PROCEDURE 1. Inspect the new O-ring seal for any sign or cracks, cuts, or damage. Replace if necessary. 2. Remove the cap or tape from the A/C refrigerant components. 3. Using a lint-free clean, dry cloth, carefully clean the sealing surfaces of the A/C refrigerant components. IMPORTANT: DO NOT allow any of the mineral base 525 viscosity refrigerant oil on the new O-ring seal to enter the refrigerant system. 4. Lightly coat the new O-ring seal with mineral base 525 viscosity refrigerant oil. IMPORTANT: DO NOT reuse O-ring seals. 5. Carefully slide the new O-ring seal onto the A/C refrigerant component. Page 2152 Diagnostic Aids Vibration from the engine operating may cause a body component or another part of the vehicle to make rumbling noise. The drive belt(s) may have a condition that can not be seen or felt. Sometimes replacing the drive belt(s) may be the only repair for the symptom. If after replacing the drive belt(s) and completing the diagnostic table, the rumbling is only heard with the drive belt(s) installed, there might be an accessory drive component failure. Varying the load on the accessory drive component(s) may aid in identifying which component is causing the rumbling noise. Test Description Steps 1 - 8 The number(s) below refer to the step(s) in the diagnostic table. 2. This test is to verify that the symptom is present during diagnosing. Other vehicle components may cause a similar symptom. 3. This test is to verify that the drive belt(s) is causing the rumbling. Rumbling may be confused with an internal engine noise due to the similarity in the description. Remove only one drive belt at a time if the vehicle has multiple drive belts. Operate the engine for a few seconds, this will verify if the rumbling noise is related to the drive belt(s) or not. With the drive belt(s) removed the water pump will not operate and the engine may overheat. Also diagnostic trouble codes (DTCs) may set when the engine is operated with the drive belt(s) removed. 4. Inspect the drive belt(s) to ensure that the drive belt(s) is not the cause of the noise. Small cracks across the ribs of the drive belt(s) will not cause Page 12156 monitor the Tech2(R) for the current time and date. REMINDER - Keep in mind that the time displayed on the Tech2(R) is in Greenwich Mean Time (GMT) and the offset is based on the time zones relationship to GMT. If replacement of the VIU/VCIM is necessary, you MUST reconfigure the OnStar® system. Failure to reconfigure the system will result in an additional customer visit for repair. OnStar® VIU, Generations 2 and 3, will require the technician to press the blue OnStar® button to reconfigure the vehicle with an OnStar® advisor. OnStar(R) VCIM, Generations 4-7 will require the technician to reconfigure the vehicle with the use of the TIS2WEB and SPS applications (pass thru only), along with the Tech2(R). The configuration and set-up procedure is a two-step process that must be completed step-by-step without interruption or delay in between each step. This procedure enables an automated activation without a button press by the technician to the OnStar(R) Call Center. Following this procedure, it may take up to 24 hours for all OnStar(R) services to be fully activated. How to Order Parts If the OnStar(R) GPS date/time stamp is non-recoverable and the unit needs to be replaced, dealers in the U.S. should contact Autocraft Electronics select the catalog item that contains this bulletin number. Canadian dealers should contact MASS Electronics. Dealers DO NOT need to call the GM Technical Assistance Center (TAC) for replacement approval. Autocraft Electronics and MASS Electronics will be responsible for verifying that the subject vehicle is a candidate for a replacement VIU/VCIM. Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use the table. Warranty Information (Saab U.S. Models) NV 3500 Fluid - M/T: Service and Repair NV 3500 Transmission Fluid Replacement ^ Tools Required J 36511 Oil Fill/Drain Plug Hex Bit (17 MM) Removal Procedure 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. Using J 36511 remove the oil fill plug. 3. Place a suitable drain pan under the transmission in order to catch the drained transmission fluid. 4. Using J 36511 remove the oil drain plug. 5. Remove any old sealant from the transmission housing. Installation Procedure Page 3049 9. Install the retaining ring. 10. Install the axle shaft. 11. Inspect the lubricant level and add, if necessary. 12. Lower the vehicle. Page 14062 Electrical Symbols ELECTRICAL SYMBOLS Electrical Symbols Part 1 Page 2315 Hose/Line HVAC: Service and Repair Evaporator Tube Replacement (Without RPO Code HP2) EVAPORATOR TUBE REPLACEMENT (W/O HP2) TOOLS REQUIRED J 39400-A Halogen Leak Detector REMOVAL PROCEDURE 1. Recover the refrigerant from the A/C system. Refer to Refrigerant Recovery and Recharging. 2. Remove the evaporator tube nut from the evaporator. 3. Remove the evaporator tube from the evaporator. 4. Remove the right park/turn signal lamp. 5. Remove the grille from the vehicle. 6. Remove the evaporator tube nut from the condenser. 7. Remove the evaporator tube from the condenser. 8. Remove the evaporator tube from the vehicle. 9. Discard all of the used sealing washers. Cap all of the open connections. INSTALLATION PROCEDURE 1. Install the evaporator tube to the condenser using new sealing washers. NOTE: Refer to Fastener Notice in Service Precautions. Page 5266 Fuel Injector 3 Locations Knock Sensors A/C - Ticking Noise From Instrument Panel/DTC's Set Control Module HVAC: All Technical Service Bulletins A/C - Ticking Noise From Instrument Panel/DTC's Set Bulletin No.: 06-01-38-003 Date: April 27, 2006 TECHNICAL Subject: Intermittent Ticking Noise from I/P, Poor A/C Performance, HVAC DTCs B0229, B0414, B0424, B3770 (Reprogram HVAC Control Module) Models: 2004-2006 Cadillac Escalade Models 2004-2006 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2004-2006 GMC Sierra Models, Yukon Models with Air Conditioning (RPOs CJ2, CJ3) Condition Some customers may comment on one or more of the following concerns: ^ Intermittent ticking/clicking noise from the instrument panel. ^ Recirculation mode does not work or Air Conditioning (A/C) system performance is poor during high ambient temperatures. ^ Unable to control the driver side temperature. ^ Unable to control the passenger side temperature. ^ Unable to change the front system modes. Cause This condition may be caused by the Heating, Ventilation and Air Conditioning (HVAC) actuators that may hunt for the correct commanded position. This cycling may cause a clicking or ticking noise. An overtravel of the HVAC system control doors may cause one or more of the concerns listed above. If an overtravel occurs, a Diagnostic Trouble Code (DTC) will be set, and the door will go to a preset default position. When a system door defaults, that door will stay at the default position until the DTC is cleared. After the DTC is cleared, the door will operate properly until the overtravel condition re-occurs. The table lists the HVAC system doors and the DTC associated with it. Correction Technicians are to perform the normal diagnostic procedures in SI for these concerns. If diagnostics show that the HVAC system door(s) travel below 5 counts (out of the lower range) or above 250 counts (out of the upper range), then update the software calibrations in the HVAC control module. The new calibrations were made available to dealerships as part of TIS2000 incremental satellite update version 2.5, which was broadcast to dealers in February 2006. Page 10057 6. Remove the power steering gear inlet hose (4) from the power steering gear. 7. Remove the power brake booster outlet hose (2) retaining clamp (3) to remove the power brake booster outlet hose from the power steering pump. 8. Remove the power brake booster inlet hose from the power steering pump. 9. Remove the power steering hose assembly from the vehicle. Installation Procedure Page 2193 Air Filter Element: Service and Repair AIR CLEANER ELEMENT REPLACEMENT REMOVAL PROCEDURE 1. Remove the air cleaner outlet duct. 2. Disconnect the mass air flow/intake air temperature (MAF/IAT) sensor electrical connector (4). 3. Loosen the air cleaner housing top screws. 4. Remove the air cleaner housing cover. 5. Remove the air filter element. INSTALLATION PROCEDURE Page 2133 2. Remove the serpentine belt from the accessory drive system. 3. Install the tool onto the power steering pulley. Position the legs of the tool into the outer grooves of the pulley, farthest from the front of the engine. 4. Install the retaining cord around the pulley and to the legs of the tool. 5. Put on the laser safety glasses provided with the tool. 6. Depress the switch on the rear of the tool to activate the light beam. 7. Rotate the power steering pulley as required to project the light beam onto the crankshaft balancer pulley grooves. 8. Inspect for proper power steering pulley alignment. - If the laser beam projects onto the second rib or raised area (1), the pulleys are aligned properly. - If the laser beam projects more than one-quarter rib 0.9 mm (0.035 in) mis-alignment, adjust the position of the power steering pulley as required. - Refer to SI for Power Steering Pulley Removal and Installation procedures. 9. Install the serpentine belt to the accessory drive system in the original orientation. 10. Operate the vehicle and verify that the belt noise concern is no longer present. Tool Information Please visit the GM service tool website for pricing information or to place your order for this tool. Page 11371 Discharge Air Temperature Sensor / Switch: Service and Repair Air Temperature Sensor Replacement - Upper Left AIR TEMPERATURE SENSOR REPLACEMENT - UPPER LEFT REMOVAL PROCEDURE 1. Remove the upper left air temperature sensor (2) from the air distributor duct (1). 2. Disconnect the electrical connector (3) from the upper left air temperature sensor (2). INSTALLATION PROCEDURE 1. Install the upper left air temperature sensor (2) to the air distributor duct (1). 2. Connect the electrical connector (3) to the upper left air temperature sensor (2). Page 16028 Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA and/or the secondary locks. Micro .64 Connectors MICRO .64 CONNECTORS TOOLS REQUIRED J 38125-D Terminal Repair Kit REMOVAL PROCEDURE Follow the steps below in order to remove terminals from Micro 64 connectors. 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. 2. Disconnect the connector from the component. Page 15050 For vehicles repaired under warranty use the table. Disclaimer Correction 1. Repair the damaged pickup box using the following procedure. When repairing any damage to the front of the pickup box, it may be necessary to remove the pickup box from the frame. A. Drill a 6 mm (0.23 in) hole in the extreme end of the crack. B. Prepare inner crack for welding. Important: Do not use oxyacetylene welding equipment. MIG WELD ONLY. C. Weld the crack using the appropriate welding technique. D. Clean and prepare all of the welding surfaces. E. Return surface contour to its original contour. Important: Prior to refinishing, refer to the GM4901M-D-2005 (English) or GM4901M-D-F 2005 (French) GM Approved Refinish Materials booklet for recommended products. The information for the 2005 GM Approved Refinish Materials booklet will now be online at the GMGOODWRENCH WEB SITE ONLY. Printed books have been discontinued. Steps to the site are as follows: a. Go to www.gmgoodwrench.com. b. Click on GM Collision Parts. c. Click on GM Technical Repair Information. d. Click on Paint Shop. Do not combine the paint systems. Refer to the paint manufacturer's recommendations. F. Refinish as necessary. Weatherstrip Replacement - Auxiliary Front Door Weatherstrip: Service and Repair Weatherstrip Replacement - Auxiliary Weatherstrip Replacement - Auxiliary Removal Procedure 1. Open the door. 2. Pull the weather-strip from the pinchweld flange. Installation Procedure 1. Push the weather-strip over the pinch-weld flange. 2. Close the door. Page 8807 - Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-D in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-D if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Brake Pipe Replacement Brake Hose/Line: Service and Repair Brake Pipe Replacement Brake Pipe Replacement Removal Procedure Caution: Refer to Brake Fluid Irritant Caution in Service Precautions. Caution: Always use double-walled steel brake pipe when replacing brake pipes. The use of any other pipe is not recommended and may cause brake system failure. Carefully route and retain replacement brake pipes. Always use the correct fasteners and in the original location for replacement brake pipes. Failure to properly route and retain brake pipes may cause damage to the brake pipes and brake system resulting in personal injury. Notice: Refer to Brake Fluid Effects on Paint and Electrical Components Notice in Service Precautions. Important: Brake pipes that run parallel to each other must maintain a 6 mm (1/4 inch) clearance. 1. Disconnect the brake pipe fittings. 2. Remove the brake pipe fasteners from the vehicle. 3. Remove the brake pipe from the vehicle. Installation Procedure 1. Bend the brake pipe to achieve proper fit. 2. Install the brake pipe to the vehicle. Maintain a clearance of 19 mm (3/4 inch) for all moving or vibrating components. 3. Install the brake pipe fasteners to the vehicle. 4. Notice: Refer to Fastener Notice in Service Precautions. Connect the brake pipe fittings. ^ Tighten the brake pipe fittings to the brake pressure modulator valve (BPMV) or the wheel jounce hoses to 25 Nm (18 ft. lbs.). ^ Tighten the brake pipe fittings to the master cylinder to 25 Nm (18 ft. lbs.). 5. Bleed the hydraulic brake system. Refer to ABS Automated Bleed Procedure in Antilock Brake System. Diagrams Clutch Start Switch (M/T) Page 13414 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Weather Pack Connectors WEATHER PACK CONNECTORS The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. Page 4286 Electrical Symbols Part 3 Page 2359 Radiator Hose: Service and Repair Radiator Vent Inlet Hose Replacement Radiator Vent Inlet Hose Replacement Removal Procedure 1. Drain the cooling system. 2. Reposition the vent inlet hose clamp from the radiator. 3. Remove the vent inlet hose from the radiator. 4. Reposition the vent inlet hose clamp from the surge tank. 5. Remove the vent inlet hose from the surge tank. Installation Procedure 1. Install the vent inlet hose to the surge tank. 2. Reposition the vent inlet hose clamp to the surge tank. 3. Install the vent inlet hose to the radiator. 4. Reposition the vent inlet hose clamp to the radiator. 5. Fill the cooling system. Page 6822 Seat the pinion yoke onto the pinion shaft by tapping it with a soft-faced hammer until a few threads show through the yoke. 13. Install the washer and a new pinion nut. 14. Install the J 8614-01 onto the pinion yoke. 15. Notice: Refer to Fastener Notice in Service Precautions. Important: If the rotating torque is exceeded, the pinion will have to be removed and a new collapsible spacer installed. ^ Tighten the pinion nut while holding the J 8614-01. ^ Tighten the pinion nut until the pinion end play is just taken up. Rotate the pinion while tightening the nut to seat the bearings. 16. Remove the J 8614-01. 17. Important: Do not apply sealant to the pinion gear bearing retainer at this time. Install the original shim to the pinion bearing retainer. If the original shim is not available, install a 0.41 mm (0.016 inch) shim to build pinion depth. 18. Install the pinion gear bearing retainer to the axle housing. 19. Install the pinion bearing retainer bolts. ^ Tighten the pinion gear retainer bolts to 88 Nm (65 ft. lbs.). 20. Measure the rotating torque of the pinion using an inch-pound torque wrench. The rotating torque of the pinion should be between 1.0-2.3 Nm (10-20 inch lbs.) for used bearings, or 1.7-3.4 Nm (15-30 inch lbs.) for new bearings. 21. If the rotating torque measurement is below 1.0 Nm (10 inch lbs.) for used bearings, or 1.7 Nm (15 inch lbs.) for new bearings, install the J 8614-01 and continue to tighten the pinion nut. ^ Tighten the pinion nut, in small increments, as needed, until the torque required in order to rotate the pinion is between 1.0-2.3 Nm (10-20 inch lbs.) for used bearings, or 1.7-3.4 Nm (15-30 inch lbs.) for new bearings. 22. Once the specified torque is obtained, rotate the pinion several times to ensure the bearings have seated. Recheck the rotating torque and adjust if necessary. 23. Install the differential assembly. 24. Adjust the differential side bearing preload. 25. Determine the selective shim thickness for the drive pinion. 26. Adjust the backlash. 27. Fill the axle with lubricant. Use the proper fluid. 28. Lower the vehicle. Page 3216 4. Install a NEW rocker cover gasket (1) into the valve rocker arm cover lip. 5. Install the valve rocker arm cover. Notice: Refer to Fastener Notice in Service Precautions. 6. Tighten the rocker arm cover bolts. ^ Tighten the bolts to 12 Nm (106 inch lbs.). Page 5430 Fuel Pump/Sender Assembly - Secondary Diagrams Courtesy/Reading Lamp - Rear (Crew Cab With RPO Code YE9) Page 13523 Electrical Symbols Part 14 Page 15086 4. Align the outboard air inlet grille panel clips and press down in order to install. 5. Install the wiper arms. Page 3626 Fan Shroud: Service and Repair Fan Shroud - Lower Fan Shroud Replacement - Lower Removal Procedure 1. Remove the cooling fan. 2. If equipped with engine oil cooler, remove the oil cooler hose clip from the lower fan shroud. 3. Lift the lower fan shroud up in order to disengage the fan shroud from the retaining clips on the radiator. Installation Procedure 1. Install the lower fan shroud to the retaining clips on the radiator and firmly push down. 2. If equipped with the engine oil cooler, Install the oil cooler hose clip to the lower fan shroud. 3. Install the cooling fan. Page 4376 Crankshaft Position (CKP) Sensor Page 15747 Backup Lamp Switch: Service and Repair NV 4500 Backup Lamp Switch Replacement Removal Procedure 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. Disconnect the backup lamp switch electrical connector (1). 3. Remove the backup lamp switch and seal. Installation Procedure 1. Ensure the seal is installed on the switch. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the backup lamp switch. ^ Tighten the switch to 28 Nm (21 ft. lbs.). Page 5974 Torque Converter Clutch Solenoid: Connector Locations Page 7802 NVG 246-NP8 Control Module: Locations NVG 246-NP8 Transfer Case Shift Control Module Transfer Case Shift Control Module 1 - I/P Harness 2 - Transfer Case Shift Control Module Connectors 3 - Transfer Case Shift Control Module 4 - Instrument Panel Page 1445 1. Notice: Refer to Fastener Notice in Service Precautions. Install the backup lamp switch. ^ Tighten the switch to 20 Nm (15 ft. lbs.). 2. If equipped with a 8.1L engine, connect the backup lamp switch electrical connector (4). 3. If equipped with a 6.6L engine, connect the backup lamp switch electrical connector (3). Lower the vehicle. Page 7259 Power Take Off (PTO) Switch - Part 1 Front Wheel Bearing Wheel Bearing: Service and Repair Front Wheel Bearing Front Wheel Hub, Bearing, and Seal Replacement (4WD) ^ Tools Required J 45859 Axle Remover Removal Procedure 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Remove the tire and wheel. 3. Remove the rotor. Refer to Brake Rotor Replacement - Front in Disc Brakes. 4. Remove the wheel speed sensor and brake hose mounting bracket bolt from the steering knuckle. 5. Remove the wheel drive shaft nut retaining cover. Page 2691 Relay Block - I/P C3 Part 2 Automatic Transmission - 4L60-E/4L65-E Pressure Regulating Solenoid: Service and Repair Automatic Transmission - 4L60-E/4L65-E Pressure Regulator Replacement Removal Procedure 1. Remove the transmission filter. 2. Compress the reverse boost valve sleeve into the bore of the oil pump to release tension on the reverse boost valve retaining ring. 3. Remove the reverse boost valve retaining ring, then slowly release tension on the reverse boost valve sleeve. 4. Remove the reverse boost valve sleeve (5) and the reverse boost valve (4). 5. Remove the pressure regulator isolator spring (3) and the pressure regulator valve spring (2). 6. Remove the pressure regulator valve (1). Installation Procedure 1. Install the pressure regulator valve (1). 2. Install the pressure regulator isolator spring (3) and the pressure regulator valve spring (2). 3. Install the reverse boost valve (4) in the reverse boost valve sleeve (5). 4. Install the reverse boost valve (4) and sleeve (5) in the oil pump cover. Page 3651 Heater Hose: Service and Repair Heater Hose Replacement - Outlet HEATER HOSE REPLACEMENT - OUTLET TOOLS REQUIRED J 43181 Quick Connect Connector Removal Tool REMOVAL PROCEDURE 1. Drain the cooling system. Refer to Draining and Filling Cooling System (with HP2)Draining and Filling Cooling System (without HP2) in Cooling System. 2. Remove the air intake tube. 3. Remove the heater and surge tank hose from the mounting clip. 4. Using the J 43181 disconnect the heater hose from the heater core outlet. 4.1. Install the J 43181 to the heater core pipe. 4.2. Close the tool around the heater core pipe. 4.3. Firmly pull the tool into the quick connect end of the heater hose. 4.4. Firmly grasp the heater hose. Pull the heater hose forward in order to disengage the hose from the heater core. 5. Remove the outlet heater hose from the engine. Locations Passenger Presence Components - Under Front Passenger Seat Page 8998 Location View Page 1362 Door Latch Assembly (Door Jamb Switch) - Front Passenger - C2 Page 5763 Fluid Pressure Sensor/Switch: Connector Locations Page 11250 Refrigerant Oil: Fluid Type Specifications REFRIGERANT OIL PAG Oil GM P/N 12378526 (Canadian P/N 88900060) Trim Height Inspection Procedure Alignment: Service and Repair Trim Height Inspection Procedure Trim Height Inspection Procedure Trim Height Measurements Trim height is a predetermined measurement relating to vehicle ride height. Incorrect trim heights can cause bottoming out over bumps, damage to the suspension components and symptoms similar to wheel alignment problems. Check the trim heights when diagnosing suspension concerns and before checking the wheel alignment. Perform the following before measuring the trim heights: 1. Make sure the vehicle is on a level surface, such as a alignment rack. 2. Remove the alignment rack floating pins. 3. Set the tire pressures to the pressure shown on the certification label. 4. Check the fuel level. Add additional weight if necessary to simulate a full tank. 5. Make sure the rear compartment is empty except for the spare tire. 6. Close the doors and hood. Z Height Measurement Important: K models only the Z height must be adjusted before the alignment. The Z height dimension measurement determines the proper ride height for the front end of the vehicle. Vehicles equipped with torsion bars use a adjusting arm in order to adjust the Z height dimension. Vehicles without torsion bars have no adjustment and could require replacement of suspension components. 1. Important: All dimensions are measured vertical to the ground. Cross vehicle Z heights should be within 12 mm (0.47 inch) to be considered correct. Place hand on the front bumper and jounce the front of the vehicle. Make sure that there is at least 38 mm (1.5 inch) of movement while jouncing. 2. Allow the vehicle to settle into position. 3. Measure from the pivot bolt center line (2) down to the lower corner (5) of the steering knuckle (1) in order to obtain the Z height measurement (4). 4. Repeat the jouncing operation 2 more times for a total of 3 times. 5. Use the highest and the lowest measurements to calculate the average height. 6. The true Z height dimension number is the average of the highest and the lowest measurements. Refer to Trim Height Specifications. Z Height Adjustment Page 12711 Page 4288 Electrical Symbols Part 5 OnStar(R) - Generation 6 Service Procedures Technical Service Bulletin # 09-08-46-001 Date: 090409 OnStar(R) - Generation 6 Service Procedures INFORMATION Bulletin No.: 09-08-46-001 Date: April 09, 2009 Subject: Servicing Vehicles Upgraded to OnStar(R) Generation 6 Digital‐Capable System (Follow Information Below) Models Attention: This bulletin is being issued to provide dealer personnel with information and the procedures to diagnose an upgraded OnStar(R) Generation 6 Digital-Capable system. Program Overview Since it was launched in 1996, OnStar® has relied on an analog wireless network to provide communication to and from OnStar-equipped vehicles. As part of an industry wide change in the North American wireless telecommunications industry, wireless carriers are transitioning to digital technology and will no longer support the analog wireless network beginning early 2008. Effective January 1, 2008, OnStar(R) service in the United States and Canada will be available only through vehicles that are capable of operating on the digital network. Refer to Corporate Bulletin Number 05-08-46-006H for information about upgrading certain vehicles to digital service. Details were covered in both the November 2006 and December 2007 issues of TechLink, which are available in the Archives of the TechLink website. Vehicles eligible for an OnStar(R) hardware upgrade are listed in this bulletin. Vehicle upgradeability can also be determined by typing the VIN into the field entitled "Determine VIN Hardware Functionality" on the OnStar(R) Online Enrollment website, located in the sales or service workbench tab of GM GlobalConnect. Canadian Dealers can use a similar tool that is available within the OnStar(R) Canada Online Enrollment site that can be accessed from the OnStar(R) Brand Resources in GlobalConnect. Access to the sales and/or service workbench in the GM GlobalConnect website can be granted by the dealership's Partner Security Coordinator (PSC). Page 5761 Vehicle Speed Sensor (VSS) Tow/Haul Switch Location Page 15221 Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. 1. Disconnect the connector from the component. 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. Interior - Erratic Memory Seat Operation Power Seat Control Module: Customer Interest Interior - Erratic Memory Seat Operation Bulletin No.: 04-08-50-016C Date: August 12, 2005 TECHNICAL Subject: Memory Seat May Not Return to Requested Position (Reprogram Driver Seat Module) Models: 2003-2005 Cadillac Escalade, Escalade ESV, Escalade EXT 2003-2005 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2003-2005 GMC Sierra, Yukon, Yukon XL, Yukon Denali All with Seat FRT, Individual (Non BKT) (RPO AN3) 2003-2005 HUMMER H2 with Seat, Front Bucket Deluxe (RPO AR9) Supercede: This bulletin is being revised to update the correction information. Please discard Corporate Bulletin Number 04-08-50-016B (Section 08 - Body and Accessories). Condition Some customers may comment that with repeated cycling of the memory seat between the "exit" and one of the "presets", the position of the seat may "creep" forward or rearward out of expected adjustment. Cause There is a coding deficiency in the software for the memory seat module. Correction Technicians are to reprogram the driver seat module with an updated software calibration. The previous bulletin stated to use a service calibration that was released with TIS satellite data update version 4.5. Feedback has proved that calibration to be ineffective in eliminating the memory seat creep condition. An updated service calibration was released with TIS satellite data update version 6.5 available June 13, 2005. This new calibration has additional memory seat creep protection. As always, make sure your Tech 2(R) is updated with the latest software version. Important: After programming is complete, move the seat all the way rearward and down, then bump the seat slightly forward and up. This position will be just off the end of travel hard stops. Reset both memory seat exit positions at this position. Having the seat set at just off the hard stops will aid in reducing the creep condition. Warranty Information Locations Turn Signal Switch: Locations Upper Steering Column Page 7657 7. Insert a flat-tipped screwdriver or a small pry bar in the space between the outer race of the seal and the transfer case. 8. Remove the outer part of the seal. Installation Procedure Page 2463 Fluid - A/T: Technical Service Bulletins A/T - Water Or Coolant Contamination Information INFORMATION Bulletin No.: 08-07-30-035B Date: November 01, 2010 Subject: Information on Water or Ethylene Glycol in Transmission Fluid Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks with Automatic Transmission Supercede: This bulletin is being revised to update model years. Please discard Corporate Bulletin Number 08-07-30-035A (Section 07 - Transmission/Transaxle). Water or ethylene glycol in automatic transmission fluid (ATF) is harmful to internal transmission components and will have a negative effect on reliability and durability of these parts. Water or ethylene glycol in ATF will also change the friction of the clutches, frequently resulting in shudder during engagement or gear changes, especially during torque converter clutch engagement. Indications of water in the ATF may include: - ATF blowing out of the transmission vent tube. - ATF may appear cloudy or, in cases of extreme contamination, have the appearance of a strawberry milkshake. - Visible water in the oil pan. - A milky white substance inside the pan area. - Spacer plate gaskets that appear to be glued to the valve body face or case. - Spacer plate gaskets that appear to be swollen or wrinkled in areas where they are not compressed. - Rust on internal transmission iron/steel components. If water in the ATF has been found and the source of the water entry has not been identified, or if a leaking in-radiator transmission oil cooler is suspected (with no evidence of cross-contamination in the coolant recovery reservoir), a simple and quick test kit is available that detects the presence of ethylene glycol in ATF. The "Gly-Tek" test kit, available from the Nelco Company, should be obtained and the ATF tested to make an accurate decision on the need for radiator replacement. This can help to prevent customer comebacks if the in-radiator transmission oil cooler is leaking and reduce repair expenses by avoiding radiator replacement if the cooler is not leaking. These test kits can be obtained from: Nelco Company Test kits can be ordered by phone or through the website listed above. Orders are shipped standard delivery time but can be shipped on a next day delivery basis for an extra charge. One test kit will complete 10 individual fluid sample tests. For vehicles repaired under warranty, the cost of the complete test kit plus shipping charges should be divided by 10 and submitted on the warranty claim as a net item. The transmission should be repaired or replaced based on the normal cost comparison procedure. Important If water or coolant is found in the transmission, the following components MUST be replaced. - Replace all of the rubber-type seals. - Replace all of the composition-faced clutch plates and/or bands. - Replace all of the nylon parts. - Replace the torque converter. - Thoroughly clean and rebuild the transmission, using new gaskets and oil filter. Important The following steps must be completed when repairing or replacing. Flush and flow check the transmission oil cooler using J 45096. Refer to Corporate Bulletin Number 02-07-30-052F- Automatic Transmission Oil Cooler Flush and Flow Test Essential Tool J 45096 TransFlow. - Thoroughly inspect the engine cooling system and hoses and clean/repair as necessary. Page 13390 Electrical Symbols Part 2 Page 11045 Parts required to complete this special coverage are to be obtained from General Motors Customer Care and Aftersales (GMCC&A;). Service Procedure Note The resistor module connector and blower motor resistor will need to be replaced if one or more of the symptoms below is present. - The HVAC blower may not function on certain or all blower speed settings - A burning plastic smell or smoke may be present in the vehicle - The HVAC blower may run continually with the ignition in the OFF position Determine if one or more of the above symptoms is present. If required refer to HVAC diagnostic information in SI. Refer to Resistor Module Connector and Blower Motor Resistor Replacement in this bulletin if one or more of the symptoms is present. Other HVAC repairs are NOT covered in this product safety special coverage bulletin. Resistor Module Connector and Blower Motor Resistor Replacement 1. Remove the blower fuses (Htr A/C & HVAC 1 fuses). 2. Lower the close-out panel enough to gain access to the resistor module connector. 3. Disconnect the connector from the resistor module. Note Connector replacement is required even if the connector was replaced on a previous service repair. 4. Remove the tape from the wiring harness to expose the wiring. 5. Cut the wires back far enough from the connector to eliminate any melted insulation on the wire. Note Use the old connector as a map for splicing the wires for the new connector. Be sure to use the correct crimping tool from the terminal repair kit J 38125. Use only Duraseal splice sleeves. Other splice sleeves may not protect the splice from moisture or provide a good electrical connection. 6. Install the new connector. Use the yellow splice sleeves provided with the connector. 7. Install the new blower motor resistor. 8. Reinstall the fuses. Test the blower motor to make sure all speeds are functional. 9. Reinstall the hush panel/close-out panel. Customer Reimbursement Customer requests for reimbursement of previously paid repairs to correct the condition described in this bulletin are to be submitted to the dealer prior to or by December 31, 2012. Repairs must have occurred within the 10 years of the date the vehicle was originally placed in service, or 240,000 kilometres, whichever occurs first. When a customer requests reimbursement, they must provide the following: Page 2866 3. Disconnect the vent valve pipe quick connect from the canister. 4. Either cut the existing valve vent pipe and leave the remaining section of pipe in the vehicle or remove along with the valve. 5. Push in the retainer and remove the existing canister vent valve from the fuel tank clip or mounting bracket. 6. Cut back the existing canister pipe approximately 51 mm (2 in) and retain the pipe for use with new valve. 7. Connect the canister pipe quick connect to the canister. 2500 Crew Cab Short Box Shown Below, Other Configurations Similar 1500 Extended Cab Short Box Shown Below, Other Configurations Similar 8. Install the new canister vent valve solenoid to the fuel tank clip or mounting bracket as shown above. The valve port closest to the electrical connector must point towards the canister. 9. Cut bulk 5/8" heater hose to a length of approximately 76 mm (3 in). Install the hose between the solenoid and the canister pipe and secure using clamps. 10. Attach bulk 5/8" heater hose to the vent port and secure using a clamp. Run a length as needed along the frame rail routing to the passenger side area above the transmission. 11. Cut the hose to determined length and install the supplied filter box. Secure using a clamp. 12. Remove the transmission heat shield, if necessary. 13. Remove the transmission support and lower the transmission assembly as necessary to allow for access to the new filter box location. 14. Secure the filter box to the transmission vent hose just forward of the hose tee-section using a tie strap. DO NOT pinch or restrict the transmission vent hose. The filter box opening should be pointing downward. 15. Raise the transmission and reinstall the transmission support. 16. Reinstall the transmission heat shield. 17. Connect the EVAP canister vent valve electrical connector. 18. Tie strap the hose as needed along the frame rail in order to keep the hose away from pinch-points and heat sources. 19. Lower the vehicle. Parts Information Page 9524 Application Tabel Part 2 Location View Diagrams Power Door Lock Switch: Diagrams Door Lock Switch - Driver (Base Only) Page 9063 Relay Block - I/P C9 Part 1 Service and Repair Rear Wheel Steering Switch: Service and Repair Rear Wheel Steering Mode Switch Replacement Removal Procedure 1. Remove the dash trim bezel. 2. Grasp the rear wheel steering mode switch housing (2) and pull outward to remove the switch assembly. 3. Disconnect the electrical connector (3) from the rear wheel steering mode switch. 4. Remove the rear wheel steering mode switch assembly (1) from the vehicle. Installation Procedure 1. Reconnect the rear wheel steering mode switch (3) electrical connectors. 2. Install the rear wheel steering mode switch (1) into the dash. 3. Reinstall the dash trim bezel. Page 10632 Disclaimer Page 9140 Note The rivet stud and surrounding panel area MUST BE properly refinished PRIOR to the installation of the electrical ground wire terminal and conductive nut to maintain a secure, stable and corrosion-free electrical ground. 11. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 12. Allow the refinished repair area to cure sufficiently before removing the protective material applied to the rivet stud threads. 13. Remove the painters tape or equivalent from the rivet stud threads. 14. Using GM approved residue-free solvent or equivalent, thoroughly clean the rivet stud threads to remove any adhesive and allow to dry. 15. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive rivet stud. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 16. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 17. Install the electrical ground wire terminal to the M6 conductive rivet stud. 18. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 19. Install the M6 conductive nut to the rivet stud and: Tighten Tighten to 8 Nm (71 lb in) 20. Verify proper system operation. Parts Information Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use: Warranty Information (Saab Models) Page 2415 ^ Knock or Clunk Noise ^ Rear Drive Axle Noises (SI Document ID #700580) ^ Launch Shudder/Vibration on Acceleration (Replace Propeller Shaft and Install a New Pinion Flange/Seal), Bulletin # 02-04-17-001 ^ Information on 2-3 Upshift or 3-2 Downshift Clunk Noise, Bulletin # 01-07-30-042 ^ Driveline Clunk When Stopping (Reprogram Powertrain Control Module (PCM), Bulletin # 03-07-30-028 Correction Replace the rear drive shaft slip yoke with a new nickel-plated slip yoke. See the parts table below. Follow the service procedure below. 1. Raise the vehicle on a hoist. 2. Reference mark the propeller shaft to the pinion flange connection. Important: Do not pound on the propeller shaft yoke ears. Never pry or place any tool between a yoke and a universal joint. 3. Remove the bolts and the yoke retainers from the pinion flange. 4. Slide the propeller shaft forward and out of the rear pinion flange. 5. Lower the rear of the propeller shaft and pull the driveshaft out of the transfer case. Note: Never clamp propeller shaft tubing in a vise. Clamping could dent or deform the tube causing an imbalance or unsafe condition. Always clamp on one of the yokes and support the shaft horizontally. Avoid damaging the slip yoke sealing surface. Nicks may damage the bushing or cut the lip seal. 6. Support the propeller shaft in a line horizontal with the table of a press. Important: Remove the front slip yoke and the universal joint together. The new nickel-plated slip yoke comes with a new universal joint. 7. Disassemble the snap rings by pinching the ends together with a pair of pliers. 8. If the ring does not readily snap out of the groove in the yoke, tap the end of the cup lightly in order to relieve the pressure from the ring. 9. Place the universal joint so that the lower ear of the yoke is supported on a 30 mm (1-1/8 in) hex head socket or a 27 mm (1-1/16 in) socket. Page 4919 10. Connect the PNP switch electrical connector (2). 11. If equipped with 4WD, install the front propeller shaft. 12. Lower the vehicle. 13. Check the PNP switch for proper operation. The engine must start in the park (P) or neutral (N) positions only. If proper operation of the switch can not be obtained, replace the switch. Park Lock Pawl and Actuator Replacement Park Lock Pawl and Actuator Replacement Removal Procedure 1. Remove the transmission filter. 2. Remove the park/neutral position (PNP) switch. 3. Remove the manual shaft nut and pin. 4. Remove the detent lever and actuator. 5. Remove the parking pawl bracket bolts. 6. Remove the parking pawl return spring. Page 2568 4. Wait 1 minute before working on the system. Enabling Procedure - Air Bag Fuse 1. Place the ignition in the OFF position. 2. Install the fuse(s) supplying power to the SDM. 3. Turn the ignition switch to the ON position. The AIR BAG indicator will flash then turn OFF. 4. Perform the Diagnostic System Check - Vehicle if the AIR BAG warning indicator does not operate as described. Disabling Procedure - Negative Battery Cable 1. Turn the steering wheel so that the vehicles wheels are pointing straight ahead. 2. Place the ignition in the OFF position. 3. Disconnect the negative battery cable from the battery. 4. Wait 1 minute before working on system. Enabling Procedure - Negative Battery Cable 1. Place the ignition in the OFF position. 2. Connect the negative battery cable to the battery. 3. Turn the ignition switch to the ON position. The AIR BAG indicator will flash then turn OFF. 4. Perform the Diagnostic System Check - Vehicle if the AIR BAG warning indicator does not operate as described. Page 12553 Page 4165 Camshaft Position Sensor: Description and Operation CAMSHAFT POSITION (CMP) SENSOR The CMP sensor is also a magneto resistive sensor, with the same type of circuits as the CKP sensor. The CMP sensor signal is a digital ON/OFF pulse, output once per revolution of the camshaft. The CMP sensor information is used by the PCM to determine the position of the valve train relative to the CKP. Page 13044 Important: Secure the wiring harness so that there is no risk of chafing and rattling. 9.4. Fold back the wiring harness and tape over the connectors (C). Fold back the wiring harness once more and secure with cable ties (D). 9.5. Install the right-hand rear luggage compartment in accordance with WIS - 8. Body - Interior equipment - Adjustment/Replacement. 10. Install the ground cable to the battery's negative terminal. 11. Clear the diagnostic trouble codes. 12. Set the date and time, see WIS - 3. Electrical system - Information display (SID_ - Technical description. 2003-2005 Saab 9-3 (9400) 4D/5D; 2004-2005 Saab 9-3 (9400) CV 2003-2005 Saab 9-3 (9440) 4D/5D; 2004-2005 Saab 9-3 (9440) CV Notice: Handle the fiber optic cables with care or the signal may be distorted. ^ It is very important that the two leads in the connector are not confused with one another. ^ Do not splice the cables. ^ Do not bend the cable in a radius smaller than 25 mm (1 in). ^ Do not expose the cable to temperatures exceeding 185°F (85°C). ^ Keep the cable ends free from dirt and grime. ^ Do not expose the cable to impact as this may cause the transparent plastic to whiten, thereby reducing the intensity of the light and causing possible communication interruptions. ^ The cable should not lie against any sharp edges as this may cause increased signal attenuation. 1. Remove the ECU CU with a Tech 2(R) according to the following: Fault diagnosis - Select model year - Select Saab 9-3 Sport (9440) - All - Add/Remove - Control Module - CU/PU - Remove. 2. Remove the ground cable from the battery's negative terminal. 3. Remove the floor console in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 4. Pry out the signal line from the SRS control module to the OnStar(R) control module and secure it: Page 10280 Disclaimer Page 874 Electrical Symbols Part 11 Page 12205 Page 6913 18. Remove the convolute retainer tool from the boot. Page 14769 Seat Heater: Removal and Replacement Seat Cushion Heater Element Replacement - Front Removal Procedure Caution: If the passenger seat cushion foam is damaged when you remove the heater element, replace the passenger pressence system in order to prevent personal injury. 1. Remove the seat trim panel. 2. Remove the seat cushion trim cover. 3. Peel the seat cushion heater off of the pad. 4. Disconnect the seat cushion heater wiring harness. Installation Procedure 1. Replace the inflatable restraint passenger presence system if the passenger seat cushion foam is damaged. 2. Connect the cushion heater wiring harness. 3. Install the seat cushion heater. 4. Install the seat cushion trim cover. 5. Install the seat trim panel. 6. Re-zero the inflatable restraint passenger presence system for the front passenger seat. Refer to Passenger Presence System Rezeroing Procedure. See: Restraint Systems/Air Bag Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Related Tests and Procedures/Passenger Presence System Rezeroing Procedure Diagrams Coolant Level Switch Page 7243 If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Sir/SRS Wiring Repairs SIR/SRS WIRING REPAIRS TOOLS REQUIRED J 38125-D Terminal Repair Kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-D contains the following items: - Special sealed splices - in order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping tool - A heat torch - An instruction manual The sealed splices have the following 2 critical features: - A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-D also serves as a generic terminal repair kit. The kit contains the following items: - A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors Page 12839 Page 8454 of failure to repair within a reasonable time. If the condition is not adequately repaired within a reasonable time, the customer may be entitled to an identical or reasonably equivalent vehicle at no charge or to a refund of the purchase price less a reasonable allowance for depreciation. To avoid having to provide these burdensome remedies, every effort must be made to promptly schedule an appointment with each customer and to repair their vehicle as soon as possible. In the recall notification letters, customers are told how to contact the US National Highway Traffic Safety Administration if the recall is not completed within a reasonable time. Dealer Recall Responsibility -- All All unsold new vehicles in dealers' possession and subject to this recall MUST be held and inspected/repaired per the service procedure of this recall bulletin BEFORE customers take possession of these vehicles. Dealers are to service all vehicles subject to this recall at no charge to customers, regardless of mileage, age of vehicle, or ownership, from this time forward. Customers who have recently purchased vehicles sold from your vehicle inventory, and for which there is no customer information indicated on the dealer listing, are to be contacted by the dealer. Arrangements are to be made to make the required correction according to the instructions contained in this bulletin. A copy of the customer letter is shown in this bulletin for your use in contacting customers. Recall follow-up cards should not be used for this purpose, since the customer may not as yet have received the notification letter. In summary, whenever a vehicle subject to this recall enters your vehicle inventory, or is in your dealership for service in the future, please take the steps necessary to be sure the recall correction has been made before selling or releasing the vehicle. Disclaimer Service Procedure Inspection Tools Required CH 47950 Hydro-Boost Checking Tool 1. With the vehicle transmission in PARK or NEUTRAL, set the park brake. 2. With the engine OFF, make a minimum of five (5) high effort brake applies until the pedal feels hard. 3. Start the engine. Important: DO NOT depress the brake pedal until instructed. 4. Turn the steering wheel to the "steering lock" (fully turned) position. Hold at the steering lock position for 1 to 2 seconds and then release the steering wheel. Repeat a total of 3 times. 5. Turn the vehicle off being careful not to step on the brake pedal. 6. For Express/Savana only: A. Remove the remote power steering reservoir mounting nuts. B. Disconnect the reservoir outlet hose from the booster unit. Keeping the hose end higher than the reservoir, reposition the reservoir forward and down out of the way. 7. Using a clean, lint-free shop cloth, wipe any dirt away from the steering pump supply hose/tube connection area on the hydro-boost (this is the center hose/tube of the three). 8. Disconnect the power steering supply hose/tube from the hydro-boost unit and wrap a clean lint-free shop cloth around the end of the hose and secure it in the engine compartment. 9. Using a clean lint-free shop cloth, clean any dirt off of the inlet port adapter valve assembly. Before installing the inlet port adapter, place a shop Page 12870 ^ Pay the dealer the regular retail price (no discounts are available) for one of the following 1-year, non-refundable OnStar(R) Analog-to-Digital Transition (ADT) Service Subscription Plans: ^ 1-year Safe & Sound Subscription: $199 ($289 in Canada) ^ 1-year Directions & Connections Subscription: $399 ($579 in Canada) ^ Pay the dealer the applicable state and local sales taxes on the subscription: ^ U.S. Dealers: Taxes only apply in these states: CT, DC, FL, HI, ND, NJ, NM, NY, SC, SD, TX, and WV ^ Canadian Dealers: All applicable taxes ^ Pay the dealer a one-time charge of $15 for the upgrade: ^ U.S. Dealers: Do not collect taxes on the $15 ^ Canadian Dealers: Collect all applicable taxes on the $15 Note: Dealers should NOT remit OnStar(R) ADT-related taxes to their taxing authority as OnStar(R) is responsible for tax remittance. Please Be Sure To Read these Important Points: ^ The 1-year OnStar(R) subscription is not refundable or transferable to another person. Upgraders can apply unused subscription months to a new or Certified Pre-Owned digital OnStar-equipped GM vehicle purchase or lease. As noted above, the digital upgrade program requires the subscriber to purchase a one-year prepaid OnStar(R) subscription. Assuming the subscriber intends to keep their vehicle, but subsequently purchases or leases a 2006 model year or newer OnStar(R)-equipped new or certified used GM vehicle, in the interest of subscriber satisfaction, they may apply remaining unused whole months of the subscription to the new vehicle. The subscription may not be applied to another person's vehicle. Important: This is a customer satisfaction measure that would usually occur several months after an upgrade. It is not intended to be leveraged as part of a new/used vehicle purchase or lease transaction. ^ The $15 charge is not refundable. ^ Dealer ADT kit orders are VIN specific. Dealer kit orders require a VIN and must be exchanged with the OnStar(R) unit in the vehicle with that VIN. Proper activation and enrollment depends on this step. ^ You must put the actual miles on the Repair Order. Do not estimate. ^ Customers will receive a Hands-Free Calling number once the digital hardware is installed and configured. ^ Any nametags that were stored in the old system will need to be re-set by the subscriber once the new hardware is installed. ^ Customers are responsible for the charges described above regardless of whether their vehicle is in or out of the New Vehicle Warranty period. In addition, customers should not be charged labor costs. Dealers can charge GM the labor for the upgrade as specified at the end of this bulletin using the listed labor operation. ^ Vehicles eligible for an OnStar(R) hardware upgrade are listed in this bulletin. Vehicle upgradeability can also be determined by typing the VIN into the field entitled "Determine VIN Hardware Functionality" on the OnStar(R) Online Enrollment website, located in the sales or service workbench tab of GM GlobalConnect. Canadian Dealers can use a similar tool that is available within InfoNET. ^ Access to the sales and/or service workbench in the GM GlobalConnect website can be granted by the dealership's Partner Security Coordinator (PSC). If you are unsure who the PSC is, check with the Sales Manager. Ordering the Upgrade Kit/Upgrade kit Installation Ordering the Upgrade Kit 1. To order a kit, you will need to access the OnStar(R) Online Enrollment webpage, located under the sales or service workbench of GM GlobalConnect (infoNET for Canadian upgrade orders). These kits cannot be ordered from GMSPO. Page 16172 Control Module References Part 6 Recall 04V240000: Incorrect Spare Tire on Vehicle Spare Tire: All Technical Service Bulletins Recall 04V240000: Incorrect Spare Tire on Vehicle Make / Models : Model/Build Years: GMC / 1500 2004 Regency / Chevrolet 1500 2004 MANUFACTURER: General Motors Corp. NHTSA CAMPAIGN ID Number : 04V240000 Recall Date : MAY 14, 2004 COMPONENT: Tires: Temporary/Emergency Spare Tire Potential Number Of Units Affected : 285 SUMMARY: The spare tire and wheel assembly that was provided on certain conversion vehicles will not fit on the front wheel hub due to offset of the wheel. However, it will fit on the rear wheels. CONSEQUENCE: If someone has a flat tire on the front wheel, they will not be able to install the provided spare tire. REMEDY: Dealers will install a spare wheel with the correct offset. Owner notification began on June 11, 2004. Owners should contact Regency at 1-800-989-4727. NOTES: Customers can also contact The National Highway Traffic Safety Administration's Auto Safety Hotline at 1-888-DASH-2-DOT (1-888-327-4236). Page 15803 Headlamp Alignment Switch: Service and Repair HEADLAMP LEVELING SWITCH REPLACEMENT REMOVAL PROCEDURE 1. Remove the instrument panel bezel. 2. Pull out the accessary switch housing. 3. Disconnect the electrical connectors. 4. Remove the head lamp leveling switch from the accessary switch housing. INSTALLATION PROCEDURE 1. Install the head lamp leveling switch into accessary switch housing. 2. Connect the electrical connectors. 3. Install the accessary switch housing. 4. Install the instrument panel bezel. Page 353 Page 6298 Disclaimer Page 10123 Install the steering gear actuator and cover (2) retaining bolts. ^ Tighten the bolts to 61 Nm (45 ft. lbs.). 3. Connect the electrical connectors to the control module (2). 4. Install the differential vent hose (1) to the vent tube (2). 5. Install the outer tie rod ends to the steering knuckle. Refer to Rear Wheel Steering Tie Rod End Replacement - Outer. 6. Install the drain plug (2) and fill the differential with fluid. 7. Install the bolts (3) retaining the steering gear protection shield. ^ Tighten the bolts to 180 Nm (132 ft. lbs.). 8. Install the tire and wheel. 9. Lower the vehicle. 10. Check the wheel alignment. Page 2682 Junction Block - Rear Lamps - C4 Relay Block - I/P C1 Page 16100 Control Module References Part 1 Page 6437 Page 10288 Disclaimer Testing and Inspection Ignition Relay: Testing and Inspection IGNITION RELAY DIAGNOSIS CIRCUIT DESCRIPTION The ignition relay is a normally open relay. The relay armature is held in the open position by spring tension. When the ignition switch is turned to the run or start position, current will flow through the relay coil. A wire connected to the other end of the relay coil completes the path to ground. The electromagnetic field created by the relay coil, overcomes the spring tension and moves the armature allowing the relay contacts to close. The closed relay contacts allow current to flow from the battery to the following fuses: PCM 1 - ETC/ECM - INJ 1 - INJ 2 - SBA, if equipped. When the ignition switch is turned to the OFF position, the electromagnetic field collapses. This action allows the spring tension to move the armature away from the relay contacts, which interrupts current flow to the fuses. If the ignition relay fails to close, the engine will crank, but will not run. The class 2 communications will be available with the use of a scan tool. The ignition relay table assumes that the vehicle battery is fully charged. TEST Page 8804 circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links CIRCUIT PROTECTION - FUSIBLE LINKS Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Flat Wire Repairs FLAT WIRE REPAIRS NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Heated Oxygen Sensor (HO2S) Wiring Repairs HEATED OXYGEN SENSOR (HO2S) WIRING REPAIRS TOOLS REQUIRED J 38125-D Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: - Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-D. Repairing Damaged Wire Insulation REPAIRING DAMAGED WIRE INSULATION Page 11511 14. Separate the right carrier case half from the left carrier case half. 15. Remove the differential case assembly from the carrier. 16. Place the differential case in a vise. 17. Remove the differential side bearings using the J 22888-20A. 18. Remove the differential case from the vise. Important: The ring gear bolts have left-hand threads. 19. Remove the ring gear bolts. 20. Remove the ring gear from the differential case. Drive the ring gear off with a brass drift if necessary. 21. Remove the pinion shaft pin. Use a hammer and a drift pin in order to drive out the pin. 22. Remove the pinion shaft. 23. Roll the differential pinion gears out of the case with the pinion gear thrust washers. 24. Remove the differential side gears and the side gear thrust washers. Mark the pinion gears and thrust washers top and bottom and the differential side gears and thrust washers left and right. 25. Lubricate the pinion and side gears using axle lubricant. Use the proper fluid. Refer to the Maintenance and Lubrication subsection. 26. Install the differential side gear thrust washers to the differential side gears. 27. Install the differential side gears and thrust washers into the new differential case. 28. Install the differential pinion gears and thrust washers by performing the following steps: 28.1. Position one pinion gear between the differential side gears. 28.2. Position the second pinion gear between the differential side gear directly opposite of the first gear. 28.3. Rotate the differential side gears until the pinion gears are directly opposite the opening in the differential case. 28.4. Install the thrust washers. Rotate the pinion gears toward the differential case opening in order to permit the sliding in of the thrust washers. 29. Install the pinion gear shaft. 30. Install the pinion gear shaft lock pin using a hammer and a brass drift. Important: The mating surface of the ring gear and the differential case must be clean and free of burrs before installing the ring gear. Service and Repair Valve Guide Seal: Service and Repair Valve Stem Oil Seal and Valve Spring Replacement ^ Tools Required J 22794 Spark Plug Port Adapter - J 38606 Valve Spring Compressor Removal Procedure 1. Remove the valve rocker arm. 2. Disconnect the spark plug wire at the spark plug. ^ Twist each plug wire boot 1/2 turn. ^ Pull only on the boot in order to remove the wire from the spark plug. 3. Important: Remove the spark plugs from the cylinder head with the engine at room temperature. Loosen the spark plug 1 or 2 turns. 4. Brush or air blast away any dirt or debris from around the spark plug. 5. Remove the spark plug. 6. Install J 22794 into the spark plug hole. 7. Attach an air hose to J 22794. 8. Apply compressed air to J 22794 in order to hold the valves in place. Page 5516 Flexible Fuel Sensor: Testing and Inspection Step 1 Steps 2 - 5 Campaign - Deactivation Of Analog OnStar(R) Technical Service Bulletin # 08089C Date: 081118 Campaign - Deactivation Of Analog OnStar(R) # 08089C: Special Coverage Adjustment - Analog OnStar Deactivation (Nov 18, 2008) Subject: 08089C -- SPECIAL COVERAGE ADJUSTMENT - ANALOG ONSTAR(R) DEACTIVATION Tires/Wheels - Low Tire/Leaking Cast Aluminum Wheels Wheels: All Technical Service Bulletins Tires/Wheels - Low Tire/Leaking Cast Aluminum Wheels TECHNICAL Bulletin No.: 05-03-10-003F Date: April 27, 2010 Subject: Low Tire Pressure, Leaking Cast Aluminum Wheels (Repair with Adhesive Sealant) Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks (Including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X with Cast Aluminum Wheels Supercede: This bulletin is being revised to update the model years and the bulletin reference information. Please discard Corporate Bulletin Number 05-03-10-003E (Section 03 - Suspension). Condition Some customers may comment on a low tire pressure condition. Diagnosis of the low tire pressure condition indicates an air leak through the cast aluminum wheel. Cause Porosity in the cast aluminum wheel may be the cause. Notice This bulletin specifically addresses issues related to the wheel casting that may result in an air leak. For issues related to corrosion of the wheel in service, please refer to Corporate Bulletin Number 08-03-10-006C - Tire Slowly Goes Flat, Tire Air Loss, Low Tire Pressure Warning Light Illuminated, Aluminum Wheel Bead Seat Corrosion (Clean and Resurface Wheel Bead Seat). Correction 1. Remove the tire and wheel assembly from the vehicle. Refer to the appropriate service procedure in SI. 2. Locate the leaking area by inflating the tire to 276 kPa (40 psi) and dipping the tire/wheel assembly in a water bath, or use a spray bottle with soap and water to locate the specific leak location. Important - If the porosity leak is located in the bead area of the aluminum rim (where the tire meets the rim), the wheel should be replaced. - If two or more leaks are located on one wheel, the wheel should be replaced. 3. If air bubbles are observed, mark the location. - If the leak location is on the tire/rubber area, refer to Corporate Bulletin Number 04-03-10-001F Tire Puncture Repair Procedures for All Cars and Light Duty Trucks. - If the leak is located on the aluminum wheel area, continue with the next step. 4. Inscribe a mark on the tire at the valve stem in order to indicate the orientation of the tire to the wheel. 5. Dismount the tire from the wheel. Refer to Tire Mounting and Dismounting. 6. Remove the tire pressure sensor. Refer to Tire Pressure Sensor removal procedure in SI. 7. Scuff the INSIDE rim surface at the leak area with #80 grit paper and clean the area with general purpose cleaner, such as 3M(R) General Purpose Adhesive Cleaner, P/N 08984, or equivalent. 8. Apply a 3 mm (0.12 in) thick layer of Silicone - Adhesive/Sealant, P/N 12378478 (in Canada, use 88900041), or equivalent, to the leak area. 9. Allow for the adhesive/sealant to dry. Notice Caution must be used when mounting the tire so as not to damage the sealer. Damaging the repair area may result in an air leak. Page 9064 Relay Block - I/P C9 Part 2 A/T - 4T65E Fluid Leaking From A/T Vent Seals and Gaskets: All Technical Service Bulletins A/T - 4T65E Fluid Leaking From A/T Vent TECHNICAL Bulletin No.: 01-07-30-032E Date: September 29, 2008 Subject: Transmission Oil Leaking From Transmission Vent (Replace Transmission Case Cover (Channel Plate) Gasket) Models: 1997-2009 GM Passenger Cars and Light Duty Trucks (including Saturn) with Hydra-Matic 4T65-E Automatic Transmission (RPOs MN3, MN7, M15, M76) Supercede: This bulletin is being revised to add the 2008 and 2009 model years. Please discard Corporate Bulletin Number 01-07-30-032D (Section 07 - Transmission/Transaxle). Condition Some customers may comment on a transmission oil leak. Cause This condition may be caused by an improperly torqued channel plate gasket. Correction To correct this condition, replace the case cover (channel plate) gaskets (429 and 430). Refer to Unit Repair publication in SI of the appropriate vehicle being serviced. Visual inspection of the upper gasket (1) will reveal damage at the referenced area. Parts Information Warranty Information Locations Full Engine View Left Side Page 6442 Shift Solenoid: Diagrams Automatic Transmission - 4L80-E/4L85-E Page 4086 7. Remove the HO2S. INSTALLATION PROCEDURE IMPORTANT: A special anti-seize compound is used on the HO2S threads. The compound consists of liquid graphite and glass beads. The graphite tends to burn away, but the glass beads remain, making the sensor easier to remove. New, or service replacement sensors already have the compound applied to the threads. If the sensor is removed from an exhaust component and if for any reason the sensor is to be reinstalled, the threads must have anti-seize compound applied before the reinstallation. 1. If reinstalling the old sensor, coat the threads with anti-seize compound GM P/N 12377953, or equivalent. NOTE: Refer to Component Fastener Tightening Notice in Service Precautions. 2. Install the HO2S. Tighten Tighten the sensor to 42 N.m (31 lb ft). Page 9267 Location View Page 13057 7.2. Remove the console (A). 7.3. Disconnect the connector (B) from the OnStar(R) control module. Important: Secure the cable harness to prevent the risk of scraping and rattling. 7.4. Fold back the cable harness and tape down the connector (C). Fold back the cable harness again and secure with cable ties (D). 7.5. 5D: Assemble the right-hand cover for the luggage compartment floor. 8. Fit the ground cable on the battery's negative cable. Page 522 Front Passenger Door Module (FPDM) - C2 (With RPO Code YE9) Part 1 Page 8500 2. Remove the master cylinder from the booster. Do not remove the pipes from the master cylinder. Set the master cylinder aside in the engine compartment. 3. Disconnect the power brake booster inlet hose, the steering gear inlet hose, and the power brake booster outlet hose from the booster assembly. 4. Disconnect the electrical connector from the stop lamp switch. 5. Remove the retainer from the brake pedal pin. 6. Remove the stop lamp switch and the pushrod to the power brake booster from the brake pedal pin. 7. Unsnap the stop lamp switch from the power brake booster pushrod. 8. Remove the 4 booster to bulkhead nuts. 9. Remove the booster assembly. 10. Remove the gasket. Installation Page 4105 Transmission Position Switch/Sensor: Adjustments Automatic Transmission - 4L80-E/4L85-E Park/Neutral Position Switch Adjustment Important: ^ The following procedure is for vehicles that have not had the park/neutral position (PNP) switch removed or replaced. If the switch has been removed or replaced, refer to Park/Neutral Position Switch Replacement for the proper adjustment procedure. ^ Apply the park brake. ^ The engine must start in the park (P) or neutral (N) positions only. ^ Check the PNP switch for proper operation. If adjustment is required, proceed as follows: 1. Place the shift lever in the neutral (N) position. 2. With an assistant in the drivers seat, raise and suitably support the vehicle. Refer to Vehicle Lifting. 3. Loosen the PNP switch bolts. 4. With the vehicle in neutral (N), rotate the PNP switch while the assistant attempts to start the engine. 5. Following a successful start, turn the engine off. 6. Notice: Refer to Fastener Notice in Service Precautions. Tighten the PNP switch bolts. ^ Tighten the bolts to 25 Nm (18 ft. lbs.). 7. Lower the vehicle. 8. Check the PNP switch for proper operation. The engine must start in the park (P) or neutral (N) positions only. 9. Replace the PNP switch if proper operation can not be achieved. Automatic Transmission - 4L60-E/4L65-E Transmission Speed Sensor: Locations Automatic Transmission - 4L60-E/4L65-E Automatic Transmission Electronic Component Views (M30/M32) Electronic Components Page 14569 Seat Memory Switch: Diagrams Driver Door Module (DDM) - C5 (Memory/Heated Seat Switch) Part 1 Page 5314 Steps 7 - 9 Page 4112 4. Position the J 41364-A onto the PNP switch. Ensure that the two slots on the switch where the manual shaft is inserted are lined up with the lower two tabs on the tool. 5. Notice: Refer to Fastener Notice in Service Precautions. Rotate J 41364-A until the upper locator pin on the tool is lined up with the slot on the top of the switch. ^ Tighten the bolts to 25 Nm (18 ft. lbs.). 6. Remove J 41364-A from the PNP switch. If installing a new switch, remove the positive assurance bracket at this time. 7. Install the control lever to the manual shaft with the nut. 8. Install the manual shaft nut. ^ Tighten the nut to 25 Nm (18 ft. lbs.). 9. Install the range selector cable end (2) to the range selector lever ball stud (1). Page 492 6. Use fingers to squeeze the 2 locking legs of the cover. 7. Apply pressure and gently rock the cover until one locking leg is unseated. 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. Page 2968 10. Align the inscribed mark on the tire with the valve stem on the wheel. 11. Reinstall the Tire Pressure Sensor. Refer to Tire Pressure Sensor installation procedure in SI. 12. Mount the tire on the wheel. Refer to Tire Mounting and Dismounting. 13. Pressurize the tire to 276 kPa (40 psi) and inspect for leaks. 14. Adjust tire pressure to meet the placard specification. 15. Balance the tire/wheel assembly. Refer to Tire and Wheel Assembly Balancing - Off-Vehicle. 16. Install the tire and wheel assembly onto the vehicle. Refer to the appropriate service procedure in SI. Parts Information Warranty Information (excluding Saab U.S. Models) Important The Silicone - Adhesive/Sealant comes in a case quantity of six. ONLY charge warranty one tube of adhesive/sealant per wheel repair. For vehicles repaired under warranty, use: One leak repair per wheel. Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table above. Disclaimer Automatic Transmission - 4L60-E/4L65-E Page 8739 Negative: Service and Repair Disconnect/Connect Procedure (Auxiliary Battery) BATTERY NEGATIVE CABLE DISCONNECT/CONNECT PROCEDURE (AUXILIARY BATTERY) REMOVAL PROCEDURE CAUTION: Refer to Battery Disconnect Caution in Service Precautions. 1. Turn off all the lamps and accessories. 2. Turn the ignition OFF. 3. Loosen the negative battery cable bolt. 4. Remove the negative battery cable. INSTALLATION PROCEDURE CAUTION: Refer to Battery Disconnect Caution in Service Precautions. IMPORTANT: Clean any existing corrosion from the battery terminal bolt flange and battery cable end. 1. Install the negative battery cable. NOTE: Refer to Fastener Notice in Service Precautions. 2. Tighten the negative battery cable bolt. Tighten Tighten the bolt to 17 N.m (13 lb ft). Page 9888 Important The M6 conductive rivet stud as shown, can accommodate a panel thickness range of 0.7-4.2 mm (0.03-0.17 in). If there are layers of sheet metal, they should be touching without any air gaps to ensure a good ground. 5. Select a M6 conductive rivet stud. Refer to the Parts Information section of this bulletin. Note Use the GE-50317 rivet stud tool kit. 6. Place the M6 conductive rivet stud (1) in the 10 mm (0.40 in) hole. Assemble the rivet stud tool (2) with the groove and flare side facing the rivet stud, then the washer and the M6 nut (3). 7. Using a wrench on the rivet stud tool, and a socket on the M6 nut, secure the M6 conductive rivet stud. 8. Ensure the rivet stud is securely fastened, WITHOUT ANY detectable movement. 9. Completely wrap the threads of the rivet stud with painters tape or equivalent. Note The rivet stud and surrounding panel area MUST BE properly refinished PRIOR to the installation of the ground wire terminal and conductive nut to maintain a secure, stable and corrosion-free electrical ground. 10. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 11. Allow the refinished repair area to cure sufficiently before removing the protective material applied to the rivet stud threads. 12. Remove the painters tape or equivalent from the rivet stud threads. 13. Using GM approved residue-free solvent or equivalent, thoroughly clean the rivet stud threads to remove any adhesive and allow to dry. 14. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive rivet stud. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. Diagram Information and Instructions Power Window Switch: Diagram Information and Instructions Truck Zoning TRUCK ZONING Truck Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that corresponds to where they are located in the vehicle. The table explains the numbering system. Page 11505 For vehicles repaired under warranty, use the table. Disclaimer Page 1402 Put unused material on the shelf for future use. Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Page 1168 Seat Adjuster Switch- Front Passenger (With RPO Code AN3) Part 2 Page 6935 17. Inspect the inboard stroke position. ^ Use measurement A for the 1500 models (except 1500 HD). ^ Use measurement B for the 1500 HD, 2500, 3500, and Hummer H2 models. Page 11909 2. Disconnect the C2 32-way blue connector from the VIU and tape the connector to a secure location. Refer to Cellular Communications Connector End Views and related schematics in SI, if required. Important: DO NOT perform the OnStar(R) reconfiguration and/or programming procedure. 3. Secure the VIU in its original brackets and/or mounting locations and reinstall the VIU and interior components that were removed to gain access to the VIU. Refer to OnStar Vehicle Interface Unit Replacement in SI. 2002 Through 2006 Model Year Vehicles (Except Saab Vehicles) 2002 through 2006 Model Year Vehicles (Except Saab Vehicles) Important: The Tech 2 diagnostic tool must be updated with version 28.002 or later in order to successfully perform the VCIM setup procedure and disable the analog system. 1. Connect the Tech 2 to the data link connector (DLC), which is located under the instrument panel of the vehicle. 2. Turn the Tech 2 ON by pressing the power button. Important: Tech 2 screen navigation to get to the setup procedure depends on the year and make of the vehicle. The actual name of the setup procedure (Setup New OnStar or VCIM Setup) depends on model year and vehicle make as well. Example Tech 2 navigation to the setup procedure Tech 2 screen is provided below. ^ Diagnostics >> (2) 2002 >> Passenger Car >> Body >> C >> OnStar >> Special Functions >> Setup New OnStar >> ^ Diagnostics >> (5) 2005 >> Passenger Car >> (4) Buick >> C >> Body >> Vehicle Comm. Interface Module >> Module Setup >> VCIM Setup >> 3. Setup VCIM using the Tech 2. Follow on-screen instructions when you have reached the setup Tech 2 screen. 2000-2002 Saab 9-3 (9400) 4D/5D; 2000-2003 Saab 9-3 (9400) CV 2000-2002 Saab 9-3 (9400) 4D/5D; 2000-2003 Saab 9-3 (9400) CV 1. Remove the ground cable from the battery's negative terminal. 2. Apply the handbrake brake. 3. Detach the floor console. 4. Remove the switch and the floor console: 3.1. Twist loose the immobilizer unit (A), bayonet fitting. Unplug the unit's connector. 3.2. Remove the ignition switch cover (B) by first undoing the rear edge of the cover and then unhooking the front edge. Unplug the ignition Page 11553 Inflatable Restraint Sensing And Diagnostic Module: Diagrams Inflatable Restraint Sensing and Diagnostic Module (SDM) - Part 1 Fuel System/Body - Fuel Filler Cap Tether Too Short Fuel Door: Customer Interest Fuel System/Body - Fuel Filler Cap Tether Too Short Bulletin No.: 05-06-04-043A Date: August 02, 2005 TECHNICAL Subject: Fuel Cap Tether Too Short to Hook On Fuel Door While Fueling Vehicle (Install Fuel Filler Housing and Cap) Models: 2004-2005 Cadillac Escalade Models 2004-2005 Chevrolet Silverado, Suburban, Tahoe Models 2004-2005 GMC Sierra, Yukon Models Supercede: This bulletin is being revised to correct the fuel filler cap P/N. P/N 15225006 is released for 2006 and 2007 model year vehicles only. The correct fuel cap for the 2004 and 2005 model year is P/N 15225005. Dealers who currently have P/N 15225006 on order (possibly back-ordered) for this concern should cancel their order and re-order P/N 15225005. Please discard Corporate Bulletin Number 05-06-04-043 (Section 06 - Engine/Propulsion System). Built Prior to the VIN Breakpoints shown. Condition Some customers may comment that the fuel cap tether is too short to hook on the fuel door while fueling the vehicle. Cause The existing fuel cap tether is too short. The existing fuel filler housing elongated hole is too small to accommodate the new fuel cap tether. Correction Page 4607 Oxygen Sensor: Service and Repair Heated Oxygen Sensor (HO2S) Replacement Bank 2 Sensor 1 HEATED OXYGEN SENSOR (HO2S) REPLACEMENT BANK 2 SENSOR 1 REMOVAL PROCEDURE 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. Disconnect the connector position assurance (CPA) retainer. 3. Remove the heated oxygen sensor (HO2S) from the clips NOTE: Refer to Heated Oxygen and Oxygen Sensor Notice in Service Precautions. 4. If equipped with a 4.8L or 5.3L engine, disconnect the HO2S electrical connector. Page 9219 C230 I/P Harness (With RPO Codes UE1 And Y91) Or Infotainment Jumper Harness (With RPO Code UE1 & Without RPO Code Y91) To Roofmarker Harness Page 7358 Park Neutral Position (PNP) Switch C175 Page 11143 Evaporator Core: Service and Repair Evaporator Core Replacement (Visteon) Air Conditioning Evaporator Core Replacement (Visteon) Removal Procedure 1. Remove the HVAC module. 2. Disconnect the electrical connector from the recirculation actuator. 3. Remove the screws from the evaporator cover (1). 4. Remove the evaporator cover (1) from the HVAC module assembly. Page 15795 1. Install the bulb (1) into the socket. 2. Connect the electrical connector. 3. Install the switch until the tabs (1) click in place. 4. Close the compartment door. Page 12917 Amplifier: Diagrams Audio Amplifier C1 - With RPO Code UQ7,Y91 Audio Amplifier C1 - With RPO Code UQ7,Y91 - Part 1 Page 8906 Control Module References Part 3 Audio - Inadvertent Steering Wheel Button Activation Remote Switch: Technical Service Bulletins Audio - Inadvertent Steering Wheel Button Activation INFORMATION Bulletin No.: 08-08-44-028 Date: August 28, 2008 Subject: Information On Inadvertent Steering Wheel Control (SWC) Button Press Causing Radio Anomalies Models: 2009 and Prior GM Passenger Cars and Trucks (Including Saturn) 2009 and Prior HUMMER H2, H3 Models 2009 and Prior Saab 9-7X All Vehicles with Steering Wheel Controls This bulletin is being issued to provide a recommendation for vehicles with a customer concern of the radio station tuning changing by itself, volume changing by itself, radio changing by itself, or radio muting or going silent when driving and turning the steering wheel. The switches on the right hand side of the steering wheel are easily pressed and may inadvertently be pressed when turning the steering wheel. These concerns may be affected by the location of the steering wheel controls. Recommendation Do Not Replace The Radio 1. Please determine that the switch controls on the steering wheel are functioning correctly. 2. Ask the customer if their hand was in close proximity to the steering wheel controls when the condition happened. Explain to the customer that bumping the controls would have caused this undesired action. Explain to the customer the proper use and function of the steering wheel controls. Disclaimer Page 6696 7. If equipped with a NV 3500 or NV 4500 transmission, remove the clutch master cylinder. 8. If equipped with a ZF S6-650 transmission, remove the clutch master cylinder. Installation Procedure 1. If equipped with a ZF S6-650 transmission, install the clutch master cylinder. 2. If equipped with a NV 3500 or NV 4500 transmission, install the clutch master cylinder. Page 6789 Differential Axle Housing: Service and Repair Rear Axle Housing Replacement Rear Axle Housing Replacement Removal Procedure 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Drain the axle lubricant. 3. Remove the rear axle assembly. 4. Remove the brake caliper brackets. 5. For the 8.6 inch and 9.5 inch axles, remove the brake rotors. 6. For the 10.5 inch and 11.5 inch axles, remove the hub and rotor assembly. 7. Remove the rear axle cover housing and gasket. 8. Remove the axle shafts. 9. Remove the brake backing plates. 10. For the 8.6 inch and 9.5 inch axles, remove the rear axle shaft oil seal and the bearing. 11. Remove the differential assembly. 12. Remove the drive pinion shaft yoke and the oil seal. 13. Remove the drive pinion and the inner pinion bearing. 14. Remove the pinion bearing cups. Installation Procedure 1. Install the pinion bearing cups. 2. Install the outer pinion bearing into the axle housing. 3. Install the drive pinion oil seal. 4. Determine the selective shim thickness for the drive pinion. 5. Install the selective shim onto the drive pinion. 6. Install the inner pinion bearing onto the drive pinion. 7. Install the drive pinion. 8. Install the pinion yoke. 9. Install the differential assembly. 10. Adjust the differential side bearing preload. 11. Adjust the drive pinion to ring gear backlash. 12. Perform a gear tooth contact pattern check. 13. Install the brake backing plates. 14. For the 10.5 inch and 11.5 inch axles, install the hub/rotor assembly. 15. For the 8.6 inch and 9.5 inch axles, install the rear axle shaft bearing and the oil seal. 16. Install the axle shafts. 17. Install the rear axle housing cover and gasket. 18. For the 8.6 inch and 9.5 inch axles, install the brake rotors. 19. Install the brake caliper brackets. 20. Install the rear axle assembly. 21. Fill the axle with lubricant. Use the proper fluid. 22. Lower the vehicle. Page 5979 4. Important: When installing the pressure control solenoid, the electrical connector (2) must be in the position shown. Install the pressure control solenoid (377). 5. Install the pressure control solenoid retainer (378) and retainer bolt (364A). ^ Tighten the bolt to 11 Nm (97 inch lbs.). 6. Install the TCC PWM solenoid to the control valve body. 7. Install the TCC PWM solenoid retainer. 8. Connect the internal wiring harness electrical connectors to the following components: ^ Transmission fluid pressure switch (1) ^ 1-2 shift control solenoid (2) ^ 2-3 shift control solenoid (3) ^ Pressure control solenoid (4) Page 1581 2. Install the fuel level sensor retaining clip. 3. Connect the fuel level sensor electrical connector. 4. Install the fuel level sensor electrical connector retaining clip. Page 14288 WA722J/25 - WA722J/25 Page 11449 Inflatable Restraint Sensing and Diagnostic Module (SDM) - Part 2 Page 7045 Page 13290 6. See wiring diagram shown above for details. 5. Replace the OnStar(R) Vehicle Communication Interface Module (VCIM) in the vehicle with the provided Digitally-Capable VCIM. Refer to the Communication Interface Module Replacement procedure in the Cellular Communication section of SI. This kit may include a new VCIM bracket. If it does, use this new bracket on the vehicle and discard the original bracket. The kit may also include a small wiring jumper cable. If it does, plug the wiring jumper cable into the connector on the VCIM and the other end to the corresponding vehicle wiring harness connector. ^ For 2001, 2002 and 2003 Chevrolet Impala and Monte Carlo, do not reinstall the black plastic OnStar(R) module cover onto the vehicle after the VCIM and module bracket have been installed. This black plastic cover will no longer fit on the vehicle. ^ The upgrade kit for 2002 Sevilles and DeVilles, and some 2003 Sevilles and DeVilles, will contain a large bracket. To install the new VCIM into this bracket you'll need to carefully line up the notch in the VCIM with the tab in the bracket. Page 1199 Memory/Heated Seat Switch - Driver (DDM C5) Part 2 Page 3083 Please note the following when referring to a specific illustration: ^ When using the illustrations for back to back comparisons of two hubs, the most obvious differences are visible on the back side of the hubs. ^ The most common area of physical difference are in the shape of the four mounting bosses and their surrounds. Disclaimer Page 10434 4. Install the shock absorber through the bolt (2) to the lower control arm. 5. Install the shock absorber through the bolt nut (3). ^ Tighten the nut to 80 Nm (59 ft. lbs.). Notice: Refer to Fastener Notice in Service Precautions. 6. Install the upper insulator to the shock absorber. Important: The upper insulators are substantially larger that the lower insulators. The upper insulator (1) must be installed above the shock mounting bracket on the frame. The plastic pilot ring (2) will assist the alignment of the isolators. 7. Install the nut to the tension end. Do not tighten the nut. 8. Remove the safety stands. 9. Lower the vehicle. 10. Hold the tension end with a wrench while torquing the nut. ^ Tighten the nut to 20 Nm (15 ft. lbs.). 11. If equipped with selectable ride, connect the electrical connector using the following procedure: 1. Verify that the connector is unlocked. 2. Align the connector so that the tabs (1) are perpendicular to the wrench flats on the tension end. 3. Engage the connector to the tension by firmly pushing the connector down. 4. Grasp the connector lock tabs (1, 2). Rotate the connector counterclockwise. Page 14477 Memory Seat Module - C4 Part 1 Page 11103 A/C Coupler O-ring: Service and Repair Sealing Washer Replacement SEALING WASHER REPLACEMENT REMOVAL PROCEDURE 1. Remove the seal washer from the A/C refrigerant component. IMPORTANT: Cap or tape the open A/C refrigerant components immediately to prevent system contamination. 2. Inspect the seal washer for signs of damage to help determine the root cause of the failure. 3. Inspect the A/C refrigerant components for damage or burrs. Repair if necessary. IMPORTANT: DO NOT reuse sealing washer. 4. Discard the sealing washer. INSTALLATION PROCEDURE IMPORTANT: Flat washer type seals do not require lubrication. 1. Inspect the new seal washer for any signs of cracks, cuts, or damage. Do not use a damaged seal washer. 2. Remove the cap or tape from the A/C refrigerant components. 3. Using a lint-free clean, dry cloth, clean the sealing surfaces of the A/C refrigerant components. 4. Carefully install the new seal washer onto the A/C refrigerant component. The washer must completely bottom against the surface of the fitting. IMPORTANT: After tightening the A/C components, there should be a slight sealing washer gap of approximately 1.2 mm (3/64 in) between the Page 4491 Electrical Symbols Part 14 Page 9686 4. Install the ground, then the washer and then the bolt to the frame. Important: It is important to use the bolts, washers and nuts specified in this bulletin. These parts have been identified due to their conductive finish. 5. Install a washer and nut to the back side of the frame. Tighten Tighten the nut to 9 Nm (79 lb in). 6. Cover the front and back side of the repair area using Rubberized Undercoating. An additional check can be made to ensure a good connection for the battery cable to frame ground. It is possible for this ground to cause similar symptoms with the ABS as described above. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Parts Information Warranty Information Disclaimer Page 10436 Suspension Strut / Shock Absorber: Service and Repair Rear Shock Absorber Shock Absorber Replacement Shock Absorber Replacement Removal Procedure 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Disconnect the electrical connector if equipped with Selectable Ride. 3. Remove the upper shock absorber nut and the bolt. 4. Remove the lower shock absorber nut and the bolt. 5. Remove the shock absorber. Installation Procedure 1. Install the shock absorber. 2. Install the upper shock absorber nut and bolt. 3. Install the lower shock absorber nut and bolt. ^ Tighten the nuts to 95 Nm (70 ft. lbs.). Notice: Refer to Fastener Notice in Service Precautions. 4. Connect the electrical connector if equipped with Selectable Ride. 5. Remove the safety stands. 6. Lower the vehicle. Shock Absorber Disposal Shock Absorber Disposal Caution: Gas charged shock absorbers contain high pressure gas. Do not remove the snap ring from inside the top of the tube. If the snap ring is removed, the contents of the shock absorber will come out with extreme force which may result in personal injury. Caution: To prevent personal injury, wear safety glasses when centerpunching and drilling the shock absorber. Use care not to puncture the shock absorber tube with the centerpunch. Fan Shroud - Upper Fan Shroud: Service and Repair Fan Shroud - Upper W/RPO M74 Fan Shroud Replacement - Upper (W/M74) Removal Procedure 1. Loosen the air cleaner outlet duct clamps from the throttle body. 2. Loosen the air cleaner outlet duct clamps from the mass airflow sensor. 3. Remove the air cleaner outlet duct. 4. Remove the A/C line retainer from the fan shroud. 5. Remove the engine harness clip from the PCM cover. 6. Remove the TCM cover bolts. 7. Remove TCM cover from the fan shroud. Page 6042 ^ TCC PWM solenoid (5) ^ 3-2 control solenoid (6) 9. Install the 1-2 accumulator. 10. Connect the transmission harness 20-way connector (1) to the transmission pass-through connector. Align the arrows on each half of the connector and insert straight down. 11. Install the transmission filter. Page 8975 Application Table Page 5680 Shift Solenoid: Diagrams Automatic Transmission - 4L80-E/4L85-E Page 6866 12. Install the axle shafts (10.5 inch, 11.5 inch axle). 13. Install the brake rotors (8.6 inch, 9.5 inch axles). 14. Install the brake calipers (8.6 inch, 9.5 inch axles). 15. Install the tire and wheel assemblies. 16. Inspect and add axle lubricant to the axle housing, if necessary. 17. Lower the vehicle. 9.75 Inch Axle Drive Pinion Flange/Yoke and/or Oil Seal Replacement (9.75 Inch Axle) ^ Tools Required J 8614-01 Flange and Pulley Holding Tool - J 45710 Pinion Bearing Oil Seal Installer Removal Procedure 1. Important: Observe and mark the positions of all the driveline components, relative to the propeller shaft and the axles, prior to disassembly. These components include the propeller shafts, drive axles, pinion flanges, output shafts, etc. Reassemble all the components in the exact places in which you removed the parts. Follow any specifications, torque values, and any measurements made prior to disassembly. Raise the vehicle. Refer to Vehicle Lifting. 2. Disconnect the propeller shaft from the rear axle pinion yoke. 3. Place an alignment mark between the pinion and the pinion yoke. 4. Install the J 8614-01 as shown. 5. Remove the pinion nut while holding the J 8614-01. Page 13541 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. REPLACEMENT PROCEDURE After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Insure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the Terminal Removal Procedure. Repairing Connector Terminals REPAIRING CONNECTOR TERMINALS TOOLS REQUIRED J 38125-D Terminal Repair Kit Use the following repair procedures in order to repair the following: - Push to Seat terminals - Pull to Seat terminals - Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-D contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100 World terminals. Soldering Micro-Pack 100 World terminals may damage the terminal. Circuit Protection - Circuit Breakers CIRCUIT PROTECTION - CIRCUIT BREAKERS A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Page 4249 Accelerator Pedal Position Sensor: Diagrams Accelerator Pedal Position (APP) Sensor Part 1 Input Shaft Speed Sensor Replacement Transmission Speed Sensor: Service and Repair Input Shaft Speed Sensor Replacement Input Shaft Speed Sensor Replacement Removal Procedure 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. Disconnect the input speed sensor electrical connector (1). 3. Remove the input speed sensor bolt. 4. Remove the input speed sensor (1). 5. Inspect the input speed sensor (1) for any evidence of damage. Installation Procedure Page 10593 Important: After drilling the holes, apply the appropriate anti-corrosion primer. Refer to the GM Refinish Material Booklet # 4901 M-D (English) or # 4901-D-F (French) for additional information. 6. Center punch the marked location and drill a 6.35 mm (1/4 in) hole. Install the plastic retainer in the hole (1) of the mud flap. 7. Tighten fastener at the hole (2) location of the mud flap. Tighten Tighten the fastener to 25 N.m (18 lb ft). 8. For vehicles with short box, use the following procedure: 8.1. Push the mud flap to make contact with the rear side of the underbody cross sill and mark the location of the hole (3) of the mud flap. 8.2. Center punch the marked location and drill a 5.159 mm (13/64 in) hole. 8.3. Install the screw. Tighten Tighten the screw to 4 N.m (35 lb in). 8.4. Repeat the above steps for hole locations 4 and 6. 9. For vehicles with long box, use the following procedure: Service and Repair Oil Pressure Sensor: Service and Repair Engine Oil Pressure Sensor and/or Switch Replacement ^ Tools Required J 41712 Oil Pressure Switch Socket Removal Procedure 1. If necessary, remove the engine sight shield. 2. Disconnect the oil pressure sensor electrical connector (1). 3. Using J 41712 or equivalent, remove the oil pressure sensor. Installation Procedure Page 4154 Flexible Fuel Sensor: Service and Repair FUEL COMPOSITION SENSOR REPLACEMENT REMOVAL PROCEDURE 1. Relieve the fuel system pressure. Refer to Fuel Pressure Relief Procedure. 2. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 3. Disconnect the fuel composition sensor electrical connector. 4. Remove the fuel line retainers (1). 5. Disconnect the fuel pipes from the fuel composition sensor. 6. Remove the fuel composition sensor nuts. 7. Remove the fuel composition sensor. 8. If required, remove the fuel composition sensor bolts and remove the sensor from the bracket. Page 8611 Page 13132 Page 4233 Spark Plug: Application and ID SPARK PLUG TYPE: AC P/N ................................................................................................................................................. .............................................................. 25171803 NGK P/N .............................................................................................................................................. .............................................................. 12567759 Page 15051 G. Apply an approved anti-corrosion material to all of the bare metal surfaces. 2. After completion of any repairs due to the use of aftermarket accessories, install new pickup box reinforcements using the following procedure and the applicable part numbers listed below. Pickup Box Reinforcement Installation Important: The reinforcements must be installed before adding a toolbox or ladder rack system. After the reinforcements have been installed, follow the instructions supplied with the toolbox/ladder rack system for installation onto the pickup box. Use the following service procedure to install the reinforcements. Use the applicable reinforcement kit part number listed below. Cross Toolbox and Rear Window Barrier Applications - Front Reinforcement Installation Important: The horizontal surfaces of the reinforcements must be flush to the horizontal surface of the pickup box top rail. Use a clamping tool when positioning the reinforcements onto the top rail to ensure flushness to the outer panel. 1. Place the front L-shaped reinforcements into position on the front top of the pickup box. For vehicles equipped with an over the rail bedliner, the bedliner should be removed with the aid of an assistant prior to installing these reinforcements. 2. Mark the holes necessary for drilling. 3. Remove the front reinforcements. Important: Use a block of wood and/or a drill stop in order to protect the back of the cab while drilling. 4. Drill two 13.5 mm (0.54 in) holes per side into the box section of the front panel. 5. Drill 7.5 mm (0.30 in) holes into the weld flange of the side outer panel. 6. Apply anti-corrosion material to the drilled holes as necessary per the GM4901M-D-2005 (English) or GM4901M-D-F 2005 (French) GM Approved Refinish Materials booklet. The information for the 2005 GM Approved Refinish Materials booklet will now be online at the GMGOODWRENCH WEB SITE ONLY. Printed books have been discontinued. Steps to the site are as follows: A. Go to www.gmgoodwrench.com. B. Click on GM Collision Parts. C. Click on GM Technical Repair Information. D. Click on Paint Shop. 7. Place the front reinforcements back onto the box, lining up the drilled holes. Page 1466 Turn Signal Multifunction Switch - C4 (With RPO Code K34) A/T - DEXRON(R)-VI Fluid Information Fluid - A/T: Technical Service Bulletins A/T - DEXRON(R)-VI Fluid Information INFORMATION Bulletin No.: 04-07-30-037E Date: April 07, 2011 Subject: Release of DEXRON(R)-VI Automatic Transmission Fluid (ATF) Models: 2008 and Prior GM Passenger Cars and Light Duty Trucks 2003-2008 HUMMER H2 2006-2008 HUMMER H3 2005-2007 Saturn Relay 2005 and Prior Saturn L-Series 2005-2007 Saturn ION 2005-2008 Saturn VUE with 4T45-E 2005-2008 Saab 9-7X Except 2008 and Prior Chevrolet Aveo, Equinox Except 2006 and Prior Chevrolet Epica Except 2007 and Prior Chevrolet Optra Except 2008 and Prior Pontiac Torrent, Vibe, Wave Except 2003-2005 Saturn ION with CVT or AF23 Only Except 1991-2002 Saturn S-Series Except 2008 and Prior Saturn VUE with CVT, AF33 or 5AT (MJ7/MJ8) Transmission Only Except 2008 Saturn Astra Attention: DEXRON(R)-VI Automatic Transmission Fluid (ATF) is the only approved fluid for warranty repairs for General Motors transmissions/transaxles requiring DEXRON(R)-III and/or prior DEXRON(R) transmission fluids. Supercede: This bulletin is being revised to update information. Please discard Corporate Bulletin Number 04-07-30-037D (Section 07 - Transmission/Transaxle). MANUAL TRANSMISSIONS / TRANSFER CASES and POWER STEERING The content of this bulletin does not apply to manual transmissions or transfer cases. Any vehicle that previously required DEXRON(R)-III for a manual transmission or transfer case should now use P/N 88861800. This fluid is labeled Manual Transmission and Transfer Case Fluid. Some manual transmissions and transfer cases require a different fluid. Appropriate references should be checked when servicing any of these components. Power Steering Systems should now use P/N 9985010 labeled Power Steering Fluid. Consult the Parts Catalog, Owner's Manual, or Service Information (SI) for fluid recommendations. Some of our customers and/or General Motors dealerships/Saturn Retailers may have some concerns with DEXRON(R)-VI and DEXRON(R)-III Automatic Transmission Fluid (ATF) and transmission warranty claims. DEXRON(R)-VI is the only approved fluid for warranty repairs for General Motors transmissions/transaxles requiring DEXRON(R)-III and/or prior DEXRON(R) transmission fluids (except as noted above). Please remember that the clean oil reservoirs of the J-45096 - Flushing and Flow Tester machine should be purged of DEXRON(R)-III and filled with DEXRON(R)-VI for testing, flushing or filling General Motors transmissions/transaxles (except as noted above). DEXRON(R)-VI can be used in any proportion in past model vehicles equipped with an automatic transmission/transaxle in place of DEXRON(R)-III (i.e. topping off the fluid in the event of a repair or fluid change). DEXRON(R)-VI is also compatible with any former version of DEXRON(R) for use in automatic transmissions/transaxles. DEXRON(R)-VI ATF General Motors Powertrain has upgraded to DEXRON(R)-VI ATF with the start of 2006 vehicle production. Current and prior automatic transmission models that had used DEXRON(R)-III must now only use DEXRON(R)-VI. Page 15916 You MUST use a silver-bearing solder to make the solder joint. DO NOT attempt this repair with conventional tin/lead alloy solders. Most suppliers have this type of solder available and it is available nationally at Radio Shack(R)*. It is sold in several diameters and either are acceptable for this repair. 5. For this step, it is permitted that two technicians be used if required. Heat the new connector on the surface of the buss bar that is to be soldered. Long nose pliers are suggested to hold the electrical connector and the defroster tab in place. Keep the solder ready and begin flowing out the solder as soon as the melting temperature has been reached. Tip If a single technician is attempting this repair, it is beneficial to wrap one turn of the solder around the new contacts base. In this manner, as the melting point of the solder is reached, a layer is deposited on the bottom side of the contact. Important Try to align the new contact so that it is positioned with the same orientation as the original contact. 6. The above illustrates an ideal finished solder joint. Additional stray solder will not harm the performance of the bond; however, while it is unlikely that customers may refer to the appearance of the rear window defroster and its components as a positive styling feature of the vehicle interior, it is easy to elicit the opposite reaction due to a poor cosmetic application. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Parts Information Acrysol(TM) can be ordered directly from Kent Automotive at 1-800-654-6333 (in Canada, 1-800-563-1717). Radio Shack(R) products can be found nationally at retail locations, www.radioshack.com, or at 1-800-843-7422. All other parts can be ordered through GMSPO or SSPO. Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use: Warranty Information (Saab U.S. Models) Page 13411 Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA and/or the secondary locks. Micro .64 Connectors MICRO .64 CONNECTORS TOOLS REQUIRED J 38125-D Terminal Repair Kit REMOVAL PROCEDURE Follow the steps below in order to remove terminals from Micro 64 connectors. 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. 2. Disconnect the connector from the component. Page 5939 ^ The reverse boost valve bushing ^ A new reverse boost valve ^ A new pressure regulator spring retainer ^ The added isolator pressure regulator spring ^ The pressure regulator spring 3. Install the pre-assembled parts into the pump bore. 4. Install the reverse boost valve bushing retainer ring while holding the reverse boost valve bushing in place. Ensure the retainer ring (2) is in the groove. 5. Install the transmission filter. 6. Fill the transmission to the proper level with Dexron® III transmission fluid. A/T - 4T65E Fluid Leaking From A/T Vent Seals and Gaskets: Customer Interest A/T - 4T65E Fluid Leaking From A/T Vent TECHNICAL Bulletin No.: 01-07-30-032E Date: September 29, 2008 Subject: Transmission Oil Leaking From Transmission Vent (Replace Transmission Case Cover (Channel Plate) Gasket) Models: 1997-2009 GM Passenger Cars and Light Duty Trucks (including Saturn) with Hydra-Matic 4T65-E Automatic Transmission (RPOs MN3, MN7, M15, M76) Supercede: This bulletin is being revised to add the 2008 and 2009 model years. Please discard Corporate Bulletin Number 01-07-30-032D (Section 07 - Transmission/Transaxle). Condition Some customers may comment on a transmission oil leak. Cause This condition may be caused by an improperly torqued channel plate gasket. Correction To correct this condition, replace the case cover (channel plate) gaskets (429 and 430). Refer to Unit Repair publication in SI of the appropriate vehicle being serviced. Visual inspection of the upper gasket (1) will reveal damage at the referenced area. Parts Information Warranty Information Diagrams Backup Lamp - Switch (Manual Trans) Page 500 Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips SPLICING COPPER WIRE USING SPLICE CLIPS IMPORTANT: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. TOOLS REQUIRED J 38125-D Terminal Repair Kit 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-D in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. Page 318 2007 Model Year Vehicles and Newer all have Digital OnStar(R) Modules. Part 1 OnStar(R) Description and Operation This OnStar(R) digital system consists of the following components: ^ Vehicle Communication Interface Module (VCIM) ^ OnStar(R) button assembly ^ Microphone ^ Cellular antenna ^ Navigation antenna Note This system also interfaces with the factory installed vehicle audio system. Vehicle Communication Interface Module (VCIM) The vehicle communication interface module (VCIM) is a cellular device that allows the user to communicate data and voice signals over the national cellular network. Power is provided by a dedicated, fused B+ circuit. Ground is provided through the vehicle wiring harness attached to the module. The ignition state is determined by the VCIM through serial data messaging. Dedicated circuits are used to connect the VCIM to a microphone, the button assembly, and to command the status LED. The VCIM communicates with the rest of the vehicle modules using the serial data bus. The module houses 2 technology systems, one to process GPS data, and another for cellular information. The cellular system connects the OnStar(R) system to the cellular carrier's communication system by interacting with the national cellular infrastructure. The module sends and receives all cellular communications over the cellular antenna and cellular antenna coax. GPS satellites orbiting earth are constantly transmitting signals of their current location. The OnStar(R) system uses the GPS signals to provide location on demand. The module also has the capability of activating the horn, initiating door lock/unlock, or activating the exterior lamps using the serial data circuits. These functions can be commanded by the OnStar(R) Call Center per: a customer request. OnStar(R) Button Assembly The OnStar(R) button assembly may be part of the rearview mirror, or a separate, stand alone unit. The button assembly is comprised of 3 buttons and a status LED. The buttons are defined as follows: ^ The answer/end call button, which is black with a white phone icon, allows the user to answer and end calls or initiate speech recognition. ^ The blue OnStar(R) call center button, which displays the OnStar(R) logo, allows the user to connect to the OnStar(R) call center. ^ The emergency button, which displays a white cross with a red background, sends a high priority emergency call to the OnStar(R) call center when pressed. The VCIM supplies 10 volts to the OnStar(R) button assembly on the keypad supply voltage circuit. When pressed, each button completes a circuit across a resistor allowing a specific voltage to be returned to the VCIM on the keypad signal circuit. Depending upon the voltage range returned the VCIM is able to identify which button has been pressed. The OnStar(R) status LED is located with the button assembly. The LED is green when the system is ON and operating normally. When the status LED is green and flashing, it is an indication that a call is in progress. When the LED is red, this indicates a system malfunction is present. In the event there is a system malfunction and the OnStar(R) system is still able to make a call, the LED will flash red during the call. If the LED does not illuminate, this may indicate that the customers OnStar(R) subscription is not active or has expired. Push the blue OnStar button to connect to an advisor who can then verify the account status. Each LED is controlled by the VCIM over dedicated LED signal circuits. Ground for the LED is provided by the wiring harness attached to the button assembly. TPMS System - Service And Re-Learning Sensor IDs Tire Pressure Sensor: Technical Service Bulletins TPMS System - Service And Re-Learning Sensor IDs INFORMATION Bulletin No.: 10-03-16-001 Date: July 19, 2010 Subject: TPMS System Service and Re-Learning Sensor IDs Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks 2010 and Prior HUMMER H2 2009 and Prior HUMMER H3 2010 and Prior Saturn Models 2009 and Prior Saab 9-7X with Wheel-Mounted Tire Pressure Sensors In the event that the spare tire, which is normally not equipped with a tire pressure monitor (TPM) sensor, is installed in place of one of the road tires and the vehicle is driven above 40 km/h (25 mph) for 20 minutes or more, the TPM indicator icon on the instrument panel cluster (IPC) will flash for approximately one minute and then remain on steady each time the ignition is turned ON, indicating a diagnostic trouble code (DTC) has been set. The driver information center (DIC), if equipped, will also display a SERVICE TIRE MONITOR type message. When the road tire is repaired and reinstalled in the original location, the TPM indicator icon illumination and DIC message may remain displayed until the DTC is cleared. To ensure that the TPM indicator and the DIC message are cleared after service, it is necessary to clear any TPM DTCs using a scan tool. If a scan tool is unavailable, performing the TPM relearn procedure using a TPM diagnostic tool will provide the same results. It is advised to perform the relearn procedure away from other vehicles to prevent picking up a stray sensor signal. If one or more of the TPM sensors are missing or damaged and have been replaced, then the relearn procedure must be performed. Disclaimer Page 6415 Park Neutral Position (PNP) Switch C175 Page 7672 Four Wheel Drive Selector Switch: Diagrams Electrical - Trailer Brakes Apply With Headlamps ON Trailer Lighting Module: All Technical Service Bulletins Electrical - Trailer Brakes Apply With Headlamps ON Bulletin No.: 02-05-22-004C Date: April 05, 2005 TECHNICAL Subject: Trailer Brakes Applied When Headlights/Park Lamps Are On, Brake Controller Illumination (Modify Brake Controller Wiring Harness) Models: 2002-2005 Cadillac Escalade, Escalade EXT 1999-2005 Chevrolet Silverado 2000-2005 Chevrolet Suburban, Tahoe 2002-2005 Chevrolet Avalanche 1999-2005 GMC Sierra 2000-2005 GMC Yukon, Yukon XL 2003-2005 HUMMER H2 Supercede: This bulletin is being revised to add additional model years. Please discard Corporate Bulletin Number 02-05-22-004B (Section 05 - Brakes). Condition Some customers may comment that when the headlamps or park lamps are on, the brakes on the trailer are always applied, or that the back lighting for the trailer brake controller only illuminates when the brakes are applied. Cause The cause of this condition may be due to wiring changes within the vehicle electrical system for the 2003 model year. Correction Inspect the brake controller wiring harness jumper that is plugged into the vehicle relay block-body. The relay block-body is located under the left side of the instrument panel near the left kick panel, behind a plastic cover. Page 13508 Body Control Module (BCM) Inlet Radiator Hose: Service and Repair Inlet Radiator Hose Replacement - Inlet (4.8, 5.3, and 6.0L Engines) Removal Procedure 1. Drain the cooling system. 2. Loosen the air cleaner outlet duct clamps at the following locations: ^ Throttle body ^ Mass Airflow/Intake Air Temperature (MAF/IAT) sensor 3. Remove the radiator inlet hose clip from the outlet hose. 4. Remove the air cleaner outlet duct. 5. If necessary, remove the engine sight shield. 6. Remove the radiator vent inlet hose from the radiator inlet hose clips. 7. Reposition the inlet hose clamp at the radiator. 8. Remove the inlet hose clip from the fan shroud. 9. Remove the inlet hose from the radiator. Page 15321 Fuel Gauge Sender: Diagrams Fuel Pump/Sender Assembly - Primary Page 8621 cloth below the booster supply port in order to capture any fluid exiting the hydro-boost unit. 10. Install the inlet port adapter, CH 47950-2 (2) into the booster supply port. 11. Using a torque wrench, slowly tighten the inlet port adapter to 16 N.m (12 lb-ft). If the clear tube was removed from the inlet port adapter assembly, be sure it is reinstalled. 12. Before each use of the accumulator pressure clamp, CH 47950-1, be sure to grease the clamp bolt and anti rotation washer with wheel bearing grease. 13. Install the accumulator pressure clamp, CH 47950-1 (1), by sliding it over the accumulator and straddling the hydro-boost housing. 14. Confirm that the accumulator pressure clamp is squarely seated onto the booster housing and accumulator, and place the 3/4 inch containment bolt into the fixture. Install the nut hand-tight onto the containment bolt. 15. Check and make sure that the fixture washer is correctly positioned between the end of the accumulator, and that the pin is engaged in the end of the bolt. The tab on the washer should be rotated clockwise so it is located below the master cylinder mounting flange ear. Caution: Incorrect installation of the washer will result in damage to the accumulator end. 16. Hand-tighten the accumulator pressure clamp bolt. Make sure the clamp is level and the tube is square to the end of the accumulator. 17. Place a shop cloth next to the opening of the inlet port adapter in order to capture any fluid exiting the hydro-boost unit. Important: Do not exceed 65 N.m (48 lb-ft) torque. Important: A torque wrench must be used to tighten the fixture clamp bolt 18. Slowly tighten the fixture clamp bolt while monitoring the inlet port adapter tube for signs of power steering fluid. Stop tightening of the bolt when either fluid is observed (below the maximum 65 N.m (48 lb-ft) torque) OR The 65 N.m (48 lb-ft) maximum bolt torque is achieved (with no fluid Page 3559 Compression Check: Testing and Inspection Engine Compression Test 1. Charge the battery if the battery is not fully charged. 2. Disable the ignition system. 3. Disable the fuel injection system. 4. Remove all the spark plugs. 5. Turn the ignition to the ON position. 6. Depress the accelerator pedal to position the throttle plate wide open. 7. Start with the compression gage at zero and crank the engine through four compression strokes, four puffs. 8. Check the compression for each cylinder. Record the readings. 9. If a cylinder has low compression, inject approximately 15 ml (1 tablespoon) of engine oil into the combustion chamber through the spark plug hole. Check the compression again and record the reading. 10. The minimum compression in any one cylinder should not be less than 70 percent of the highest cylinder. No cylinder should read less than 690 kPa (100 psi). For example, if the highest pressure in any one cylinder is 1 035 kPa (150 psi), the lowest allowable pressure for any other cylinder would be 725 kPa (105 psi). (1 035 x 70% = 725) (150 x 70% = 105). ^ Normal - Compression builds up quickly and evenly to the specified compression for each cylinder. ^ Piston Rings Leaking - Compression is low on the first stroke. Compression builds up with the following strokes, but does not reach normal. Compression improves considerably when you add oil. ^ Valves Leaking - Compression is low on the first stroke. Compression usually does not build up on the following strokes. Compression does not improve much when you add oil. ^ If two adjacent cylinders have lower than normal compression, and injecting oil into the cylinders does not increase the compression, the cause may be a head gasket leaking between the cylinders. Page 14715 The GM Vehicle Care Odor Eliminator product is an effective odor elimination product when used properly. It must come into direct contact with the odor source. It should be used in conjunction with diagnostic procedures to first eliminate the root cause of the odor. Some procedures for use after odor root cause correction are: STEP TWO: ^ Use the trigger spray head. ^ Put a drop of dish soap the size of a quarter in the bottom of a bottle. ^ Add 8 oz. of GM Vehicle Care Odor Eliminator (1 cup) to the dish soap and top off the bottle with tap water. ^ This formula should be used on hard surfaces (dash, interior plastic molding, and floor pan) STEP THREE: The third step to neutralizing the vehicle is a light to medium treatment of all carpeting and upholstered seats with the GM Vehicle Care Odor Eliminator formula and a wide fan spray setting (at full strength) (i.e.: carpeting on the driver's side requires 4-5 triggers pulls for coverage). The headliner and trunk should be sprayed next. Lightly brushing the formula into the carpeting and upholstery is a recommended step for deep odor problems. The dash and all hard surfaces should be sprayed with dish soap/water mixture. Let stand for 1-2 minutes then wipe off the surface. STEP FOUR: (vehicle ventilation system treatment) The ventilation system is generally the last step in the treatment of the vehicle. a. Spray the GM Vehicle Care Odor Eliminator formula into all dash vents. (1-2 trigger pulls per vent). b. Start the vehicle and turn the vehicle fan on high cool (not A/C setting). c. Spray the formula (10 trigger pulls) into the outside fresh air intake vent (cowl at base of windshield) d. Enter the vehicle after 1 minute and wipe off the excess formula spurting out of the dash vents. e. Smell the air coming from the dash vents. If odors are still present, spray another 5 triggers into the cowl, wait another minute and smell the results. Once you have obtained a fresh, clean smell coming from the vents, turn the system to the A/C re-circulation setting. Roll up the windows, spray 3-5 pumps into the right lower IP area and let the vehicle run with the fan set on high for 5-7 minutes. Please follow this diagnosis process thoroughly and complete each step. If the condition exhibited is resolved without completing every step, the remaining steps do not need to be performed. If these steps do not resolve the condition, please contact GM TAC for further diagnostic assistance. Additional Suggestions to Increase Customer Satisfaction Here are some additional ideas to benefit your dealership and to generate greater customer enthusiasm for this product. ^ Keep this product on-hand for both the Service Department and the Used Car lot. Add value to your used car trades; treat loaner and demo cars during service and at final sale to eliminate smoke, pet, and other common odors offensive to customers. Make deodorizing a vehicle part of your normal vehicle detailing service. ^ Consider including GM Vehicle Care Odor Eliminator as a give-away item with new vehicle purchases. Many dealers give away as "gifts" various cleaning supplies at time of delivery. GM Odor Eliminator is one of a few products GM offers that has as many uses in the home as in the vehicle. Customers may find this product can be used for a host of recreational activities associated with their new vehicle, such as deodorizing a boat they tow, or a camper. ^ GM Odor Eliminator and many of the GM Vehicle Care products offer you the chance to increase dealership traffic as these superior quality products cannot be purchased in stores. Many Dealerships have product displays at the parts counter. Consider additional displays in the Customer Service Lounge, the Showroom and at the Service Desk or Cashier Window. Many customers who purchase vehicles and receive regular maintenance at your dealership may never visit the parts counter, and subsequently are not exposed to the variety and value that these products offer. Parts Information Page 9419 Refer to the table as a guide in selecting the correct test adapter for frontprobing connectors: Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure SCAN TOOL SNAPSHOT PROCEDURE Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: - Snapshot - taken from the Snapshot menu choice - Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information Page 15248 Cigar Lighter/Auxiliary Outlets Diagram 4 (2 Of 2) Page 15579 Cargo Lamp Switch: Service and Repair LAMP SWITCH ASSEMBLY REPLACEMENT - FRONT FOG LAMP AND CARGO LAMP REMOVAL PROCEDURE 1. Remove the instrument cluster bezel. 2. Remove the fog lamp switch and cargo switch from the housing. 3. Disconnect the electrical connector(s) from the fog lamp switch. 4. Remove the fog lamp and cargo lamp switch from the housing. INSTALLATION PROCEDURE 1. Connect the electrical connector(s) to the fog lamp and cargo lamp switch. 2. Install the fog lamp switch into the housing. 3. Install the IP trim bezel to the instrument panel. Locations Below Driver Seat - Restraint Systems Wiring Fuel Pump Relay Fuel Pump Relay: Locations Fuel Pump Relay FUEL PUMP RELAY Fuse Block-Underhood Page 7881 Page 1855 Tire Pressure Sensor: Technical Service Bulletins Tire Monitor System - TPM Sensor Information INFORMATION Bulletin No.: 08-03-16-003 Date: May 12, 2008 Subject: Warranty Reduction - Transfer of Tire Pressure Monitoring (TPM) Sensors to Replacement Wheels and Allowable TPM Sensor Replacements Models: 2000-2009 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2009 HUMMER H2 2006-2009 HUMMER H3 2005-2009 Saab 9-7x with On-Wheel TPM Sensors TPM Sensor / Wheel Warranty Reviews During the last warranty review period it was noted that wheels being returned under the GM New Vehicle Warranty were being shipped back to General Motors with the TPM sensor still attached to the wheel. Return rates ran as high as 60% with the TPM sensors still attached. Operational TPM sensors should not be returned to GM and are to be transferred to replacement wheels if they become necessary. Important: Operational TPM Sensors that are returned under warranty to General Motors will be charged back to the dealer.Sensors have a 10 year /150,000 mile (240,000 km) battery life, and should be transferred if one or more wheels are replaced. TPM Valve Stem / Grommet (0-ring) Replacement When the TPM sensors are transferred to new wheels you should replace the component used to seal the TPM sensor stem to the wheel. On sensors with an aluminum stem and visible nut on the outside of the wheel a replacement grommet (0-ring) should be used to assure a proper seal. The sensor retaining nut (except Aveo) should be tightened to 7 N.m (62 lb in) for all vehicles except Pontiac Vibe (4.0 N.m (35.4 lb in)). Important: ^ DO NOT overtorque the retaining nut. Notice: ^ Factory installed TPM Sensors come with plastic aluminum or nickel-plated brass stem caps. These caps should not be changed. Chrome plated steel caps may cause corrosion of aluminum valve stems due to incompatibility of the metals. On current style sensors the entire rubber stem is replaceable. The service interval on the revised TPM sensor with replaceable stem is the same as for any other traditional valve stem. Replace the stem at the time of tire replacement sensor transfer or whenever air seepage is suspected at the valve stem. When replacing the valve stem tighten the screw to 1.3 N.m (11.5 lb in). For either style of TPM sensor see the service parts guide for the correct GM part numbers to order and use. Disclaimer Page 13666 2. Release the upper extension by pulling outward on the front edge in order to release the upper retainer clips. 3. Remove the upper extension from the trim panel by lifting up and out. Installation Procedure 1. Position the lower retainer to the trim panel. 2. Align the upper retainer clips to the door frame. 3. Press inward on the upper extension until the clips fully engage securing the panel to the door. Page 5785 10. Connect the PNP switch electrical connector (2). 11. If equipped with 4WD, install the front propeller shaft. 12. Lower the vehicle. 13. Check the PNP switch for proper operation. The engine must start in the park (P) or neutral (N) positions only. If proper operation of the switch can not be obtained, replace the switch. Park Lock Pawl and Actuator Replacement Park Lock Pawl and Actuator Replacement Removal Procedure 1. Remove the transmission filter. 2. Remove the park/neutral position (PNP) switch. 3. Remove the manual shaft nut and pin. 4. Remove the detent lever and actuator. 5. Remove the parking pawl bracket bolts. 6. Remove the parking pawl return spring. Page 8387 2. Install the park brake cable to the lever. 3. Notice: Refer to Fastener Notice in Service Precautions. Install the rear park brake cable bracket bolt. ^ Tighten the rear park brake cable bracket bolt to 61 Nm (45 ft. lbs.). 4. Install the park brake cable to the differential clip. 5. Install the park brake cable bolt to the rear axle clip. ^ Tighten the park brake cable bolt to 25 Nm (18 ft. lbs.). 6. Install the park brake cable taking care to correctly route the cable though the guides and the body mounts. 7. Install the park brake cable into the mounting bracket until the locking tabs snap into place. Page 9636 5. Push on the tab (3) so that the electrical center can be rotated on the studs located at (2). 6. Remove all connectors by removing the bolt (1) for each connector. 7. Disconnect all connectors from the electrical center block. 8. Push on the tabs (2) in order to lift the electrical center (1) out of the housing. 9. To replace the engine electrical center bracket remove the 4 retaining bolts (1). 10. Remove the engine electrical center bracket assembly from the fender. INSTALLATION PROCEDURE Page 8859 Multifunction Accessory Switch (HP2) Page 10458 5. Tighten the wheel bearing adjusting nut using the J 2222-C. ^ Rotate the hub in the opposite direction to the way the adjuster nut is turning. ^ Ensure the inner bearing and the seal seats against the spindle shoulder. TIGHTEN ^ Adjusting nut to 70 Nm (52.0 lb ft). 6. Turn the adjusting nut counterclockwise until the nut is loose using the J 2222-C. 7. Turn the adjusting nut clockwise until the nut contacts the bearing cone. Torque on the nut must be zero to finger tight. 8. Insert the adjusting nut lock key into the keyway using one of the following procedures: ^ If the adjusting nut slot is in alignment with the keyway in the axle spindle, insert the adjusting nut lock key into the keyway in the axle spindle. IMPORTANT: Do not turn the adjusting nut more than one slot counterclockwise in order to align the adjusting nut slot with the keyway in the axle spindle. ^ If the adjusting nut slot is not aligned with the keyway in the axle spindle, turn the adjusting nut counterclockwise until the adjusting nut slot is in alignment with the keyway in the axle spindle and insert the adjusting nut lock key. Emissions - MIL ON/DTC P0446 Stored In ECM Evaporative Check Valve: Customer Interest Emissions - MIL ON/DTC P0446 Stored In ECM TECHNICAL Bulletin No.: 02-06-04-037I Date: September 16, 2010 Subject: Check Engine Light On, Fuel Tank Hard to Fill, DTCs P0442, P0446, P0455 or P0449 Set (Replace Evaporative Emission (EVAP) Vent Valve Solenoid Assembly and Add/Relocate Filter Box Using Service Kit) Models: 1999-2007 Chevrolet Silverado (Classic) Models 1999-2007 GMC Sierra (Classic) Models 2007-2010 Chevrolet Silverado Models (Including Hybrid) 2007-2010 GMC Sierra Models (Including Hybrid) Supercede: This bulletin is being revised to add the 2010 model year and to include the Hybrid models. Please discard Corporate Bulletin Number 02-06-04-037H (Section 06 - Engine/Propulsion System). Condition Some customers may comment about the check engine light being illuminated. They may also comment that their vehicle is difficult to fill with fuel or when filling, the pump continuously shuts off before the tank is full. When checking the vehicle for DTCs, the ECM may report one or more of the following DTCs set as current or in history: P0442, P0446, P0449 or P0455. Cause The EVAP canister vent solenoid (CVS) valve draws fresh air into the system through a vent. Under certain operating conditions, dirt and dust intrusion into the EVAP CVS fresh air intake/venting system, may result in restricted air flow. Under certain operating conditions, water, if ingested into the EVAP CVS fresh air intake/venting system, may reach the CVS valve causing corrosion in the CVS valve, and may cause restrictions in the fresh air intake path, when the valve is in the closed position. Correction (1999-2007 Classic/Old Style Models) After following the published SI diagnostics and determining that the EVAP canister vent valve is the cause of the MIL light, replace the existing EVAP canister vent valve assembly with a new assembly. This new assembly is a sealed unit that is designed to be vented through a remote filter box. To ensure correct installation, follow the procedures below. Important DO NOT replace the EVAP canister assembly for this concern unless it fails the leak test. 1999-2003 Model Year (Use Service Kit P/N 19207762) 1. Raise the vehicle. Suitably support the vehicle. 2. Disconnect the EVAP canister vent valve electrical connector, if equipped. 3. Disengage the two vent valve pipe clips securing the pipe to the underbody. Remove the clips from the underbody and discard. 4. Disconnect the vent valve pipe at the EVAP canister. 5. Remove and retain the EVAP canister vent valve bracket mounting bolt. 6. Remove the complete EVAP canister vent valve assembly with bracket attached and discard. Page 9342 Important The following information MUST be documented on the repair order. Failure to do so may result in a chargeback. - Customer vehicle condition. - Was a Service Lamp or Service Message illuminated? If yes, specify which Service Lamp or Service Message. - Was a DTC(s) set? If yes, specify which DTC(s) were set. - After following the procedure contained within this bulletin, could the condition be duplicated? ‹› If the condition was not duplicated, then document the affected module/component connector name and number on the repair order. - If the condition was duplicated after the procedure contained within this bulletin was followed, and additional diagnosis led to the replacement of a module or component, the SI Document ID Number MUST be written on the repair order. Parts Information Alternate Distributor For All of North America Note NyoGel(R) 760G Lubricant* is equivalent to GMSPO P/N 12377900, and P/N 10953529 (Canada), specified for use to correct the condition in this bulletin. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to: Warranty Information (Saab Models) Page 16033 Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. 1. Disconnect the connector from the component. 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. Page 11382 and close between 275-317 kPa (40-46 psi). 11. Remove special tool GE-47742 after diagnosis is complete. 12. Install a new O-ring on the A/C low pressure switch port on the accumulator. Lightly coat the new O-ring seal with mineral base 525 viscosity refrigerant oil. 13. Install the A/C low pressure switch onto the accumulator. Tighten Tighten the A/C low pressure switch to 6 Nm (44 lb in). Important Remember to install the seal back onto the A/C low pressure switch wire harness connector. Failure to replace the seal could result in terminal corrosion. 14. Reconnect the wire harness to the A/C low pressure switch. Disclaimer Page 2582 For vehicles repaired under warranty, use the table. Disclaimer Page 13226 ^ An OnStar(R) Call Center button press WILL NOT connect the vehicle with OnStar(R). The vehicle must be upgraded to reactivate the account. The customer will hear a demo message stating that there is not a current OnStar(R) subscription for the vehicle. The message will also instruct the customer how to upgrade and reactivate services. ^ OnStar(R) personal calling (OPC) will not be available, as this feature requires the customer to have a current OnStar(R) account. Attempts to use this feature will result in cellular connection failure messages and the inability to connect to the number dialed. Note For deactivated vehicles, a no connect response should be considered normal system operation. Further diagnosis and subsequent repair is only necessary should the customer elect to become an active OnStar(R) subscriber and upgrade the account subscription. OnStar(R) Cellular, GPS, and Diagnostic Limitations The proper operation of the OnStar(R) System is dependent on several elements outside the components integrated into the vehicle. These include the National Cellular Network Infrastructure, the cellular telephone carriers within the network, and the GPS. The cellular operation of the OnStar(R) system may be inhibited by factors such as the users range from a digital cellular tower, the state of the cellular carrier's equipment, and the location where the call is placed. Making an OnStar(R) key press in areas that lack sufficient cellular coverage or have a temporary equipment failure will result in either the inability of a call to complete with a data transfer or the complete inability to connect to the OnStar(R) Call Center. The OnStar(R) system may also experience connection issues if the identification numbers for the module, station identification number (STID), electronic serial number (ESN) or manufacturers electronic ID (MEID), are not recognized by the cellular carriers local signal receiving towers. The satellites that orbit earth providing the OnStar system with GPS data have almost no failures associated with them. In the event of a no GPS concern, the failure will likely lie with the inability of the system to gain GPS signals because of its location, i.e. in a parking structure, hardware failure, or being mistaken with an OnStar(R) call which has reached the Call Center without vehicle data. During diagnostic testing of the OnStar(R) system, the technician should ensure the vehicle is located in an area that has a clear unobstructed view of the open sky, and preferably, an area where digital cellular calls have been successfully placed. These areas can be found by successfully making an OnStar(R) keypress in a known good OnStar(R) equipped vehicle and confirming success with the OnStar(R) Call Center advisor. Such places can be used as a permanent reference for future OnStar(R) testing. Mobile Identification Number and Mobile Directory Number The vehicle communication interface module (VCIM) utilizes 2 numbers for cellular device identification, call routing and connection. They are: ^ A mobile identification number (MIN) ^ A mobile directory number (MDN) Note The MIN represents the number used by the cellular carrier for call routing purposes. The MDN represents the number dialed to reach the cellular device. Diagnostic Information Symptoms - Cellular Communication The following steps must be completed before using the symptom table. 1. Perform the Diagnostic System Check - Vehicle, before using the Symptom Tables in order to verify that the following are true: ^ There are no DTCs set. ^ The control modules can communicate via the serial data link. 2. Review the system operation in order to familiarize yourself with the system functions. Refer to Radio/Audio System Description and Operation in SI. Diagnostic Starting Point - Displays and Gages Begin the displays and gages system diagnosis with Diagnostic System Check - Vehicle or the audible warning system diagnosis with Diagnostic System Page 15995 Steps 6-11 Procedures Power Door Lock Switch: Procedures Switch Replacement - Door Lock and Side Window - Driver SWITCH REPLACEMENT - DOOR LOCK AND SIDE WINDOW - DRIVER REMOVAL PROCEDURE 1. Remove the front door trim panel. 2. Disconnect the electrical connectors. 3. Remove the screw that retains the switch panel bezel (1) from the front door panel. 4. Remove the switch panel bezel from the door panel using a flat-bladed tool. 5. Using a wide plastic flat-bladed tool, release the retaining clips on both sides of the door module. Diagram Information and Instructions Auxiliary Power Outlet: Diagram Information and Instructions Truck Zoning TRUCK ZONING Truck Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that corresponds to where they are located in the vehicle. The table explains the numbering system. Page 15534 Tire Pressure Sensor: Technical Service Bulletins Tire Monitor System - TPM Sensor Information INFORMATION Bulletin No.: 08-03-16-003 Date: May 12, 2008 Subject: Warranty Reduction - Transfer of Tire Pressure Monitoring (TPM) Sensors to Replacement Wheels and Allowable TPM Sensor Replacements Models: 2000-2009 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2009 HUMMER H2 2006-2009 HUMMER H3 2005-2009 Saab 9-7x with On-Wheel TPM Sensors TPM Sensor / Wheel Warranty Reviews During the last warranty review period it was noted that wheels being returned under the GM New Vehicle Warranty were being shipped back to General Motors with the TPM sensor still attached to the wheel. Return rates ran as high as 60% with the TPM sensors still attached. Operational TPM sensors should not be returned to GM and are to be transferred to replacement wheels if they become necessary. Important: Operational TPM Sensors that are returned under warranty to General Motors will be charged back to the dealer.Sensors have a 10 year /150,000 mile (240,000 km) battery life, and should be transferred if one or more wheels are replaced. TPM Valve Stem / Grommet (0-ring) Replacement When the TPM sensors are transferred to new wheels you should replace the component used to seal the TPM sensor stem to the wheel. On sensors with an aluminum stem and visible nut on the outside of the wheel a replacement grommet (0-ring) should be used to assure a proper seal. The sensor retaining nut (except Aveo) should be tightened to 7 N.m (62 lb in) for all vehicles except Pontiac Vibe (4.0 N.m (35.4 lb in)). Important: ^ DO NOT overtorque the retaining nut. Notice: ^ Factory installed TPM Sensors come with plastic aluminum or nickel-plated brass stem caps. These caps should not be changed. Chrome plated steel caps may cause corrosion of aluminum valve stems due to incompatibility of the metals. On current style sensors the entire rubber stem is replaceable. The service interval on the revised TPM sensor with replaceable stem is the same as for any other traditional valve stem. Replace the stem at the time of tire replacement sensor transfer or whenever air seepage is suspected at the valve stem. When replacing the valve stem tighten the screw to 1.3 N.m (11.5 lb in). For either style of TPM sensor see the service parts guide for the correct GM part numbers to order and use. Disclaimer Page 9903 of the possible harness chafing/pinching. Also, on any of the above listed vehicles, the PCM wiring harness may be chafing against the precharge pump bracket or the battery tray. Correction On RPO AN3 vehicles, inspect the routing of the seat wiring harness. Reroute the seat wiring harness and attaching harness fastener (1) to the opposite side of the seat module bracket. Repair the harness as necessary. Refer to Wiring Repairs in the Wiring Systems sub-section of SI. The seat may have to be removed for ease of access and proper repair of the wiring harness. Inspect the routing of the PCM wiring harness at the precharge pump bracket and the battery tray. Repair the harness as necessary. Refer to Wiring Repairs in the Wiring Systems sub-section of SI. If any of the above conditions still remain after this repair, refer to SI for further diagnostic information. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Diagrams Engine Oil Level Switch Page 14095 If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Sir/SRS Wiring Repairs SIR/SRS WIRING REPAIRS TOOLS REQUIRED J 38125-D Terminal Repair Kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-D contains the following items: - Special sealed splices - in order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping tool - A heat torch - An instruction manual The sealed splices have the following 2 critical features: - A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-D also serves as a generic terminal repair kit. The kit contains the following items: - A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors Page 6565 10. Connect the PNP switch electrical connector (2). 11. If equipped with 4WD, install the front propeller shaft. 12. Lower the vehicle. 13. Check the PNP switch for proper operation. The engine must start in the park (P) or neutral (N) positions only. If proper operation of the switch can not be obtained, replace the switch. Park Lock Pawl and Actuator Replacement Park Lock Pawl and Actuator Replacement Removal Procedure 1. Remove the transmission filter. 2. Remove the park/neutral position (PNP) switch. 3. Remove the manual shaft nut and pin. 4. Remove the detent lever and actuator. 5. Remove the parking pawl bracket bolts. 6. Remove the parking pawl return spring. Page 525 Front Passenger Door Module (FPDM) - C3 (With RPO Code YE9) Part 2 Page 5723 For vehicles repaired under warranty, use the table. Disclaimer Page 12879 Service and Repair Wheel Seal: Service and Repair Wheel Hub, Bearing, and Seal Replacement (4WD) ^ Tools Required J 45859 Axle Remover Removal Procedure 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Remove the tire and wheel. 3. Remove the rotor. Refer to Brake Rotor Replacement - Front in Disc Brakes. 4. Remove the wheel speed sensor and brake hose mounting bracket bolt from the steering knuckle. 5. Remove the wheel drive shaft nut retaining cover. 6. Important: Page 5744 Control Module: Diagrams A/T - 4L60-E/4L65-E Harsh 1-2 Upshift Diagnosis Accumulator: Technical Service Bulletins A/T - 4L60-E/4L65-E Harsh 1-2 Upshift Diagnosis Bulletin No.: 01-07-30-030B Date: October 18, 2005 INFORMATION Subject: 4L60-E/4L65-E Automatic Transmission Diagnostic Information on Harsh 1-2 Upshift Models: 2001-2006 GM Passenger Cars and Light Duty Trucks 2003-2006 HUMMER H2 2006 HUMMER H3 2005-2006 Saab 9-7X with 4L60-E or 4L65-E Automatic Transmission Supercede: This bulletin is being revised to add model years and models. Please discard Corporate Bulletin Number 01-07-30-030A (Section 07 - Transmission/Transaxle). The following four conditions have been found to cause the majority of consistent, harsh 1-2 shift comments. ^ Chips/Sediment/Debris/Contamination found in the valve body, 1-2 accumulator valve (371) bore, may cause the 1-2 accumulator valve to stick or hang-up. ^ Chips/Sediment/Debris/Contamination found in the valve body, 4-3 sequence valve (383) bore, may cause the 4-3 sequence valve to stick or hang-up. Page 10984 ^ Reinstall the fuse and fuse panel cover. ^ Press the "Enter" button to perform the "Refresh" function. ^ "Test in Progress" will be displayed and the right front passenger door lock will cycle once. ^ The screen will display "Procedure Completed". ^ Press the "Exit" button as necessary to return to the main menu screen. 3. Using the switches in the right front passenger door, verify that the power window and power door lock located in that door function properly. Important: The calibrations required for performing SPS reprogram in the next step are based on the type of exterior rearview mirror the vehicle has. To determine the correct calibration, check the Service Parts Identification Label on the vehicle for the RPO code for exterior mirrors. 4. Follow normal Service Programming System (SPS) to reprogram the passenger door module with the current calibration available in TIS 2000. 5. After reprogramming is complete, using the switches in the right front passenger door, verify that the power window and power door lock located in that door function properly. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 16139 Power Window Switch: Diagnostic Aids Basic Knowledge Required BASIC KNOWLEDGE REQUIRED Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the Service Data. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories CHECKING AFTERMARKET ACCESSORIES Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: - Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions INDUCING INTERMITTENT FAULT CONDITIONS In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: - Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. Page 14867 Seat Front Vertical Position Sensor - Driver (With RPO Code AN3) Service and Repair Engine Valley Cover: Service and Repair Engine Valley Cover Replacement Removal Procedure 1. Remove the intake manifold. 2. Gently pry up the rubber covers. 3. Disconnect the knock sensor electrical connectors. 4. Remove the knock sensors. 5. Remove the engine valley cover bolts. 6. Remove the engine valley cover and gasket. 7. Discard the old gasket. Adjustments Axle Bearing: Adjustments WHEEL BEARING ADJ. (With Full Floating 10.5" or 11.5" Ring Gear) IMPORTANT: Ensure the brakes are fully released and do not drag. ^ Pull or push the tire at the top back and forth in order to test the wheel bearing play. ^ Use a pry bar under the tire as an alternative. ^ If the wheel bearing adjustment is correct, the movement will be barely noticeable. ^ If the movement is excessive, adjust the bearings. Adjustment Procedure Tools Required J 2222-C Wheel Bearing Nut Wrench 1. Raise the vehicle. 2. Remove the axle shaft. 3. Remove the hub adjuster nut retaining ring. 4. Remove the adjuster nut lock key. Recall 04V045000: Possible Hydro-Boost Defect Hydraulic Brake Booster: Recalls Recall 04V045000: Possible Hydro-Boost Defect DEFECT: Certain sport utility vehicles, pickup trucks, and passenger vans fail to comply with the requirements of Federal Motor Vehicle Safety Standard No. 135, "Passenger Car Brake Systems." Some of these vehicles were produced with an out-of-specification brake hydro-boost housing relief valve bore. Consequently, the valve O-ring seal may fracture. Steering efforts may be slightly increased while braking or parking. Under certain driving conditions, a fractured seal may also require an increase in the applied brake pedal effort to achieve the same vehicle deceleration. REMEDY: Dealers are to replace the hydro-boost relief valve. The manufacturer has reported that owner notification is expected to begin during the second quarter of 2004. Owners may contact Cadillac at 1-866-982-2339; Chevrolet at 1-800-630-2438; GMC at 1-866-996-9463; or Hummer at 1-866-486-6376. Page 1354 Solar Sensor: Service and Repair SUN LOAD SENSOR REPLACEMENT REMOVAL PROCEDURE 1. Remove the instrument panel (I/P) upper trim panel. 2. Remove the sun load sensor (2) from the upper trim panel. 3. Disconnect the electrical connector. INSTALLATION PROCEDURE 1. Connect the electrical connector. 2. Install the sun load sensor (2) to the upper trim panel. 3. Install the I/P upper trim panel- Page 5606 Step 24 Page 4294 Electrical Symbols Part 12 OnStar(R) - Analog/Digital Ready System Digital Upgrade Technical Service Bulletin # 05-08-46-006Q Date: 081028 OnStar(R) - Analog/Digital Ready System Digital Upgrade INFORMATION Bulletin No.: 05-08-46-006Q Date: October 28, 2008 Subject: Information on Upgrading Certain OnStar(R) Analog/Digital-Ready Systems to OnStar(R) Generation 6 Digital-Capable System Models Supercede: This bulletin is being revised to update the upgrade kit installation information for the 2001 Chevrolet Impala and Monte Carlo. Please discard Corporate Bulletin Number 05-08-46-006P (Section 08 - Body and Accessories). This bulletin is being issued to provide dealer personnel with information and procedures to follow should an owner wish to upgrade their OnStar(R) Analog/Digital-Ready system to an OnStar(R) Generation 6 Digital-Capable system. Disclaimer Program Overview Program Overview To upgrade their vehicle to an OnStar(R) Generation 6 Digital-Capable system, all that a customer must do is: ^ Take their vehicle to their dealer for the system upgrade. Service and Repair Headlamp Bulb: Service and Repair HEADLAMP ASSEMBLY OR HEADLAMP BULB REPLACEMENT (OLD STYLE) REMOVAL PROCEDURE CAUTION: Halogen bulbs contain gas under pressure. Handling a bulb improperly could cause it to shatter into flying glass fragments. To help avoid personal injury: Turn off the lamp switch and allow the bulb to cool before changing the bulb. - Leave the lamp switch OFF until the bulb change is complete. - Always wear eye protection when changing a halogen bulb. - Handle the bulb only by its base. Avoid touching the glass. - Keep dirt and moisture off the bulb. - Properly dispose of the used bulb. - Keep halogen bulbs out of the reach of children. NOTE: Avoid touching the bulb or letting the bulb come in contact with anything damp. Oil from your skin or moisture on the bulb can cause the bulb to explode when the bulb is turned on. If either comes in contact with the bulb, clean the bulb with alcohol or a suitable degreaser and wipe the bulb dry. 1. Open the hood. Rotate the headlamp retainer pins. 2. Remove the headlamp retainer pins. 3. Pull out the headlamp assembly in order to access the electrical connector. 4. Disconnect the electrical connector. Page 7829 Torque Converter Clutch Solenoid: Service and Repair Torque Converter Clutch Pulse Width Modulation (TCC PWM) Solenoid, TCC Solenoid, and Wiring Harness ^ Tools Required J 28458 Seal Protector Retainer Installer Removal Procedure 1. Remove the transmission filter. 2. Disconnect the transmission harness 20-way connector (1) from the transmission internal harness pass-through connector. Depress both tabs on the connector and pull straight up; do not pry the connector. 3. Important: Removal of the valve body is not necessary for the following procedure. Remove the 1-2 accumulator. Do not remove the spacer plate. 4. Disconnect the internal wiring harness electrical connectors from the following components: ^ Transmission fluid pressure switch (1) ^ 1-2 shift control solenoid (2) ^ 2-3 shift control solenoid (3) ^ Pressure control solenoid (4) ^ Torque converter clutch pulse width modulation (TCC PWM) solenoid (5) ^ 3-2 control solenoid (6) 5. Remove the TCC PWM solenoid retainer. 6. Remove the TCC PWM solenoid in order to access one of the TCC solenoid bolts. Page 11943 For vehicles repaired under warranty use, the table. Disclaimer Page 5696 12. Inspect the TCC solenoid and wiring harness for the following defects: ^ Damage ^ Cracked connectors ^ Exposed wires ^ Loose pins Installation Procedure 1. Install the wiring harness and TCC solenoid with a new O-ring seal to the transmission. 2. Install the pass-through electrical connector to the transmission case. 3. Notice: Refer to Fastener Notice in Service Precautions. Install the valve body bolts which retain the internal wiring harness and install the TCC solenoid bolts. ^ Tighten the control valve body bolts to 11 Nm (97 inch lbs.). ^ Tighten the TCC solenoid bolts to 11 Nm (97 inch lbs.). Keyless Entry - Inoperative Keyless Entry Module: All Technical Service Bulletins Keyless Entry - Inoperative Bulletin No.: 04-08-52-005 Date: June 15, 2004 TECHNICAL Subject: Remote Keyless Entry (RKE) System Inoperative (Reprogram Passenger Door Module (PDM)) Models: 2004 Cadillac Escalade, Escalade ESV, Escalade EXT 2004 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2004 GMC Sierra, Yukon, Yukon XL Condition Some customers may comment on any of the following conditions: ^ The RKE key fob does not function. ^ The "Service Tire Pressure Monitoring System" message is displayed, if equipped. ^ The passenger door will not unlock from the passenger's or driver's door switches. ^ The passenger door window is inoperative. Correction Reprogram the PDM with the Tech 2(R). Currently the Tech 2(R) software is not available for the 2004 model year. Engineering is aware of this and are working to release a new service calibration. In the meantime, build the Tech 2(R) as a 2003 model year and perform the reprogram using the procedure listed below. 1. Turn the ignition switch to the ON position. 2. Connect the Tech 2(R) to the vehicle's diagnostic link connector (DLC), power it up and press enter. ^ Select: Diagnostics. ^ Select model year: 2003. ^ Select: Light truck. ^ Select: Body. ^ Select the proper Product line. ^ Select the proper HVAC Type. ^ Select the proper Radio System type. ^ Select: Passenger Door Module. ^ Select: Special Functions. ^ Select: Refresh. Important: You must remove the described fuse in the next step for the "Refresh" program to be performed. If you do not remove the fuse for five seconds, the Tech 2 will continue to display "Test in Progress" and the program will not complete. ^ Remove the PDM fuse for 5 seconds from the fuse center located behind the panel on the left end of the instrument panel. Page 9815 1. Install the engine electrical center bracket assembly to the front fender. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the 4 retaining bolts (1). Tighten Tighten the 4 retaining bolts (1) to 9 N.m (80 lb in). 3. Align the electrical center block (1) stubs in the slots so that the tabs (2) retains it in place. Page 13545 SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-D. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: - The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair Tools Required J 38125-D Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-D. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Page 16087 6. Use fingers to squeeze the 2 locking legs of the cover. 7. Apply pressure and gently rock the cover until one locking leg is unseated. 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. Page 15863 Upper Steering Column Page 2864 Important The new canister vent valve will be installed in a new location, outside of the frame. 7. Position and secure the new valve assembly to the frame bracket on the outside of the frame using the existing hole and mounting bolt. Tighten Tighten the bracket mounting bolt to 12 Nm (106 lb in). 8. Connect the vent valve pipe to the EVAP canister. 9. Install the two vent valve pipe clips into the existing underbody holes. 10. Connect the EVAP canister vent valve electrical connector, if equipped. 11. Attach bulk 5/8" heater hose to the vent valve port and secure using a clamp. Run a length as needed along the frame rail routing to the area above the transmission. 12. Cut the hose to determined length and install the supplied filter box. Secure using a clamp. 13. Remove the transmission support and lower the transmission assembly as necessary to allow for access to the new filter box location. 14. Secure the filter box to the transmission vent hose just forward of the hose tee-section using a tie strap. DO NOT pinch or restrict the transmission vent hose. The filter box opening should be pointing downward. 15. Raise the transmission and reinstall the transmission support. 16. Tie strap the hose as needed along the frame rail in order to keep the hose away from pinch-points and heat sources. 17. Lower the vehicle. 2004-2007 Model Year (Use Service Kit P/N 19152349) 1. Raise the vehicle. Suitably support the vehicle. 2. Disconnect the EVAP canister vent valve electrical connector. 3. Disconnect the canister pipe from the vent valve. 4. Push in the retainer and remove the existing canister vent valve from the fuel tank clip or mounting bracket. Discard the old valve. 5. Cut back the existing canister pipe approximately 51 mm (2 in) to remove the quick connect end. Crew Cab Short Box Shown Below, Other Configurations Similar Page 8146 13. Remove the caliper guide pin bolts. 14. Remove the brake caliper from the vehicle. 15. Inspect the caliper assembly. Refer to Brake Caliper Inspection. Installation Procedure 1. Important: Use denatured alcohol to clean the outside surface of caliper boot before installing new brake pads. If you are installing new brake pads, use a C-clamp in order to compress the piston to the bottom of the caliper bore. Use the old brake pad, a metal plate or a wooden block across the face of the piston in order to protect the piston and the caliper boot. 2. Important: Use a small flat-bladed tool and lift the inner edge caliper boot next to the piston to release any trapped air. Ensure that the piston boot is below the level of the piston face. 3. Install the caliper to the caliper mounting bracket. 4. Perform the following procedure before installing the caliper guide pin bolts (15 Series pickups only). 1. Remove all traces of the original adhesive patch. 2. Clean the threads of the bolt with brake parts cleaner or the equivalent and allow to dry. 3. Apply Threadlocker GM P/N 12345493 (Canadian P/N 10953488) to the threads of the bolt. Body - Vehicle Glass Distortion Information Quarter Window Glass: Technical Service Bulletins Body - Vehicle Glass Distortion Information INFORMATION Bulletin No.: 00-08-48-005D Date: September 10, 2010 Subject: Distortion in Outer Surface of Vehicle Glass Models: 2011 and Prior GM Passenger Cars and Trucks 2009 and Prior HUMMER H2 2010 and Prior HUMMER H3 2005-2009 Saab 9-7X 2010 and Prior Saturn Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 00-08-48-005C (Section 08 - Body and Accessories). Distortion in the outer surface of the windshield glass, door glass or backlite glass may appear after the vehicle has: - Accumulated some mileage. - Been frequently washed in automatic car washes, particularly "touchless" car washes. This distortion may look like a subtle orange peel pattern, or may look like a drip or sag etched into the surface of the glass. Some car wash solutions contain a buffered solution of hydrofluoric acid which is used to clean the glass. This should not cause a problem if used in the correct concentration. However, if not used correctly, hydrofluoric acid will attack the glass, and over time, will cause visual distortion in the outer surface of the glass which cannot be removed by scraping or polishing. If this condition is suspected, look at the area of the windshield under the wipers or below the belt seal on the side glass. The area of the glass below the wipers or belt seal will not be affected and what looks like a drip or sag may be apparent at the edge of the wiper or belt seal. You may also see a line on the glass where the wiper blade or the belt seal contacts the glass. Important The repair will require replacing the affected glass and is not a result of a defect in material or workmanship. Therefore, is not covered by New Vehicle Warranty. Disclaimer Page 1961 2. Connect the speed sensor electrical connector (4). 3. Lower the vehicle. Page 2733 8. Install the left side end panel. Page 12276 analyzed. Therefore, technicians should be checking for loose connections and installing cable connector clamps to ensure a positive and robust connection. Technicians are to install a video cable connector clamp on each cable connector located under each front seat. A total of four cable connector clamps, P/N 19159659, are required for each vehicle. The illustration above shows a pair of display monitor cable connectors without the cable clamps installed. The illustration above shows the display monitor cable connectors with the cable connector clamps. The lower cable connector clamp is installed but not locked together. The upper cable connector clamp is closed and locked. The cable connector clamps have now been added as a permanent component to all GM Accessories Headrest DVD Systems installation kits. Parts Information Warranty Information (excluding Saab U.S. Models) Page 14650 Seat Bolster/Lumbar Switch - Driver (With RPO Code AN3) Page 12695 Page 12877 5. Choose the outstanding core you wish to process, by selecting the Virtual Core Button on the far right side of the screen. 6. Enter the information in the required fields and select the submit button. Record the confirmation number. Canadian Dealers 1. Return the removed Analog / Digital-Ready OnStar(R) VCIM to the Parts Manager. 2. The Parts Manager will log onto https://adt.onstar.gm.mass.ca and enter information as prompted. All Dealers If the website indicates that the VCIM needs to be physically returned to the distributor, please use the pre-paid shipping label that was included in the kit to return the removed VCIM. Important: To avoid a $250 core non-return charge, you must do one of the following within 30 days of kit shipment: 1. Submit the necessary VCIM data through the website, as indicated above. 2. Mail the removed core from the customer's vehicle back to the distributor. 3. Return the unused digital upgrade kit back to the distributor using the pre-paid shipping label that is included in the kit box. Returning the Upgraded Vehicle to the Customer Returning the Upgraded Vehicle to the Customer 1. Place the new OnStar Subscriber Information (Owner's Manual kit) in the customer's vehicle where they can review some of the new features of the Digital-Capable system. The continuous digit dialing feature should be highlighted to the customer to avoid a return to the dealership for dialing instructions. Advise the customer to discard any existing OnStar(R) Owner's Manuals that may be in the vehicle. 2. Have the Service Advisor, Service Manager or Sales Consultant review the new OnStar(R) Hands-Free Calling procedure with the customer. The customer is uses to their analog OnStar(R) Hands-Free Calling system, which uses individual digit dial to make a call. The Generation 6 Digital-Capable system uses continuous digit dial, and the customer needs to be made aware of this change. 3. U.S. Dealers Only: Staple the "Tip Sheet - OnStar(R) Generation 6 Digitally-Capable System", that was included in the kit, to the customer's copy of the repair order. This tip sheet will help your customer better understand their new OnStar(R) system. 4. Canadian Dealers Only: Refer the customer to the Hands-Free Calling Quick Review Card from the new OnStar(R) Owner's Manual kit for help with the new dialing procedure. 5. Fill out the form entitled "GM Limited Warranty for Upgraded OnStar(R) Digital Equipment Program Participants" and staple a copy of this to the customer's repair order. You may want to keep a copy for your records. 6. Encourage your customer to press their blue OnStar(R) button the next day. The OnStar(R) Advisor will be able to review some of the new features of their digital OnStar(R) system. Closing the Onstar(R) Upgrade Exchange Closing the OnStar(R) Upgrade Exchange 1. Collect payment from the customer. Your dealership's open account (sales) will be charged for the cost of the chosen subscription plan, any applicable subscription taxes, and the $15 upgrade charge after the vehicle has been configured through the TIS2WEB process. 2. None of the costs associated with the OnStar Digital Upgrade program may be claimed as a GM goodwill event. These costs must be paid by the customer, and may not be included in any goodwill offered to the customer. GM employees or representatives or field personnel are not able to offer goodwill for this program. If the dealership decides to pay for the upgrade for their customer, be aware that your GM or OnStar(R) contact will not be able to reimburse you for this cost. 3. Use labor code Z2096 to submit your claim for the labor time published below plus 0.2 hr Administrative Allowance and an additional $20.00 Net Amount. ^ For all dealer claim submissions (excluding U.S. Saturn), use Complaint Code MH - Technical Bulletin, and Failure Code 93 - Technical Service Bulletin. Service and Repair Rear Door Limiter: Service and Repair Door Check Link Replacement Removal Procedure 1. Fully open the door. 2. Remove the door trim panel. 3. Remove the water deflector. 4. Remove the body-side check strap bolt. 5. Remove the check strap plug. 6. Remove the door-side check strap nuts. 7. Pull the check strap from the inside of the door. Installation Procedure 1. Install the check strap in the door. 2. Install the check strap in the body. Notice: Refer to Fastener Notice in Service Precautions. 3. Install the check strap nuts. Tighten the nuts to 9 N.m (80 lb in). 4. Install the check strap bolt. Tighten the bolt to 25 N.m (18 lb in). 5. Install the water deflector. 6. Install the door trim panel. Locations Instrument Panel Switches-LH Page 4679 Body Control Module: Connector Views Body Control Module (BCM) - C1 Page 13810 13. Disconnect the cable end from the hood latch assembly. 14. Use needle nose pliers to squeeze the tabs in order to remove the cable end from the handle. 15. Lift the cable from the lock. Installation Procedure 1. Insert and pull the cable toward the front of the vehicle through the hole in the cowl. 2. Ensure that the grommet is seated. 3. Attach the cable end to the latch assembly. 4. Attach the cable to the retainer clips. 5. Attach the cable end to the cable handle. 6. Install the radiator air baffle and deflector. Page 8860 Right Rear Corner of Bed (HP2) Page 10600 Do not use cleaning solutions that contain hydrofluoric, oxalic and most other acids on chrome wheels (or any wheels). If the customer is unsure of the chemical make-up of a particular wheel cleaner, it should be avoided. For wheels showing signs of milky staining from acidic cleaners, refer to Customer Assistance and Instructions below. Warranty of Stained Chrome Wheels Stained wheels are not warrantable. Most acid based cleaners will permanently stain chrome wheels. Follow-up with dealers has confirmed that such cleaners were used on wheels that were returned to the Warranty Parts Center (WPC). Any stained wheels received by the WPC will be charged back to the dealership. To assist the customer, refer to Customer Assistance and Instructions below. Pitting or Spotted Appearance of Chrome Wheels Figure 2 A second type or staining or finish disturbance may result from road chemicals, such as calcium chloride used for dust control of unpaved roads. The staining will look like small pitting (refer to Figure 2). This staining will usually be on the leading edges of each wheel spoke, but may be uniformly distributed. If a vehicle must be operated under such conditions, the chrome wheels should be washed with mild soap and water and thoroughly rinsed as soon as conveniently possible. Important Road chemicals, such as calcium chloride used for dust control of unpaved roads, can also stain chrome wheels. The staining will look like small pitting. This staining will usually be on the leading edges of each wheel spoke. This is explained by the vehicle traveling in the forward direction while being splashed by the road chemical. If a vehicle must be operated under such conditions, the chrome wheels should be washed with mild soap and water and thoroughly rinsed as soon as conveniently possible. Warranty of Pitted or Spotted Chrome Wheels Wheels returned with pitting or spotting as a result of road chemicals may be replaced one time. Damage resulting from contact with these applied road chemicals is corrosive to the wheels finish and may cause damage if the wheels are not kept clean. Important Notify the customer that this is a one time replacement. Please stress to the customer the vital importance of keeping the wheels clean if they are operating the vehicle in an area that applies calcium chloride or other dust controlling chemicals! "GM of Canada" dealers require prior approval by the District Manager - Customer Care and Service Process (DM-CCSP). "Stardust" Corrosion of Chrome Wheels Figure 3 A third type of finish disturbance results from prolonged exposure to brake dust and resultant penetration of brake dust through the chrome. As brakes are applied hot particles of brake material are thrown off and tend to be forced through the leading edge of the wheel spoke windows by airflow. These Page 12313 Electrical Symbols Part 3 OnStar(R) - Number Incorrect/Incorrectly Assigned Navigation System: Customer Interest OnStar(R) - Number Incorrect/Incorrectly Assigned INFORMATION Bulletin No.: 05-08-46-004C Date: December 23, 2010 Subject: OnStar(R) Phone Number Concerns (Phone Number Incorrect/Assigned to Another Vehicle/Phone) That Occur During Diagnosis of OnStar(R) System Models: 2000-2011 GM Passenger Cars and Trucks Equipped with OnStar(R) (RPO UE1) Supercede: This bulletin is being revised to update model years up to 2011. Please discard Corporate Bulletin Number 05-08-46-004B (Section 08 - Body and Accessories). During diagnosis of an OnStar(R) concern, the technician may be told that the OnStar(R) phone number is incorrect or tied to another vehicle and/or phone of some kind. To resolve these concerns, the Tech 2(R) with software version 22.005 (or higher), has the capability to change the OnStar(R) phone number. Service Procedure 1. With the Tech 2(R), build the vehicle to specifications within the Diagnostics area of the Tech 2(R). 2. For vehicles with physical-based diagnostics - under Body, go to the OnStar(R) section. Then select the Special Functions menu. For vehicles with functional-based diagnostics - under Body and Accessories, go to the Cellular Communication section. Select Module Setup and then Vehicle Communication Interface Module. 3. Locate the Program Phone Number prompt and select it. The original phone number will be displayed on the Tech 2(R) screen. 4. Contact the OnStar(R) team at the GM Technical Assistance Center (TAC) to obtain a new phone number. 5. Highlight the digits of the phone number one at a time and enter the new phone number using the number keys on the Tech 2(R). 6. Press the Soft key at the base of the screen for Done once these numbers have been changed on the screen. 7. Press the Soft key for Done again. The area code or new phone number has now been programmed into the phone. 8. Cycle the ignition to Off and open the driver's door. 9. Press the blue OnStar(R) button to make sure that a normal connection can be made to the OnStar(R) call center. If applicable, make sure the Hands-Free Calling (HFC) works properly by making a phone call. 10. If the system is working properly, fax or voicemail a case closing into the OnStar(R) team at TAC with the results. Dealers in Canada should submit case closing information through the GM infoNET. Please follow this diagnostic process thoroughly and complete each step. If the condition exhibited is resolved WITHOUT completing every step, the remaining steps do not need to be performed. If the procedure above does not resolve the condition, you must contact TAC for further assistance. This diagnostic approach was developed specifically for this condition and should not automatically be used for other vehicles with similar symptoms. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use: Warranty Information (Saab Models) For vehicles repaired under warranty, use the table. Page 13432 Control Module References Part 3 Page 13074 For vehicles repaired under warranty use, the table. Disclaimer Page 8791 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground TESTING FOR SHORT TO GROUND NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting With A Digital Multimeter TROUBLESHOOTING WITH A DIGITAL MULTIMETER NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TROUBLESHOOTING WITH A TEST LAMP Page 15080 Notice: Refer to Fastener Notice in Service Precautions. 2. Loosely install the pickup box fasteners (1) to the frame rails. Tighten the retaining bolts to the frame rail to 85 N.m (63 lb ft). 3. Install the end gate. 4. Fasten the screws and the push-pin around the fuel filler neck. 5. Close the fuel filler door. 6. Install the tail lamp assembly. 7. Connect the tail lamp wiring connectors (1) at the rear lamps bussing block, at the rear of the vehicle. Page 16180 INSTALLATION PROCEDURE 1. Install the door module into the switch panel bezel until it snaps into place. 2. Install the switch panel bezel and module to the door panel. NOTE: Refer to Fastener Notice in Service Precautions. 3. Install the screw that retains the switch panel bezel (1) to the front door panel. Tighten Tighten the screw to 2 N.m (18 lb in). 4. Connect the electrical connectors. Engine Controls - MIL ON/Rough Idle/Misfire/DTC's Set PROM - Programmable Read Only Memory: All Technical Service Bulletins Engine Controls - MIL ON/Rough Idle/Misfire/DTC's Set Bulletin No.: 05-06-04-063 Date: October 12, 2005 TECHNICAL Subject: LM7, L59 or L33 Engines with Cold Start Rough or Incorrect Idle, Misfire, Malfunction Indicator Lamp (MIL) or Flashing Requiring 02 Sensor Replacement (Reprogram PCM) Models: 2004-2005 Cadillac Escalade 2004-2005 Chevrolet Avalanche, Silverado 1500, Suburban, Tahoe 2005 Chevrolet Silverado Hybrid (HP2) 2004-2005 GMC Sierra 1500, Yukon, Yukon XL 2005 GMC Sierra Hybrid (PH2) with Vortec 5300 5.3L V-8 Engine (VINs T, Z, B - RPOs LM7, L59, L33) Condition Some customers may comment on a Malfunction Indicator Lamp (MIL) On or that the MIL is flashing. An actual engine misfire may or may not be felt along with an incorrect idle speed. Typically this occurs during cold winter months, on cold engine starts. Some vehicles may have been previously serviced for the same condition. Technicians may also find the following DTCs stored with the Tech 2(R) P0131, P0133, P0134, P0137, P0138, P0140, P0151, P0153, P0154, P0157, P1133, which may be in conjunction with P0171, P0174, P0300 and P1138. Cause Water shock occurs when water droplets are present in the exhaust. The water in the exhaust contacts the sensor element inside the H02 sensor, causing the H02 sensor element to crack. Correction Upon diagnostic investigation, the technician may find that the H02 sensor requires replacement. In addition to replacing the affected H02 sensor, these vehicles should also be reflashed with the latest PCM calibration. An updated PCM calibration will be available to dealerships as part of TIS 2000 incremental satellite update 11.0 (NAO version 25.010) or greater. Always, make sure your Tech 2 is updated with the latest software version. Important: If a DTC P0420 or P0430 is stored along with DTC(s) P0300, the catalytic converter diagnostics in Service Information (SI) must be followed to determine if the catalytic converters are operating properly. Warranty Information For vehicles repaired under warranty, use the table. Page 7664 1. Install the J 43484 (2) to the J 8092 (1). 2. Install the seal onto the J 43484 (2). 3. Using the J 43484 (2) and the J 8092 (1), install the seal. 4. Install the front propeller shaft. 5. Check the fluid level, add fluid if necessary. 6. Install the transfer case shield, if equipped. Transfer Case Output Shaft Seal Replacement - Rear Transfer Case Output Shaft Seal Replacement - Rear ^ Tools Required J 37668-A Seal Installer - J 45380 Transfer Case Rear Bushing Remover and Installer Removal Procedure 1. Remove the transfer case shield, if equipped. 2. Remove the rear propeller shaft. 3. Remove the rear output shaft seal. Page 16174 Power Window Switch: Connector Views Window Switch - LR (Crew Cab Only) Page 15325 Fuel Gauge Sender: Description and Operation Fuel System Description (Cab Chassis) FUEL LEVEL SENSOR The fuel level sensor is a part of the fuel sender assembly. The position of the float arm indicates the fuel level. The fuel level sensor contains a variable resistor which changes resistance in correspondence with the amount of fuel in the fuel tank. On models that are equipped with a single fuel tank, the fuel level sensor is wired directly to the instrument panel (IP) cluster. On models equipped with dual fuel tanks, both fuel level sensors are wired to the PCM. The PCM calculates the total fuel level in both tanks. The instrument panel (IP) fuel gage displays the total fuel level in both fuel tanks. Page 5934 Pressure Regulating Solenoid: Connector Locations Page 11897 Page 8985 Location View Page 3774 Electrical Symbols ELECTRICAL SYMBOLS Electrical Symbols Part 1 Page 10097 8. Remove the clamps (3,5) retaining the power steering return hoses to the power steering pump and remove the hoses. 9. Remove the lower intermediate shaft from the steering gear. Refer to Intermediate Steering Shaft Replacement - Lower in Steering Wheel and Column. 10. Remove the bolt retaining the rear bracket to the engine. 11. Remove the bolts from the front of the pump. 12. Remove the pump from the vehicle. 13. Remove the bracket (3) from the rear of the pump (1). Installation Procedure Page 15894 Turn Signal Multifunction Switch - C3 Page 11670 Seat Belt Retractor: Service and Repair Right Front SEAT BELT RETRACTOR REPLACEMENT - RIGHT FRONT CAUTION: To avoid personal injury to the occupants of the vehicle, observe the following precautions: - More than one supplier's seat belts are used, therefore, install ONLY the seat belt components specified in the GM parts catalog. - To verify that the correct seat belt components were installed, insert the seat belt latch in the seat belt buckle. The latch must be fully seated and be retained in the buckle until purposely released. REMOVAL PROCEDURE 1. Move the front seat to the full forward position. IMPORTANT: Do not remove the seat back cover from the head restraint retainers. 2. Remove the seat back cover and pad. 3. Separate the seat foam from the cardboard to gain access to the retainer on the seat belt side. 4. Remove the seat belt side cardboard retainers. 5. Move the cardboard outwards to gain access to the lower seat belt retractor bolt. 6. Remove the retractor bolt. 7. Remove the retractor tower retaining screw. 8. Remove the retractor tower cover. Page 6534 2. Hook one of the open ends of the retaining ring in one of the slots in the quick connect fitting. 3. Rotate the retaining ring around the fitting until the retaining ring is positioned with all three ears through the three slots on the fitting. 4. Do not install the new retaining ring onto the fitting by pushing the retaining ring. 5. Ensure that the three retaining ring ears are seen from inside the fitting and that the retaining ring moves freely in the fitting slots. Page 925 Door Control Module Diagram 2 Part 1 Page 10571 Refer to the appropriate section of SI for specifications and repair procedures that are related to the vibration concern. Disclaimer Component Locations Torque Converter Clutch Solenoid: Component Locations Automatic Transmission - 4L60-E/4L65-E Automatic Transmission Electronic Component Views (M30/M32) Electronic Components Page 4757 Accelerator Pedal Position (APP) Sensor Part 2 Page 7254 Control Module References Part 4 Page 2518 3. Install the fill plug. ^ Tighten the plug to 20 Nm (15 ft. lbs.). 4. Install the transfer case shield, if equipped. Diagrams Engine Oil Level Switch Page 7548 3. Install the fill plug. ^ Tighten the plug to 20 Nm (15 ft. lbs.). 4. Lower the vehicle. Page 12450 Page 10244 Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. 1. Disconnect the connector from the component. 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. Page 15926 Inside Rearview Mirror Page 6211 Disclaimer Page 2630 Junction Block - I/P Wire Entry Part 4 Page 13853 Page 14310 WA9260/74 - WA9260/74 Page 1693 Vehicle Speed Sensor: Service and Repair Manual Transmission - ZF S6-650 Vehicle Speed Sensor (VSS) Replacement Removal Procedure 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. If equipped with the 6.6L engine, disconnect the vehicle speed sensor (VSS) electrical connector (4). 3. If equipped with the 8.1L engine, disconnect the VSS electrical connector (5). 4. Remove the VSS bolt, sensor and seal. Installation Procedure Page 15939 Electrical Symbols Part 12 Page 2336 1. Remove the power steering outlet hose (4) from the power steering gear (3). 2. Remove the power steering outlet hose (4) from the power steering cooler (5). Installation Procedure 1. Connect the power steering outlet hose (4) to the power steering cooler (5). 2. Connect the power steering outlet hose (4) to the power steering gear (3). Hand tighten only. 3. Notice: Refer to Fastener Notice in Service Precautions. Connect the power steering outlet hose (2) to the power steering pump (1). ^ Tighten both hose connections to 28 Nm (20 ft. lbs.). 4. Bleed the power steering system. Refer to Bleeding the Power Steering System. 5. Inspect all the hose connections for leaks. Power Brake Booster Inlet Hose Replacement Power Brake Booster Inlet Hose Replacement Removal Procedure 1. Notice: Refer to Power Steering Hose Disconnected Notice in Service Precautions. Install a drain pan under the vehicle. Page 15211 When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage TESTING FOR A SHORT TO VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity TESTING FOR CONTINUITY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents TESTING FOR ELECTRICAL INTERMITTENTS Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground - Testing for Continuity - Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 msRECORD and emits an audible tone (beep). Page 8221 (W/NYS) Brake Rotor Replacement - Rear (W/NYS) ^ Tools Required J 41013 Rotor Resurfacing Kit - J 42450-A Wheel Hub Resurfacing Kit Caution: Refer to Brake Dust Caution in Service Precautions. Removal Procedure 1. Release the park brake. 2. Raise and suitably support the vehicle. Refer Vehicle Lifting 3. Remove the tire and wheel assembly. 4. Mark the relationship of the rotor to the hub. 5. Install a C-clamp over the body of the brake caliper, with the C-clamp ends against the rear of the caliper body and the outboard disc brake pad. 6. Slowly tighten the C-clamp until the pistons are pushed into the caliper bores enough to remove the caliper from the pads. 7. Remove the C-clamp from the caliper. 8. Remove the nut and the bolt from the quarter shaft shield. 9. Remove the shield. Page 5649 Park Neutral Position (PNP) Switch C175 Page 12860 12.2. Cars with brackets for e.g. an amplifier: Remove the pin strap (A) from the bracket and remove the tape (B) holding the optic cables. 12.3. Remove the locking strip (C) on the 2-pin connector (H2-9). Open the terminal housing with a screwdriver. Remove the secondary catch (E) on the connector and remove the optic cables coming from the OnStar(R) control modules. 12.4. Loosen one of the optic cables remaining in H2-9 (F), connect it to the connector and fit the secondary catch (E). Connect the connector so that the optic cables are opposite each other (G). Connect the terminal housing (D) and refit the locking strip (C). Page 13035 Involved are certain vehicles within the VIN breakpoints shown above. PARTS INFORMATION -- Saab US Only Customer Notification General Motors will notify customers of this special coverage on their vehicles (see copy of typical customer letter shown in this bulletin - actual divisional letter may vary slightly). Diagrams Door Latch Assembly (Key Cylinder Switch) - Driver C3 Page 5905 For vehicles repaired under warranty, use the table. Disclaimer Page 10607 longer. Important Whenever a wheel is refinished, the mounting surface and the wheel nut contact surfaces must not be painted or clearcoated. Coating these surfaces could affect the wheel nut torque. When re-mounting a tire on an aluminum wheel, coated balance weights must be used in order to reduce the chance of future cosmetic damage. Disclaimer Page 11578 Involved are certain 2003-2005 Cadillac Escalade, Escalade ESV, Escalade EXT; Chevrolet Avalanche, Silverado Crew Cab, Suburban, Tahoe; GMC Sierra Crew Cab, Yukon, Yukon XL; and 2004-2005 HUMMER H2 vehicles built within the VIN breakpoints shown. Important: Dealers should confirm vehicle eligibility through GMVIS (GM Vehicle Inquiry System) prior to beginning recall repairs. [Not all vehicles within the above breakpoints may be involved.] For US and Canada For dealers with involved vehicles, a Campaign Initiation Detail Report containing the complete Vehicle Identification Number, customer name and address data has been prepared and will be loaded to the GM DealerWorld (US) Recall Information, GMinfoNet (Canada) Recall Reports. Dealers will not have a report available if they have no involved vehicles currently assigned. For Export For dealers with involved vehicle, a Campaign Initiation Detail Report containing the complete Vehicle Identification Number, customer name and address data has been prepared, and is being furnished to involved dealers. Dealers will not receive a report with the recall bulletin if they have no involved vehicles currently assigned. The Campaign Initiation Detail Report may contain customer names and addresses obtained from Motor Vehicle Registration Records. The use of such motor vehicle registration data for any purpose other than follow-up necessary to complete this recall is a violation of law in several states/provinces/countries. Accordingly, you are urged to limit the use of this report to the follow-up necessary to complete this recall. Parts Information Page 9239 C321 Seat Jumper Harness To Seat Harness (With RPO Code AN3) Part 1 Locations Upper Steering Column Page 8432 Parking Brake Shoe: Service and Repair Parking Brake Shoe Replacement (RPO NYS) Parking Brake Shoe Replacement (RPO NYS) Removal Procedure Caution: Avoid taking the following actions when you service wheel brake parts: - Do not grind brake linings. - Do not sand brake linings. - Do not clean wheel brake parts with a dry brush or with compressed air. Some models or aftermarket brake parts may contain asbestos fibers which can become airborne in dust. Breathing dust with asbestos fibers may cause serious bodily harm. Use a water-dampened cloth in order to remove any dust on brake parts. Equipment is available commercially in order to perform this washing function. These wet methods prevent fibers from becoming airborne. 1. Release the park brake. 2. Raise and support the vehicle. 3. Remove the tire and wheel assembly. 4. Relieve the tension from the park brake cable by pulling down on the intermediate cable then release the cable from the equalizer bar. 5. Remove the rear park brake bracket bolt. Page 5160 1. Install the accelerator pedal assembly. NOTE: Refer to the Fastener Notice in Service Precautions. 2. Install the accelerator pedal nuts. Tighten Tighten the nuts to 20 N.m (15 lb ft). 3. Connect the APP sensor electrical connector. 4. Reposition the carpet. 5. Connect a scan tool in order to test for proper throttle-opening and throttle-closing range. 6. Operate the accelerator pedal and monitor the throttle angles. The accelerator pedal should operate freely, without binding, between a closed throttle, and a wide open throttle (WOT). 7. Verify that the vehicle meets the following conditions: - The vehicle is not in a reduced engine power mode. - The ignition is ON. - The engine is OFF. 8. Inspect the carpet fit under the accelerator pedal. Page 2856 Extended Cab Short Box Shown Below, Other Configurations Similar 6. Install the new canister vent valve solenoid to the fuel tank clip or mounting bracket as shown above. The valve port closest to the electrical connector must point towards the canister. 7. Cut bulk 5/8" heater hose to a length of approximately 76 mm (3 in). Install the hose between the solenoid and the canister pipe and secure using clamps. 8. Attach bulk 5/8" heater hose to the vent port and secure using a clamp. Run a length as needed along the frame rail routing to the area above the transmission. 9. Cut the hose to determined length and install the supplied filter box. Secure using a clamp. 10. Remove the transmission support and lower the transmission assembly as necessary to allow for access to the new filter box location. 11. Secure the filter box to the transmission vent hose just forward of the hose tee-section using a tie strap. DO NOT pinch or restrict the transmission vent hose. The filter box opening should be pointing downward. 12. Raise the transmission and reinstall the transmission support. 13. Connect the EVAP canister vent valve electrical connector. 14. Tie strap the hose as needed along the frame rail in order to keep the hose away from pinch-points and heat sources. 15. Lower the vehicle. Correction (2007-2010 New Style Models) After following the published SI diagnostics and determining that the EVAP canister vent valve is the cause of the MIL light, replace the EVAP canister vent valve assembly and relocate the remote filter box. To ensure correct installation, follow the procedures below. Important DO NOT replace the EVAP canister assembly for this concern unless it fails the leak test. Use Service Kit P/N 19207763 1. Raise the vehicle. Suitably support the vehicle. 2. Disconnect the EVAP canister vent valve electrical connector. Page 7633 Page 832 Relay Box: Application and ID Relay Block - I/P Location View Page 7725 Speed Sensor: Service and Repair Transfer Case - NVG 261-NP2 Transfer Case Speed Sensor Replacement Removal Procedure 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. Disconnect the speed sensor electrical connector (4). 3. Remove the speed sensor. Installation Procedure 1. Notice: Refer to Fastener Notice in Service Precautions. Install the speed sensor. ^ Tighten the sensor to 15 Nm (11 ft. lbs.). Interior - Intermittent Seat Heater Operation Seat Heater Control Module: All Technical Service Bulletins Interior - Intermittent Seat Heater Operation Bulletin No.: 05-08-50-008 Date: August 19, 2005 TECHNICAL Subject: Intermittent Heated Seats Inoperative, DTC B3941 Set (Reprogram Driver Seat Module) Models: 2003-2005 Cadillac Escalade, Escalade ESV, Escalade EXT 2003-2005 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2003-2005 GMC Sierra, Yukon, Yukon XL, Yukon Denali All with Seat FRT, Individual (Non BKT) (RPO AN3) 2003-2005 HUMMER H2 with Seat, Front Bucket Deluxe (RPO AR9) Condition Some customers may comment that occasionally the seat heater will not operate when activated. If the ignition key is cycled OFF and back ON again, the heated seat will operate correctly. Also, on some LB7 diesel engine vehicles, the seat heater may turn itself off during the first 10 minutes of operation. This occurs only with the first activation for the day and works correctly with subsequent activations immediately after the event. These conditions are intermiffent and DTC B3941 may be set. Correction Technicians are to reprogram the driver seat module with an updated software calibration. This new service calibration was released with TIS satellite data update version 6.5 available June 13, 2005. As always, make sure your Tech 2(R) is updated with the latest software version. Warranty Information Page 9137 15. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 16. Install the electrical ground wire terminal to the rivet stud. 17. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 18. Install the M6 conductive nut to the rivet stud and: Tighten Tighten to 8 Nm (71 lb in). 19. Verify proper system operation. M6 Weld Nut Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M6 weld nut at the electrical ground location is damaged or stripped, a M7 conductive self-threading bolt may be used to secure the ground wire terminal. 2. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the weld nut and allow to dry. 3. Remove any loose metal particles from the damaged or stripped weld nut with a stiff brush. 4. Select a M7 conductive self-threading bolt. Refer to the Parts Information section of this bulletin 5. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M7 conductive self-threading bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 6. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 7. Install the electrical ground wire terminal to the M7 conductive self-threading bolt. 8. Install the M7 conductive self-threading bolt and: Tighten Tighten to 9 Nm (80 lb in). 9. Verify proper system operation. M6 Weld Nut Alternative Repair Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the electrical ground location is accessible from both sides of the panel, a M6 conductive bolt and a M6 conductive nut may be used to secure the electrical ground wire terminal. Refer to the Parts Information section of this bulletin. 2. Select a location adjacent the damaged M6 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the new electrical ground site. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the ground location and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 8.5 mm (0.33 in) diameter hole through the panel. 5. Remove paint and primer from the area surrounding the 8.5 mm (0.33 in) hole until bare metal is visible. 6. Select a M6 conductive bolt. Refer to the Parts Information section of this bulletin. 7. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 8. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 9. Install the electrical ground wire terminal and the M6 conductive bolt to the ground location. 10. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 11. Install the M6 conductive nut to the bolt and: Page 6549 3. Lower the transmission. 4. Install the transmission mount to the transmission support retaining nut or nuts. ^ Tighten the nut or nuts to 40 Nm (30 ft. lbs.). 5. Remove the transmission jack. 6. Lower the vehicle. Antenna Extension Cable Replacement Antenna Cable: Service and Repair Antenna Extension Cable Replacement ANTENNA EXTENSION CABLE REPLACEMENT REMOVAL PROCEDURE 1. Remove the instrument panel trim panel. 2. Disconnect the extension cable from the radio. 3. Disconnect the extension cable from the HVAC duct. 4. Disconnect the extension cable from the antenna. Page 15157 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground TESTING FOR SHORT TO GROUND NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting With A Digital Multimeter TROUBLESHOOTING WITH A DIGITAL MULTIMETER NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TROUBLESHOOTING WITH A TEST LAMP Page 5370 14. Install the fuel line clips to the brackets on the transmission. 15. Install the HO2S sensor connector to the bracket. 16. Install the fuel pipe bracket to the bellhousing stud. 17. Install the fuel pipe bracket nut. Tighten Tighten the nut to 10 N.m (89 lb in). 18. Lower the vehicle. 19. Remove the caps from the fuel rail and EVAP line. 20. Connect the fuel feed line (1) at the engine. 21. Connect the EVAP canister purge tube line (2). 22. Install the fuel fill cap. 23. Connect the negative battery cable. 24. Use the following procedure in order to inspect for leaks: 24.1. Turn the ignition ON, with the engine OFF, for 2 seconds. 24.2. Turn the ignition OFF for 10 seconds. 24.3. Turn the ignition ON, with the engine OFF. 24.4. Inspect for fuel leaks. Fuel Hose/Pipes Replacement - Chassis 2 FUEL HOSE/PIPES REPLACEMENT - CHASSIS REMOVAL PROCEDURE IMPORTANT: Clean all fuel pipe connections and surrounding areas before disconnecting the pipes in order to avoid possible fuel system contamination. Heater Hose Replacement - Inlet Heater Hose: Service and Repair Heater Hose Replacement - Inlet HEATER HOSE REPLACEMENT - INLET TOOLS REQUIRED J 43181 Quick Connect Connector Removal Tool REMOVAL PROCEDURE 1. Drain the cooling system. Refer to Draining and Filling Cooling System (with HP2)Draining and Filling Cooling System (without HP2) in Cooling System. 2. Remove the air intake tube. 3. Remove the heater and surge tank hose from the mounting clip. 4. Using the J 43181 disconnect the heater hose from the heater core inlet. 4.1. Install the J 43181 to the heater core pipe. 4.2. Close the tool around the heater core pipe. 4.3. Firmly pull the tool into the quick connect end of the heater hose. 4.4. Firmly grasp the heater hose. Pull the heater hose forward in order to disengage the hose from the heater core. 5. Remove the inlet heater hose from the engine. Page 7673 Page 5387 1. Install the rear fuel line bundle. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the rear fuel line bundle clip nuts. Tighten Tighten the nuts to 12 N.m (106 lb in). 3. Remove the caps from the fuel and balance lines at the fuel tank. 4. Connect the fuel feed and pressure balance lines to the rear tank. 5. Remove the caps from the fuel and balance lines at the fuel tank. 6. Connect the fuel feed and pressure balance lines to the front tank. 7. Install the fuel fill cap. 8. Connect the negative battery cable. 9. Perform the following procedure in order to inspect for leaks. 9.1. Turn the ignition ON, with the engine OFF, for 2 seconds. Page 6039 7. Remove the pressure control solenoid retainer bolt (364A) and retainer (378). 8. Remove the pressure control solenoid (377). 9. Remove the TCC solenoid bolts and the valve body bolts which retain the internal wiring harness. 10. Using J 28458 , release the pass-through electrical connector from the transmission case. 1. Use the small end of the J 28458 over the top of the connector. 2. Twist in order to release the four tabs retaining the connector. 3. Pull the harness connector down through the transmission case. 11. Remove the TCC solenoid (with O-ring seal) and wiring harness. Page 9062 Relay Block - I/P C8 (With RPO Codes 5G4/5X7/5Y0/TRW) Page 9466 Steps 5-7 The numbers below refer to the step numbers on the diagnostic table. 4. Lack of communication may be due to a partial malfunction of the class 2 serial data circuit or due to a total malfunction of the class 2 serial data circuit. The specified procedure will determine the particular condition. 5. The symptom list in Symptoms will determine the correct diagnostic procedure to use. 6. The presence of DTCs which begin with "U" indicate some other module is not communicating. The specified procedure will compile all the available information before tests are performed. Page 11020 A/C Compressor Clutch Page 5425 For vehicles repaired under warranty, use the table. Disclaimer Fuel System/Body - Fuel Filler Cap Tether Too Short Fuel Filler Cap: Customer Interest Fuel System/Body - Fuel Filler Cap Tether Too Short Bulletin No.: 05-06-04-043A Date: August 02, 2005 TECHNICAL Subject: Fuel Cap Tether Too Short to Hook On Fuel Door While Fueling Vehicle (Install Fuel Filler Housing and Cap) Models: 2004-2005 Cadillac Escalade Models 2004-2005 Chevrolet Silverado, Suburban, Tahoe Models 2004-2005 GMC Sierra, Yukon Models Supercede: This bulletin is being revised to correct the fuel filler cap P/N. P/N 15225006 is released for 2006 and 2007 model year vehicles only. The correct fuel cap for the 2004 and 2005 model year is P/N 15225005. Dealers who currently have P/N 15225006 on order (possibly back-ordered) for this concern should cancel their order and re-order P/N 15225005. Please discard Corporate Bulletin Number 05-06-04-043 (Section 06 - Engine/Propulsion System). Built Prior to the VIN Breakpoints shown. Condition Some customers may comment that the fuel cap tether is too short to hook on the fuel door while fueling the vehicle. Cause The existing fuel cap tether is too short. The existing fuel filler housing elongated hole is too small to accommodate the new fuel cap tether. Correction Page 9799 Junction Block - Rear Lamps - C2 Page 8394 2. Install the park brake cable (2) to the lever (1). 3. Perform the following procedure to install the cable (2) to the backing plate (4): 1. Compress the spring (3) by pushing towards the lever (1). 2. Route the cable (2) through the slot in the backing plate. 3. Push the cable housing into the backing plate (4) until the locking tabs snap into place. 4. Notice: Refer to Fastener Notice in Service Precautions. Install the cable at the shock absorber bracket and install the bolt. ^ Tighten the bolt to 25 Nm (18 ft. lbs.). 5. Install the cable to the mounting bracket until the locking tabs snap into place. 6. For 25/35 series vehicles, connect the cable at the equalizer. Page 3208 9. Remove the positive crankcase ventilation (PCV) hose. 10. Loosen the valve rocker arm cover bolts. 11. Remove the valve rocker arm cover. Page 9403 Electrical Symbols ELECTRICAL SYMBOLS Electrical Symbols Part 1 Page 4774 Camshaft Position (CMP) Sensor Restraints - Passenger Presence System Information Seat Occupant Sensor: All Technical Service Bulletins Restraints - Passenger Presence System Information INFORMATION Bulletin No.: 06-08-50-009F Date: December 23, 2010 Subject: Information on Passenger Presence Sensing System (PPS or PSS) Concerns With Custom Upholstery, Accessory Seat Heaters or Other Comfort Enhancing Devices Models: 2011 and Prior GM Passenger Cars and Trucks Equipped with Passenger Presence Sensing System Supercede: This bulletin is being revised to update the model years. Please discard Corporate Bulletin Number 06-08-50-009E (Section 08 - Body and Accessories). Concerns About Safety and Alterations to the Front Passenger Seat Important ON A GM VEHICLE EQUIPPED WITH A PASSENGER SENSING SYSTEM, USE THE SEAT COVERS AND OTHER SEAT-RELATED EQUIPMENT AS RELEASED BY GM FOR THAT VEHICLE. DO NOT ALTER THE SEAT COVERS OR SEAT-RELATED EQUIPMENT. ANY ALTERATIONS TO SEAT COVERS OR GM ACCESSORIES DEFEATS THE INTENDED DESIGN OF THE SYSTEM. GM WILL NOT BE LIABLE FOR ANY PROBLEMS CAUSED BY USE OF SUCH IMPROPER SEAT ALTERATIONS, INCLUDING ANY WARRANTY REPAIRS INCURRED. The front passenger seat in many GM vehicles is equipped with a passenger sensing system that will turn off the right front passenger's frontal airbag under certain conditions, such as when an infant or child seat is present. In some vehicles, the passenger sensing system will also turn off the right front passenger's seat mounted side impact airbag. For the system to function properly, sensors are used in the seat to detect the presence of a properly-seated occupant. The passenger sensing system may not operate properly if the original seat trim is replaced (1) by non-GM covers, upholstery or trim, or (2) by GM covers, upholstery or trim designed for a different vehicle or (3) by GM covers, upholstery or trim that has been altered by a trim shop, or (4) if any object, such as an aftermarket seat heater or a comfort enhancing pad or device is installed under the seat fabric or between the occupant and the seat fabric. Aftermarket Seat Heaters, Custom Upholstery, and Comfort Enhancing Pads or Devices Important ON A GM VEHICLE EQUIPPED WITH A PASSENGER SENSING SYSTEM, USE ONLY SEAT COVERS AND OTHER SEAT-RELATED EQUIPMENT RELEASED AS GM ACCESSORIES FOR THAT VEHICLE. DO NOT USE ANY OTHER TYPE OF SEAT COVERS OR SEAT-RELATED EQUIPMENT, OR GM ACCESSORIES RELEASED FOR OTHER VEHICLE APPLICATIONS. GM WILL NOT BE LIABLE FOR ANY PROBLEMS CAUSED BY USE OF SUCH IMPROPER SEAT ACCESSORIES, INCLUDING ANY WARRANTY REPAIRS MADE NECESSARY BY SUCH USE. Many types of aftermarket accessories are available to customers, upfitting shops, and dealers. Some of these devices sit on top of, or are Velcro(R) strapped to the seat while others such as seat heaters are installed under the seat fabric. Additionally, seat covers made of leather or other materials may have different padding thickness installed that could prevent the Passenger Sensing System from functioning properly. Never alter the vehicle seats. Never add pads or other devices to the seat cushion, as this may interfere with the operation of the Passenger Sensing System and either prevent proper deployment of the passenger airbag or prevent proper suppression of the passenger air bag. Disclaimer Page 10619 onto the subject vehicle. - After match mounting, the tire/wheel assembly must be rebalanced. If match mounting tires to in-spec wheels produces assembly values higher than these, tire replacement may be necessary. Replacing tires at lower values will probably mean good tires are being condemned. Because tires can sometimes become temporarily flat-spotted, which will affect force variation, it is important that the vehicle be driven at least 16 km (10 mi) prior to measuring. Tire pressure must also be adjusted to the usage pressure on the vehicle's tire placard prior to measuring. Most GM vehicles will tolerate radial force variation up to these levels. However, some vehicles are more sensitive, and may require lower levels. Also, there are other tire parameters that equipment such as the Hunter GSP9700 cannot measure that may be a factor. In such cases, TAC should be contacted for further instructions. Important - When mounting a GM wheel to a wheel balancer/force variation machine, always use the wheel's center pilot hole. This is the primary centering mechanism on all GM wheels; the bolt holes are secondary. Usually a back cone method to the machine should be used. For added accuracy and repeatability, a flange plate should be used to clamp the wheel onto the cone and machine. This system is offered by all balancer manufacturers in GM's dealer program. - Any type of service equipment that removes tread rubber by grinding, buffing or truing is NOT recommended, and may void the tire warranty. However, tires may have been ground by the tire company as part of their tire manufacturing process. This is a legitimate procedure. Steering Wheel Shake Worksheet When diagnosing vibration concerns, use the following worksheet in conjunction with the appropriate Vibration Analysis-Road testing procedure in the Vibration Correction sub-section in SI. Page 11608 Seat Belt: Service and Repair Center Front SEAT BELT REPLACEMENT - CENTER FRONT CAUTION: To avoid personal injury to the occupants of the vehicle, observe the following precautions: - More than one supplier's seat belts are used, therefore, install ONLY the seat belt components specified in the GM parts catalog. - To verify that the correct seat belt components were installed, insert the seat belt latch in the seat belt buckle. The latch must be fully seated and be retained in the buckle until purposely released. REMOVAL PROCEDURE 1. Remove the center front seat belt latch bolt. Remove the seat belt latch assembly from the vehicle. 2. Remove the center front seat belt buckle bolt. 3. Remove the buckle assembly from the seat. INSTALLATION PROCEDURE 1. Install the seat belt buckle assembly to the center front seat. NOTE: Refer to Fastener Notice in Service Precautions. Page 11266 Low Pressure Sensor / Switch: Description and Operation A/C LOW PRESSURE SWITCH The A/C low pressure switch protects the A/C system from a low pressure condition that could damage the A/C compressor or cause evaporator icing. The HVAC control module applies 5 volts to the A/C low pressure switch signal circuit. The switch will open when the A/C low side pressure reaches 165-200 kPa (24-29 psi). This prevents the A/C compressor from operating. The switch will then close when A/C low pressure side reaches 275-310 kPa (40-45 psi). This enables the A/C compressor to turn back ON. The low pressure switch uses refrigerant pressure to open and close a set of electrical contacts. When A/C request is authorized, the switch is closed and shows normal status. During this state, the switch will show 0 volts on the A/C low pressure sensor signal circuit. When A/C request is denied due to a low pressure condition, the switch will be open. During this state, the switch will show 5 volts on the A/C low pressure sensor signal circuit. Page 13840 5. Remove all adhesive from the pickup cab panel surface and the back of the emblem/nameplate using 3M(TM) scotch brite molding adhesive remover disk 3M(TM) P/N 07501 or equivalent. 6. Clean the pickup cab surface using varnish makers and painters (VMP) naptha. Installation Procedure 1. If the location of the emblem/nameplate has not been marked apply tape, using the dimensions in the graphic. 2. Warm the pickup cab surface with a heat gun J 25070 152 mm (6.0 in) from the surface to a minimum of 21°C (70°F). Important: Do not touch the adhesive backing of the emblem/nameplate. 3. Remove the backing from the front end of the emblem/nameplate. 4. Press the emblem/nameplate to the pickup cab panel surface while continuing to remove the backing. 5. Hand roll the emblem/nameplate to the pickup cab panel to ensure proper adhesion. 6. Inspect the emblem/nameplate for bonding. 7. Remove the tape from the area around the pickup cab emblem. Page 7084 Page 7212 Electrical Symbols Part 3 Page 8535 Page 12821 Page 13049 7.1. Remove the console (A) together with the OnStar(R) control modules. 7.2. Remove the connectors (B). Important: The optic cable must not be bent with a radius less than 25 mm (1 in). Important: Secure the wiring harness so that there is no risk of chafing and rattling. 7.3. Fold back the wiring harness and tape over the connectors (C). Fold back the wiring harness once more and secure with cable ties (D). 7.4. Fit the parcel shelf trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 8. CV: Removing the OnStar(R) control modules and securing the wiring: Adjustment/Replacement. 8.1. Open the luggage compartment floor. Page 5811 Vehicle Speed Sensor (VSS) Tow/Haul Switch Location Locations Accelerator Pedal Position (APP) Sensor Connector Page 2014 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-8 (12085115) crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-8 (12085115) until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes SPLICING INLINE HARNESS DIODES Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate Service Data wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. 9. Tape the diode to the harness or connector using electrical tape. Page 3637 1. Install the heater core (2) to the HVAC module assembly (3). 2. Install the heater core cowl gasket (1) to the heater core (2). 3. Install the heater core cover (1) to the HVAC module assembly (2). NOTE: Refer to Fastener Notice in Service Precautions. 4. Install the screws to the heater core cover (1). Tighten Tighten the screws to 2 N.m (18 lb in). 5. Install the HVAC module assembly. Page 3890 Engine Control Module: Description and Operation Throttle Actuator Control (Tac) System POWERTRAIN CONTROL MODULE The PCM determines the driver's intent, then calculates the appropriate throttle response. This information is sent to the TAC module through a dedicated serial data line. Page 4192 Steps 7 - 9 Page 15820 3. Install the horn plunger to the steering column. 4. Install the inflator module. 5. Enable the SIR system. Page 12181 Test Description DTC U1001 and U1254 Circuit/System Description Modules connected to the Class 2 serial data circuit monitor for serial data communications during normal vehicle operation. Operating information and commands are exchanged among the modules. When a module receives a message for a critical operating parameter, the module records the identification number of the module which sent the message for State of Health monitoring. A critical operating parameter is one which, when not received, requires that the module use a default value for that parameter. Once an identification number is learned by a module, it will monitor for that module's Node Alive message. Each module on the class 2 serial data circuit which is powered and performing functions that require detection of a communications malfunction is required to send a Node Alive message every 2 seconds. When no message is detected from a learned identification number for 5 seconds, a DTC U1XXX where XXX is equal to the 3-digit identification number is set. Page 15212 IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections TESTING FOR INTERMITTENT AND POOR CONNECTIONS TOOLS REQUIRED - J 35616-C GM-Approved Terminal Test Kit - J 38125-D Terminal Repair Kit - J 42675 Flat-Wire Probe Adapter Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector. - Poor terminal to wire connection - Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. - Wire insulation which is rubbed through - This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. - Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. Testing For Proper Terminal Contact It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-D or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-D, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 4L60/4L60-E/4L65-E Transmission Tow/Haul Switch: Testing and Inspection 4L60/4L60-E/4L65-E Transmission Tow/Haul Switch/Indicator Always On or Inoperative Circuit Description Tow/haul mode enables the operator to achieve enhanced shift performance when towing or hauling a load. When tow/haul mode is selected, the tow/haul switch input signal to the body control module (BCM) is momentarily toggled to zero volts. This signals the powertrain control module (PCM) to extend the length of time between upshifts and increase transmission line pressure. Cycling the tow/haul switch again disables tow/haul mode and returns the transmission to a normal shift pattern. Diagnostic Aids If the electrical circuit tests are OK and the tow/haul shift pattern is not occurring, there may be a mechanical/hydraulic condition that prevents tow/haul operation. Refer to Symptoms - Automatic Transmission. Page 12005 Page 1494 Upper Steering Column Page 6828 1. Install the oil seal by doing the following: 1. Position the oil seal over the seal bore. 2. Install the J 36366 over the oil seal. 3. Strike the J 36366 with a hammer until the seal flange seats on the axle housing surface. 2. Apply sealant GM P/N 12346004 (Canadian P/N 10953480) or equivalent to the splines of the drive pinion yoke. 3. Install the pinion yoke. Align the reference marks made during removal. 4. Seat the pinion yoke onto the pinion shaft by tapping it with a soft-faced hammer until a few pinion shaft threads show through the yoke. Notice: Refer to Pinion Flange/Yoke Installation Notice in Service Precautions. 5. Install the washer and a new pinion nut. 6. Install the J 8614-01 onto the pinion yoke as shown. 7. Tighten the pinion nut while holding the J 8614-01. ^ Tighten the pinion nut until the pinion end play is just taken up. Rotate the pinion while tightening the nut to seat the bearings. Notice: Refer to Fastener Notice in Service Precautions. Important: If the rotating torque is exceeded, the pinion will have to be removed and a new collapsible spacer installed. 8. Measure the rotating torque of the pinion using an inch-pound torque wrench.Compare the measurement with the rotating torque recorded earlier. ^ Tighten the pinion nut, in small increments, as needed, until the torque required in order to rotate the pinion is 0.40-0.57 Nm (3-5 inch lbs.) greater than the torque recorded during removal. 9. Once the specified torque is obtained, rotate the pinion several times to ensure the bearings have seated. Recheck the rotating torque and adjust if necessary. Page 3538 Fuel Pressure Release: Service and Repair Fuel Pressure Relief Procedure FUEL PRESSURE RELIEF PROCEDURE TOOLS REQUIRED J 34730-1A Fuel Pressure Gage CAUTION: Relieve the fuel system pressure before servicing fuel system components in order to reduce the risk of fire and personal injury. After relieving the system pressure, a small amount of fuel may be released when servicing the fuel lines or connections. In order to reduce the chance of personal injury, cover the regulator and the fuel line fittings with a shop towel before disconnecting. This will catch any fuel that may leak out. Place the towel in an approved container when the disconnection is complete. 1. Disconnect the negative battery cable. 2. Install the J 34730-1A. 3. Loosen the fuel fill cap in order to relieve fuel tank vapor pressure. 4. Open the valve on J 34730-1A in order to bleed the system pressure. The fuel connections are now safe for servicing. 5. Drain any fuel remaining in the gage into an approved container. 6. Once the system pressure is completely relieved, remove the J 34730-1A. Page 12596 1. Remove the ground cable from the battery's negative cable. 2. Remove the center console, see WIS - Body - Interior. 3. Loosen the gear shift housing (A). AUT: Disconnect the 6-pin connector (B) to improve access to the gear shift housing screws. 4. Disconnect the signal cable from the SRS control module to the OnStar(R) control module and secure the cable. 4.1. Disconnect the connector (A) from the SRS control module and cut the cable tie (B). Page 9993 7. Lower the vehicle. 8. Perform a four wheel alignment. Page 12569 Page 8875 Electrical Symbols Part 14 Page 4500 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly, Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Pull to Seat Connectors PULL TO SEAT CONNECTORS TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Page 2031 Power Window Switch: Service and Repair Switch Replacement - Door Lock and Side Window Passenger SWITCH REPLACEMENT - DOOR LOCK AND SIDE WINDOW - PASSENGER REMOVAL PROCEDURE 1. Remove the front door trim panel. 2. Disconnect the electrical connectors. 3. Remove the screw that retains the switch panel bezel (1) from the front door panel. 4. Remove the switch panel bezel from the door panel using a flat-bladed tool. 5. Using a wide plastic flat-bladed tool, release the retaining clips on both sides of the door module. 6. Remove the door module from the switch panel bezel. Page 14352 Electrical Symbols Part 13 Automatic Transmission Input Shaft Speed (AT ISS) Sensor Connector End Gate Latch Handle Bezel Tailgate Release Handle: Service and Repair End Gate Latch Handle Bezel Removal and Installation 1. Release the adhesive blocks after the upper retaining tabs are released. 2. Install the latch handle bezel with the end gate in the closed position. 3. Clean the sheet metal at the right and left sides of the bezel opening with an alcohol wipe prior to the bezel installation. 4. Peel the protective tape liner from the foam block on both sides. 5. Seat the bezel at the bottom of the opening in the end gate. 6. Roll the bezel forward seating and securing the upper integral locking tabs. 7. Apply palm pressure to both outer edges of the bezel in order to wet out the adhesive foam blocks. 8. Integral Locking Tabs (Upper). ^ ENTRY Tip, gently pry downward with a small flat-bladed tool at the two locations in order to release the upper retaining tabs. 9. Integral Retention Tabs (Lower). 10. End Gate Latch Handle Bezel. ^ ENTRY Tip, once in position, gently wet out the adhesive foam blocks to the end gate panel. Bezel Replacement Front Door Panel: Service and Repair Bezel Replacement Handle Bezel Replacement - Inside Handle Bezel Replacement - Inside Removal Procedure 1. Insert a flat-bladed tool between the door handle bezel and the trim panel in order to release the handle bezel tab retainers. 2. Remove the door handle bezel from the door panel. Installation Procedure 1. Position the door handle bezel in the door trim panel. 2. Install the door handle bezel to the door panel by pressing the bezel into place until the bezel is completely seated. Door Handle Bezel Replacement (Inside Side Access) Door Handle Bezel Replacement (Inside Side Access) Removal Procedure 1. Insert a flat-bladed tool at the top between the door bezel and the door panel. 2. Carefully bend outward the retaining clips while pulling out the bezel. Installation Procedure Page 15070 Parts Information ^ P/N 15068208 contains the reinforcements necessary to install ladder rack systems and/or side-mounted toolboxes. ^ P/N 15068209 contains the reinforcements for cross toolbox and/or rear window barrier applications only. Disclaimer Diagrams Headlamp Leveling Switch (Export) Page 16013 Electrical Symbols Part 9 Page 2024 Window Switch - RR (Crew Cab Only) Part 1 Page 12454 2. Disconnect the C2 32-way blue connector from the VIU and tape the connector to a secure location. Refer to Cellular Communications Connector End Views and related schematics in SI, if required. Important: DO NOT perform the OnStar(R) reconfiguration and/or programming procedure. 3. Secure the VIU in its original brackets and/or mounting locations and reinstall the VIU and interior components that were removed to gain access to the VIU. Refer to OnStar Vehicle Interface Unit Replacement in SI. 2002 Through 2006 Model Year Vehicles (Except Saab Vehicles) 2002 through 2006 Model Year Vehicles (Except Saab Vehicles) Important: The Tech 2 diagnostic tool must be updated with version 28.002 or later in order to successfully perform the VCIM setup procedure and disable the analog system. 1. Connect the Tech 2 to the data link connector (DLC), which is located under the instrument panel of the vehicle. 2. Turn the Tech 2 ON by pressing the power button. Important: Tech 2 screen navigation to get to the setup procedure depends on the year and make of the vehicle. The actual name of the setup procedure (Setup New OnStar or VCIM Setup) depends on model year and vehicle make as well. Example Tech 2 navigation to the setup procedure Tech 2 screen is provided below. ^ Diagnostics >> (2) 2002 >> Passenger Car >> Body >> C >> OnStar >> Special Functions >> Setup New OnStar >> ^ Diagnostics >> (5) 2005 >> Passenger Car >> (4) Buick >> C >> Body >> Vehicle Comm. Interface Module >> Module Setup >> VCIM Setup >> 3. Setup VCIM using the Tech 2. Follow on-screen instructions when you have reached the setup Tech 2 screen. 2000-2002 Saab 9-3 (9400) 4D/5D; 2000-2003 Saab 9-3 (9400) CV 2000-2002 Saab 9-3 (9400) 4D/5D; 2000-2003 Saab 9-3 (9400) CV 1. Remove the ground cable from the battery's negative terminal. 2. Apply the handbrake brake. 3. Detach the floor console. 4. Remove the switch and the floor console: 3.1. Twist loose the immobilizer unit (A), bayonet fitting. Unplug the unit's connector. 3.2. Remove the ignition switch cover (B) by first undoing the rear edge of the cover and then unhooking the front edge. Unplug the ignition Page 10240 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the cover up until the dress cover releases. Repeat this procedure for the other locking tab. 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. 5. If the connector has a nose piece, use a small flat-blade tool to remove the nose piece by inserting the blade into the slot on the front of the connector and prying up on the nose piece. IMPORTANT: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 6. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. IMPORTANT: Be careful not to angle or rock the J 38125-13A tool when inserting it into the connector or the tool may break. Service and Repair Turn Signal Flasher: Service and Repair HAZARD AND TURN SIGNAL FLASHER REPLACEMENT REMOVAL PROCEDURE 1. Remove the knee bolster. 2. On the back side of the fuse block release the retainer while pulling the flasher (1) outwards. 3. Remove the flasher (1) from the fuse block. INSTALLATION PROCEDURE 1. Install the flasher (1) to the fuse block until the retainer clicks into place. 2. Install the knee bolster. Electrical - Information For Electrical Ground Repair Grounding Point: All Technical Service Bulletins Electrical - Information For Electrical Ground Repair INFORMATION Bulletin No.: 10-08-45-001B Date: October 25, 2010 Subject: Information for Electrical Ground Repair - Use New Replacement Fasteners with Conductive Finish Models: 2011 and Prior GM Passenger Cars and Trucks (including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X Supercede: This bulletin is being revised to add the 2011 model year and update the Warranty Information. Please discard Corporate Bulletin Number 10-08-45-001A (Section 08 - Body and Accessories). Electrical Ground Repair Overview Proper electrical system function relies on secure, stable and corrosion-free electrical ground connections. Loose, stripped, or corroded connections increase the possibility of improper system function and loss of module communication. These conditions may also lead to unnecessary repairs and component replacement. In general, electrical ground connections are accomplished using one, or a combination of the following attachment methods: - Welded M6 stud and nut - Welded M6 nut and bolt - Welded M8 nut and bolt Determine which attachment method is used and perform the appropriate or alternative repair as described in this bulletin. M6 Weld Stud Replacement Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. Select a location adjacent the damaged or missing M6 ground stud having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the M6 conductive rivet stud flange. 2. Using GM approved residue-free solvent or equivalent, remove any grease from the repair site and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 3. Drill a 10 mm (0.40 in) diameter hole through the panel. 4. Remove paint and primer from the area surrounding the 10 mm (0.40 in) hole until bare metal is visible. Page 14371 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. REPLACEMENT PROCEDURE After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Insure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the Terminal Removal Procedure. Repairing Connector Terminals REPAIRING CONNECTOR TERMINALS TOOLS REQUIRED J 38125-D Terminal Repair Kit Use the following repair procedures in order to repair the following: - Push to Seat terminals - Pull to Seat terminals - Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-D contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100 World terminals. Soldering Micro-Pack 100 World terminals may damage the terminal. Circuit Protection - Circuit Breakers CIRCUIT PROTECTION - CIRCUIT BREAKERS A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Page 11938 Important: This bulletin does NOT apply to 2006 vehicles built AFTER the VIN breakpoints listed above. Refer to applicable diagnostics in SI for those vehicles that exhibit this condition. Remove the OnStar(R) fuse from the fuse box, wait five minutes and reinstall the fuse. (For Saturn VUE vehicles, remove the "INT LTS" fuse from the I/P fuse block for five minutes, then reinstall the fuse.) If the OnStar(R) system DOES NOT return to normal functionality, then follow the diagnostics in SI for this condition. If the OnStar(R) system DOES return to normal functionality, perform the following steps: 1. Install the Tech 2(R) and determine what generation hardware and software ID is in the vehicle. 2. If the vehicle is equipped with Generation 5 hardware and a software version 146, the VCIM should have the B1000 reprogramming performed as described in Corporate Bulletin Number 04-08-46-004A. The system should be tested and if the concern returns, the VCIM should be replaced. 3. If Gen 5 with a software version OTHER than 146 or Gen 6 and above, the VCIM needs to be replaced and the system reconfigured. Refer to the current version of Corporate Bulletin 03-08-46-004 for details on how to order a new VCIM. Important: As with any OnStar(R) VCIM replacement, the OnStar(R) system must be reconfigured after replacement. Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use the table. Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table. Disclaimer Page 12022 12.2. Cars with brackets for e.g. an amplifier: Remove the pin strap (A) from the bracket and remove the tape (B) holding the optic cables. 12.3. Remove the locking strip (C) on the 2-pin connector (H2-9). Open the terminal housing with a screwdriver. Remove the secondary catch (E) on the connector and remove the optic cables coming from the OnStar(R) control modules. 12.4. Loosen one of the optic cables remaining in H2-9 (F), connect it to the connector and fit the secondary catch (E). Connect the connector so that the optic cables are opposite each other (G). Connect the terminal housing (D) and refit the locking strip (C). Page 5299 3. Once installed, pull on both sides of the quick-connect fittings in order to make sure the connection is secure. Rear Axle Housing Cover and Gasket Replacement Differential Axle Housing: Service and Repair Rear Axle Housing Cover and Gasket Replacement Rear Axle Housing Cover and Gasket Replacement Removal Procedure 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Drain the rear axle. 3. Remove the rear axle housing cover bolts (1).Discard the rear axle housing cover bolts. 4. Remove the rear axle housing cover (2) from the axle housing. 1. Catch the oil in a drain pan. 2. Remove any gasket material from the rear axle housing and/or the rear axle housing cover. Installation Procedure 1. Install the rear axle housing cover (2) and a new gasket. Notice: Refer to Fastener Notice in Service Precautions. 2. Important: Do not reuse the rear axle housing cover bolts. Install the new rear axle housing cover bolts (1). ^ Tighten the rear axle housing cover bolts in a crosswise pattern to 40 Nm (30 ft. lbs.). 3. Fill the rear axle. Use the proper fluid. 4. Lower the vehicle. Page 8190 Important If runout is still present, contact the brake lathe supplier. ON-CAR TYPE LATHE Use the following procedure to calibrate an On-Car brake lathe: 1. Connect the lathe to a vehicle using the appropriate adapter. 2. Attach a vise-grip dial indicator to a fixed point in the wheel well and bring the dial indicator to a flat surface on the cutting head. 3. Turn on the lathe and press the "start" button so the lathe begins to compensate. 4. Once compensation is complete, note the runout as measured by the dial indicator. Measured runout at this point is overstated given that it is outside the rotor diameter. 5. If runout is in excess of 0.1016 mm (0.004 in) (0.050 mm (0.002 in) as measured within the rotor diameter), calibration must be tightened. Follow manufacturer's instructions for tightening the calibration of the lathe. This information is found in the manual supplied with the lathe. Important If the machine is taking a long time to compensate during normal use, prior to checking the lathe calibration, it is recommended that the machine be disconnected from the adapter and the adapter (still connected to the vehicle) is rotated 180 degrees and the machine reattached. This will accomplish two things: - It will re-verify the machine is properly attached to the adapter. - It will change the location of the runout (phase) relative to the machine and thus possibly allow for quick compensation as a result of the position change. The following information has been added as a reference to ensure your Pro-Cut PFM lathe provides a consistent smooth surface finish over long term usage. Cutting Tips / Depth of Cut / Tip Life The cutting tips must be right side up. Reference marks always face up. The cutting tips may not have chips or dings in the surface of the points. Cuts of 0.1016-0.381 mm (0.004-0.015 in) will provide the best surface finish and the optimal tip life. When cleaning or rotating the cutting bits, make sure that the seat area for the tip on the tool is free and clear of debris. Cutting Head On each brake job, the technician must center the cutting head for that particular vehicle using one of the mounting bolt holes on the slide plate. Once the head is centered, it is vital that the technician use one hand to push the head firmly and squarely back into the dovetail on the slide plate while using the other hand to tighten the Allen-Hex bolt that secures the head. Failure to do this could result in chatter occurring during the cut. Tool Holder Plate (Cutting Head) The tool holder plate is the plate that the cutting arms are attached to. It can bend or break if a technician accidently runs the cutting arms into the hub of the rotor while the rotor is turning. (Cuts of more than 0.508 mm (0.020 in) can also bend this plate). Once bent, the lathe will most likely not cut properly until the tool holder plate is replaced. In order to verify the condition of the tool holder plate on a machine that will not cut right, remove the mounting bolt and remove the cutting head from the slide plate. With the cutting head titled at an angle, lay the long edge of the tool holder plate down on the flat part of the slide plate. If any gap can be seen between the edge and the slide plate, the tool holder plate is bent and the source of vibration. Also check to ensure that the cutting arms are lying flat on the upper side of the tool holder plate. If the mounting arm post is bent, it will show itself by having the back of the cutting arm lifting off the surface of the tool holder. Gib Adjustment / Loose Gib As wear occurs between the slide plate and the box it rides on, you must take up the slack. You do this by way of a moveable wedge, which we call the gib. Your lathe manual details adjustment process, which you should perform when required after monthly checks or whenever surface finish is inconsistent. Brake Pulsation BRAKE PULSATION Brake pulsation is caused by brake rotor thickness variation. Brake rotor thickness variation causes the piston in the brake caliper, when applied, to "pump" in and out of the caliper housing. The "pumping" effect is transmitted hydraulically to the brake pedal. Brake pulsation concerns may result from two basic conditions: Restraints - Extender Availability For Seat Belt Seat Belt Extension: Technical Service Bulletins Restraints - Extender Availability For Seat Belt INFORMATION Bulletin No.: 99-09-40-005F Date: June 23, 2010 Subject: Seat Belt Extender Availability Models: 2011 and Prior GM Passenger Cars and Trucks (Including Saturn) 2009 and Prior HUMMER H2 2010 and Prior HUMMER H3 2005-2009 Saab 9-7X Supercede: This bulletin is being revised to add the 2009‐2011 model years and update the Warranty Information. Please discard Corporate Bulletin Number 99-09-40-005E (Section 09 Restraints). Important: DO NOT use belt extenders when securing a child restraint. The seat and shoulder belt restraint systems used in all General Motors vehicles have sufficient belt length to accommodate most drivers and passengers. Consequently, requests for belt extensions (extenders) should be minimal. Seat belt extenders are available ONLY IN BLACK for most GM passenger cars and trucks produced in recent years. They are available in two different lengths, 23 cm (9 in) and 38 cm (15 in). They are designed to be coupled with the existing belts in each vehicle. When in use, the extender makes the belt arrangement a "custom fit" and use by anyone else or in another vehicle will lessen or nullify the protection offered by the vehicle's restraint system. For this reason, it is extremely important that the correct length extender be used for the vehicle and occupant intended. Important: Do not use an extender just to make it easier to buckle the safety belt. Use an extender only when you cannot buckle the safety belt without using an extender. Parts Information For part numbers, usage and availability of extenders, see Extension Kit in Group 14.875 (cars) or Group 16.714 (trucks) of the appropriate parts catalog. Saturn retailers should refer to the appropriate model year Parts & Illustration catalog for the vehicle. U.S. Saab dealers should contact the Parts Help line. Canadian Saab dealers should fax requests to Partech Canada. Warranty Information ^ Seat belt extenders are a NO CHARGE item to all GM customers who request them for their specific vehicles. ^ Dealers should not be charging part costs since these extenders are supplied by GM to the dealers. ^ Dealers should not be charging labor costs since the extender can be customer installed. Disclaimer Page 6990 Wheel Bearing: Adjustments Rear Wheel Bearing Adjustment (With Full Floating 10.5" or 11.5" Ring Gear) IMPORTANT: Ensure the brakes are fully released and do not drag. ^ Pull or push the tire at the top back and forth in order to test the wheel bearing play. ^ Use a pry bar under the tire as an alternative. ^ If the wheel bearing adjustment is correct, the movement will be barely noticeable. ^ If the movement is excessive, adjust the bearings. Adjustment Procedure Tools Required J 2222-C Wheel Bearing Nut Wrench 1. Raise the vehicle. 2. Remove the axle shaft. 3. Remove the hub adjuster nut retaining ring. 4. Remove the adjuster nut lock key. Page 2991 Install a new spring bumper assembly for 2WD 1500 Series Only with 20" wheels. Reuse the nut from the original bumper. Install the nut to the spring bumper stud. Tighten Tighten the nut to 30 N.m (22 lb ft). Remove the safety stands. Lower the vehicle. Knee Bolster Deflector This modification is required for the following vehicles and ONLY applies to Extended Cab Long Box (K15953) Pickup models: 1999-2005 Chevrolet Silverado and GMC Sierra (1500 Series Only): 2005 Vehicles Built in Pontiac (VIN Code E) prior to VIN Breakpoint 5E100134 2005 Vehicles Built in Oshawa (VIN Code 1) prior to VIN Breakpoint 51113131 2005 Vehicles Built in Ft. Wayne (VIN Code Z) prior to VIN Breakpoint 5Z126605 The following procedure should be followed: Apply the parking brake to prevent the vehicle from moving. Remove the fuse panel cover. Remove the I/P cluster trim plate bezel. Remove the knee bolster. Remove the 2 mm (0.078 in) thick knee bolster deflector. Install the 1.5 mm (0.059 in) thick knee bolster deflector, P/N 12499966. A detailed instruction sheet will be provided with the service part. Re-Programming Locations Driver Door Page 9318 Location View Page 3703 10. Remove the left exhaust manifold pipe nuts. 11. Remove the right exhaust manifold pipe nuts. 12. Remove the exhaust muffler nuts. 13. Remove the catalytic converter. 14. If necessary, remove the oxygen sensors. Installation Procedure Notice: Refer to Fastener Notice in Service Precautions. Page 12033 2. Click on the Analog-to-Digital Program link to start the ordering process. 3. To order a kit, you will need the information shown above. 4. After submitting the order, the "Terms and Conditions of Your OnStar(R) Service" page will display. This is your confirmation that the upgrade kit order has been created. U.S. Dealers will also receive an e-mail from Autocraft within several hours of ordering an upgrade kit (Canadian Dealers will receive an e-mail from MASS Electronics). 5. Print the "Terms and Conditions of Your OnStar(R) Service" page, and have the customer sign a copy. 6. A copy of this form should be stapled to the customer's copy of the Repair Order and one copy should be retained in the customer service folder. 7. If the kit you ordered is available, you will receive the upgrade kit within 4 business days of entering your order through the OnStar(R) Online Enrollment webpage. 8. To check on kit availability or the status of your order, U.S. Dealers can log onto the distributor's website at www.autocraft.com. Canadian dealers can call MASS Electronics at 877-410-6277. Upgrade Kit Installation 1. Skip to the next step if the vehicle to be upgraded is not shown above. Entertainment System - DVD Monitor Display Inoperative Television / Monitor: Customer Interest Entertainment System - DVD Monitor Display Inoperative Bulletin No.: 07-08-44-016A Date: August 28, 2007 TECHNICAL Subject: GM Accessories Headrest DVD System Display Monitor Inoperative (Install Cable Connector Clamps) Models Supercede: This bulletin is being revised to update the models affected list. Please discard Corporate Bulletin Number 07-08-44-016 (Section 08 - Body & Accessories). Condition Some customers may comment on an inoperative display monitor or monitors in the GM Accessories Headrest DVD System. Cause This condition may be caused by a loose connection at the display monitor cable connectors. These connectors are located at the lower rear part of both front seats. Two cables are routed to the display monitor in each seat. Correction A number of headrest monitors have been replaced under warranty and in many cases, no trouble was found by the supplier when these units were Page 4644 Body Control Module: Diagnostic Aids Basic Knowledge Required BASIC KNOWLEDGE REQUIRED Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the Service Data. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories CHECKING AFTERMARKET ACCESSORIES Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: - Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions INDUCING INTERMITTENT FAULT CONDITIONS In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: - Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. Locations Ambient Light Sensor Page 12089 Page 594 Driver Seat (1 Of 2) Body - Vehicle Glass Distortion Information Front Corner Window Glass: Technical Service Bulletins Body - Vehicle Glass Distortion Information INFORMATION Bulletin No.: 00-08-48-005D Date: September 10, 2010 Subject: Distortion in Outer Surface of Vehicle Glass Models: 2011 and Prior GM Passenger Cars and Trucks 2009 and Prior HUMMER H2 2010 and Prior HUMMER H3 2005-2009 Saab 9-7X 2010 and Prior Saturn Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 00-08-48-005C (Section 08 - Body and Accessories). Distortion in the outer surface of the windshield glass, door glass or backlite glass may appear after the vehicle has: - Accumulated some mileage. - Been frequently washed in automatic car washes, particularly "touchless" car washes. This distortion may look like a subtle orange peel pattern, or may look like a drip or sag etched into the surface of the glass. Some car wash solutions contain a buffered solution of hydrofluoric acid which is used to clean the glass. This should not cause a problem if used in the correct concentration. However, if not used correctly, hydrofluoric acid will attack the glass, and over time, will cause visual distortion in the outer surface of the glass which cannot be removed by scraping or polishing. If this condition is suspected, look at the area of the windshield under the wipers or below the belt seal on the side glass. The area of the glass below the wipers or belt seal will not be affected and what looks like a drip or sag may be apparent at the edge of the wiper or belt seal. You may also see a line on the glass where the wiper blade or the belt seal contacts the glass. Important The repair will require replacing the affected glass and is not a result of a defect in material or workmanship. Therefore, is not covered by New Vehicle Warranty. Disclaimer Page 6481 Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 2110 6. The Melco(R) (1) ignition coil is a square design. 7. The Delphi(R) (2) ignition coil is a round design. 8. The Melco(R) ignition coil bracket (1) is a square design. 9. The Delphi(R) ignition coil bracket (2) is a round design. INSTALLATION PROCEDURE 1. Install the spark plug wire to the ignition coil. 2. Install the spark plug wire to the spark plug. 3. Inspect the spark plug wire for proper installation: 3.1. Push sideways on each boot in order to inspect the seating. Wheels - Plastic Wheel Nut Covers Loose/Missing Wheel Fastener: Customer Interest Wheels - Plastic Wheel Nut Covers Loose/Missing Bulletin No.: 01-03-10-009A Date: July 27, 2004 TECHNICAL Subject: Plastic Wheel Nut Covers Missing and/or Loose (Replace Missing Covers and Add Sealant to All Covers) Models: 2005 and All Prior Passenger Cars (Except All Cadillac Models and Pontiac GTO) with Plastic Wheel Nut Covers Supercede: This bulletin is being revised to add additional models years. Please discard Corporate Bulletin Number 01-03-10-009. Condition Some customers may comment that the plastic wheel nut covers are missing and/or loose. Correction Important: ^ DO NOT USE a silicone-based adhesive. ^ Do not apply the *permatex(R) around the threads in a circular pattern. ^ Apply a single bead across the threads approximately 10 mm (0.4 in) in length, 5 mm (0.2 in) in height and 5 mm (0.2 in) in width. Replace any missing plastic wheel nut covers with the appropriate covers and apply Permatex(R) # 2 Form A Gasket Sealant(R) to the threads of all the plastic wheel nut covers. Tighten finger tight plus a 1/4 turn with a hand wrench. *We believe this source and their products to be reliable. There may be additional manufacturers of such material. General Motors does not endorse, indicate any preference for or assume any responsibility for the products from this firm or for any other such items which may be available from other sources. Permatex(R) # 2 Form A Gasket Sealant(R) part numbers (available at your local parts supplier) ^ P/N 80009 (2A/2AR) - 44 ml (1.5 oz) tube boxed ^ P/N 80015 (2AR) - 44 ml (1.5 oz) tube carded ^ P/N 80010 (2B/2BR) - 89 ml (3 oz) tube boxed ^ P/N 80016 (2BR) - 89 ml (3 oz) tube carded ^ P/N 80011 (2C) - 325 ml (11 oz) tube boxed Warranty Information For vehicles repaired under warranty, use the table. Page 14735 Seat Cushion: Removal and Replacement Seat Cushion Cover and Pad Replacement - Rear Seat Cushion Cover and Pad Replacement - Rear Removal Procedure 1. Remove the rear seat from the vehicle. 2. Remove the rear passenger seat riser. 3. Remove the hog rings and/or the J-clips from the rear edge of the seat cushion cover (3). 4. Disconnect the rear heater connector, if equipped. 5. Remove the seat belt buckles, if required. 6. Remove all of the remaining hog rings, and/or the J-clips that are retaining the seat cushion cover (3) to the seat cushion frame (8). 7. Release the hook, and the loop-strips that are retaining the seat cushion cover to the foam pad (4). 8. Remove the center screw retaining the latch cover, if equipped. 9. Remove the seat cushion cover from the foam pad. Installation Procedure 1. Install the seat cushion cover to the foam pad. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the center screw retaining the latch cover, if removed. Tighten the screw to 2 N.m (18 lb in). 3. Engage the hook, and the loop-strips that are retaining the seat cushion cover (3) to the foam pad (4). 4. Install the seat buckles, if removed. 5. Connect the rear heater connector, if equipped. 6. Install the hog rings, and/or the J-clips in order to retain the seat cushion cover to the seat cushion frame (8). 7. Install the rear passenger seat risers. 8. Install the rear seat to the vehicle. Page 8174 Brake Pad: Service and Repair Brake Pads Replacement - Rear Brake Pads Replacement - Rear (15 Series W/O NYS) Caution: Refer to Brake Dust Caution in Service Precautions. Removal Procedure 1. Inspect the fluid level in the brake master cylinder reservoir. 2. If the brake fluid level is midway between the maximum-full point and the minimum allowable level, no brake fluid needs to be removed from the reservoir before proceeding. 3. If the brake fluid level is higher than midway between the maximum-full point and the minimum allowable level, remove brake fluid to the midway point before proceeding. 4. Raise and support the vehicle. Refer Vehicle Lifting 5. Remove the tire and wheel assembly. 6. Notice: Support the brake caliper with heavy mechanic's wire, or equivalent, whenever it is separated from its mount and the hydraulic flexible brake hose is still connected. Failure to support the caliper in this manner will cause the flexible brake hose to bear the weight of the caliper, which may cause damage to the brake hose and in turn may cause a brake fluid leak. Remove the caliper from the mounting bracket and support the caliper with heavy mechanic's wire or equivalent. DO NOT disconnect the hydraulic brake flexible hose from the caliper. Refer to Brake Caliper Replacement Front. 7. Inspect the caliper assembly. Refer to Brake Caliper Inspection. 8. Remove the brake pads from the brake caliper bracket. 9. Remove the brake pad retainers from the brake caliper bracket. Installation Procedure 1. Using a C-clamp (1), bottom the piston into the caliper bore. Use an old brake pad (2) or wooden block placed across the face of the piston. Do not damage the piston or the caliper boot. Page 4447 1. Install the PCM. Ensure that the mounting tabs are engaged. 2. Secure the spring latch to the PCM. 3. Connect the PCM electrical connectors. NOTE: Refer to Fastener Notice in Service Precautions. 4. Tighten the PCM electrical connector bolts (2). Wheels/Tires - 20 Inch Wheels Available From GM Wheels: All Technical Service Bulletins Wheels/Tires - 20 Inch Wheels Available From GM Bulletin No.: 03-03-10-006F Date: September 27, 2006 INFORMATION Subject: 20" Wheels Available Through GM Accessories Models: 1999-2007 Chevrolet Silverado 1500 Series Only (Classic) 1999-2007 GMC Sierra 1500 Series Only (Classic) Excludes 1999-2000 Vehicles with 4.3L Engine (VIN W - RPO L35) Excludes Vehicles with Quadrasteer (RPO NYS) Excludes Parallel Hybrid Truck (RPO HP2) Excludes 2001-2004 Vehicles with Traction Control (RPO NW7) combined with 3.42 Axle Ratio (RPO GU6) Page 15932 Electrical Symbols Part 4 Page 15618 Door Latch Assembly (Door Jamb Switch) - LR - C2 (Crew Cab Only) Tire Monitor System - TPM Sensor Information Tire Pressure Monitor Receiver / Transponder: Technical Service Bulletins Tire Monitor System TPM Sensor Information INFORMATION Bulletin No.: 08-03-16-003 Date: May 12, 2008 Subject: Warranty Reduction - Transfer of Tire Pressure Monitoring (TPM) Sensors to Replacement Wheels and Allowable TPM Sensor Replacements Models: 2000-2009 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2009 HUMMER H2 2006-2009 HUMMER H3 2005-2009 Saab 9-7x with On-Wheel TPM Sensors TPM Sensor / Wheel Warranty Reviews During the last warranty review period it was noted that wheels being returned under the GM New Vehicle Warranty were being shipped back to General Motors with the TPM sensor still attached to the wheel. Return rates ran as high as 60% with the TPM sensors still attached. Operational TPM sensors should not be returned to GM and are to be transferred to replacement wheels if they become necessary. Important: Operational TPM Sensors that are returned under warranty to General Motors will be charged back to the dealer.Sensors have a 10 year /150,000 mile (240,000 km) battery life, and should be transferred if one or more wheels are replaced. TPM Valve Stem / Grommet (0-ring) Replacement When the TPM sensors are transferred to new wheels you should replace the component used to seal the TPM sensor stem to the wheel. On sensors with an aluminum stem and visible nut on the outside of the wheel a replacement grommet (0-ring) should be used to assure a proper seal. The sensor retaining nut (except Aveo) should be tightened to 7 N.m (62 lb in) for all vehicles except Pontiac Vibe (4.0 N.m (35.4 lb in)). Important: ^ DO NOT overtorque the retaining nut. Notice: ^ Factory installed TPM Sensors come with plastic aluminum or nickel-plated brass stem caps. These caps should not be changed. Chrome plated steel caps may cause corrosion of aluminum valve stems due to incompatibility of the metals. On current style sensors the entire rubber stem is replaceable. The service interval on the revised TPM sensor with replaceable stem is the same as for any other traditional valve stem. Replace the stem at the time of tire replacement sensor transfer or whenever air seepage is suspected at the valve stem. When replacing the valve stem tighten the screw to 1.3 N.m (11.5 lb in). For either style of TPM sensor see the service parts guide for the correct GM part numbers to order and use. Disclaimer Page 12532 Action Taken When the DTCs Sets The module suspends all message transmission. The module uses default values for all parameters received on the serial data circuits. The module inhibits the setting of all other communication DTCs. Conditions for Clearing the DTC A current DTC clears when the malfunction is no longer present. A history DTC clears when the module ignition cycle counter reaches the reset threshold of 50, without a repeat of the malfunction. Circuit/System Verification Refer to Data Link References to determine which serial data system is used for a specific module. This DTC cannot be retrieved with a current status. Diagnosis is accomplished using the following symptom procedures: Scan Tool Does Not Communicate with High Speed GMLAN Device in SI. OR Scan Tool Does Not Communicate with Low Speed GMLAN Device in SI. DTC U0140 - U0184 Circuit Description Modules connected to the GMLAN serial data circuit monitor for serial data communications during normal vehicle operation. Operating information and commands are exchanged among the modules. In addition to this, Node Alive messages are transmitted by each module on the GMLAN serial data circuit. When the module detects one of the following conditions on the GMLAN serial data circuit, a DTC will set. Operating information and commands are exchanged among the modules. In addition to this, Node Alive messages are transmitted by each module on the GMLAN serial data circuit. Conditions for Setting the DTCs Diagnostic algorithms are designed so that a single point failure within a particular node shall result in a single DTC/FTB combination being set. Any recognized faults shall generate one DTC. Recognized faults may include but are not limited to the following: ^ Open or shorted condition on an I/O Circuit outside of normal operation of that circuit. ^ Erratic signal of a circuit, outside of normal operation, which can be readily and repeatedly recognized as erratic. ^ A condition, outside of normal operation, which causes a customer perception of a performance problem. ^ A condition whether hardware or data link error, which causes a device to operate in a default or fail soft mode. ^ A condition which changes or limits system performance. ^ Network supervision/signal supervision errors. ^ ECU Internal errors. ^ Criteria determined by legislation. An initialization or shutdown self-test shall be performed and may include but is not limited to the following: ^ RAM check ^ ROM/EEPROM/Flash check Page 13366 - HVAC Actuator - Inflatable Restraint Sensing and Diagnostic Module (SDM) - Any AIR BAG module - Seatbelt Lap Anchor Pretensioner - Seatbelt Retractor Pretensioner - An SIR system connection or connector condition resulting in the following DTCs being set: B0015, B0016, B0019, B0020, B0022, or B0023 - Powertrain Control Module (PCM) - Remote Control Door Lock Receiver (RCDLR) - Transmission Control Module (TCM) Correction Important DO NOT replace the control module, wiring or component for the following conditions: - The condition is intermittent and cannot be duplicated. - The condition is present and by disconnecting and reconnecting the connector the condition can no longer be duplicated. Use the following procedure to correct the conditions listed above. 1. Install a scan tool and perform the Diagnostic System Check - Vehicle. Retrieve and record any existing history or current DTCs from all of the control modules (refer to SI). ‹› If any DTC(s) are set, refer to Diagnostic Trouble Code (DTC) List - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). ‹› If DTCs are not set, refer to Symptoms - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). 2. When identified, use the appropriate DTC Diagnostics, Symptoms, Schematics, Component Connector End Views and Component Locator documents to locate and disconnect the affected harness connector(s) which are causing the condition. Note Fretting corrosion looks like little dark smudges on electrical terminals and appear where the actual electrical contact is being made. In less severe cases it may be unable to be seen or identified without the use of a magnifying glass. Important DO NOT apply an excessive amount of dielectric lubricant to the connectors as shown, as hydrolock may result when attempting to mate the connectors. Use ONLY a clean nylon brush that is dedicated to the repair of the conditions in this bulletin. 3. With a one-inch nylon bristle brush, apply dielectric lubricant to both the module/component side and the harness side of the affected connector(s). 4. Reconnect the affected connector(s) and wipe away any excess lubricant that may be present. 5. Attempt to duplicate the condition by using the following information: - DTC Diagnostic Procedure - Circuit/System Description - Conditions for Running the DTC - Conditions for Setting the DTC - Diagnostic Aids - Circuit/System Verification ‹› If the condition cannot be duplicated, the repair is complete. ‹› If the condition can be duplicated, then follow the appropriate DTC, Symptom or Circuit/System Testing procedure (refer to SI). Repair Order Documentation Page 6627 Valve Body Spring and Bore Plug Chart (inch) Page 13646 NOTE: Do NOT drill into the door -drill through hinge ONLY (Fig.1.18). If necessary, use a chisel to separate the hinge from door. 5. At each punch location, drill through hinge base only using a 13 mm (1/2 inch) rotabroach saw, or equivalent. (Fig.1.18) 6. Remove all remaining weld from door surface to ensure a flush fit of service hinge. INSTALL OR CONNECT 1. Repair any damage done to door during drilling or removal. 2. Clean and prepare hinge and backing plate mounting surfaces to ensure a flush fit of the service hinge. 3. Position the service template on door using 3M Repositionable Adhesive (part #6091), or equivalent. 4. Center punch each hole location on the door according to the template. 5. Drill a 3 mm (1/8 inch) pilot hole at each center punch location. 6. Using pilot hole as guide, drill a 13 mm (1/2 inch) hole through door at pilot locations (Fig.1.19). 7. Clean and prepare all surfaces, as necessary for refinish. IMPORTANT: Prior to refinishing, refer to GM P/N 4901.M-D Refinish Manual for recommended products. 8. Apply approved anti-corrosion primer. 9. Apply full-bodied caulk to the entire hinge mounting surface to ensure a proper seal. Page 2340 1. Install the gear inlet hose to the gear (4). Notice: Refer to Installing Hoses Without Twists or Bends Notice in Service Precautions. Important: Following this sequence ensures correct routing and orientation. 2. Install the booster inlet hose to the pump. Important: Ensure that the hose contacts the power steering pump as shown. Service and Repair Air Door Cable: Service and Repair MODE CONTROL CABLE REPLACEMENT REMOVAL PROCEDURE 1. Remove the radio. 2. Remove the heater control assembly. 3. Disconnect the mode cable from the heater/ventilation module. 4. Remove the mode cable from the IP carrier. INSTALLATION PROCEDURE 1. Install the mode cable to the IP carrier. 2. Connect the mode cable to the heater/ventilation module. 3. Install the heater control assembly. 4. Install the radio. Page 8996 Junction Block - I/P Wire Entry Part 3 Page 9693 15. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 16. Install the electrical ground wire terminal to the rivet stud. 17. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 18. Install the M6 conductive nut to the rivet stud and: Tighten Tighten to 8 Nm (71 lb in). 19. Verify proper system operation. M6 Weld Nut Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M6 weld nut at the electrical ground location is damaged or stripped, a M7 conductive self-threading bolt may be used to secure the ground wire terminal. 2. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the weld nut and allow to dry. 3. Remove any loose metal particles from the damaged or stripped weld nut with a stiff brush. 4. Select a M7 conductive self-threading bolt. Refer to the Parts Information section of this bulletin 5. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M7 conductive self-threading bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 6. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 7. Install the electrical ground wire terminal to the M7 conductive self-threading bolt. 8. Install the M7 conductive self-threading bolt and: Tighten Tighten to 9 Nm (80 lb in). 9. Verify proper system operation. M6 Weld Nut Alternative Repair Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the electrical ground location is accessible from both sides of the panel, a M6 conductive bolt and a M6 conductive nut may be used to secure the electrical ground wire terminal. Refer to the Parts Information section of this bulletin. 2. Select a location adjacent the damaged M6 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the new electrical ground site. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the ground location and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 8.5 mm (0.33 in) diameter hole through the panel. 5. Remove paint and primer from the area surrounding the 8.5 mm (0.33 in) hole until bare metal is visible. 6. Select a M6 conductive bolt. Refer to the Parts Information section of this bulletin. 7. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 8. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 9. Install the electrical ground wire terminal and the M6 conductive bolt to the ground location. 10. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 11. Install the M6 conductive nut to the bolt and: Page 3989 Knock Sensor (KS) Page 3445 Disclaimer Page 12558 Campaign - Deactivation Of Analog OnStar(R) Technical Service Bulletin # 08089C Date: 081118 Campaign - Deactivation Of Analog OnStar(R) # 08089C: Special Coverage Adjustment - Analog OnStar Deactivation (Nov 18, 2008) Subject: 08089C -- SPECIAL COVERAGE ADJUSTMENT - ANALOG ONSTAR(R) DEACTIVATION Page 5865 2. Connect the speed sensor electrical connector (4). 3. Lower the vehicle. Page 14625 Seat Horizontal Position Sensor - Driver (With RPO Code AN3) Page 3811 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Diagram Information and Instructions Auxiliary Power Outlet: Diagram Information and Instructions Truck Zoning TRUCK ZONING Truck Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that corresponds to where they are located in the vehicle. The table explains the numbering system. Page 2109 Ignition Cable: Service and Repair SPARK PLUG WIRE REPLACEMENT REMOVAL PROCEDURE 1. Remove the spark plug wire from the spark plug. 1.1. Twist the spark plug wire boot a 1/2 turn. 1.2. Pull only on the boot in order to remove the wire from the spark plug. 2. Remove the spark plug wire from the ignition coil. 2.1. Twist the spark plug wire boot a 1/2 turn. 2.2. Pull only on the boot in order to remove the wire from the ignition coil. IMPORTANT: The Melco(R) spark plug wires MUST be used only with the Melco(R) coils and bracket, like wise the Delphi(R) spark plug wires MUST be used only with Delphi(R) coils and bracket. The components are NOT interchangeable. 3. There are 2 different manufacturers for the spark plug wire, ignition coils and coil brackets. They are as follows: 4. The Melco(R) spark plug wire (1) will have a blue foil mark on it, and the wire is 145 mm (5.70 in) in length from cable seal to cable seal. 5. The Delphi(R) spark plug wire (2) will have a white foil mark on it, and the wire is 110 mm (4.30 in) in length cable seal to cable seal. Specifications Water Pump: Specifications Water Pump Bolts First Pass ............................................................................................................................................. ............................................... 15 Nm (11 ft lb) Final Pass .................................................................. ......................................................................................................................... 30 Nm (22 ft lb) Page 4298 High Temperature Conditions Tools Required J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency MEASURING FREQUENCY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage MEASURING VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop MEASURING VOLTAGE DROP NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Page 4747 Engine Control Module: Description and Operation Throttle Actuator Control (Tac) System POWERTRAIN CONTROL MODULE The PCM determines the driver's intent, then calculates the appropriate throttle response. This information is sent to the TAC module through a dedicated serial data line. Page 3212 10. If equipped with RPO HP2, remove the auxiliary heater water pump bracket nuts (4). 11. Remove the auxiliary heater water pump from the studs, and reposition out of the way. 12. If equipped with RPO HP2, remove the starter/generator control module (SGCM) cover bolts, and cover. 13. Remove the 3-phase cable nuts to the SGCM. 14. Remove the 3-phase cable from the SGCM. Air Temperature Sensor Replacement - Upper Right Discharge Air Temperature Sensor / Switch: Service and Repair Air Temperature Sensor Replacement - Upper Right AIR TEMPERATURE SENSOR REPLACEMENT - UPPER RIGHT REMOVAL PROCEDURE 1. Remove the I/P upper trim panel. 2. Disconnect the electrical connector (1) from the upper right air temperature sensor (2). 3. Remove the upper right air temperature sensor (1) from the air distributor duct (3). INSTALLATION PROCEDURE 1. Install the upper right air temperature sensor (1) to the air distributor duct (3). 2. Connect the electrical connector (1) from the upper right air temperature sensor (2). 3. Install the I/P upper trim panel. Page 16039 If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Sir/SRS Wiring Repairs SIR/SRS WIRING REPAIRS TOOLS REQUIRED J 38125-D Terminal Repair Kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-D contains the following items: - Special sealed splices - in order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping tool - A heat torch - An instruction manual The sealed splices have the following 2 critical features: - A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-D also serves as a generic terminal repair kit. The kit contains the following items: - A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors Page 15839 Tail Lamp: Description and Operation PARK, TAIL AND MARKER LAMPS The park, tail and marker lamps, including the license lamps, are turned on when the headlamp switch is placed in the PARK or HEAD position or anytime the headlights are requested. The underhood fuse block supplies battery positive voltage to both the park lamp relay switch contacts and the park lamp coil circuit. The body control module (BCM) provides a ground or control circuit to the park lamp relay coil circuit. When the park lamps are turned on the BCM energizes the park lamp relay. Current flow is from the park lamp relay to the FR PRK 10-amp fuse, RR PRK 10-amp fuse, LR PRK 10-amp fuse, and the TRL PRK 10-amp fuse, and to their respective park and marker lamps. The front park and marker lamps are grounded at G100. The rear park and marker lamps are grounded at G401. The license lamps are grounded at G410. If the headlight switch is left in the ON position, the inadvertent power control feature will turn off the park, tail and marker lamps approximately 10 minutes after the ignition switch is turned to the OFF position. If the driver places the headlight switch in the ON position after the ignition switch has been turned OFF, or if the ignition switch is in the ACCY position, the park, tail and marker lamps will remain ON until turned OFF or the battery runs dead. Interior - Erratic Memory Seat Operation Memory Positioning Module: All Technical Service Bulletins Interior - Erratic Memory Seat Operation Bulletin No.: 04-08-50-016C Date: August 12, 2005 TECHNICAL Subject: Memory Seat May Not Return to Requested Position (Reprogram Driver Seat Module) Models: 2003-2005 Cadillac Escalade, Escalade ESV, Escalade EXT 2003-2005 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2003-2005 GMC Sierra, Yukon, Yukon XL, Yukon Denali All with Seat FRT, Individual (Non BKT) (RPO AN3) 2003-2005 HUMMER H2 with Seat, Front Bucket Deluxe (RPO AR9) Supercede: This bulletin is being revised to update the correction information. Please discard Corporate Bulletin Number 04-08-50-016B (Section 08 - Body and Accessories). Condition Some customers may comment that with repeated cycling of the memory seat between the "exit" and one of the "presets", the position of the seat may "creep" forward or rearward out of expected adjustment. Cause There is a coding deficiency in the software for the memory seat module. Correction Technicians are to reprogram the driver seat module with an updated software calibration. The previous bulletin stated to use a service calibration that was released with TIS satellite data update version 4.5. Feedback has proved that calibration to be ineffective in eliminating the memory seat creep condition. An updated service calibration was released with TIS satellite data update version 6.5 available June 13, 2005. This new calibration has additional memory seat creep protection. As always, make sure your Tech 2(R) is updated with the latest software version. Important: After programming is complete, move the seat all the way rearward and down, then bump the seat slightly forward and up. This position will be just off the end of travel hard stops. Reset both memory seat exit positions at this position. Having the seat set at just off the hard stops will aid in reducing the creep condition. Warranty Information OnStar(R) - Aftermarket Device Interference Information Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Aftermarket Device Interference Information INFORMATION Bulletin No.: 08-08-46-004 Date: August 14, 2008 Subject: Information on Aftermarket Device Interference with OnStar(R) Diagnostic Services Models: 2009 and Prior GM Passenger Car and Truck (including Saturn) 2009 and Prior HUMMER H2, H3 Models 2009 and Prior Saab 9-7X with OnStar(R) (RPO UE1) This bulletin is being issued to provide dealer service personnel with information regarding aftermarket devices connected to the Diagnostic Link Connector (DLC) and the impact to OnStar(R) diagnostic probes and Vehicle Diagnostic e-mails. Certain aftermarket devices, when connected to the Diagnostic Link Connector, such as, but not limited to, Scan Tools, Trip Computers, Fuel Economy Analyzers and Insurance Tracking Devices, interfere with OnStar's ability to perform a diagnostic probe when requested (via a blue button call) by a subscriber. These devices also prohibit the ability to gather diagnostic and tire pressure data for a subscriber's scheduled OnStar(R) Vehicle Diagnostic (OVD) e-mail. These aftermarket devices utilize the Vehicles serial data bus to perform data requests and/or information gathering. When these devices are requesting data, OnStar(R) is designed not to interfere with any data request being made by these devices as required by OBD II regulations. The OnStar(R) advisor is unable to definitively detect the presence of these devices and will only be able to inform the caller or requester of the unsuccessful or incomplete probe and may in some cases refer the subscriber/requester to take the vehicle to a dealer for diagnosis of the concern. When performing a diagnostic check for an unsuccessful or incomplete OnStar(R) diagnostic probe, or for concerns regarding completeness of the OnStar(R) Vehicle Diagnostic (OVD) e-mail, verify that an aftermarket device was not present at the time of the requested probe. Regarding the OVD e-mail, if an aftermarket device is interfering (including a Scan Tool of any type), the e-mail will consistently display a "yellow" indication in diagnostics section for all vehicle systems except the OnStar(R) System and Tire Pressure data (not available on all vehicles) will not be displayed (i.e. section is collapsed). Successful diagnostic probes and complete OVD e-mails will resume following the removal or disconnecting of the off-board device. Disclaimer Page 12561 Diagnostic Tips Review # 5 - Alpine Silver Box Navigation Radio Disclaimer Page 13830 Body Emblem: Service and Repair Emblem Replacement - Grille (Chevrolet) Emblem Replacement - Grille (Chevrolet) Removal Procedure 1. Remove the upper grille baffle. 2. Remove the retaining nuts (3) from the rear of the grille emblem (1). 3. Separate and remove the emblem (1) from the grille (2). Installation Procedure Page 7106 8. Install two M11x1.5 mm bolts (1) to the threaded holes of the spacer, if applicable. 9. Rotate the bolts clockwise to remove the spacer. 10. Remove the spacer from the rear of the crankshaft, if applicable. Installation Procedure Important: ^ The flywheel does not use a locating pin for alignment and will not initially seat against the crankshaft flange or spacer (if applicable), but will be pulled onto the crankshaft by the engine flywheel bolts. This procedure requires a three stage tightening process. ^ Certain applications (4.8 L manual transmissions or all 6.0 L) require a spacer and longer bolts for proper flywheel position. Page 2198 Cabin Air Filter: Service and Repair This Article has been updated by bulletin #PIT3330, dated December 22, 2004. Condition/Concern: A customer may inquire about the availability of the passenger compartment air filter. Recommendation/Instructions: Starting in 2003 model year, the passenger compartment air filter is no longer available as a factory option. With the redesigned HVAC case, there is no longer a cavity for the filter. The GM parts catalog indicates there is a replacement filter available; however, there is no provision for it. Page 9317 Junction Block - I/P Wire Entry Part 4 Service and Repair Crankshaft Main Bearing Seal: Service and Repair Crankshaft Rear Oil Seal Replacement (4.8L, 5.3L, and 6.0L Engines) ^ Tools Required J 41479 Crankshaft Rear Oil Seal Installer Removal Procedure 1. Remove the engine flywheel. 2. Remove the crankshaft rear oil seal (1) from the rear cover. Installation Procedure Important: ^ The flywheel spacer (if applicable) must be removed prior to oil seal installation. ^ Do not lubricate the oil seal inside diameter (ID) or the crankshaft surface. ^ Do not reuse the crankshaft rear oil seal. 1. Lubricate the outside diameter (OD) of the oil seal (1) with clean engine oil.DO NOT allow oil or other lubricants to contact the seal surface. 2. Lubricate the rear cover oil seal bore with clean engine oil.DO NOT allow oil or other lubricants to contact the crankshaft surface. 3. Install the J 41479 tapered cone (2) and bolts onto the rear of the crankshaft. 4. Tighten the bolts until snug. Do not overtighten. 5. Install the rear oil seal onto the tapered cone (2) and push the seal to the rear cover bore. 6. Thread the J 41479 threaded rod into the tapered cone until the tool (1) contacts the oil seal. 7. Align the oil seal into the tool (1). Fuel System - Fuel Injector Maintenance Cleaning Fuel Injector: Technical Service Bulletins Fuel System - Fuel Injector Maintenance Cleaning Bulletin No.: 04-06-04-051B Date: January 04, 2006 INFORMATION Subject: Maintenance Cleaning of Fuel Injectors Models: 2006 and Prior All General Motors Passenger Cars and Trucks 2003-2006 HUMMER H2 2006 HUMMER H3 Supercede: This bulletin is being revised to add models and model years and update the name and part number of GM Fuel System Treatment. Please discard Corporate Bulletin Number 04-06-04-051A (Section 06 - Engine/Propulsion System). General Motors is aware that some companies are marketing tools, equipment and programs to support fuel injector cleaning as a preventative maintenance procedure. General Motors does not endorse, support or acknowledge the need for fuel injector cleaning as a preventative maintenance procedure. Fuel injector cleaning is approved only when performed as directed by a published GM driveability or DTC diagnostic service procedure. Due to variation in fuel quality in different areas of the country, the only preventative maintenance currently endorsed by GM regarding its gasoline engine fuel systems is the addition of GM Fuel System Treatment PLUS, P/N 88861011 (for U.S. ACDelco(R), use P/N 88861013) (in Canada, P/N 88861012), added to a tank of fuel at each oil change. Refer to Corporate Bulletin Number 03-06-04-030A for proper cleaning instructions. Disclaimer Page 13409 TOOLS REQUIRED J 34142-B 12 V Unpowered Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. When testing for voltage: 1. Attach 1 lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach 1 lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Using Connector Test Adapters USING CONNECTOR TEST ADAPTERS NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-B Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires USING FUSED JUMPER WIRES TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Connector Position Assurance Locks CONNECTOR POSITION ASSURANCE LOCKS The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Terminal Position Assurance Locks TERMINAL POSITION ASSURANCE LOCKS The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Push to Seat Connectors PUSH TO SEAT CONNECTORS TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Page 2771 Relay Box: Service and Repair I/P Electrical Center or Junction Block Replacement - Left INSTRUMENT PANEL ELECTRICAL CENTER OR JUNCTION BLOCK REPLACEMENT - LEFT REMOVAL PROCEDURE 1. Remove the left side end panel. 2. Remove the knee bolster. 3. Disconnect all the wiring connectors from the fuse block. 4. Remove all the fuses. 5. Remove the turn signal relay from the back of the fuse block. 6. From behind the fuse block, remove the retaining bolt. 7. Insert a screw driver between the fuse block and the wire harness block to separate. 8. Push on the retainers in order to remove the fuse block. 9. Remove the fuse block from the vehicle. INSTALLATION PROCEDURE 1. Install the fuse block onto the I/P assembly until it clicks in place. 2. Install the wire harness block to the back of the fuse block. NOTE: Refer to Fastener Notice in Service Precautions. 3. Install the bolt. Tighten Tighten the bolt to 6 N.m (53 lb in). 4. Install the turn signal relay to the back of the fuse block. 5. Using the wiring diagram on the cover of the fuse panel, install the fuses. 6. Install the electrical connectors. 7. Install the knee bolster. Page 13113 Action Taken When the DTCs Sets The module suspends all message transmission. The module uses default values for all parameters received on the serial data circuits. The module inhibits the setting of all other communication DTCs. Conditions for Clearing the DTC A current DTC clears when the malfunction is no longer present. A history DTC clears when the module ignition cycle counter reaches the reset threshold of 50, without a repeat of the malfunction. Circuit/System Verification Refer to Data Link References to determine which serial data system is used for a specific module. This DTC cannot be retrieved with a current status. Diagnosis is accomplished using the following symptom procedures: Scan Tool Does Not Communicate with High Speed GMLAN Device in SI. OR Scan Tool Does Not Communicate with Low Speed GMLAN Device in SI. DTC U0140 - U0184 Circuit Description Modules connected to the GMLAN serial data circuit monitor for serial data communications during normal vehicle operation. Operating information and commands are exchanged among the modules. In addition to this, Node Alive messages are transmitted by each module on the GMLAN serial data circuit. When the module detects one of the following conditions on the GMLAN serial data circuit, a DTC will set. Operating information and commands are exchanged among the modules. In addition to this, Node Alive messages are transmitted by each module on the GMLAN serial data circuit. Conditions for Setting the DTCs Diagnostic algorithms are designed so that a single point failure within a particular node shall result in a single DTC/FTB combination being set. Any recognized faults shall generate one DTC. Recognized faults may include but are not limited to the following: ^ Open or shorted condition on an I/O Circuit outside of normal operation of that circuit. ^ Erratic signal of a circuit, outside of normal operation, which can be readily and repeatedly recognized as erratic. ^ A condition, outside of normal operation, which causes a customer perception of a performance problem. ^ A condition whether hardware or data link error, which causes a device to operate in a default or fail soft mode. ^ A condition which changes or limits system performance. ^ Network supervision/signal supervision errors. ^ ECU Internal errors. ^ Criteria determined by legislation. An initialization or shutdown self-test shall be performed and may include but is not limited to the following: ^ RAM check ^ ROM/EEPROM/Flash check Page 498 SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-D. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: - The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair Tools Required J 38125-D Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-D. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Page 6295 The first phase also machined a case chamfer leading into the pump bore (2). The chamfer is designed to help eliminate possible 0-ring seal damage during pump installation. Phase two modified the case casting and the chamfer into the pump bore. The casting change left additional material in the surrounding pump bore to allow deeper bore machining in order to create the necessary sealing surface for a new pump seal design. The leading surface into the pump bore was also machined with a modified chamfer (1). Page 14232 Disclaimer Wheels - Plastic Wheel Nut Covers Loose/Missing Wheel Fastener: All Technical Service Bulletins Wheels - Plastic Wheel Nut Covers Loose/Missing Bulletin No.: 01-03-10-009A Date: July 27, 2004 TECHNICAL Subject: Plastic Wheel Nut Covers Missing and/or Loose (Replace Missing Covers and Add Sealant to All Covers) Models: 2005 and All Prior Passenger Cars (Except All Cadillac Models and Pontiac GTO) with Plastic Wheel Nut Covers Supercede: This bulletin is being revised to add additional models years. Please discard Corporate Bulletin Number 01-03-10-009. Condition Some customers may comment that the plastic wheel nut covers are missing and/or loose. Correction Important: ^ DO NOT USE a silicone-based adhesive. ^ Do not apply the *permatex(R) around the threads in a circular pattern. ^ Apply a single bead across the threads approximately 10 mm (0.4 in) in length, 5 mm (0.2 in) in height and 5 mm (0.2 in) in width. Replace any missing plastic wheel nut covers with the appropriate covers and apply Permatex(R) # 2 Form A Gasket Sealant(R) to the threads of all the plastic wheel nut covers. Tighten finger tight plus a 1/4 turn with a hand wrench. *We believe this source and their products to be reliable. There may be additional manufacturers of such material. General Motors does not endorse, indicate any preference for or assume any responsibility for the products from this firm or for any other such items which may be available from other sources. Permatex(R) # 2 Form A Gasket Sealant(R) part numbers (available at your local parts supplier) ^ P/N 80009 (2A/2AR) - 44 ml (1.5 oz) tube boxed ^ P/N 80015 (2AR) - 44 ml (1.5 oz) tube carded ^ P/N 80010 (2B/2BR) - 89 ml (3 oz) tube boxed ^ P/N 80016 (2BR) - 89 ml (3 oz) tube carded ^ P/N 80011 (2C) - 325 ml (11 oz) tube boxed Warranty Information For vehicles repaired under warranty, use the table. Page 10016 Wheel Alignment. Page 15158 TOOLS REQUIRED J 34142-B 12 V Unpowered Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. When testing for voltage: 1. Attach 1 lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach 1 lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Using Connector Test Adapters USING CONNECTOR TEST ADAPTERS NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-B Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires USING FUSED JUMPER WIRES TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Connector Position Assurance Locks CONNECTOR POSITION ASSURANCE LOCKS The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Terminal Position Assurance Locks TERMINAL POSITION ASSURANCE LOCKS The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Push to Seat Connectors PUSH TO SEAT CONNECTORS TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Page 14594 Memory Seat Module - C3 Part 3 Page 5267 Fuel Injector 4 OnStar(R) - Cellular Antenna Replacement Parts Antenna, Navigation: All Technical Service Bulletins OnStar(R) - Cellular Antenna Replacement Parts Bulletin No.: 00-08-46-002A Date: April 12, 2005 INFORMATION Subject: OnStar(R) System Cellular Antenna Replacement Parts Availability Models: 1996-2005 Passenger Cars and Light Duty Trucks 2003-2005 HUMMER H2 with OnStar(R) and Glass Mounted Antennas Supercede: This bulletin is being revised to update the model years, models and parts information. Please discard Corporate Bulletin Number 00-08-46-002 (Section 08 - Body & Accessories). Replacement parts for the OnStar(R) system cellular antenna are available as follows: ^ Cellular Antenna Kit - If the antenna mast or exterior base is damaged or missing or if the antenna base has separated from the exterior glass surface. ^ Cellular Antenna Inner Coupling - If the antenna coupling on the inside of the glass requires replacement. Important: If glass replacement is required, both the Cellular Antenna Kit and the Cellular Antenna Inner Coupling are required. The kits listed contain all the necessary parts and instructions needed to properly install a new cellular antenna exterior base or interior coupling to the glass surface. To obtain maximum adhesion during installation, the instructions included in the kits must be followed carefully and exactly as written. Important: Do not attempt to reinstall the original cellular antenna exterior base or interior coupling using any type of glue, adhesive tapes, etc. Doing so may eliminate the cellular signal transfer through the glass and reduce the maximum performance of the system that includes air bag deployment notification. Important: To obtain maximum adhesion between the new cellular exterior base or interior coupling and the glass surface, the base, coupling and glass must be kept dry and above 15°C (60°F) during the installation and for the 24 hours immediately following the installation. Not keeping the vehicle dry and above the temperature listed for 24 hours may result in the new cellular antenna exterior base or interior coupling coming off. Parts Information Parts are currently available from GMSPO. Page 15674 Headlamp Switch Part 2 Page 5069 Extended Cab Short Box Shown Below, Other Configurations Similar 6. Install the new canister vent valve solenoid to the fuel tank clip or mounting bracket as shown above. The valve port closest to the electrical connector must point towards the canister. 7. Cut bulk 5/8" heater hose to a length of approximately 76 mm (3 in). Install the hose between the solenoid and the canister pipe and secure using clamps. 8. Attach bulk 5/8" heater hose to the vent port and secure using a clamp. Run a length as needed along the frame rail routing to the area above the transmission. 9. Cut the hose to determined length and install the supplied filter box. Secure using a clamp. 10. Remove the transmission support and lower the transmission assembly as necessary to allow for access to the new filter box location. 11. Secure the filter box to the transmission vent hose just forward of the hose tee-section using a tie strap. DO NOT pinch or restrict the transmission vent hose. The filter box opening should be pointing downward. 12. Raise the transmission and reinstall the transmission support. 13. Connect the EVAP canister vent valve electrical connector. 14. Tie strap the hose as needed along the frame rail in order to keep the hose away from pinch-points and heat sources. 15. Lower the vehicle. Correction (2007-2010 New Style Models) After following the published SI diagnostics and determining that the EVAP canister vent valve is the cause of the MIL light, replace the EVAP canister vent valve assembly and relocate the remote filter box. To ensure correct installation, follow the procedures below. Important DO NOT replace the EVAP canister assembly for this concern unless it fails the leak test. Use Service Kit P/N 19207763 1. Raise the vehicle. Suitably support the vehicle. 2. Disconnect the EVAP canister vent valve electrical connector. Page 9765 C320 Seat Jumper Harness To Seat Harness (With RPO Code AN3) Part 2 Page 9911 Tighten Tighten to 8 Nm (71 lb in). Note The repair area MUST BE properly refinished to maintain a secure, stable and corrosion-free electrical ground. 12. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 13. Verify proper system operation. M8 Weld Nut Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M8 weld nut electrical ground location is accessible from both sides of the panel, a M8 conductive bolt and a M8 conductive nut may be used to secure the electrical ground wire terminal. Refer to the Parts Information section of this bulletin. 2. Select a location adjacent the M8 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the new electrical ground site. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the ground location and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 10 mm (0.40 in) diameter hole through the panel. 5. Remove paint and primer from the area surrounding the 10 mm (0.40 in) hole until bare metal is visible. 6. Select a M8 conductive bolt. Refer to the Parts Information section of this bulletin. 7. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M8 conductive bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 8. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 9. Install the electrical ground wire terminal and the M8 conductive bolt to the ground location. 10. Select a M8 conductive nut. Refer to the Parts Information section of this bulletin. 11. Install the M8 conductive nut to the bolt and: Tighten Tighten to 22 Nm (16 lb ft). Note The repair area MUST BE properly refinished to maintain a secure, stable and corrosion-free electrical ground. 12. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 13. Verify proper system operation. M8 Weld Nut Alternative Repair Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M8 weld nut electrical ground location is not accessible from both sides of the panel, a M6 conductive rivet stud and a M6 conductive nut may be used to secure the electrical ground wire terminal. 2. Select a location adjacent the damaged M8 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the M6 conductive rivet stud flange. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the repair site and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 10 mm (0.40 in) diameter hole through the panel. Electrical - Trailer Brakes Apply With Headlamps ON Trailer Lighting Module: All Technical Service Bulletins Electrical - Trailer Brakes Apply With Headlamps ON Bulletin No.: 02-05-22-004C Date: April 05, 2005 TECHNICAL Subject: Trailer Brakes Applied When Headlights/Park Lamps Are On, Brake Controller Illumination (Modify Brake Controller Wiring Harness) Models: 2002-2005 Cadillac Escalade, Escalade EXT 1999-2005 Chevrolet Silverado 2000-2005 Chevrolet Suburban, Tahoe 2002-2005 Chevrolet Avalanche 1999-2005 GMC Sierra 2000-2005 GMC Yukon, Yukon XL 2003-2005 HUMMER H2 Supercede: This bulletin is being revised to add additional model years. Please discard Corporate Bulletin Number 02-05-22-004B (Section 05 - Brakes). Condition Some customers may comment that when the headlamps or park lamps are on, the brakes on the trailer are always applied, or that the back lighting for the trailer brake controller only illuminates when the brakes are applied. Cause The cause of this condition may be due to wiring changes within the vehicle electrical system for the 2003 model year. Correction Inspect the brake controller wiring harness jumper that is plugged into the vehicle relay block-body. The relay block-body is located under the left side of the instrument panel near the left kick panel, behind a plastic cover. Page 10879 Electrical Symbols ELECTRICAL SYMBOLS Electrical Symbols Part 1 Page 13289 2. Skip to the next step if the vehicle to be upgraded is not shown above. 3. Skip to the next step if the vehicle to be upgraded is not a 2005 Cadillac STS. The 2005 Cadillac STS kit may include a new inside rearview (ISRV) mirror assembly and a new ISRV mirror wiring cover. If the kit you receive includes these parts, please remove the existing ISRV mirror and wire cover from the vehicle and install the ones provided in the kit per the instructions in SI. 4. Skip this step if the vehicle to be upgraded is not listed below. ^ 2003-2004 Saturn L-Series ^ 2003 Saturn ION ^ 2002-2003 Saturn VUE 1. Locate and remove the Right Audio output signal terminal 7 from Connector C2 at the Vehicle Communication Interface Module (VCIM). 2. Remove the terminal end and strip the wire. 3. Locate the Left Audio output signal wire from terminal 1 in Connector C2. 4. Splice the Right Audio output signal wire from terminal 7 with the Left Audio output signal wire from terminal 1. 5. See Wiring Repairs in SI for approved splicing methods. Service and Repair Trailer Hitch: Service and Repair Trailer Hitch Replacement Removal Procedure 1. Disconnect the trailer wiring harness. 2. Remove the hitch platform bolts from the frame rails and the rear bumper. 3. Remove the hitch platform from the vehicle. Installation Procedure 1. Position the hitch platform to the vehicle. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the platform hitch bolts to the frame rails and the rear bumper. Tighten the bolts to 125 N.m (92 lb ft). Park Brake Cable Guide Replacement Parking Brake Cable: Service and Repair Park Brake Cable Guide Replacement Park Brake Cable Guide Replacement Removal Procedure 1. Release the parking brake. 2. Raise and support the vehicle. Refer Vehicle Lifting 3. Remove the park brake cable guide bolt from the frame. 4. Remove the park brake cable guide. 5. Remove the park brake guide from the park brake cable. Installation Procedure 1. Install the park brake cable guide to the park brake cable. 2. Install the park brake cable guide. 3. Notice: Refer to Fastener Notice in Service Precautions. Install the park brake cable guide bolt to the frame. ^ Tighten the bolt to 12 Nm (106 inch lbs.). 4. Remove the safety stands. 5. Lower the vehicle. Page 12962 Speaker - LF - Tweeter - With RPO Code UQ7 Page 9679 5. Remove paint and primer from the area surrounding the 10 mm (0.40 in) until bare metal is visible. Important The M6 conductive rivet stud as shown, can accommodate a panel thickness range of 0.7-4.2 mm (0.03-0.17 in). If there are layers of sheet metal, they should be touching without any air gaps to ensure a good ground. 6. Select a M6 conductive rivet stud. Refer to the Parts Information section of this bulletin. Note Use the GE-50317 rivet stud tool kit. 7. Place the M6 conductive rivet stud (1) in the 10 mm (0.40 in) hole. Assemble the rivet stud tool (2) with the groove and flare side facing the rivet stud, then the washer and the M6 nut (3). 8. Using a wrench on the rivet stud tool, and a socket on the M6 nut, secure the M6 conductive rivet stud. 9. Ensure the new rivet stud is securely fastened, WITHOUT ANY detectable movement. 10. Completely wrap the threads of the rivet stud with painters tape or equivalent. Page 2056 Alignment: Description and Operation Caster Description Caster is the tilting of the uppermost point of the steering axis either forward or backward, when viewed from the side of the vehicle. A backward tilt is positive (+) and a forward tilt is negative (-). Caster influences directional control of the steering but does not affect the tire wear. Caster is affected by the vehicle height, therefore it is important to keep the body at its designed height. Overloading the vehicle or a weak or sagging rear spring will affect caster. When the rear of the vehicle is lower than its designated trim height, the front suspension moves to a more positive caster. If the rear of the vehicle is higher than its designated trim height, the front suspension moves to a less positive caster. With too little positive caster, steering may be touchy at high speed and wheel returnability may be diminished when coming out of a turn. If one wheel has more positive caster than the other, that wheel will pull toward the center of the vehicle. This condition will cause the vehicle to pull or lead to the side with the least amount of positive caster. Camber Description Camber is the tilting of the wheels from the vertical when viewed from the front of the vehicle. When the wheels tilt outward at the top, the camber is positive (+). When the wheel tilts inward at the top, the camber is negative (-). The amount of tilt is measured in degrees from the vertical. Camber settings influence the directional control and the tire wear. Too much positive camber will result in premature wear on the outside of the tire and cause excessive wear on the suspension parts. Too much negative camber will result in premature wear on the inside of the tire and cause excessive wear on the suspension parts. Unequal side-to-side camber of 1 degree or more will cause the vehicle to pull or lead to the side with the most positive camber. Toe Description Page 16081 Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA and/or the secondary locks. Micro .64 Connectors MICRO .64 CONNECTORS TOOLS REQUIRED J 38125-D Terminal Repair Kit REMOVAL PROCEDURE Follow the steps below in order to remove terminals from Micro 64 connectors. 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. 2. Disconnect the connector from the component. Page 869 Electrical Symbols Part 5 Page 4285 Electrical Symbols Part 2 Page 13550 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-8 (12085115) crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-8 (12085115) until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes SPLICING INLINE HARNESS DIODES Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate Service Data wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. 9. Tape the diode to the harness or connector using electrical tape. Input Shaft Speed Sensor Replacement Transmission Speed Sensor: Service and Repair Input Shaft Speed Sensor Replacement Input Shaft Speed Sensor Replacement Removal Procedure 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. Disconnect the input speed sensor electrical connector (1). 3. Remove the input speed sensor bolt. 4. Remove the input speed sensor (1). 5. Inspect the input speed sensor (1) for any evidence of damage. Installation Procedure Page 3792 IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections TESTING FOR INTERMITTENT AND POOR CONNECTIONS TOOLS REQUIRED - J 35616-C GM-Approved Terminal Test Kit - J 38125-D Terminal Repair Kit - J 42675 Flat-Wire Probe Adapter Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector. - Poor terminal to wire connection - Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. - Wire insulation which is rubbed through - This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. - Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. Testing For Proper Terminal Contact It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-D or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-D, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. Page 4972 Top Of Engine Page 13103 Check - Vehicle. The Diagnostic System Check will provide the following information: ^ The identification of the control modules which command the system ^ The ability of the control modules to communicate through the serial data circuit ^ The identification of any stored diagnostic trouble codes (DTCs) and their status The use of the Diagnostic System Check will identify the correct procedure for diagnosing the system and where the procedure is located. Visual/Physical Inspection Perform the following visual inspections; ^ Inspect for aftermarket devices which could affect the operation of the Radio/Audio System. Refer to Checking Aftermarket Accessories in SI. ^ Inspect the easily accessible and visible system components for obvious damage or conditions which could cause the symptom. Intermittent Conditions Faulty electrical connections or wiring may be the cause of intermittent conditions. Refer to Testing for Intermittent Conditions and Poor Connections in SI. Symptom List Page 11688 Inflatable Restraint I/P Module Disable Switch (With RPO Code C99) Diagram Information and Instructions Steering Mounted Controls Transmitter: Diagram Information and Instructions Truck Zoning TRUCK ZONING Truck Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that corresponds to where they are located in the vehicle. The table explains the numbering system. Page 6055 6. Ensure that the solenoid screens (1, 2) are in place on the spacer plate. 7. Place the checkball (3) on the spacer plate in the location shown. 8. Place the 3-4 accumulator spring (4) on the spacer plate. 9. Install the spacer plate and related components to the transmission. 10. Notice: Refer to Fastener Notice in Service Precautions. Install the spacer plate support and the spacer plate support bolts. ^ Tighten the bolts to 11 Nm (97 inch lbs.). 11. After installing the spacer plate support (2), look through the hole in the spacer plate to ensure that the checkball (1) has remained in the proper location. 12. Install a new 1-2 accumulator piston seal (1) to the 1-2 accumulator piston. Page 7184 Shifter M/T: Service and Repair ZF S6-650 Shift Lever Assembly Replacement Removal Procedure Important: ^ Ensure that the control lever is positioned into the mechanical third or fourth gear prior to removal of the shift lever assembly from the transmission. The transmission must remain in this state when the shift lever assembly is removed. ^ When removing the shift lever assembly from the transmission, use the exposed bolts on the base of the shift lever assembly. 1. Remove the control lever and boot. 2. With a flat-bladed tool, pull back the insulator between the body and transmission to access the shift tower bolts. 3. Remove the boot. 4. Remove the shift lever bolts. 5. Remove the shift lever and seal. 6. Remove the shift lever insulator. Installation Procedure OnStar(R) - Analog/Digital System Information Navigation System: All Technical Service Bulletins OnStar(R) - Analog/Digital System Information INFORMATION Bulletin No.: 06-08-46-008C Date: September 18, 2008 Subject: Information on OnStar(R) Dual-Mode (Analog/Digital) Systems Models Supercede: This bulletin is being revised to correct the model year range for the Chevrolet Impala and Monte Carlo and update the reference to GM Dealerworld. Please discard Corporate Bulletin Number 06-08-46-008B (Section 08 - Body and Accessories). All 2000-2003 model year vehicles equipped with OnStar® from the list above were built with Analog/Digital-Ready OnStar(R) Hardware. Some of these vehicles may have been upgraded to Dual-Mode (Analog/Digital). Certain 2004-2005 model year vehicles equipped with OnStar(R) from the list above may have been either: ^ Originally built at the factory with Dual-Mode (Analog/Digital) OnStar(R) Hardware with Dual-Mode (Analog/Digital) OnStar(R) Hardware OR ^ Upgraded to Dual-Mode (Analog/Digital) Hardware All 2006 model year and newer vehicles equipped with OnStar(R) were built at the factory with Dual-Mode (Analog/Digital) OnStar(R) Hardware. If a vehicle has Dual-Mode (Analog/Digital) OnStar(R) Hardware, then the system is capable of operating on both the analog and digital cellular Page 11136 3. Place a protective cover over the carpet below the evaporator core. 4. Remove the cabin air filter, if equipped, and cover the opening prior to applying the Cooling Coil Coating, as the product may clog the filter. If the cabin air filter appears to have little or no remaining life, suggest a replacement to your customer. 5. If the HVAC module has a blower motor cooling tube, be careful NOT TO SPRAY THE COOLING COIL COATING INTO THE BLOWER MOTOR COOLING TUBE. 6. Attach the Flexible Applicator Pressure Spray Tool (J-43810-20A) to a compressed air line operating at 586 kPa (85 psi) to 793 kPa (115 psi). 7. Shake the bottle of Cooling Coil Coating well. Screw the bottle onto the cap on the applicator tool's pick-up tube. Note The pick-up tube is designed for 120 ml (4 oz) and 240 ml (8 oz) bottles and should coil slightly in the bottom of a 120 ml (4 oz) bottle. 8. Use one of the following three methods to apply the Cooling Coil Coating. Important If the Pressure Applicator Spray Tool (J-43810-20A) is not available, the Cooling Coil Coating is also available in an aerosol can (P/N 12377951 (in Canada, 10953503)). Application Through Blower Motor Control Module Opening - Remove the blower motor control module (blower motor resistor). Refer to the applicable procedure in SI. - Clean any debris or foreign material from inside the HVAC module and on the evaporator core surface. - Apply the Cooling Coil Coating directly to the evaporator core through the blower motor blower motor control module (blower motor resistor) opening. - Use the flexible wand to direct the Cooling Coil Coating over the entire evaporator core and surrounding gasket surfaces. - When the application is complete, install the blower motor blower motor control module (blower motor control module). Application Through Blower Motor Opening - Remove the blower motor. Refer to the applicable blower motor removal procedure in SI. - Clean any debris or foreign material from inside the HVAC module and on the evaporator core surface. - Apply the Cooling Coil Coating directly to the evaporator core through the blower motor opening. - Use the flexible wand to direct the Cooling Coil Coating over the entire evaporator core and surrounding gasket surfaces. - When the application is complete, install the blower motor. Application Through a Hole in the HVAC Module - If neither of the two previous application methods are available, it may be necessary to drill a hole in the HVAC module. - Locate an area of the HVAC module between the blower motor and the evaporator core. Drill a 10 mm (3/8 in) hole in the HVAC module. Use caution to keep the drill clear of the evaporator core and the blower motor fan. - With the air distribution vents closed and the blower motor fan speed on HIGH, insert the applicator tool into the hole and spray the Cooling Coil Coating into the airstream toward the evaporator core. - Use a GM approved RTV sealant to plug the hole in the HVAC module. 9. After the Cooling Coil Coating application is complete, start and run the vehicle for approximately 10 minutes, with the compressor disabled, HVAC mode set to Recirculate/Max, heat set to full warm, blower motor fan speed on high, and one window open approximately 12 mm (1/2 in). This cures the Cooling Coil Coating onto the evaporator core surface. 10. While the engine is running, rinse the applicator tool with warm water to prolong the life of the tool. Be sure to spray warm water through the nozzle to rinse out any residual Cooling Coil Coating still in the capillary pick up tube, otherwise it will dry and clog the applicator tool. Also remove the small green valve from the bottle cap and rinse it thoroughly while rolling it between two fingers and then reinstall it. If this valve is clogged , the Cooling Coil Coating will not flow through the applicator tool. 11. Shut off the engine and enable the compressor again. 12. Verify proper HVAC system operation. 13. Remove the protective cover from inside the vehicle. 14. Remove the drain pan from underneath the vehicle. 15. Reinstall the cabin air filter if necessary. Page 15997 Heated Glass Element: Component Tests and General Diagnostics DEFOGGER GRID LINES DIAGNOSIS This test is for reference only. A grid line fault requires the rear window replacement. Refer to Rear Window Replacement (Pickup). 1. Start the engine. 2. Activate the rear window defogger system. 3. Connect a test lamp to a good ground. IMPORTANT: The test lamp brilliance will decrease proportionately to the increased resistance in the grid line as the probe is moved from the battery positive bus wire to the ground bus wire. The test lamp brilliance may vary from one window to another. 4. Move the test lamp probe from zone 5 to zone 1 along each grid line. - If the test lamp shows full brilliance at both ends of the grid lines. Inspect for an open or poor connection in the ground circuit of the rear window defogger grid. - If the test lamp goes out, test the grid line in at least 2 places (1,3) to eliminate the possibility of bridging the open (2) in the grid line. Page 5379 7. Install the EHCU (1). 8. Install the bolts (4) attaching the EHCU bracket to the frame (5). Tighten Tighten the bolts to 25 N.m (18 lb ft). 9. Connect the brake lines to the BPMV. Tighten Tighten the fittings to 25 N.m (18 lb ft). 10. Connect the chassis electrical harness connectors to the EBCM. 11. Install the transfer case harness to the clip bracket. 12. Install the clip to the bracket on the frame. 13. Install the fuel line clip to the bracket on the transfer case, if equipped with 4WD. Page 5057 Extended Cab Short Box Shown Below, Other Configurations Similar 6. Install the new canister vent valve solenoid to the fuel tank clip or mounting bracket as shown above. The valve port closest to the electrical connector must point towards the canister. 7. Cut bulk 5/8" heater hose to a length of approximately 76 mm (3 in). Install the hose between the solenoid and the canister pipe and secure using clamps. 8. Attach bulk 5/8" heater hose to the vent port and secure using a clamp. Run a length as needed along the frame rail routing to the area above the transmission. 9. Cut the hose to determined length and install the supplied filter box. Secure using a clamp. 10. Remove the transmission support and lower the transmission assembly as necessary to allow for access to the new filter box location. 11. Secure the filter box to the transmission vent hose just forward of the hose tee-section using a tie strap. DO NOT pinch or restrict the transmission vent hose. The filter box opening should be pointing downward. 12. Raise the transmission and reinstall the transmission support. 13. Connect the EVAP canister vent valve electrical connector. 14. Tie strap the hose as needed along the frame rail in order to keep the hose away from pinch-points and heat sources. 15. Lower the vehicle. Correction (2007-2010 New Style Models) After following the published SI diagnostics and determining that the EVAP canister vent valve is the cause of the MIL light, replace the EVAP canister vent valve assembly and relocate the remote filter box. To ensure correct installation, follow the procedures below. Important DO NOT replace the EVAP canister assembly for this concern unless it fails the leak test. Use Service Kit P/N 19207763 1. Raise the vehicle. Suitably support the vehicle. 2. Disconnect the EVAP canister vent valve electrical connector. Suspension - Revised Upper Control Arm Replacement Control Arm: Technical Service Bulletins Suspension - Revised Upper Control Arm Replacement Bulletin No.: 06-03-08-002 Date: March 09, 2006 SERVICE MANUAL UPDATE Subject: Revised Upper Control Arm Replacement Models: 2003-2006 Cadillac Escalade Models 2003-2006 Chevrolet Avalanche, Silverado, Suburban, Tahoe Models 2003-2006 GMC Sierra, Yukon Models 2003-2006 HUMMER H2 This bulletin is being issued to revise the Upper Control Arm Replacement procedure in the Front Suspension sub-section of the Service Manual. Please replace the current information in the Service Manual with the following information. The following information has been updated within SI. If you are using a paper version of this Service Manual, please make a reference to this bulletin on the affected page. Use of special tool J 42188-B eliminates the need to remove the wheel drive shaft on 4WD models. Upper Control Arm Replacement (Escalades, Avalanche, Silverado, Sierra, Suburban, Tahoe, Yukons) Tools Required J 42188-B Ball Joint Separator Removal Procedure 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information. 2. Remove the tire and wheel. Refer to Tire and Wheel Removal and Installation in Tires and Wheels. 3. Disconnect the electronic suspension control (ESC) link rod from the sensor, if equipped. Refer to Front Position Sensor Link Assembly - Electronic Suspension in Electronic Suspension Control. 4. Remove the retaining bolt for the brake hose and the wheel speed sensor brackets. Page 358 1. To receive credit, submit a claim with the information above. Disclaimer 2001 and Older Model Year Vehicles (Except Saab Vehicles) 2001 and Older Model Year Vehicles (Except Saab Vehicles) Important: 2001 and older model year vehicles require the removal of the battery power from the OnStar(R) vehicle interface unit (VIU) to eliminate the possibility of an inadvertent OnStar(R) or emergency/airbag call. 1. Locate and gain access to the OnStar® VIU. Refer to OnStar Vehicle Interface Unit Replacement in SI. Important: Complete removal of the VIU is usually not required. Perform only the steps required to gain access to the C2 32-way blue connector. Residing in the C2 connector are the battery positive (+) circuits. Removal of the C2 connector will deactivate the unit and eliminate the possibility of an inadvertent OnStar(R) or emergency/airbag call. Page 15197 Electrical Symbols Part 4 Page 13695 1. Repair any damage done to the pillar during the drilling or the removal. 2. Position the service hinge within the scribe marks on the pillar. 3. Center punch each stud location on the hinge pillar according to the service hinge (1). 4. Drill a 3 mm (1/8 in) pilot hole (2) at each center punch location. Important: The drill bit must be the exact size. 5. Drill an 11.5 mm (29/64 in) hole at the pilot locations for the studs. 6. Clean and prepare all of the bare metal surfaces. Important: Prior to refinishing, refer to the publication GM 4901M-D-2000 GM Approved Refinish Materials for recommended products. Do not combine paint systems. Refer to manufacturer's recommendations. 7. Apply an approved anti-corrosion primer. 8. Feed fish wire, GM P/N 15017229 of the equivalent, through the hinge (1), the hinge stud hole and out of the conduit hole in the pillar. 9. Install the stud, GM P/N 15017230, supplied with the service hinge, into the wire end. Pull the stud into position. 10. Hold the stud in position with the hinge and remove the fish wire. 11. Draw the stud (4) tight through the pillar. Use the nuts GM P/N 11516746, supplied. 12. Repeat steps 7 through 10 on the remaining stud locations. 13. Remove each service nut. 14. Apply a full-bodied caulk to the entire hinge mounting surface in order to ensure a proper seal. 15. Install the hinge (2) to the pillar (3). Use the supplied nuts (1). Notice: Refer to Fastener Notice in Service Precautions. 16. Install the hinge (2) to the pillar (3). Use the supplied nuts (1). Page 7097 Universal Joint: Service and Repair Universal Joint Replacement - External Snap Ring Universal Joint Replacement - External Snap Ring ^ Tools Required J 9522-3 U-Joint Bearing Separator - J 9522-5 U-Joint Bearing Spacer Remover Disassembly Procedure Notice: Never clamp propeller shaft tubing in a vise. Clamping could dent or deform the tube causing an imbalance or unsafe condition. Always clamp on one of the yokes and support the shaft horizontally. Avoid damaging the slip yoke sealing surface. Nicks may damage the bushing or cut the lip seal. 1. Support the propeller shaft in a line horizontal with the table of a press. 2. Mark the propeller shaft in order to show which end connects to the transmission and which end goes to the rear axle. 3. Disassemble the snap rings by pinching the ends together with a pair of pliers. 4. If the ring does not readily snap out of the groove in the yoke, tap the end of the cup lightly in order to relieve the pressure from the ring. 5. Place the universal joint so that the lower ear of the yoke is supported on a 30 mm (1-1/8 inch) hex head socket or a 27 mm (1-1/16 inch) socket. 6. Place J 9522-3 on the open horizontal bearing cups. Press the lower bearing cup out of the yoke ear. 7. If you do not completely remove the bearing cup, lift the cross and insert J 9522-5 between the seal and the bearing cup you are removing. Continue pressing the bearing cup out of the yoke. 8. Rotate the propeller shaft . Press the opposite bearing cup out of the yoke. 9. Mark the orientation of the slip yoke to the tube for proper reassembly. 10. Remove the cross from the yoke. 11. Remove the remaining universal joint parts from the yoke. 12. If you are replacing the front universal joint, remove the bearing cups in the slip yoke in the same manner. 13. Inspect the retaining ring grooves for dirt, corrosion, or pieces of the old ring. 14. Inspect the bearing cup bores for burrs or imperfections. 15. Clean the retaining ring grooves. Corrosion, dirt, rust, or pieces of the old retaining ring may prevent the bearing cups from pressing into place or prevent the bearing retainers from properly seating. Assembly Procedure 1. Remove the bearing cups from the universal joint. Emissions - MIL ON/DTC P0446 Stored In ECM Canister Purge Volume Control Valve: Customer Interest Emissions - MIL ON/DTC P0446 Stored In ECM TECHNICAL Bulletin No.: 02-06-04-037I Date: September 16, 2010 Subject: Check Engine Light On, Fuel Tank Hard to Fill, DTCs P0442, P0446, P0455 or P0449 Set (Replace Evaporative Emission (EVAP) Vent Valve Solenoid Assembly and Add/Relocate Filter Box Using Service Kit) Models: 1999-2007 Chevrolet Silverado (Classic) Models 1999-2007 GMC Sierra (Classic) Models 2007-2010 Chevrolet Silverado Models (Including Hybrid) 2007-2010 GMC Sierra Models (Including Hybrid) Supercede: This bulletin is being revised to add the 2010 model year and to include the Hybrid models. Please discard Corporate Bulletin Number 02-06-04-037H (Section 06 - Engine/Propulsion System). Condition Some customers may comment about the check engine light being illuminated. They may also comment that their vehicle is difficult to fill with fuel or when filling, the pump continuously shuts off before the tank is full. When checking the vehicle for DTCs, the ECM may report one or more of the following DTCs set as current or in history: P0442, P0446, P0449 or P0455. Cause The EVAP canister vent solenoid (CVS) valve draws fresh air into the system through a vent. Under certain operating conditions, dirt and dust intrusion into the EVAP CVS fresh air intake/venting system, may result in restricted air flow. Under certain operating conditions, water, if ingested into the EVAP CVS fresh air intake/venting system, may reach the CVS valve causing corrosion in the CVS valve, and may cause restrictions in the fresh air intake path, when the valve is in the closed position. Correction (1999-2007 Classic/Old Style Models) After following the published SI diagnostics and determining that the EVAP canister vent valve is the cause of the MIL light, replace the existing EVAP canister vent valve assembly with a new assembly. This new assembly is a sealed unit that is designed to be vented through a remote filter box. To ensure correct installation, follow the procedures below. Important DO NOT replace the EVAP canister assembly for this concern unless it fails the leak test. 1999-2003 Model Year (Use Service Kit P/N 19207762) 1. Raise the vehicle. Suitably support the vehicle. 2. Disconnect the EVAP canister vent valve electrical connector, if equipped. 3. Disengage the two vent valve pipe clips securing the pipe to the underbody. Remove the clips from the underbody and discard. 4. Disconnect the vent valve pipe at the EVAP canister. 5. Remove and retain the EVAP canister vent valve bracket mounting bolt. 6. Remove the complete EVAP canister vent valve assembly with bracket attached and discard. Page 7095 2. Assemble 1 bearing cup part way into 1 side of the yoke. 3. Turn the yoke ear toward the bottom. 4. Assemble the cross into the yoke so the trunnion seats freely into the bearing cup. 5. With the trunnion seated in the bearing cup, press the bearing cup into the yoke until the bearing cup is flush with the yoke ear. 6. Assemble the opposite bearing cup part way into the yoke ear. 7. Ensure that the trunnions start straight and true into both bearing cups. 8. Press the opposite bearing cup into the yoke ear while working the cross all the time in order to inspect for a free unbinding movement of the trunnions in the bearing cups. 9. Press the bearing cup into the yoke until the bearing retainer groove clears the inside of the yoke. Important: If there seems to be a hangup or binding, stop pressing, and inspect the needle bearings for misalignment in the bearing cup. 10. Assemble the bearing retainer in the retainer groove. 11. Continue pressing until you can snap both retainers into place. Page 12764 Disclaimer Page 7838 Transfer Case Actuator: Service and Repair Transfer Case Encoder Motor Replacement Removal Procedure 1. Remove the transfer case shield, if equipped. 2. Remove the front propeller shaft. 3. Disconnect the encoder motor electrical connector. 4. Remove the encoder motor bolts. 5. Remove the encoder motor. 6. Remove the actuator insulator gasket. 7. If replacing the encoder motor, remove the locating pins from the old motor. Installation Procedure Important: ^ If the encoder motor is being replaced because it is defective, ensure that the transfer case is in the neutral position. Manually shift the unit at the shift shaft. Use a crescent wrench, if necessary. ^ If the encoder motor is being replaced, a new gasket will come with the encoder motor. DO NOT reuse the old gasket. ^ A NEW encoder motor does NOT come with locating pins. Page 8293 19. Important: Care must be used when removing the piston boot and seal from the caliper. Use a small plastic or wood tool for removal. Do not use a metal tool because it may damage the caliper bore or seal groove. Remove the piston boots from the brake caliper. 20. Remove the piston seals from the brake caliper. 21. Remove the brake caliper bleeder valve and cap from the brake caliper. 22. Important: Do not use abrasives to clean the brake caliper piston. Clean the brake caliper piston bore and seal counterbore, and the caliper piston with denatured alcohol, or equivalent. 23. Dry the caliper piston bores and counterbores, and the piston with non-lubricated, filtered air. 24. Inspect all of the brake caliper parts as follows. ^ Piston - Inspect for scoring, nicks, cracks, wear, or corrosion. Replace the pistons if any damage is found. ^ Caliper Bore - Inspect for scoring, nicks, cracks, wear, or corrosion. Use crocus cloth to polish out light corrosion. Otherwise, replace the caliper. Do not hone the caliper bore. ^ Seal groove in the caliper bore for nicks or burrs. If found, replace the caliper. 25. Install the brake caliper bleeder valve and bleeder valve cap into the brake caliper. 26. Lubricate the new piston seal with Delco Supreme 11®, GM P/N 12377967 (Canadian P/N 10953488) or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. 27. Install the lubricated, new piston seals into the caliper bores. 28. Install the caliper piston into the caliper bore. 29. Install the new piston dust boot seal over the piston. 30. Using the J 45515 , fully seat the piston dust boot seal in the caliper. 31. Install the brake caliper to the vehicle. Refer to Brake Caliper Replacement - Front. Brake Caliper Replacement - Rear Brake Caliper Replacement - Rear (1500 Series) Caution: Refer to Brake Dust Caution in Service Precautions. Caution: Refer to Brake Fluid Irritant Caution in Service Precautions. Removal Procedure 1. Inspect the fluid level in the brake master cylinder reservoir. 2. If the brake fluid level is midway between the maximum-full point and the minimum allowable level, no brake fluid needs to be removed from the reservoir before proceeding. 3. If the brake fluid level is higher than midway between the maximum-full point and the minimum allowable level, remove brake fluid to the midway point before proceeding. Page 9762 C310 Body Harness To Left Rear Door Harness (Crew Cab) Part 1 Page 12585 Important: Secure the wiring harness so that there is no risk of chafing and rattling. 9.4. Fold back the wiring harness and tape over the connectors (C). Fold back the wiring harness once more and secure with cable ties (D). 9.5. Install the right-hand rear luggage compartment in accordance with WIS - 8. Body - Interior equipment - Adjustment/Replacement. 10. Install the ground cable to the battery's negative terminal. 11. Clear the diagnostic trouble codes. 12. Set the date and time, see WIS - 3. Electrical system - Information display (SID_ - Technical description. 2003-2005 Saab 9-3 (9400) 4D/5D; 2004-2005 Saab 9-3 (9400) CV 2003-2005 Saab 9-3 (9440) 4D/5D; 2004-2005 Saab 9-3 (9440) CV Notice: Handle the fiber optic cables with care or the signal may be distorted. ^ It is very important that the two leads in the connector are not confused with one another. ^ Do not splice the cables. ^ Do not bend the cable in a radius smaller than 25 mm (1 in). ^ Do not expose the cable to temperatures exceeding 185°F (85°C). ^ Keep the cable ends free from dirt and grime. ^ Do not expose the cable to impact as this may cause the transparent plastic to whiten, thereby reducing the intensity of the light and causing possible communication interruptions. ^ The cable should not lie against any sharp edges as this may cause increased signal attenuation. 1. Remove the ECU CU with a Tech 2(R) according to the following: Fault diagnosis - Select model year - Select Saab 9-3 Sport (9440) - All - Add/Remove - Control Module - CU/PU - Remove. 2. Remove the ground cable from the battery's negative terminal. 3. Remove the floor console in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 4. Pry out the signal line from the SRS control module to the OnStar(R) control module and secure it: Page 4331 Control Module References Part 7 Page 14892 Seat Adjuster Switch- Front Passenger (With RPO Code AN3) Part 2 Page 1989 High Temperature Conditions Tools Required J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency MEASURING FREQUENCY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage MEASURING VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop MEASURING VOLTAGE DROP NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Diagrams Page 2038 Washer Fluid Level Switch: Service and Repair WASHER SOLVENT CONTAINER LEVEL SENSOR REPLACEMENT REMOVAL PROCEDURE 1. Remove the washer solvent container. 2. Using a small flat-bladed tool, remove the washer solvent container level sensor (1) and seal (2) from the container. INSTALLATION PROCEDURE 1. Position the washer solvent container level sensor (1) and the seal (2) to the container by pressing in until fully seated. 2. Install the washer solvent container. Page 15791 Fog/Driving Lamp Switch: Service and Repair Fog Lamp Switch Replacement - Rear FOG LAMP SWITCH REPLACEMENT - REAR REMOVAL PROCEDURE 1. Remove the instrument panel bezel. 2. Pull out the accessary switch housing. 3. Disconnect the electrical connectors. 4. Remove the fog lamp switch from the accessary switch housing. INSTALLATION PROCEDURE 1. Install the fog lamp switch into accessary switch housing. 2. Connect the electrical connectors. 3. Install the accessary switch housing. 4. Install the instrument panel bezel. Page 7813 Page 8608 Tighten Tighten the nuts to 50 N.m (37 lb-ft). 3. Install the booster pump rod to the lever. 4. Install the stop lamp switch to the lever. 5. Install the booster pump rod retainer. 6. Connect the power brake booster outlet hose, the steering gear inlet hose, and the power brake booster inlet hose. Tighten ^ Tighten the power brake booster inlet hose to 28 N.m (20 lb-ft). ^ Tighten the steering gear inlet hose to 28 N.m (20 lb-ft). 7. Install the master cylinder. 8. Install the mounting nuts. Tighten Tighten the mounting bolts to 50 Nm (37 lb-ft). 9. Install the electrical connectors to the electrohydraulic pump and the flow switch. 10. Fill the hydraulic pump reservoir. Important: Maintain the fluid level throughout the bleed procedure. 11. Remove the pump reservoir cap. Important: Steering - 'Service Rear Wheel Steering' Message Body Control Module: Customer Interest Steering - 'Service Rear Wheel Steering' Message Bulletin No.: 05-02-118-002 Date: February 03, 2005 TECHNICAL Subject: DTC C0455, "Service Rear Wheel Steering", System Jumps from 4-Wheel Steer to 2-Wheel Steer (Reprogram BCM) Models: 2003-2005 Chevrolet Silverado, Suburban 2003-2005 GMC Sierra, Yukon XL with 4-Wheel Steer (RPO NYS) Condition Some customers may comment that the system will jump from 4-wheel steer to 2-wheel steer and the DIC displays the message "Service Rear Wheel Steering". Diagnosis will show DTC C0455-Front Steering Position Sensor malfunction. Cause This condition may be caused by a Class2 communication issue. Correction Reprogram the BCM. 2005 Model Year Vehicles: New software calibration, P/N 15248410, was released on TIS version 12 - broadcast to dealers on December 4, 2004. 2003-2004 Model Year Vehicles: New software calibration, P/N 15259330 ('03 Model Year) and P/N 15259331 ('04 04 Model Year), was released on TIS version 1.75 - broadcast to dealers on January 24, 2005. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 6353 Disclaimer Initial Inspection and Diagnostic Overview Drive/Propeller Shaft: Initial Inspection and Diagnostic Overview Diagnostic Starting Point - Propeller Shaft Begin the system diagnosis by reviewing the system Description and Operation. Reviewing the Description and Operation information will help you determine the correct symptom diagnostic procedure when a malfunction exists. Reviewing the Description and Operation information will also help you determine if the condition described by the customer is normal operation. Refer to Symptoms - Propeller Shaft in order to identify the correct procedure for diagnosing the system and where the procedure is located. See: Symptom Related Diagnostic Procedures/- Symptoms Propeller Shaft Page 12287 For vehicles repaired under warranty, use the table. Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table. Disclaimer Recall 04V240000: Incorrect Spare Tire on Vehicle Spare Tire: All Technical Service Bulletins Recall 04V240000: Incorrect Spare Tire on Vehicle Make / Models : Model/Build Years: GMC / 1500 2004 Regency / Chevrolet 1500 2004 MANUFACTURER: General Motors Corp. NHTSA CAMPAIGN ID Number : 04V240000 Recall Date : MAY 14, 2004 COMPONENT: Tires: Temporary/Emergency Spare Tire Potential Number Of Units Affected : 285 SUMMARY: The spare tire and wheel assembly that was provided on certain conversion vehicles will not fit on the front wheel hub due to offset of the wheel. However, it will fit on the rear wheels. CONSEQUENCE: If someone has a flat tire on the front wheel, they will not be able to install the provided spare tire. REMEDY: Dealers will install a spare wheel with the correct offset. Owner notification began on June 11, 2004. Owners should contact Regency at 1-800-989-4727. NOTES: Customers can also contact The National Highway Traffic Safety Administration's Auto Safety Hotline at 1-888-DASH-2-DOT (1-888-327-4236). A/T - 4T80E, Slips in Gear/L/H Axle Seal Leaks Clutch: Customer Interest A/T - 4T80E, Slips in Gear/L/H Axle Seal Leaks TECHNICAL Bulletin No.: 08-07-30-009B Date: May 01, 2008 Subject: HYDRA-MATIC(R) Front Wheel Drive 4T80-E (MH1) Left Front Axle Seal Leak, Transmission Slips in Gear (Replace Third Clutch Housing with Revised Service Part) Models: 2001-2008 GM Passenger Cars with HYDRA-MATIC(R) Front Wheel Drive 4T80-E Automatic Transmission (RPO - MH1) Supercede: This bulletin is being updated to revise the Warranty Information. Please discard Corporate Bulletin Number 08-07-30-009A (Section 07 - Transmission/Transaxle). Condition Some customers may comment on a transmission oil leak and/or that the transmission slips in gear. Cause An oil leak may be caused by bushing wear in the third clutch housing, causing excessive fluid build-up at axe sea. Correction Important: DO NOT replace the transmission for above concerns. Replace the third clutch housing with service P/N 8682114, which has revised bushing material to extend life and reduce left front axle seal leaks. Refer to Automatic/Transaxle - 4T80-E Transmission Off-Vehicle Repair Instructions for the replacement of the third clutch housing in SI. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 9253 C399 Body Harness To Passenger Seat Harness Part 2 Page 7920 10. Connect the PNP switch electrical connector (2). 11. If equipped with 4WD, install the front propeller shaft. 12. Lower the vehicle. 13. Check the PNP switch for proper operation. The engine must start in the park (P) or neutral (N) positions only. If proper operation of the switch can not be obtained, replace the switch. Park Lock Pawl and Actuator Replacement Park Lock Pawl and Actuator Replacement Removal Procedure 1. Remove the transmission filter. 2. Remove the park/neutral position (PNP) switch. 3. Remove the manual shaft nut and pin. 4. Remove the detent lever and actuator. 5. Remove the parking pawl bracket bolts. 6. Remove the parking pawl return spring. Page 14965 8. Remove the bolt holding the latch assembly. 9. Disengage the linkage rod from the latch assembly. 10. Remove the latch assembly from the endgate. Installation Procedure 1. Engage the linkage rod to the latch assembly. 2. Install the latch assembly to the vehicle. Notice: Refer to Fastener Notice in Service Precautions. 3. Install the latch assembly bolts. Tighten the bolts to 25 N.m (18 lb ft). Page 12696 Page 3178 2. Use the J 41665 in order to install the crankshaft balancer. 1. Assemble the threaded rod, nut, washer and installer.Insert the smaller end of the installer into the front of the balancer. 2. Use a wrench and hold the hex end of the threaded rod. 3. Use a second wrench and rotate the installation tool nut clockwise until the balancer is started onto the crankshaft. 4. Remove the tool and reverse the installation tool.Position the larger end of the installer against the front of the balancer. 5. Use a wrench and hold the hex end of the threaded rod. 6. Use a second wrench and rotate the installation tool nut clockwise until the balancer is installed onto the crankshaft. 7. Remove the balancer installation tool. 3. Install the used crankshaft balancer bolt. ^ Tighten the USED crankshaft balancer bolt to 330 Nm (240 ft. lbs.). 4. Remove the used crankshaft balancer bolt. Important: The nose of the crankshaft should be recessed 2.4-4.48 mm (0.094-0.176 inch) into the balancer bore. 5. Measure for a correctly installed balancer.If the balancer is not installed to the proper dimensions, install the J 41665 and repeat the installation procedure. 6. Install a NEW crankshaft balancer bolt. 1. Tighten the bolt a first pass to 50 Nm (37 ft. lbs.). 2. Tighten the bolt a second pass to 140 degrees using J 45059. 7. Remove the J 42386-A and bolts. 8. Install the starter motor. 9. Install the fan shroud - lower. 10. Install the A/C drive belt. 11. Perform the crankshaft position (CKP) system variation learn procedure. Page 3793 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground TESTING FOR SHORT TO GROUND NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting With A Digital Multimeter TROUBLESHOOTING WITH A DIGITAL MULTIMETER NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TROUBLESHOOTING WITH A TEST LAMP Page 15548 Ambient Light Sensor: Service and Repair AMBIENT LIGHT SENSOR REPLACEMENT REMOVAL PROCEDURE 1. Remove the instrument panel top cover. 2. Disconnect the electrical connector (1) to the ambient light sensor on the underside of the IP top cover. 3. Turn the ambient light sensor 1/4 turn and remove it from the IP top cover. INSTALLATION PROCEDURE 1. Install the ambient light sensor to the underside of the IP top cover, turning it 1/4 turn to secure it in place. 2. Connect the electrical connector (1) to the ambient light sensor on the underside of the IP top cover. 3. Install the instrument panel top cover. Suspension - Squeak Noise From Front of Vehicle Suspension Strut / Shock Absorber: All Technical Service Bulletins Suspension - Squeak Noise From Front of Vehicle Bulletin No.: 03-03-08-003 Date: November 24, 2003 TECHNICAL Subject: Squeak Noise Coming From Front of Vehicle (Align Shock Absorber Upper Mount) Models: 2004 Chevrolet Silverado 1500 Series Pickups 2004 GMC Sierra 1500 Series Pickups with 4WD and Built at Oshawa Plant (1 in VIN position 11) Prior to VIN Breakpoint 41211859 Condition Some customers may comment on a squeak noise coming from the front of the vehicle. Cause The cause of this condition may be due to the front shock(s) not being centered in the frame hole resulting in metal to metal contact. Correction Align the shock absorber upper mount to the correct location using the procedure listed below. DO NOT replace the shock absorber. 1. Open the hood. 2. Remove the upper shock absorber nut. Hold the tennon end with a wrench while removing the nut. 3. Remove the upper portion (1) of the upper mount from the shock. 4. Center the lower portion (3) of the upper mount in the frame hole. 5. Remove the plastic pilot ring (2) from the upper portion and place on the steel sleeve of the shock to ensure proper alignment. 6. Reinstall the upper portion of the upper mount onto the shock. 7. Reinstall the upper shock absorber nut. Hold the tennon end with a wrench while torquing the nut. Tighten: Tighten the nut to 20 N.m (15 lb ft). 8. Repeat for other side if necessary. Page 9445 Control Module References Part 2 Page 6651 ^ Reinstall the fuse and fuse panel cover. ^ Press the "Enter" button to perform the "Refresh" function. ^ "Test in Progress" will be displayed and the right front passenger door lock will cycle once. ^ The screen will display "Procedure Completed". ^ Press the "Exit" button as necessary to return to the main menu screen. 3. Using the switches in the right front passenger door, verify that the power window and power door lock located in that door function properly. Important: The calibrations required for performing SPS reprogram in the next step are based on the type of exterior rearview mirror the vehicle has. To determine the correct calibration, check the Service Parts Identification Label on the vehicle for the RPO code for exterior mirrors. 4. Follow normal Service Programming System (SPS) to reprogram the passenger door module with the current calibration available in TIS 2000. 5. After reprogramming is complete, using the switches in the right front passenger door, verify that the power window and power door lock located in that door function properly. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Keyless Entry - Inoperative Keyless Entry Module: All Technical Service Bulletins Keyless Entry - Inoperative Bulletin No.: 04-08-52-005 Date: June 15, 2004 TECHNICAL Subject: Remote Keyless Entry (RKE) System Inoperative (Reprogram Passenger Door Module (PDM)) Models: 2004 Cadillac Escalade, Escalade ESV, Escalade EXT 2004 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2004 GMC Sierra, Yukon, Yukon XL Condition Some customers may comment on any of the following conditions: ^ The RKE key fob does not function. ^ The "Service Tire Pressure Monitoring System" message is displayed, if equipped. ^ The passenger door will not unlock from the passenger's or driver's door switches. ^ The passenger door window is inoperative. Correction Reprogram the PDM with the Tech 2(R). Currently the Tech 2(R) software is not available for the 2004 model year. Engineering is aware of this and are working to release a new service calibration. In the meantime, build the Tech 2(R) as a 2003 model year and perform the reprogram using the procedure listed below. 1. Turn the ignition switch to the ON position. 2. Connect the Tech 2(R) to the vehicle's diagnostic link connector (DLC), power it up and press enter. ^ Select: Diagnostics. ^ Select model year: 2003. ^ Select: Light truck. ^ Select: Body. ^ Select the proper Product line. ^ Select the proper HVAC Type. ^ Select the proper Radio System type. ^ Select: Passenger Door Module. ^ Select: Special Functions. ^ Select: Refresh. Important: You must remove the described fuse in the next step for the "Refresh" program to be performed. If you do not remove the fuse for five seconds, the Tech 2 will continue to display "Test in Progress" and the program will not complete. ^ Remove the PDM fuse for 5 seconds from the fuse center located behind the panel on the left end of the instrument panel. Page 4587 Disclaimer Page 9987 2. Rotate the coil hub slowly, counterclockwise until the centering window appears yellow and both arrows (2) line up. This is the CENTER position. 3. While holding the coil hub in the CENTER position, align the SIR coil with the horn tower and slide onto the steering shaft assembly. 4. If the front side (3) of the SIR coil has NO centering window, but the back side (2) includes a spring service lock (1), perform the following steps: 0. Hold the SIR coil with the back side up. 1. While depressing the spring service lock, rotate the coil hub in the direction of the arrow (4) until the coil ribbon stops. 2. Still pressing the spring service lock, rotate the coil hub in the opposite direction 21⁄2 revolutions. 3. Release the spring service lock between locking tabs. The SIR coil is now centered. 4. Align the centered SIR coil with the horn tower and slide onto the steering shaft assembly. 5. If the front side (2) of the SIR coil has NO centering window, and the back side (1) includes NO spring service lock, perform the following steps: 0. Hold the SIR coil with the face up. 1. Rotate the coil hub in the direction of the arrow until the coil ribbon stops. 2. Rotate the coil hub, slowly, counterclockwise, for 21⁄2 revolutions. This is the CENTER position. 3. While maintaining the coil hub in the CENTER position, align the centered SIR coil with the horn tower and slide onto the steering shaft assembly. 6. If double wire harness strap is installed onto the wire harness assembly and column, you must route the wires up against the steering column. One wire harness strap will surround one lead from the coil to the steering column. The other wire harness strap will surround all leads to the steering column. Page 4744 The malfunction indicator lamp (MIL) is located in the instrument panel cluster. The MIL will display as either SERVICE ENGINE SOON or one of the following symbols when commanded ON: The MIL indicates that an emissions related fault has occurred and vehicle service is required. The following is a list of the modes of operation for the MIL: - The MIL illuminates when the ignition is turned ON, with the engine OFF. This is a bulb test to ensure the MIL is able to illuminate. - The MIL turns OFF after the engine is started if a diagnostic fault is not present. - The MIL remains illuminated after the engine is started if the control module detects a fault. A diagnostic trouble code (DTC) is stored any time the control module illuminates the MIL due to an emissions related fault. The MIL turns OFF after three consecutive ignition cycles in which a Test Passed has been reported for the diagnostic test that originally caused the MIL to illuminate. - The MIL flashes if the control module detects a misfire condition which could damage the catalytic converter. - When the MIL is illuminated and the engine stalls, the MIL will remain illuminated as long as the ignition is ON. - When the MIL is not illuminated and the engine stalls, the MIL will not illuminate until the ignition is cycled OFF and then ON. TRIP A trip is an interval of time during which the diagnostic test runs. A trip may consist of only a key cycle to power up the PCM, allow the diagnostic to run, then cycle the key off to power down the PCM. A trip may also involve a PCM power up, meeting specific conditions to run the diagnostic test, then powering down the PCM. The definition of a trip depends upon the diagnostic. Some diagnostic tests run only once per trip (i.e., catalyst monitor) while other tests run continuously during each trip (i.e. misfire). WARM-UP CYCLE The PCM uses warm-up cycles to run some diagnostics and to clear any diagnostic trouble codes (DTCs). A warm-up cycle occurs when the engine coolant temperature increases 22°C (40°F) from the start-up temperature. The engine coolant must also achieve a minimum temperature of 71°C (160°F). The PCM counts the number of warm-up cycles in order to clear the malfunction indicator lamp (MIL). The PCM will clear the DTCs when 40 consecutive warm-up cycles occur without a malfunction. DIAGNOSTIC TROUBLE CODES (DTCS) The PCM is programmed with test routines that test the operation of the various systems the PCM controls. Some tests monitor internal PCM functions. Many tests are run continuously. Other tests run only under specific conditions, referred to as Conditions for Running the DTC. When the vehicle is operating within the conditions for running a particular test, the PCM monitors certain parameters and determines if the values are within an expected range. The parameters and values considered outside the range of normal operation are listed as Conditions for Setting the DTC. When the Page 9307 Location View Location View Page 5587 Steps 28 - 31 120 Volt Receptacle Replacement Auxiliary Power Outlet: Service and Repair 120 Volt Receptacle Replacement 120 VOLT RECEPTACLE REPLACEMENT REMOVAL PROCEDURE 1. Remove the receptacle outlet screws (2). 2. Remove the receptacle outlet (3) from the receptacle box (1). 3. Disconnect the receptacle electrical connections. INSTALLATION PROCEDURE 1. Connect the receptacle electrical connections. 2. Install the receptacle outlet (3) to the receptacle box (1). NOTE: Refer to Fastener Notice in Service Precautions. 3. Install the receptacle outlet screws (2). Tighten Tighten the screws to 2 N.m (18 lb in). Interior - Elimination Of Unwanted Odors Seat Cover: All Technical Service Bulletins Interior - Elimination Of Unwanted Odors INFORMATION Bulletin No.: 00-00-89-027E Date: September 29, 2008 Subject: Eliminating Unwanted Odors in Vehicles Models: 2009 and Prior GM Passenger Cars and Trucks (including Saturn) 2009 and Prior HUMMER H2, H3 Vehicles 2009 and Prior Saab 9-7X Supercede: This bulletin is being revised to add model years and refine the instructions. Please discard Corporate Bulletin Number 00-00-89-027D (Section 00 - General Information). Vehicle Odor Elimination General Motors offers a product that may control or eliminate odors in the interior and luggage compartment areas of GM vehicles. GM Vehicle Care Odor Eliminator is a non-toxic, biodegradable odor remover. This odorless product has been shown to greatly reduce or remove objectionable smells of mold and mildew resulting from vehicle water leaks (as well as customer created odors, i.e. smoke). You may use GM Vehicle Care Odor Eliminator on fabrics, vinyl, leather, carpet and sound deadening materials. It may also be induced into HVAC modules and instrument panel ducts (for the control of non-bacterial related odors). Important: This product leaves no residual scent and should not be sold as or considered an air freshener. Product action may result in the permanent elimination of an odor and may be preferable to customers with allergies who are sensitive to perfumes. How to Use This Product GM Vehicle Care Odor Eliminator may be sprayed on in a ready-to-use formula or used in steam cleaners as an additive with carpet shampoo. This water-based, odorless product is safe for all vehicle interiors. Do not wet or soak any interior surface that plain water would cause to deteriorate, as this product will have the same effect. Also avoid letting this product come into contact with vinegar or any acidic substance. Acid-based products will hamper the effectiveness of, or render GM Vehicle Care Odor Eliminator inert. Note: Complete eight page treatment sheets are enclosed within each case of GM Vehicle Care Odor Eliminator. These treatment instructions range from simple vehicle odor elimination to full step by step procedures for odor removal from water leaks. If lost, contact 800-977-4145 to get a replacement set faxed or e-mailed to your dealership. Instructions and cautions are printed on the bottle, but additional help is available. If you encounter a difficult to eliminate or reoccurring odor, you may call 1-800-955-8591 (in Canada, 1-800-977-4145) to obtain additional information and usage suggestions. Important: This product may effectively remove odors when directly contacting the odor source. It should be used in conjunction with diagnostic procedures (in cases such as a water leak) to first eliminate the root cause of the odor, and then the residual odor to permanently correct the vehicle condition. Vehicle Waterleak Odor Elimination STEP ONE: Confirm that all water leaks have been repaired. Determine what areas of the vehicle were water soaked or wet. Components with visible mold/mildew staining should be replaced. Isolate the odor source inside the vehicle. Often an odor can be isolated to an area or component of the vehicle interior by careful evaluation. Odor evaluation may need to be performed by multiple persons. Another method of isolating an odor source is to remove and segregate interior trim and components. Plastic sheeting or drop cloths can be used to confine seats, headliners, etc. to assist in evaluation and diagnoses. If appropriate the vehicle and interior trim should be evaluated separately to determine if the odor stays with the vehicle or the interior components. Odors that stay with the vehicle may be isolated to insulating and sound deadening materials (i.e. water leak at the windshield or standing water in the front foot well area caused mold/mildew to form on the bulkhead or kick panel sound deadening pads. If the interior is removed the floor pan and primed/painted surfaces should be treated with bleach/soap solution, rinsed with clean water and dried. Interior surfaces should then be treated with GM Vehicle Care Odor Eliminator product before reinstalling carpet or reassembling. Page 9139 5. Remove paint and primer from the area surrounding the 10 mm (0.40 in) until bare metal is visible. Important The M6 conductive rivet stud as shown, can accommodate a panel thickness range of 0.7-4.2 mm (0.03-0.17 in). If there are layers of sheet metal, they should be touching without any air gaps to ensure a good ground. 6. Select a M6 conductive rivet stud. Refer to the Parts Information section of this bulletin. Note Use the GE-50317 rivet stud tool kit. 7. Place the M6 conductive rivet stud (1) in the 10 mm (0.40 in) hole. Assemble the rivet stud tool (2) with the groove and flare side facing the rivet stud, then the washer and the M6 nut (3). 8. Using a wrench on the rivet stud tool, and a socket on the M6 nut, secure the M6 conductive rivet stud. 9. Ensure the new rivet stud is securely fastened, WITHOUT ANY detectable movement. 10. Completely wrap the threads of the rivet stud with painters tape or equivalent. Page 15963 SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-D. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: - The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair Tools Required J 38125-D Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-D. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Page 13261 Page 11468 6. Remove and discard the centering tab (1). NOTE: Gently pull on the lower coil assembly wire in order to remove any wire kinks inside of the column assembly. Verify that there are NO kinks or bends in the SIR coil assembly wire. If a kink or bend is present, interference may occur with the shaft lock mechanism. Turning the steering wheel may cut or damage the wire. 7. Install the retaining ring (1). Verify that the ring (1) is firmly seated in the groove on the upper shaft (2). 8. Install the wire harness assembly (4) into the wire strap (5). 9. Install the wire harness strap (2) into the upper tilt head assembly (1). 10. Install wire harness straps (3) to the wire harness assembly. Steering - 'Service Rear Wheel Steering' Message Body Control Module: All Technical Service Bulletins Steering - 'Service Rear Wheel Steering' Message Bulletin No.: 05-02-118-002 Date: February 03, 2005 TECHNICAL Subject: DTC C0455, "Service Rear Wheel Steering", System Jumps from 4-Wheel Steer to 2-Wheel Steer (Reprogram BCM) Models: 2003-2005 Chevrolet Silverado, Suburban 2003-2005 GMC Sierra, Yukon XL with 4-Wheel Steer (RPO NYS) Condition Some customers may comment that the system will jump from 4-wheel steer to 2-wheel steer and the DIC displays the message "Service Rear Wheel Steering". Diagnosis will show DTC C0455-Front Steering Position Sensor malfunction. Cause This condition may be caused by a Class2 communication issue. Correction Reprogram the BCM. 2005 Model Year Vehicles: New software calibration, P/N 15248410, was released on TIS version 12 - broadcast to dealers on December 4, 2004. 2003-2004 Model Year Vehicles: New software calibration, P/N 15259330 ('03 Model Year) and P/N 15259331 ('04 04 Model Year), was released on TIS version 1.75 - broadcast to dealers on January 24, 2005. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 2286 6. Remove the inlet heater hose. INSTALLATION PROCEDURE 1. Install the inlet heater hose. 2. Install the inlet heater hose to the engine. 3. Connect the heater and surge tank hose to the heater core. Firmly push the quick connect onto the heater core pipe until you hear an audible click. 4. Install the heater and surge tank hose to the mounting clip. 5. Install the air intake tube. 6. Fill the cooling system. Refer to Draining and Filling Cooling System (with HP2)Draining and Filling Cooling System (without HP2) in Cooling System. OnStar(R) - Number Incorrect/Incorrectly Assigned Navigation System: All Technical Service Bulletins OnStar(R) - Number Incorrect/Incorrectly Assigned INFORMATION Bulletin No.: 05-08-46-004C Date: December 23, 2010 Subject: OnStar(R) Phone Number Concerns (Phone Number Incorrect/Assigned to Another Vehicle/Phone) That Occur During Diagnosis of OnStar(R) System Models: 2000-2011 GM Passenger Cars and Trucks Equipped with OnStar(R) (RPO UE1) Supercede: This bulletin is being revised to update model years up to 2011. Please discard Corporate Bulletin Number 05-08-46-004B (Section 08 - Body and Accessories). During diagnosis of an OnStar(R) concern, the technician may be told that the OnStar(R) phone number is incorrect or tied to another vehicle and/or phone of some kind. To resolve these concerns, the Tech 2(R) with software version 22.005 (or higher), has the capability to change the OnStar(R) phone number. Service Procedure 1. With the Tech 2(R), build the vehicle to specifications within the Diagnostics area of the Tech 2(R). 2. For vehicles with physical-based diagnostics - under Body, go to the OnStar(R) section. Then select the Special Functions menu. For vehicles with functional-based diagnostics - under Body and Accessories, go to the Cellular Communication section. Select Module Setup and then Vehicle Communication Interface Module. 3. Locate the Program Phone Number prompt and select it. The original phone number will be displayed on the Tech 2(R) screen. 4. Contact the OnStar(R) team at the GM Technical Assistance Center (TAC) to obtain a new phone number. 5. Highlight the digits of the phone number one at a time and enter the new phone number using the number keys on the Tech 2(R). 6. Press the Soft key at the base of the screen for Done once these numbers have been changed on the screen. 7. Press the Soft key for Done again. The area code or new phone number has now been programmed into the phone. 8. Cycle the ignition to Off and open the driver's door. 9. Press the blue OnStar(R) button to make sure that a normal connection can be made to the OnStar(R) call center. If applicable, make sure the Hands-Free Calling (HFC) works properly by making a phone call. 10. If the system is working properly, fax or voicemail a case closing into the OnStar(R) team at TAC with the results. Dealers in Canada should submit case closing information through the GM infoNET. Please follow this diagnostic process thoroughly and complete each step. If the condition exhibited is resolved WITHOUT completing every step, the remaining steps do not need to be performed. If the procedure above does not resolve the condition, you must contact TAC for further assistance. This diagnostic approach was developed specifically for this condition and should not automatically be used for other vehicles with similar symptoms. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use: Warranty Information (Saab Models) For vehicles repaired under warranty, use the table. Page 4299 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors USING CONNECTOR TEST ADAPTERS IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-B Connector Test Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Page 8623 2. Remove the master cylinder from the booster. Do not remove the pipes from the master cylinder. Set the master cylinder aside in the engine compartment. 3. Disconnect the power brake booster inlet hose, the steering gear inlet hose, and the power brake booster outlet hose from the booster assembly. 4. Disconnect the electrical connector from the stop lamp switch. 5. Remove the retainer from the brake pedal pin. 6. Remove the stop lamp switch and the pushrod to the power brake booster from the brake pedal pin. 7. Unsnap the stop lamp switch from the power brake booster pushrod. 8. Remove the 4 booster to bulkhead nuts. 9. Remove the booster assembly. 10. Remove the gasket. Installation Page 12531 The number above refers to the step number on the diagnostic table. DTC U0073 or U2100 DTC Descriptors DTC U0073 00: Control Module Communication Bus Off DTC U0073 71: ECU HS Bus Off DTC U0073 72: ECU LS Bus Off DTC U2100 00: Controller Area Network (CAN) Bus Communication DTC U2100 47: Controller Area Network (CAN) Bus Communication Circuit/System Description The serial data circuits are serial data buses used to communicate information between the control modules. The serial data circuits also connect directly to the data link connector (DLC). Conditions for Running the DTCs Supply voltage at the modules are in the normal operating range. The vehicle power mode requires serial data communications. Conditions for Setting the DTC The module setting the DTC has attempted to establish communications on the serial data circuits more than 3 times. Page 7036 Sealers, Adhesives, and Lubricants Page 4304 TOOLS REQUIRED J 34142-B 12 V Unpowered Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. When testing for voltage: 1. Attach 1 lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach 1 lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Using Connector Test Adapters USING CONNECTOR TEST ADAPTERS NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-B Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires USING FUSED JUMPER WIRES TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Connector Position Assurance Locks CONNECTOR POSITION ASSURANCE LOCKS The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Terminal Position Assurance Locks TERMINAL POSITION ASSURANCE LOCKS The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Push to Seat Connectors PUSH TO SEAT CONNECTORS TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Page 1838 Looking at the FRONT of the sensor, align the sensor with the steering shaft and install into the adapter and bearing assembly. 24. Install the connector to the sensor. Page 8781 Electrical Symbols Part 11 Page 12789 Diagnostic Trouble Codes DTC U1000 and U1255 Circuit/System Description Modules connected to the Class 2 serial data circuit monitor for serial data communications during normal vehicle operation. Operating information and commands are exchanged among the modules. When a module receives a message for a critical operating parameter, the module records the identification number of the module which sent the message for State of Health monitoring. A critical operating parameter is one which, when not received, requires that the module use a default value for that parameter. When a module does not associate an identification number with at least one critical parameter within 5 seconds of beginning serial data communication, DTC U1000 or U1255 DTC is set. When more than one critical parameter does not have an identification number associated with it, the DTC will only be reported once. The Class 2 serial data communications circuit on this vehicle are in a hybrid ring and star configuration. Each module on the ring has 2 serial data circuits connected to it, except the following modules which have only 1 serial data circuit connected them: Page 15685 3. Install the horn plunger to the steering column. 4. Install the inflator module. 5. Enable the SIR system. OnStar(R) - Aftermarket Device Interference Information Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Aftermarket Device Interference Information INFORMATION Bulletin No.: 08-08-46-004 Date: August 14, 2008 Subject: Information on Aftermarket Device Interference with OnStar(R) Diagnostic Services Models: 2009 and Prior GM Passenger Car and Truck (including Saturn) 2009 and Prior HUMMER H2, H3 Models 2009 and Prior Saab 9-7X with OnStar(R) (RPO UE1) This bulletin is being issued to provide dealer service personnel with information regarding aftermarket devices connected to the Diagnostic Link Connector (DLC) and the impact to OnStar(R) diagnostic probes and Vehicle Diagnostic e-mails. Certain aftermarket devices, when connected to the Diagnostic Link Connector, such as, but not limited to, Scan Tools, Trip Computers, Fuel Economy Analyzers and Insurance Tracking Devices, interfere with OnStar's ability to perform a diagnostic probe when requested (via a blue button call) by a subscriber. These devices also prohibit the ability to gather diagnostic and tire pressure data for a subscriber's scheduled OnStar(R) Vehicle Diagnostic (OVD) e-mail. These aftermarket devices utilize the Vehicles serial data bus to perform data requests and/or information gathering. When these devices are requesting data, OnStar(R) is designed not to interfere with any data request being made by these devices as required by OBD II regulations. The OnStar(R) advisor is unable to definitively detect the presence of these devices and will only be able to inform the caller or requester of the unsuccessful or incomplete probe and may in some cases refer the subscriber/requester to take the vehicle to a dealer for diagnosis of the concern. When performing a diagnostic check for an unsuccessful or incomplete OnStar(R) diagnostic probe, or for concerns regarding completeness of the OnStar(R) Vehicle Diagnostic (OVD) e-mail, verify that an aftermarket device was not present at the time of the requested probe. Regarding the OVD e-mail, if an aftermarket device is interfering (including a Scan Tool of any type), the e-mail will consistently display a "yellow" indication in diagnostics section for all vehicle systems except the OnStar(R) System and Tire Pressure data (not available on all vehicles) will not be displayed (i.e. section is collapsed). Successful diagnostic probes and complete OVD e-mails will resume following the removal or disconnecting of the off-board device. Disclaimer Page 7315 1. Disconnect the shift control module electrical connectors. 2. Unsnap and remove the shift control module from the bracket. Installation Procedure Page 8789 When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage TESTING FOR A SHORT TO VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity TESTING FOR CONTINUITY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents TESTING FOR ELECTRICAL INTERMITTENTS Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground - Testing for Continuity - Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 msRECORD and emits an audible tone (beep). Page 9593 Relay Block - I/P C1 Part 4 Page 4128 Vehicle Speed Sensor: Service and Repair Manual Transmission - ZF S6-650 Vehicle Speed Sensor (VSS) Replacement Removal Procedure 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. If equipped with the 6.6L engine, disconnect the vehicle speed sensor (VSS) electrical connector (4). 3. If equipped with the 8.1L engine, disconnect the VSS electrical connector (5). 4. Remove the VSS bolt, sensor and seal. Installation Procedure Page 1160 7. From inside the vehicle remove the upper bolt from the upper intermediate steering shaft (1) to the steering column connection. 8. Remove the upper intermediate steering shaft assembly. 1. From inside the vehicle slide the shaft down and off the steering column. 2. From inside the vehicle slide the upper intermediate shaft through the dash boot seal and remove the shaft from the vehicle. 9. Replace the upper intermediate shaft. 10. Install the upper intermediate steering shaft through the dash boot seal and slide the lower end into the steering gear coupling shaft. 11. Raise the upper end of the intermediate steering shaft and install into the steering column shaft. 12. Install the upper bolt and nut. Tighten Tighten the bolt to 47 N.m (35 lb ft). 13. Install the lower bolt and nut. Tighten Tighten the bolt to 50 N.m (37 lb ft). 14. For vehicles equipped with adjustable foot pedals perform the following steps: 1. Reposition the accelerator pedals into position on the bulkhead. 2. Install the two retaining nuts. Tighten Tighten the nuts to 20 N.m (15 lb ft). 3. Reposition the carpet into place. Parts Information Warranty Information For vehicles repaired under warranty use, the table. Page 14731 6. Install the lumbar actuator (5). 7. Install the seat switch bezel. 8. Place the cushion on the rear plastic holders (1) on the underside of the seat cushion, and push rearward. 9. Connect the lumbar cable to the underside of the seat cushion (6). Connect the lumbar wire harness, if equipped with power lumbar. Page 8193 A: Because the Pro-Cut on-car lathe adjusts in a live mode while spinning the hub/rotor, the dynamics of a floating axle are effectively eliminated. Once the lathe is compensated, there is no difference in the cutting/surface finish and LRO are just the same as with a non-floating axle. - Q: Which lathe is essential for performing brake work, the bench or on-car? A: Dealers must have a well maintained bench lathe and well maintained on-car lathe. These lathes need to be calibrated on a monthly basis. BOTH lathes are essential to providing quality brake service. - Q: What is the expected tip life for an on-car lathe? A: The geometry and composition of the Pro-Cut tips are designed for "single pass" cutting. When using the Pro-Cut the cutting depth should be set to take all material needed to get below rust grooves, eliminate all run-out and resurface the entire disc in a single pass. Cuts of 0.1016-0.381 mm (0.004-0.015 in) will provide the best surface finish and the optimal tip life. No "skim cut" or "finish cut" is needed. Failure to follow this procedure will shorten tip life. The Pro-cut tips will last between 7-12 cuts per corner. With three usable corners, a pair of tips is good for at least 21 cuts. - Q: Why does GM recommend the use of single pass (referred to as "positive rake") bench and on-car brake lathes? A: GM Service and GM Brake Engineering have performed competitive evaluations on a significant number of bench and on-car brake lathes. These tests measured critical performance characteristics such as flatness, surface finish and the ability of the lathe to repeat accuracy over many uses. In each test, single pass lathe designs out performed the competitors. Single pass brake lathes are more productive requiring less time to perform the same procedure. - Q: Is it okay to leave the caliper/pads installed while cutting rotors using an on-car lathe? A: On-car lathes should never be used with the pads and calipers installed on the vehicle. The debris from cutting the rotors can contaminate the brake pads/calipers which can lead to other brake concerns and comebacks. - Q: What information needs to be documented on the Repair Order? A: Any claim that is submitted using the labor operations in this bulletin, must have the Original Rotor Thickness and Refinish Rotor Thickness (if refinished) documented on the repair order. For more information, refer to the "Repair Order Required Documentation" section of this bulletin. All Warranty Repair Orders paid by GM, are subject to review for compliance and may be debited where the repair does not comply with this procedure. Brake Warranty BRAKE WARRANTY Brake Rotors: - Brake rotor warranty is covered under the terms of the GM New Vehicle Limited Warranty. Reference the vehicle's warranty guide for verification. - Rotors should not be refinished or replaced during normal/routine pad replacement. - Rotors should not be refinished or replaced and is ineffective in correcting brake squeal type noises and/or premature lining wear out. - Rotors should not be refinished or replaced for cosmetic corrosion. Clean up of braking surfaces can be accomplished by 10-15 moderate stops from 56-64 km/h (35-40 mph) with cooling time between stops. - Rotors should not be refinished or replaced for rotor discoloration/hard spots. - Rotors should be refinished NOT replaced for Customer Pulsation concerns. This condition is a result of rotor thickness variation, usually caused by LRO (wear induced over time and miles) or corrosion (Lot Rot). - When rotor refinishing, only remove the necessary amount of material from each side of the rotor and note that equal amounts of material do not have to be removed from both sides on any brake system using a floating caliper. - Rotors should be refinished for severe scoring - depth in excess of 1.5 mm (0.060 in). Important If the scoring depth is more than 1.5 mm (0.060 in) after the rotor is refinished, it should be replaced. Page 14273 1275 Round Table Dr. Dallas, TX 75247 (800) 826-0828 (Toll-Free) or (214) 631-4000 (Local) Fax (214) 634-1342 www.automagic.com [email protected] E038 Fallout Gel or E038E Liquid Fallout Remover II available from: Valvoline Car Brite Company 1910 South State Avenue Indianapolis, In 46203 (800) 347-2439 (Toll Free) or (317) 788-9925 (Local) Fax (317) 788-9930 www.carbrite.com [email protected] *We believe these sources and their products to be reliable. There may be additional manufacturers of such products. General Motors does not endorse, indicate any preference for or assume any responsibility for the products from these firms or for any such items which may be available from other sources. If rail dust remover is not available in your area, call one of the numbers listed above for a distributor near your location. Warranty Information (excluding Saab U.S. Models) Important Refer to the Policy & Procedures Manual, section 1.2.1.7 for detailed information regarding warranty coverage for this condition. Important In certain cases where the vehicle finish is severely damaged and the actual repair time exceeds the published time, the additional time should be submitted in the "Other Labor Hours" field. Warranty Information (Saab U.S. Models) Disclaimer A/T - Fluid Oil Cooler Flush Transmission Cooler: Technical Service Bulletins A/T - Fluid Oil Cooler Flush INFORMATION Bulletin No.: 02-07-30-052G Date: March 02, 2011 Subject: Automatic Transmission Oil Cooler Flush and Flow Test Essential Tool J 45096 TransFlow(R) Models: 2011 and Prior Passenger Cars and Light Duty Trucks 2003-2010 HUMMER H2 2006-2010 HUMMER H3 with Automatic Transmission/Transaxle including Allison(R) Transmissions Supercede: This bulletin is being revised to update the model years. Please discard Corporate Bulletin Number 02-07-30-052F (Section 07 - Transmission/Transaxle). Important All labor operations that include removal of the transmission from the vehicle include labor time to flush the transmission oil cooler system. The J 45096 transmission oil cooling system flush and flow test tool replaces current tool J 35944-A. J 45096 is a self-contained unit utilizing a 12-volt flow meter, shop air supply and DEXRON(R) VI automatic transmission fluid (ATF). In the flush mode, transmission fluid is cycled through the transmission oil cooling system. High-pressure air is automatically injected into the fluid stream adding agitation to the ATF oil to enhance the removal of contaminated ATF oil and debris. In the flow mode, an electronic flow meter is used to measure the flow capability of the ATF oil cooling system. A digital display indicates the ATF oil flow rate in gallons per minute (GPM) along with the amount of ATF oil in the supply vessel, supply vessel ATF oil temperature, machine cycles and the operating mode. The supply oil vessel has 30 L (32 qt) capacity and the waste oil vessel has 32 L (34 qt) capacity. The waste oil vessel is constructed of a translucent composite material that allows the user to easily identify the oil level. The waste oil vessel can accommodate vacuum evacuation and gravity draining. In the code mode, a random, encrypted code is generated that can be used for verification of flow test results. Current essential cooler line adapters are used to connect the J 45096 to the automatic transmission oil cooler lines that allows J 45096 to adapt to General Motors passenger cars and light duty trucks, current and past models (except the Pontiac Vibe, Wave and Chevrolet Aveo). The tool may be adapted for use on the Pontiac Vibe, Wave and Chevrolet Aveo by dealership personnel with a barbed hose connector and rubber hose obtained locally. The Vibe's/Wave's/Aveo's transmission has a transmission oil requirement which is slightly different than DEXRON(R) VI ATF. However, flushing the cooler with DEXRON(R) VI automatic transmission fluid is an acceptable service procedure. Very little fluid remains in the cooler after the flush procedure and the residual DEXRON(R) VI ATF in the cooler is compatible with the Vibe's/Wave's/Aveo's transmission fluid. Notice Insufficient oil flow through the ATF oil cooling system will cause premature transmission failure. The required minimum ATF oil flow rate reading is directly related to the supply oil temperature. Refer to the flow rate reference chart for the oil flow rate specification based on the temperature of the ATF in the supply vessel. Helpful Hints for Maintaining the Temperature at or above 18°C (65°F) Important - The temperature of the supply vessel oil must be 18°C (65°F) or greater for J 45096 to operate. It is recommended to store the J 45096 in an area of the dealership where the room temperature remains at or above 18°C (65°F) when not in use. - Do not attempt to increase the fluid temperature in the Transflow(R) machine with an engine oil dipstick, or any other immersion type heater. The Transflow(R) machine has a check valve in the supply reservoir. Inserting a heater will damage the check valve and the subsequent repair expense would be the dealer's responsibility. - A heater blanket, P/N J-45096-10, is available for the Transflow(R) transmission cooling system flushing tool. This heater fastens around the Transflow(R) internal supply vessel and runs on 110 volts AC. The heater will warm the ATF in the supply vessel to at least 18°C (65° F) and has a thermostat to hold a constant temperature. Store the Transmission Cooling System Service Tool, J 45096, Transflow(R) machine in a room where the temperature is maintained at or above 18°C (65°F). Keep the ATF level in the reservoir low when the Transmission Cooling System Service Tool, J 45096, Transflow(R), is not in use. Store several gallons of oil in an area where the temperature is maintained at or above 18°C (65°F). Fill the reservoir of the J 45096 as needed before using the machine on Page 8210 5. Install the rotor by slowly turning the rotor while pushing the rotor towards the axle. 6. If the brake rotor was removed and installed as part of a brake system repair, measure the assembled lateral runout (LRO) of the brake rotor to ensure optimum performance of the disc brakes. Refer to Brake Rotor Assembled Lateral Runout (LRO) Measurement. 7. If the brake rotor assembled LRO measurement exceeds the specification, bring the LRO to within specifications. Refer to Brake Rotor Assembled Lateral Runout (LRO) Correction. 8. Install the brake caliper and the brake caliper mounting bracket as an assembly to the vehicle. 9. Perform the following procedure before installing the 2 brake caliper bracket mounting bolts. 1. Remove all traces of the original adhesive patch. 2. Clean the threads of the bolts with brake parts cleaner or the equivalent and allow to dry. 3. Apply Threadlocker GM P/N 12345493 (Canadian P/N 10953488) to the threads of the bolts. 10. Notice: Refer to Fastener Notice in Service Precautions. Install the brake caliper bracket mounting bolts. ^ Tighten the brake caliper bracket mounting bolts to 200 Nm (148 ft. lbs.). 11. Install the quarter shaft shield. 12. Install the quarter shaft shield nut and the bolt. ^ Tighten the quarter shaft shield nut and the bolt to 25 Nm (18 ft. lbs.). 13. Install the tire and wheel assembly. 14. Lower the vehicle. 15. With the engine OFF gradually apply the brake pedal to approximately 2/3 of it's travel distance. 16. Slowly release the brake pedal. 17. Wait 15 seconds then repeat steps 15-16 until a firm pedal is obtained. This will properly seat the brake caliper pistons and brake pads. Underhood Fuse Block LR Of The Engine Compartment (With RPO Code 9L4) Page 9324 5. Push on the tab (3) so that the electrical center can be rotated on the studs located at (2). 6. Remove all connectors by removing the bolt (1) for each connector. 7. Disconnect all connectors from the electrical center block. 8. Push on the tabs (2) in order to lift the electrical center (1) out of the housing. 9. To replace the engine electrical center bracket remove the 4 retaining bolts (1). 10. Remove the engine electrical center bracket assembly from the fender. INSTALLATION PROCEDURE Page 3001 Important: After drilling the holes, apply the appropriate anti-corrosion primer. Refer to the GM Refinish Material Booklet # 4901 M-D (English) or # 4901-D-F (French) for additional information. 6. Center punch the marked location and drill a 6.35 mm (1/4 in) hole. Install the plastic retainer in the hole (1) of the mud flap. 7. Tighten fastener at the hole (2) location of the mud flap. Tighten Tighten the fastener to 25 N.m (18 lb ft). 8. For vehicles with short box, use the following procedure: 8.1. Push the mud flap to make contact with the rear side of the underbody cross sill and mark the location of the hole (3) of the mud flap. 8.2. Center punch the marked location and drill a 5.159 mm (13/64 in) hole. 8.3. Install the screw. Tighten Tighten the screw to 4 N.m (35 lb in). 8.4. Repeat the above steps for hole locations 4 and 6. 9. For vehicles with long box, use the following procedure: Page 10249 circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links CIRCUIT PROTECTION - FUSIBLE LINKS Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Flat Wire Repairs FLAT WIRE REPAIRS NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Heated Oxygen Sensor (HO2S) Wiring Repairs HEATED OXYGEN SENSOR (HO2S) WIRING REPAIRS TOOLS REQUIRED J 38125-D Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: - Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-D. Repairing Damaged Wire Insulation REPAIRING DAMAGED WIRE INSULATION Keyless Entry - Inoperative Keyless Entry Module: All Technical Service Bulletins Keyless Entry - Inoperative Bulletin No.: 04-08-52-005 Date: June 15, 2004 TECHNICAL Subject: Remote Keyless Entry (RKE) System Inoperative (Reprogram Passenger Door Module (PDM)) Models: 2004 Cadillac Escalade, Escalade ESV, Escalade EXT 2004 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2004 GMC Sierra, Yukon, Yukon XL Condition Some customers may comment on any of the following conditions: ^ The RKE key fob does not function. ^ The "Service Tire Pressure Monitoring System" message is displayed, if equipped. ^ The passenger door will not unlock from the passenger's or driver's door switches. ^ The passenger door window is inoperative. Correction Reprogram the PDM with the Tech 2(R). Currently the Tech 2(R) software is not available for the 2004 model year. Engineering is aware of this and are working to release a new service calibration. In the meantime, build the Tech 2(R) as a 2003 model year and perform the reprogram using the procedure listed below. 1. Turn the ignition switch to the ON position. 2. Connect the Tech 2(R) to the vehicle's diagnostic link connector (DLC), power it up and press enter. ^ Select: Diagnostics. ^ Select model year: 2003. ^ Select: Light truck. ^ Select: Body. ^ Select the proper Product line. ^ Select the proper HVAC Type. ^ Select the proper Radio System type. ^ Select: Passenger Door Module. ^ Select: Special Functions. ^ Select: Refresh. Important: You must remove the described fuse in the next step for the "Refresh" program to be performed. If you do not remove the fuse for five seconds, the Tech 2 will continue to display "Test in Progress" and the program will not complete. ^ Remove the PDM fuse for 5 seconds from the fuse center located behind the panel on the left end of the instrument panel. Page 8788 Refer to the table as a guide in selecting the correct test adapter for frontprobing connectors: Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure SCAN TOOL SNAPSHOT PROCEDURE Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: - Snapshot - taken from the Snapshot menu choice - Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information Emissions - MIL ON/DTC P0446 Stored In ECM Evaporative Check Valve: All Technical Service Bulletins Emissions - MIL ON/DTC P0446 Stored In ECM TECHNICAL Bulletin No.: 02-06-04-037I Date: September 16, 2010 Subject: Check Engine Light On, Fuel Tank Hard to Fill, DTCs P0442, P0446, P0455 or P0449 Set (Replace Evaporative Emission (EVAP) Vent Valve Solenoid Assembly and Add/Relocate Filter Box Using Service Kit) Models: 1999-2007 Chevrolet Silverado (Classic) Models 1999-2007 GMC Sierra (Classic) Models 2007-2010 Chevrolet Silverado Models (Including Hybrid) 2007-2010 GMC Sierra Models (Including Hybrid) Supercede: This bulletin is being revised to add the 2010 model year and to include the Hybrid models. Please discard Corporate Bulletin Number 02-06-04-037H (Section 06 - Engine/Propulsion System). Condition Some customers may comment about the check engine light being illuminated. They may also comment that their vehicle is difficult to fill with fuel or when filling, the pump continuously shuts off before the tank is full. When checking the vehicle for DTCs, the ECM may report one or more of the following DTCs set as current or in history: P0442, P0446, P0449 or P0455. Cause The EVAP canister vent solenoid (CVS) valve draws fresh air into the system through a vent. Under certain operating conditions, dirt and dust intrusion into the EVAP CVS fresh air intake/venting system, may result in restricted air flow. Under certain operating conditions, water, if ingested into the EVAP CVS fresh air intake/venting system, may reach the CVS valve causing corrosion in the CVS valve, and may cause restrictions in the fresh air intake path, when the valve is in the closed position. Correction (1999-2007 Classic/Old Style Models) After following the published SI diagnostics and determining that the EVAP canister vent valve is the cause of the MIL light, replace the existing EVAP canister vent valve assembly with a new assembly. This new assembly is a sealed unit that is designed to be vented through a remote filter box. To ensure correct installation, follow the procedures below. Important DO NOT replace the EVAP canister assembly for this concern unless it fails the leak test. 1999-2003 Model Year (Use Service Kit P/N 19207762) 1. Raise the vehicle. Suitably support the vehicle. 2. Disconnect the EVAP canister vent valve electrical connector, if equipped. 3. Disengage the two vent valve pipe clips securing the pipe to the underbody. Remove the clips from the underbody and discard. 4. Disconnect the vent valve pipe at the EVAP canister. 5. Remove and retain the EVAP canister vent valve bracket mounting bolt. 6. Remove the complete EVAP canister vent valve assembly with bracket attached and discard. Page 10581 Important Other forms of slow air leaks are possible. If the body of the tire, valve stem and wheel flange show no signs of air seepage, refer to Corporate Bulletin Number 05-03-10-003D for additional information on possible wheel porosity issues. 3. Bead seat corrosion is identified by what appears like blistering of the wheel finish, causing a rough or uneven surface that is difficult for the tire to maintain a proper seal on. Below is a close-up photo of bead seat corrosion on an aluminum wheel that was sufficient to cause slow air loss. Close-Up of Bead Seat Corrosion 4. If corrosion is found on the wheel bead seat, measure the affected area as shown below. - For vehicles with 32,186 km (20,000 mi) or less, the total allowable combined linear area of repairable corrosion is 100 mm (4 in) or less. If the total area(s) of corrosion exceed these dimensions, the wheel should be replaced. - For vehicles that have exceeded 32,186 km (20,000 mi), the total allowable combined linear area of repairable corrosion is 200 mm (8 in) or less. If the total area(s) of corrosion exceed these dimensions, the wheel should be replaced. 5. In order to correct the wheel leak, use a clean-up (fine cut) sanding disc or biscuit to remove the corrosion and any flaking paint. You should remove the corrosion back far enough until you reach material that is stable and firmly bonded to the wheel. Try to taper the edge of any flaking paint as best you can in order to avoid sharp edges that may increase the chance of a leak reoccurring. The photo below shows an acceptable repaired surface. Notice Corrosion that extends up the lip of the wheel, where after the clean-up process it would be visible with the tire mounted, is only acceptable on the inboard flange. The inboard flange is not visible with the wheel assembly in the mounted position. If any loose coatings or corrosion extend to the visible surfaces on the FACE of the wheel, that wheel must be replaced. Important Remove ONLY the material required to eliminate the corrosion from the bead seating surface. DO NOT remove excessive amounts of material. ALWAYS keep the sealing surface as smooth and level as possible. Page 15858 The information shown is for the 1999-2002 wiring harnesses and for the 2003-05 wiring harness. To modify a 12171982, 15366255 or 15086884 harness for use in a 2003-05 vehicle, switch the wires in cavities "A" and "D". To modify a 15085418 harness for use in a 1999-2002 vehicle (see model list at the front of this bulletin for applicable models), switch the wires in cavities "A" and "D". Warranty Information When the correct wiring harness P/N is matched to the specific model year of the vehicle, everything works properly. Therefore, conversion of an incorrect wiring jumper to match the vehicle would not be considered a warrantable repair. Disclaimer Page 2692 Relay Block - I/P C4 Steering Wheel Position Sensor or Steering Shaft Lower Bearing Replacement Steering Column Position Sensor: Service and Repair Steering Wheel Position Sensor or Steering Shaft Lower Bearing Replacement Steering Wheel Position Sensor or Steering Shaft Lower Bearing Replacement (Centering Required) ^ Tools Required J 42640 Steering Column Anti-Rotation Pin Removal Procedure 1. Set the front wheels in the straight-ahead position. 2. Install J 42640 or set the steering wheel in the LOCKED position. 3. Caution: Refer to SIR Caution in Service Precautions. Disconnect the negative battery cable. 4. Disable the SIR. 5. Important: You MUST make an alignment mark on the upper intermediate shaft to the steering column shaft, where they connect. You will need the alignment marks for installation. Make an alignment mark on the upper intermediate shaft and the steering column shaft, where they connect, before removal. 6. Remove the nut and the bolt from the upper to the lower steering shaft connection. Slide the lower shaft down. 7. Remove the steering wheel position sensor connector by using a suitable tool in order to pull the connector down around the right side of the steering column for accessibility. 8. Important: Do not apply force to the steering wheel position sensor and the adapter and bearing assembly in a sideways direction. If reusing the existing steering wheel position sensor, it MUST be centered before removal. Verify the type of steering wheel position sensor before removal. Refer to Steering Wheel Position Sensor Centering. 9. Remove the steering wheel position sensor and adapter and bearing assembly from the steering column jacket by pulling the assembly straight out. 10. Remove the steering wheel position sensor from the clips in the adapter and bearing assembly. Installation Procedure 1. Important: A new sensor MUST come with a pin installed. If pin is not installed, return and reorder sensor. Verify the following before installing the steering wheel position sensor: ^ The front wheels are in the straight-ahead position. ^ That J 42640 is installed or the steering wheel is in the LOCKED position. 2. If reusing the existing steering wheel position sensor, verify the type of sensor you have before installing. Refer to Steering Wheel Position Sensor Centering. 3. Install the steering wheel position sensor into the adapter and bearing assembly. 4. Install the adapter and bearing assembly into the steering column jacket. 1. Align the notches on the adapter and bearing assembly and the steering column jacket. 2. Important: Page 12528 Test Description DTC U1001 and U1254 Circuit/System Description Modules connected to the Class 2 serial data circuit monitor for serial data communications during normal vehicle operation. Operating information and commands are exchanged among the modules. When a module receives a message for a critical operating parameter, the module records the identification number of the module which sent the message for State of Health monitoring. A critical operating parameter is one which, when not received, requires that the module use a default value for that parameter. Once an identification number is learned by a module, it will monitor for that module's Node Alive message. Each module on the class 2 serial data circuit which is powered and performing functions that require detection of a communications malfunction is required to send a Node Alive message every 2 seconds. When no message is detected from a learned identification number for 5 seconds, a DTC U1XXX where XXX is equal to the 3-digit identification number is set. Page 1832 Do not apply force to the steering wheel position sensor and the adapter and bearing assembly in a sideways direction. Seat the adapter and bearing assembly into the steering column jacket. 5. Connect the steering wheel position sensor connector. 6. Notice: Refer to Fastener Notice in Service Precautions. Align the marks on the upper intermediate shaft and the steering column shafts, where they connect, that you made during the removal procedure. 7. Install the intermediate shaft to the steering column pinch bolt. ^ Tighten the nut to 62 Nm (46 ft. lbs.). 8. Connect the negative battery cable. 9. Enable the SIR system. Page 7051 6. Slide the rear propeller shaft forward in order to remove the propeller shaft from the rear axle pinion yoke. Notice: When removing the propeller shaft, do not attempt to remove the shaft by pounding on the yoke ears or using a tool between the yoke and the universal joint. If the propeller shaft is removed by using such means, the injection joints may fracture and lead to premature failure of the joint. 7. Slide the rear propeller shaft rearward in order to disconnect the rear propeller shaft from the front propeller shaft stub shaft. 8. Remove the rear propeller shaft from the vehicle. 9. Remove the boot from the front propeller shaft stub shaft (if applicable). 10. Remove the center bearing support nuts (1). 11. Remove the center bearing support (2). 12. Remove the front propeller shaft by sliding the front propeller shaft rearward from the transmission or the transfer case, w/o RPO MW3 or M74. 13. Remove the bolts and the yoke retainers from the transmission pinion yoke, w/ RPO MW3 or M74. 14. Remove the front propeller shaft by disconnecting the front propeller shaft from the transmission pinion yoke, w/ RPO MW3 or M74. Installation Procedure Page 3983 Intake Air Temperature (IAT)/Mass Air Flow (MAF) Sensor Page 9930 Frame Angle Measurement (Express / Savana Only) ........ Page 8896 If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Sir/SRS Wiring Repairs SIR/SRS WIRING REPAIRS TOOLS REQUIRED J 38125-D Terminal Repair Kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-D contains the following items: - Special sealed splices - in order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping tool - A heat torch - An instruction manual The sealed splices have the following 2 critical features: - A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-D also serves as a generic terminal repair kit. The kit contains the following items: - A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors Page 15076 Use a block of wood and/or a drill stop in order to protect the back of the cab while drilling. 4. Drill two 13.5 mm (0.54 in) holes per side into the box section of the front panel. 5. Drill 7.5 mm (0.30 in) holes into the weld flange of the side outer panel. 6. Apply anti-corrosion material to the drilled holes as necessary per the GM 4901M-D-2005 (English) or 4901M-D-F 2005 (French) Approved Refinish Materials booklet. The information for the 2005 GM Approved Refinish Materials booklet will now be online at the GMGOODWRENCH WEB SITE ONLY. Printed books have been discontinued. Steps to the site are as follows: A. Go to www.gmgoodwrench.com. B. Click on GM Collision Parts. C. Click on GM Technical Repair Information. D. Click on Paint Shop. 7. Place the front reinforcements back onto the box, lining up the drilled holes. 8. Install the large shoulder (M8) bolts into the reinforcement and front panel (total of 4) and the small (M6) bolts into the reinforcement and side outer panel (total of 6) with the nuts. Tighten ^ Tighten the M8 bolts to 25 Nm (18 lb-ft). ^ Tighten the M6 bolts to 9 Nm (79 lb-in). 9. Remove all metal shavings from the pickup box afier installation. 10. Install the bedliner if equipped with the aid of an assistant. The bedliner may need to be trimmed in order to obtain the necessary clearance for the reinforcements. Ladder Rack and/or Side ToolBox Applications - Reinforcement Kit Installation 1. Install the LH and RH front L-shaped reinforcements using the procedure above. 2. Remove the LH and RH rear taillamp assemblies. This is necessary to gain access to install the rearmost bolt of the rear reinforcement. 3. Place the LH and RH rear reinforcements into position on the pickup box. 4. Mark the holes necessary for drilling and remove the reinforcements. 5. Drill 7.5 mm (0.30 in) holes into the weld flange of the side outer panel. 6. Apply anti-corrosion material to the drilled holes as necessary. Refer to step 6 under Front Reinforcement Installation procedure. 7. Place the rear reinforcements back onto the pickup box. 8. Install the M6 bolts through the reinforcement and side panel with the nuts. Tighten Tighten the bolts to 9 Nm (79 lb-in). Locations Forward Lamp Harness Page 6249 1. Install the filter neck seal. 2. Install the oil filter. 3. Install the oil pan gasket to the pan. 4. Install the magnet into the bottom of the pan, if necessary. 5. Install the oil pan and bolts. ^ Tighten the oil pan bolts to 24 Nm (18 ft. lbs.). 6. Position the bracket with cable. Install the transmission range selector cable bracket (2) and bolts to the transmission. ^ Tighten the selector bracket bolts to 25 Nm (18 ft. lbs.). 7. Connect the range selector cable end (2) to the transmission range selector lever ball stud (1). Page 15780 Door Latch Assembly (Door Jamb Switch) - LR - C2 (Crew Cab Only) Page 12574 Page 10625 10. Align the inscribed mark on the tire with the valve stem on the wheel. 11. Reinstall the Tire Pressure Sensor. Refer to Tire Pressure Sensor installation procedure in SI. 12. Mount the tire on the wheel. Refer to Tire Mounting and Dismounting. 13. Pressurize the tire to 276 kPa (40 psi) and inspect for leaks. 14. Adjust tire pressure to meet the placard specification. 15. Balance the tire/wheel assembly. Refer to Tire and Wheel Assembly Balancing - Off-Vehicle. 16. Install the tire and wheel assembly onto the vehicle. Refer to the appropriate service procedure in SI. Parts Information Warranty Information (excluding Saab U.S. Models) Important The Silicone - Adhesive/Sealant comes in a case quantity of six. ONLY charge warranty one tube of adhesive/sealant per wheel repair. For vehicles repaired under warranty, use: One leak repair per wheel. Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table above. Disclaimer Campaign - HVAC Blower Not Functional Runs Continuously Control Module HVAC: All Technical Service Bulletins Campaign - HVAC Blower Not Functional Runs Continuously SPECIAL COVERAGE Bulletin No.: 11046 Date: April 07, 2011 Subject: 11046 - Special Coverage Adjustment - Heating, Ventilation, and Air Conditioning Blower Not Fully Functional on All Blower Speeds, Inoperative, or Runs Continuously with the Ignition Off Models: 2003-2006 Chevrolet Avalanche, Suburban, Tahoe 2003-2007 Chevrolet Silverado 2003-2006 GMC Yukon, Yukon XL 2003-2007 GMC Sierra Equipped with Manual HVAC (CJ3) or Heavy Duty Heater (C42) Due to part availability, owner letters will be released in phases starting with older model year first. Owners for model year vehicles not included in first phase owner mailing will receive an owner advisory letter. The letter will inform the customer that parts are not yet available and that another letter will be sent to them when parts become available. A copy of this letter will be attached to the dealer message announcing this bulletin. In the meantime, if a customer brings their vehicle to the dealership with the condition described in this bulletin, repair the vehicle using the parts called out in this bulletin. Condition On some 2003-2006 model year Chevrolet Avalanche, Suburban, Tahoe; GMC Yukon, Yukon XL; and 2003-2007 model year Chevrolet Silverado and GMC Sierra vehicles equipped with a manual heating, ventilation, and air conditioning (HVAC) system (CJ3) or heavy duty heater (C42), the interface between the electrical terminals of the relay resistor module and the wiring connector that powers the module may be incapable of conducting higher current levels for sustained periods of blower motor operation. In addition, moisture and other contaminants may enter the fresh air intake plenum and contact the internal circuit of the module or corrode the terminals. Either of the above may cause the relay resistor module or wiring connector to overheat, resulting in one or more of the following symptoms: - The HVAC blower may not function on certain or all blower speed settings - A burning plastic smell or smoke may be present in the vehicle - The HVAC blower may run continually with the ignition in the OFF position In very rare events, if the above symptoms are ignored, a fire could occur. Special Coverage Adjustment This special coverage covers the condition described above for a period of 10 years or 240,000 km, whichever occurs first, from the date the vehicle was originally placed in service, regardless of ownership. Dealers are to install a new blower motor resistor and resistor module connector. The repairs will be made at no charge to the customer. For vehicles covered by Vehicle Service Contracts, all eligible claims with repair orders on or after April 8, 2011 are covered by this special coverage and must be submitted using the labor operation codes provided with this bulletin. Claims with repair orders prior to April 8, 2011 must be submitted to the Service Contract provider. Vehicles Involved Involved are certain 2003-2006 model year Chevrolet Avalanche, Suburban, Tahoe; GMC Yukon, Yukon XL; and 2003-2007 model year Chevrolet Silverado and GMC Sierra vehicles equipped with a manual HVAC (CJ3) or heavy duty heater (C42). Important Dealers are to confirm vehicle eligibility prior to beginning repairs by using the Applicable Warranties section in the Global Warranty Management system. Parts Information Page 7935 1. Lubricate the input speed sensor seal with automatic transmission fluid. 2. Install the input speed sensor (1). Notice: Refer to Fastener Notice in Service Precautions. 3. Install the input speed sensor bolt. ^ Tighten the bolt to 11 Nm (96 inch lbs.). 4. Connect the input speed sensor electrical connector (1). 5. Lower the vehicle. Propshaft Speed Sensor - Front Page 12606 2. Skip to the next step if the vehicle to be upgraded is not shown above. 3. Skip to the next step if the vehicle to be upgraded is not a 2005 Cadillac STS. The 2005 Cadillac STS kit may include a new inside rearview (ISRV) mirror assembly and a new ISRV mirror wiring cover. If the kit you receive includes these parts, please remove the existing ISRV mirror and wire cover from the vehicle and install the ones provided in the kit per the instructions in SI. 4. Skip this step if the vehicle to be upgraded is not listed below. ^ 2003-2004 Saturn L-Series ^ 2003 Saturn ION ^ 2002-2003 Saturn VUE 1. Locate and remove the Right Audio output signal terminal 7 from Connector C2 at the Vehicle Communication Interface Module (VCIM). 2. Remove the terminal end and strip the wire. 3. Locate the Left Audio output signal wire from terminal 1 in Connector C2. 4. Splice the Right Audio output signal wire from terminal 7 with the Left Audio output signal wire from terminal 1. 5. See Wiring Repairs in SI for approved splicing methods. Page 3139 6. Rotate the crankshaft until the number one piston is at top dead center (TDC) of the compression stroke.In this position, cylinder number one rocker arms will be off lobe lift, and the crankshaft sprocket key will be at the 1:30 position.The engine firing order is 1, 8, 7, 2, 6, 5, 4, 3.Cylinders 1, 3, 5 and 7 are the left bank.Cylinder 2, 4, 6 and 8 are the right bank. Notice: Refer to Fastener Notice in Service Precautions. 7. With the engine in the number one firing position, tighten the following valve rocker arm bolts: ^ Tighten the cylinders 1, 2, 7 and 8 exhaust valve rocker arm bolts to 30 Nm (22 ft. lbs.). ^ Tighten the cylinders 1, 3, 4 and 5 intake valve rocker arm bolts to 30 Nm (22 ft. lbs.). 8. Rotate the crankshaft 360 degrees. 9. Tighten the following valve rocker arm bolts: ^ Tighten the cylinders 3, 4, 5 and 6 exhaust valve rocker arm bolts to 30 Nm (22 ft. lbs.). ^ Tighten the cylinders 2, 6, 7 and 8 intake valve rocker arm bolts to 30 Nm (22 ft. lbs.). 10. Install the valve rocker arm cover. Page 6969 Remove all rust from the ground terminal, the cylinder head and the retaining nut or bolt. Position the main engine wiring harness ground terminal and install the nut or bolt. Tighten: Tighten the retaining nut or bolt to 16 N.m (12 lb ft). Apply some type of electrical moisture sealant to protect the harness terminal from further corrosion. Disclaimer Page 16076 When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage TESTING FOR A SHORT TO VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity TESTING FOR CONTINUITY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents TESTING FOR ELECTRICAL INTERMITTENTS Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground - Testing for Continuity - Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 msRECORD and emits an audible tone (beep). Page 9589 Junction Block - Rear Lamps - C4 Relay Block - I/P C1 Page 5202 - Shell - Shell-Canada - Entec Stations located in the greater Montgomery, Alabama area. - MFA Oil Company located throughout Missouri. - Kwik Trip, Inc. in Minnesota and Wisconsin and Kwik Star convenience stores in Iowa. The Somerset Refinery, Inc. at Somerset Oil stations in Kentucky. Aloha Petroleum - Tri-Par Oil Company - Turkey Hill Minit Markets - Texaco - Petro-Canada - Sunoco-Canada - Road Ranger located in Illinois, Indiana, Iowa, Kentucky, Missouri, Ohio and Wisconsin What is TOP TIER Detergent Gasoline? TOP TIER Detergent Gasoline is a new class of gasoline with enhanced detergency. It meets new, voluntary deposit control standards developed by six automotive companies that exceed the detergent requirements imposed by the EPA. Where Can TOP TIER Detergent Gasoline Be Purchased? The TOP TIER program began on May 3, 2004 and many fuel marketers have joined the program and have introduced TOP TIER Detergent Gasoline. This is a voluntary program and not all fuel marketers will offer this product. Once fuel marketers make public announcements, they will appear on a list of brands that meet the TOP TIER standards. Where Can I find the Latest Information on TOP TIER Fuel and Retailers? On the web, please visit www.toptiergas.com for additional information and updated retailer lists. Who developed TOP TIER Detergent Gasoline standards? TOP TIER Detergent Gasoline standards were developed by six automotive companies: Audi, BMW, General Motors, Honda, Toyota and Volkswagen. Why was TOP TIER Detergent Gasoline developed? TOP TIER Detergent Gasoline was developed to increase the level of detergent additive in gasoline. The EPA requires that all gasoline sold in the U.S. contain a detergent additive. However, the requirement is minimal and in many cases, is not sufficient to keep engines clean. In order to meet TOP TIER Detergent Gasoline standards, a higher level of detergent is needed than what is required by the EPA. Also, TOP TIER was developed to give fuel marketers the opportunity to differentiate their product. Why did the six automotive companies join together to develop TOP TIER? All six corporations recognized the benefits to both the vehicle and the consumer. Also, joining together emphasized that low detergency is an issue of concern to several automotive companies. What are the benefits of TOP TIER Detergent Gasoline? TOP TIER Detergent Gasoline will help keep engines cleaner than gasoline containing the "Lowest Additive Concentration" set by the EPA. Clean engines help provide optimal fuel economy and performance and reduced emissions. Also, use of TOP TIER Detergent Gasoline will help reduce deposit related concerns. Disclaimer Page 7271 Steps 10-13 The numbers below refer to the step numbers on the diagnostic table. 3. This step checks for other system DTCs that may affect the PTO. 6. This step tests the PCM for the PTO Enable signal. 7. This step tests the communication between the PCM and the TAC module. 8. This step tests the PTO On Switch Signal circuit. 9. This step tests the PTO On Switch-Signal circuit for an open, high resistance or short to ground. 10. This step tests the Serial Data circuits for an open, high resistance or short to ground. Power Take-Off (PTO) Does Not Engage POWER TAKE-OFF (PTO) DOES NOT ENGAGE CIRCUIT DESCRIPTION This symptom table aids in the diagnosis of a failed power take-off (PTO) solenoid engagement. This diagnostic does not expose a mechanical condition with the PTO itself. Voltage is supplied at all times through the cruise fuse to the secondary side of the relay. When the relay is energized, the contacts close and current is allowed to flow to the PTO solenoid. The solenoid has its own external ground. When the ignition switch is in the RUN position, voltage is present at the PTO switch. When the PTO switch is in the ON position, voltage is present at the coil of the relay and at the PCM. If the PCM sees all of the conditions necessary to engage the solenoid, the PCM grounds the primary circuit of the relay. TEST DESCRIPTION Page 3682 1. If installing the old sensor, coat the threads with sealant GM P/N 12346004 (Canadian P/N 10953480) or equivalent. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the ECT sensor. Tighten Tighten the sensor to 20 N.m (15 lb ft). 3. Connect the ECT sensor electrical connector (5). 4. Refill the cooling. Refer to Draining and Filling Cooling System in Cooling System. Page 12698 Diagnostic Tips Review Table Page 1103 3. Notice: Refer to Fastener Notice in Service Precautions. Install a new 4 mm bolt (1), with LOCTITETM , to the brake pedal position sensor. ^ Tighten the bolt to 9 Nm (80 inch lbs.). 4. Calibrate the brake pedal position sensor. Page 530 Door Control Module Diagram 2 Part 1 Page 11129 3. Place a protective cover over the carpet below the evaporator core. 4. Remove the cabin air filter, if equipped, and cover the opening prior to applying the Cooling Coil Coating, as the product may clog the filter. If the cabin air filter appears to have little or no remaining life, suggest a replacement to your customer. 5. If the HVAC module has a blower motor cooling tube, be careful NOT TO SPRAY THE COOLING COIL COATING INTO THE BLOWER MOTOR COOLING TUBE. 6. Attach the Flexible Applicator Pressure Spray Tool (J-43810-20A) to a compressed air line operating at 586 kPa (85 psi) to 793 kPa (115 psi). 7. Shake the bottle of Cooling Coil Coating well. Screw the bottle onto the cap on the applicator tool's pick-up tube. Note The pick-up tube is designed for 120 ml (4 oz) and 240 ml (8 oz) bottles and should coil slightly in the bottom of a 120 ml (4 oz) bottle. 8. Use one of the following three methods to apply the Cooling Coil Coating. Important If the Pressure Applicator Spray Tool (J-43810-20A) is not available, the Cooling Coil Coating is also available in an aerosol can (P/N 12377951 (in Canada, 10953503)). Application Through Blower Motor Control Module Opening - Remove the blower motor control module (blower motor resistor). Refer to the applicable procedure in SI. - Clean any debris or foreign material from inside the HVAC module and on the evaporator core surface. - Apply the Cooling Coil Coating directly to the evaporator core through the blower motor blower motor control module (blower motor resistor) opening. - Use the flexible wand to direct the Cooling Coil Coating over the entire evaporator core and surrounding gasket surfaces. - When the application is complete, install the blower motor blower motor control module (blower motor control module). Application Through Blower Motor Opening - Remove the blower motor. Refer to the applicable blower motor removal procedure in SI. - Clean any debris or foreign material from inside the HVAC module and on the evaporator core surface. - Apply the Cooling Coil Coating directly to the evaporator core through the blower motor opening. - Use the flexible wand to direct the Cooling Coil Coating over the entire evaporator core and surrounding gasket surfaces. - When the application is complete, install the blower motor. Application Through a Hole in the HVAC Module - If neither of the two previous application methods are available, it may be necessary to drill a hole in the HVAC module. - Locate an area of the HVAC module between the blower motor and the evaporator core. Drill a 10 mm (3/8 in) hole in the HVAC module. Use caution to keep the drill clear of the evaporator core and the blower motor fan. - With the air distribution vents closed and the blower motor fan speed on HIGH, insert the applicator tool into the hole and spray the Cooling Coil Coating into the airstream toward the evaporator core. - Use a GM approved RTV sealant to plug the hole in the HVAC module. 9. After the Cooling Coil Coating application is complete, start and run the vehicle for approximately 10 minutes, with the compressor disabled, HVAC mode set to Recirculate/Max, heat set to full warm, blower motor fan speed on high, and one window open approximately 12 mm (1/2 in). This cures the Cooling Coil Coating onto the evaporator core surface. 10. While the engine is running, rinse the applicator tool with warm water to prolong the life of the tool. Be sure to spray warm water through the nozzle to rinse out any residual Cooling Coil Coating still in the capillary pick up tube, otherwise it will dry and clog the applicator tool. Also remove the small green valve from the bottle cap and rinse it thoroughly while rolling it between two fingers and then reinstall it. If this valve is clogged , the Cooling Coil Coating will not flow through the applicator tool. 11. Shut off the engine and enable the compressor again. 12. Verify proper HVAC system operation. 13. Remove the protective cover from inside the vehicle. 14. Remove the drain pan from underneath the vehicle. 15. Reinstall the cabin air filter if necessary. Page 2019 Control Module References Part 4 Specifications Clutch Fluid: Specifications HYDRAULIC CLUTCH FLUID 5-SPEED TRANS. Hydraulic Clutch Fluid (GM Part No. U.S. 12345347, in Canada 10953517) or equivalent DOT-3 brake fluid. 6-SPEED TRANS. Hydraulic Clutch Fluid. Use only GM Part No. U.S. 88958860, in Canada 88901244, DOT-4 brake fluid. Page 4807 5. Connect the fuel pump electrical connector. 6. Install the sending unit. Page 2022 Control Module References Part 7 Page 12001 Page 3831 Body Control Module (BCM) - C6 Part 1 Page 16160 SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-D. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: - The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair Tools Required J 38125-D Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-D. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Page 6302 The purpose of this bulletin is to identify the correct oil pump rotor (212) and slide (203) usage for the two different transmission oil pump designs. Manufacturing of the first design oil pump rotor (212) and slide (203) ended November 30, 2000. Manufacturing of the second design oil pump rotor (212) and slide (203) began December 1, 2000. Important: It is critical that the first and second design oil pump rotors and slides do not become intermixed. Do not use first design pump components with second design pump components. If the pump components from either design are intermixed, pump efficiency will be affected resulting in less than optimal pump performance. The first design oil pump rotor (212) and slide (203) DO NOT have any identification markings. Page 1533 Accelerator Pedal Position Sensor: Description and Operation ACCELERATOR PEDAL POSITION (APP) SENSOR The accelerator pedal assembly contains 2 individual APP sensors within the assembly. The APP sensors 1 and 2 are potentiometer type sensors, each with the following circuits: - A 5-volt reference circuit - A low reference circuit - A signal circuit The APP sensors are used to determine the pedal angle. The control module provides each APP sensor a 5-volt reference circuit and a low reference circuit. The APP sensors then provide the control module with signal voltage proportional to pedal movement. Both APP sensor signal voltages are low at rest position and increase as the pedal is applied. Automatic Transmission - 4L60-E/4L65-E Page 5786 7. Use the modified screw extractor in order to remove the plug. 8. Remove the parking pawl shaft retainer, shaft and pawl. 9. Important: If the manual shaft binds in the case during removal, file or sand the shaft in the area adjacent to the detent lever. Remove the manual shaft. 10. Remove the manual shaft seal. Installation Procedure 1. Install the pawl shaft. 2. Install the parking pawl. 3. Install the plug using a 8 mm or (5/16 inch) rod with Loctite® or equivalent. 4. Install the retainer. 5. Install the pawl return spring. 6. Install the detent lever to the actuator. 7. Install the actuator over the parking pawl. 8. Install the manual shaft seal. 9. Lubricate the manual shaft with transmission oil and install the manual shaft into the case. 10. Install the nut on the shaft. 11. Install the roll pin. 12. Notice: Refer to Fastener Notice in Service Precautions. Page 6784 Disclaimer Page 12211 1. To receive credit, submit a claim with the information above. Disclaimer 2001 and Older Model Year Vehicles (Except Saab Vehicles) 2001 and Older Model Year Vehicles (Except Saab Vehicles) Important: 2001 and older model year vehicles require the removal of the battery power from the OnStar(R) vehicle interface unit (VIU) to eliminate the possibility of an inadvertent OnStar(R) or emergency/airbag call. 1. Locate and gain access to the OnStar® VIU. Refer to OnStar Vehicle Interface Unit Replacement in SI. Important: Complete removal of the VIU is usually not required. Perform only the steps required to gain access to the C2 32-way blue connector. Residing in the C2 connector are the battery positive (+) circuits. Removal of the C2 connector will deactivate the unit and eliminate the possibility of an inadvertent OnStar(R) or emergency/airbag call. Locations Vehicle Speed Sensor (VSS) - 4 Wheel Drive Manual Transmission Page 11559 6. Push down the flex lock button (3) and slide the connector locking cover (4) to the close position. 7. Install the connector position assurance (CPA) (1) to the inflatable restraint sensing and diagnostic module (SDM) wiring harness connector (2). 8. Position the carpet to cover the inflatable restraint sensing and diagnostic module (SDM). 9. Install the door sill plate. 10. Install the driver seat. IMPORTANT: The AIR BAG indicator may remain ON after the SDM has been replaced. DTC B1001 may set requiring the SDM part number to be set in multiple modules. If the indicator remains ON after enabling the SIR system, perform the diagnostic system check and follow the steps thoroughly to ensure that the SDM is set properly. 11. Enable the SIR system. Refer to SIR Disabling and Enabling Zone 7. Page 6560 7. Remove the transmission control lever from the manual shaft. 8. Remove the PNP switch bolts. 9. Remove the PNP switch from the manual shaft. If the PNP switch did not slide off the manual shaft, file the outer edge of the manual shaft in order to remove any burrs. Installation Procedure 1. Install the PNP switch to the transmission manual shaft by aligning the switch hub flats with the manual shaft flats. 2. Slide the PNP switch onto the transmission manual shaft until the switch mounting bracket contacts the mounting bosses on the transmission. 3. Important: If a NEW PNP switch is being installed, the switch will come with a positive assurance bracket. The positive assurance bracket aligns the new switch in its proper position for installation and the use of the park neutral switch aligner will not be necessary. Install the PNP switch bolts finger tight. 4. Install J 41364-A onto the PNP switch. Ensure that the two slots on the switch where the manual shaft is inserted are lined up with the lower two tabs on the tool. 5. Notice: Refer to Fastener Notice in Service Precautions. Rotate the tool until the upper locator pin on the tool is lined up with the slot on the top of the switch. ^ Tighten the bolts to 25 Nm (18 ft. lbs.). 6. Remove the J 41364-A from the switch. If installing a new switch, remove the positive assurance bracket at this time. 7. Install the transmission control lever to the manual shaft with the nut. ^ Tighten the nut to 25 Nm (18 ft. lbs.). Page 8337 Brake Master Cylinder: Service and Repair Master Cylinder Replacement (Hydraulic Boost) Master Cylinder Replacement (Hydraulic Boost) Removal Procedure Caution: Refer to Brake Fluid Irritant Caution in Service Precautions. Notice: Refer to Brake Fluid Effects on Paint and Electrical Components Notice in Service Precautions. 1. Apply the park brake and block the wheels. 2. Disconnect the electrical connector from the brake fluid level sensor. 3. Important: Install a rubber cap or plug to the exposed brake pipe fitting ends in order to prevent brake fluid loss and contamination. Disconnect the brake pipes from the master cylinder. 4. Plug the open brake pipe ends. 5. Remove the master cylinder mounting nuts. 6. Remove the master cylinder from the vehicle. 7. Remove the master cylinder reservoir. Installation Procedure 1. Install the master cylinder reservoir. Page 2766 5. Push on the tab (3) so that the electrical center can be rotated on the studs located at (2). 6. Remove all connectors by removing the bolt (1) for each connector. 7. Disconnect all connectors from the electrical center block. 8. Push on the tabs (2) in order to lift the electrical center (1) out of the housing. 9. To replace the engine electrical center bracket remove the 4 retaining bolts (1). 10. Remove the engine electrical center bracket assembly from the fender. INSTALLATION PROCEDURE Lighting - Exterior Lamp Condensation and Replacement Turn Signal Lamp: Technical Service Bulletins Lighting - Exterior Lamp Condensation and Replacement INFORMATION Bulletin No.: 01-08-42-001H Date: January 05, 2011 Subject: Exterior Lamp Condensation and Replacement Guidelines Models: 2011 and Prior GM Passenger Cars and Trucks (including Saturn) Supercede: This bulletin is being revised to add the 2011 model year. Please discard Corporate Bulletin Number 01-08-42-001G (Section 08 - Body and Accessories). The following information is being provided to better define the causes of condensation in exterior lamps and includes guidelines for determining the difference between a lamp with a normal atmospheric condition (condensation) and a lamp with a water leak. Some exterior lamps, such as cornering, turn signal, backup, headlamps or tail lamps may exhibit very small droplets of water, a fine mist or white fog (condensation) on the inside of the lamp lens. This may be more noticeable on lamps with "multi-lens" designs and may be normal during certain weather conditions. Condensation occurs when the air inside the lamp assembly, through atmospheric changes, reaches the "dew point". When this takes place, the moisture in the air within the lamp assembly condenses, creating a fine mist or white fog on the inside surface of the lamp lens. Most exterior lamps on General Motors vehicles use a vented design and feature a replaceable bulb assembly. They are designed to remove any accumulated moisture vapor by expelling it through a vent system. The vent system operates at all times, however, it is most effective when the lamps are ON or when the vehicle is in motion. Depending on the size, shape and location of the lamp on the vehicle, and the atmospheric conditions occurring, the amount of time required to clear the lamp may vary from 2 to 6 hours. Completely sealed headlamp assemblies (sealed beams) are still used on a limited number of models being manufactured today. These lamps require the replacement of the complete lamp assembly if a bulb filament burns out. Condensation 2006 TrailBlazer Shown A Fine Mist or White Fog on the Inside Surface of the Lamp Lens Occurring After a Period of High Humidity - May be located primarily in the lens corners (near the vents) and SHOULD NOT cover more than half the lens surface. - The condition should clear of moisture when the vehicle is parked in a dry environment, or when the vehicle is driven with the lights ON. - A comparison of the equivalent lamp on the opposing side of the vehicle indicates a SIMILAR performance. If the above conditions are noted, the customer should be advised that replacement of a lamp assembly may not correct this condition. Water Leak New Style Pickup Shown Page 7001 4. Drive the bearing cup into the wheel hub using the J 44419 (2) and the J 8092 (1). 5. Install the retaining ring into the groove. Make sure the retaining ring is fully and evenly seated in the groove. 6. Install the inner bearing cup. 7. Drive the inner bearing cup into the wheel hub using the J 24427 (2) and the J 8092 (1). Page 4448 Tighten Tighten the bolts to 8 N.m (71 lb in). 5. Install the PCM cover. 6. If equipped with RPO NYS, install the harness ground clip to the PCM cover. 7. Connect the negative battery cable. 8. If a NEW PCM was installed, program the PCM. Refer to Service Programming System (SPS) in Programming. See: Testing and Inspection/Programming and Relearning 9. Perform the crankshaft position (CKP) system variation learn procedure. Refer to CKP System Variation Learn Procedure. See: Testing and Inspection/Programming and Relearning 10. If necessary, reset the engine oil life monitor. Refer to GM Oil Life System - Resetting in Maintenance and Lubrication. Page 12322 Electrical Symbols Part 13 Service and Repair Oil Pick Up/Strainer: Service and Repair Oil Pump, Pump Screen and Deflector Replacement Removal Procedure 1. Remove the oil pan. 2. Remove the engine front cover. 3. Remove the oil pump screen bolt and nuts. 4. Remove the oil pump screen with O-ring seal. 5. Remove the O-ring seal from the pump screen. 6. Discard the O-ring seal. 7. Remove the remaining crankshaft oil deflector nuts. 8. Remove the crankshaft oil deflector. 9. Remove the oil pump bolts. Important: Do not allow dirt or debris to enter the oil pump assembly, cap end as necessary. 10. Remove the oil pump. 11. If required, clean and inspect the oil pump. Installation Procedure Page 920 Body Control Module (BCM) - C4 Part 2 Page 13925 2. Install the bolts retaining the frame brace to the frame. Tighten the frame brace retaining bolts to 50 N.m (37 lb ft). 3. Lower the vehicle. Page 5058 3. Disconnect the vent valve pipe quick connect from the canister. 4. Either cut the existing valve vent pipe and leave the remaining section of pipe in the vehicle or remove along with the valve. 5. Push in the retainer and remove the existing canister vent valve from the fuel tank clip or mounting bracket. 6. Cut back the existing canister pipe approximately 51 mm (2 in) and retain the pipe for use with new valve. 7. Connect the canister pipe quick connect to the canister. 2500 Crew Cab Short Box Shown Below, Other Configurations Similar 1500 Extended Cab Short Box Shown Below, Other Configurations Similar 8. Install the new canister vent valve solenoid to the fuel tank clip or mounting bracket as shown above. The valve port closest to the electrical connector must point towards the canister. 9. Cut bulk 5/8" heater hose to a length of approximately 76 mm (3 in). Install the hose between the solenoid and the canister pipe and secure using clamps. 10. Attach bulk 5/8" heater hose to the vent port and secure using a clamp. Run a length as needed along the frame rail routing to the passenger side area above the transmission. 11. Cut the hose to determined length and install the supplied filter box. Secure using a clamp. 12. Remove the transmission heat shield, if necessary. 13. Remove the transmission support and lower the transmission assembly as necessary to allow for access to the new filter box location. 14. Secure the filter box to the transmission vent hose just forward of the hose tee-section using a tie strap. DO NOT pinch or restrict the transmission vent hose. The filter box opening should be pointing downward. 15. Raise the transmission and reinstall the transmission support. 16. Reinstall the transmission heat shield. 17. Connect the EVAP canister vent valve electrical connector. 18. Tie strap the hose as needed along the frame rail in order to keep the hose away from pinch-points and heat sources. 19. Lower the vehicle. Parts Information Page 12017 Important: The optic cable must not be bent with a radius less than 25 mm (1 in). 6.17. Fold back the wiring harness and tape over the connectors (G). Fold back the wiring harness once more and secure with cable ties (H). 6.18. Secure the new optic cable on the parcel shelf along the existing wiring harness by the ordinary securing points and by the speaker (I). 6.19. Thread the optic cable down next to the old cable from the parcel shelf to the left-hand wheel housing, next to REC. The cable is secured in the existing clips. 6.20. Fit the right-hand C-pillar trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.21. Fit the parcel shelf trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.22. Fit the passenger seat in accordance with WIS - 8. Body - Seats - Adjustment/Replacement. 6.23. Fit the right-hand side bolster in accordance with WIS - 8. Body - Seats Adjustment/Replacement. 6.24. Fold up the rear seat backrest. 6.25. Fit the right-hand B-pillar trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.26. Fit the A-pillar's lower side piece. 7. M04-05, 4D: Removing the OnStar® control modules and securing the wiring: Page 10332 6. For 15-Series 2WD/4WD and 25/35 Series 2WD, remove the control arm using the following procedure: 6.1. Remove the upper control arm nuts and the adjustment cams (2). 6.2. Remove the upper control arm bolts (4). 6.3. Remove the upper control arm. 7. For the 25/35 Series 4WD, remove the control arm using the following procedure: 7.1. Remove the upper control arm nuts and adjuster cams (2). 7.2. Remove the upper control arm bolts (4). 7.3. Remove the upper control arm. Installation Procedure 1. Install the upper control arm. Page 5115 22. If vehicle is a regular cab, remove the fuel feed, EVAP, and return pipe assembly nuts. 23. If vehicle is a crew or extended cab, remove the fuel feed, EVAP, and return pipe assembly nuts. 24. Remove the fuel feed, EVAP, and return pipe assembly. INSTALLATION PROCEDURE 1. Install the fuel feed, EVAP, and return pipe assembly. NOTE: Refer to Fastener Notice in Service Precautions. 2. If vehicle is a crew or extended cab, install the fuel feed, EVAP, and return pipe assembly nuts. Tighten Tighten the nuts to 12 N.m (106 lb in). Page 8196 Page 15984 Steps 4-7 The numbers below refer to the step numbers on the diagnostic table. 2. Lack of communication may be due to a partial malfunction of the class 2 serial data circuit. The specified procedure will determine the particular condition. 4. The Symptom Table will determine the correct diagnostic procedure to use. 5. The presence of DTCs which begin with "U" indicate some other module is not communicating. The specified procedure will compile all the available information before tests are performed. Page 13097 Page 9890 Tighten Tighten to 8 Nm (71 lb in). Note The repair area MUST BE properly refinished to maintain a secure, stable and corrosion-free electrical ground. 12. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 13. Verify proper system operation. M8 Weld Nut Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M8 weld nut electrical ground location is accessible from both sides of the panel, a M8 conductive bolt and a M8 conductive nut may be used to secure the electrical ground wire terminal. Refer to the Parts Information section of this bulletin. 2. Select a location adjacent the M8 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the new electrical ground site. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the ground location and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 10 mm (0.40 in) diameter hole through the panel. 5. Remove paint and primer from the area surrounding the 10 mm (0.40 in) hole until bare metal is visible. 6. Select a M8 conductive bolt. Refer to the Parts Information section of this bulletin. 7. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M8 conductive bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 8. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 9. Install the electrical ground wire terminal and the M8 conductive bolt to the ground location. 10. Select a M8 conductive nut. Refer to the Parts Information section of this bulletin. 11. Install the M8 conductive nut to the bolt and: Tighten Tighten to 22 Nm (16 lb ft). Note The repair area MUST BE properly refinished to maintain a secure, stable and corrosion-free electrical ground. 12. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 13. Verify proper system operation. M8 Weld Nut Alternative Repair Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M8 weld nut electrical ground location is not accessible from both sides of the panel, a M6 conductive rivet stud and a M6 conductive nut may be used to secure the electrical ground wire terminal. 2. Select a location adjacent the damaged M8 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the M6 conductive rivet stud flange. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the repair site and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 10 mm (0.40 in) diameter hole through the panel. Automatic Transmission - 4L60-E/4L65-E Extension Housing: Service and Repair Automatic Transmission - 4L60-E/4L65-E Transmission Extension Housing Assembly Replacement Removal Procedure 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. Support the transmission with a transmission jack. 3. Place a drain pan under the vehicle. 4. Remove the propeller shaft. 5. Remove the transmission mount. 6. Remove the case extension bolts (1). 7. Remove the case extension (2). 8. Remove and discard the case extension O ring seal (3). Installation Procedure 1. Install a new case extension O ring seal (3). 2. Install the case extension (2). Notice: Refer to Fastener Notice in Service Precautions. 3. Install the case extension bolts (1). ^ Tighten the bolts (1) to 45 Nm (33 ft. lbs.). 4. Install the transmission mount. 5. Install the propeller shaft. 6. Remove the drain pan and the transmission jack. 7. Lower the vehicle. 8. Fill the transmission to the proper level with DEXRON® III transmission fluid. Page 4608 5. If equipped with a 6.0L engine, disconnect the HO2S electrical connector. 6. Remove the HO2S. INSTALLATION PROCEDURE IMPORTANT: A special anti-seize compound is used on the HO2S threads. The compound consists of liquid graphite and glass beads. The graphite tends to burn away, but the glass beads remain, making the sensor easier to remove. New, or service replacement sensors already have the compound applied to the threads. If the sensor is removed from an exhaust component and if for any reason the sensor is to be reinstalled, the threads must have anti-seize compound applied before the reinstallation. 1. If reinstalling the old sensor, coat the threads with anti-seize compound GM P/N 12377953, or equivalent. NOTE: Refer to Component Fastener Tightening Notice in Service Precautions. Page 2625 Location View Page 9607 Relay Block I/P C7 (With RPO Codes Z82 Or T89) Page 9572 Fuse Block- I/P C1 Part 6 Page 12015 Important: Secure the wiring harness so that there is no risk of chafing or rattling. 6.1. Remove the passenger seat in accordance with WIS 8. Body - Seats Adjustment/Replacement. 6.2. Remove the right-hand B-pillar trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.3. Remove the right-hand C pillar trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.4. Fold the rear seat backrest forward. 6.5. Remove the right-hand side bolster in accordance with WIS - 8. Body - Seats Adjustment/Replacement. 6.6. Remove the A-pillar's lower side piece. 6.7. Open the cover on the right-hand wiring harness channels. 6.8. Loosen the locking strip (A) on the 2-pin connector (H2-11) for the optic cable, located by the right-hand A-pillar. 6.9. Loosen the catch (B) and remove the optic cable that runs backward in the car. 6.10. Dismantle the end cap from the new optic cable (12 783 577) and connect it to the connector H2-11. Push in the optic cable and make sure the catch (B) locks and refit the locking strip (A). 6.11. Secure the connector and the old optic cable using the cable tie for the existing wiring harness (C). Disabling the Park Brake Cable Automatic Adjuster Parking Brake Cable: Adjustments Disabling the Park Brake Cable Automatic Adjuster Disabling the Park Brake Cable Automatic Adjuster Before any components of the parking brake system are serviced, the following procedure must be followed. Two technicians are required to perform this procedure: one inside the vehicle and one outside the vehicle. 1. Raise and support the vehicle. Refer Vehicle Lifting 2. Hold the pedal in the FULL upward position. 3. Pull rearward on the front park brake cable until the pedal drum (2) reaches its full reset position. 4. Insert a scribe or the shaft of a thin screwdriver (1) on an upward angle through the hole in the front of the pedal assembly, past the retracted pedal drum, and into the hole in the back of the pedal assembly (3). 5. Slowly release the cable. 6. Remove the component that requires service. Page 2161 6. Slowly release the tension on the A/C belt tensioner. 7. Remove the ratchet from the A/C belt tensioner. 8. Inspect the A/C belt for proper installation and alignment. 9. Install the engine shield. Notice: Refer to Fastener Notice in Service Precautions. 10. Install the engine shield bolts. ^ Tighten the bolts to 20 Nm (15 ft. lbs.). 11. Lower the vehicle. 12. Install the accessory drive belt. Page 10926 Control Module References Part 7 Page 5047 Important The new canister vent valve will be installed in a new location, outside of the frame. 7. Position and secure the new valve assembly to the frame bracket on the outside of the frame using the existing hole and mounting bolt. Tighten Tighten the bracket mounting bolt to 12 Nm (106 lb in). 8. Connect the vent valve pipe to the EVAP canister. 9. Install the two vent valve pipe clips into the existing underbody holes. 10. Connect the EVAP canister vent valve electrical connector, if equipped. 11. Attach bulk 5/8" heater hose to the vent valve port and secure using a clamp. Run a length as needed along the frame rail routing to the area above the transmission. 12. Cut the hose to determined length and install the supplied filter box. Secure using a clamp. 13. Remove the transmission support and lower the transmission assembly as necessary to allow for access to the new filter box location. 14. Secure the filter box to the transmission vent hose just forward of the hose tee-section using a tie strap. DO NOT pinch or restrict the transmission vent hose. The filter box opening should be pointing downward. 15. Raise the transmission and reinstall the transmission support. 16. Tie strap the hose as needed along the frame rail in order to keep the hose away from pinch-points and heat sources. 17. Lower the vehicle. 2004-2007 Model Year (Use Service Kit P/N 19152349) 1. Raise the vehicle. Suitably support the vehicle. 2. Disconnect the EVAP canister vent valve electrical connector. 3. Disconnect the canister pipe from the vent valve. 4. Push in the retainer and remove the existing canister vent valve from the fuel tank clip or mounting bracket. Discard the old valve. 5. Cut back the existing canister pipe approximately 51 mm (2 in) to remove the quick connect end. Crew Cab Short Box Shown Below, Other Configurations Similar Page 5079 3. Disconnect the vent valve pipe quick connect from the canister. 4. Either cut the existing valve vent pipe and leave the remaining section of pipe in the vehicle or remove along with the valve. 5. Push in the retainer and remove the existing canister vent valve from the fuel tank clip or mounting bracket. 6. Cut back the existing canister pipe approximately 51 mm (2 in) and retain the pipe for use with new valve. 7. Connect the canister pipe quick connect to the canister. 2500 Crew Cab Short Box Shown Below, Other Configurations Similar 1500 Extended Cab Short Box Shown Below, Other Configurations Similar 8. Install the new canister vent valve solenoid to the fuel tank clip or mounting bracket as shown above. The valve port closest to the electrical connector must point towards the canister. 9. Cut bulk 5/8" heater hose to a length of approximately 76 mm (3 in). Install the hose between the solenoid and the canister pipe and secure using clamps. 10. Attach bulk 5/8" heater hose to the vent port and secure using a clamp. Run a length as needed along the frame rail routing to the passenger side area above the transmission. 11. Cut the hose to determined length and install the supplied filter box. Secure using a clamp. 12. Remove the transmission heat shield, if necessary. 13. Remove the transmission support and lower the transmission assembly as necessary to allow for access to the new filter box location. 14. Secure the filter box to the transmission vent hose just forward of the hose tee-section using a tie strap. DO NOT pinch or restrict the transmission vent hose. The filter box opening should be pointing downward. 15. Raise the transmission and reinstall the transmission support. 16. Reinstall the transmission heat shield. 17. Connect the EVAP canister vent valve electrical connector. 18. Tie strap the hose as needed along the frame rail in order to keep the hose away from pinch-points and heat sources. 19. Lower the vehicle. Parts Information Fuel Level Sensor Fuel Gauge Sender: Description and Operation Fuel Level Sensor FUEL LEVEL SENSOR The fuel level sensor consists of a float, a wire float arm, and a ceramic resistor cord. The position of the float arm indicates the fuel level. The fuel level sensor contains a variable resistor, which changes resistance in correspondence to the amount of fuel in the fuel tank. The powertrain control module (PCM) sends the fuel level information via the class 2 circuit to the instrument panel (I/P) cluster. This information is used for the I/P fuel gage and the low fuel warning indicator, if applicable. The PCM also monitors the fuel level input for various diagnostics. Page 6936 18. Remove the convolute retainer tool from the boot. Page 5751 Control Module: Service and Repair NVG 263-NP1 Transfer Case Shift Control Module Replacement Transfer Case Shift Control Module Replacement Removal Procedure 1. Disconnect the shift control module electrical connectors. 2. Unsnap and remove the shift control module from the bracket. Installation Procedure Heater Core Replacement Heater Core: Service and Repair Heater Core Replacement HEATER CORE REPLACEMENT (HEAT ONLY) REMOVAL PROCEDURE 1. Remove the heater/vent module. See: 2. Remove the heater core cover screws. 3. Remove the heater core cover. 4. Remove the heater core. INSTALLATION PROCEDURE 1. Install the heater core. Interior - Front Heated Seat(s) Inoperative Seat Heater Switch: All Technical Service Bulletins Interior - Front Heated Seat(s) Inoperative Bulletin No.: 04-08-50-007 Date: March 12, 2004 INFORMATION Subject: Service Information for Front Heated Seat Inoperative/Cold Models: 2003-2004 Cadillac Escalade/ESV/EXT 2003-2004 Chevrolet Avalanch/Silverado/Suburban/Tahoe 2003-2004 GMC Denali/Sierra/Yukon/Yukon XL 2003-2004 Hummer H2 The purpose of this bulletin is to provide the technician with the following service information: ^ Heated Seats Switch Operation ^ Heated Seats Switch Diagnostics ^ Heated Seats Switch Customer Information Switch Operation 1. The engine must be running for the heated seat feature to work. The heated seats will shut off automatically when the ignition is turned off. 2. Two buttons, located on the door, are used to control the heated seat. ^ Press the horizontal (RH) button to heat the entire seat, back and cushion. ^ Press the vertical (LH) button to heat ONLY the seat back. ^ The three light bars are an indicator of the level of heat selected for either the entire seat (horizontal button) or ONLY the seat back (vertical button). 3. To heat both the seat back and seat cushion at the same time, press the horizontal (RH) button with the heated seat symbol one time. ^ All 3 light bars will glow indicating the HIGH temperature setting. ^ The horizontal (RH) button does NOT have an ON/OFF indicator light. Page 9595 Relay Block - I/P C1 Part 6 Wheels - Chrome Wheel Brake Dust Accumulation/Pitting Wheels: All Technical Service Bulletins Wheels - Chrome Wheel Brake Dust Accumulation/Pitting Bulletin No.: 04-03-10-012B Date: February 01, 2008 INFORMATION Subject: Pitting and Brake Dust on Chrome wheels Models: 2008 and Prior GM Passenger Cars and Trucks (including Saturn) 2008 and Prior HUMMER H2, H3 2005-2008 Saab 9-7X Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 04-03-10-012A (Section 03 - Suspension). Analysis of Returned Wheels Chrome wheels returned under the New Vehicle Limited Warranty for pitting concerns have recently been evaluated. This condition is usually most severe in the vent (or window) area of the front wheels. This "pitting" may actually be brake dust that has been allowed to accumulate on the wheel. The longer this accumulation builds up, the more difficult it is to remove. Cleaning the Wheels In all cases, the returned wheels could be cleaned to their original condition using GM Vehicle Care Cleaner Wax, P/N 12377966 (in Canada, P/N 10952905). When using this product, you should confine your treatment to the areas of the wheel that show evidence of the brake dust build-up. This product is only for use on chromed steel or chromed aluminum wheels. Parts Information Warranty Information Wheel replacement for this condition is NOT applicable under the terms of the New Vehicle Limited Warranty. Disclaimer Page 6991 5. Tighten the wheel bearing adjusting nut using the J 2222-C. ^ Rotate the hub in the opposite direction to the way the adjuster nut is turning. ^ Ensure the inner bearing and the seal seats against the spindle shoulder. TIGHTEN ^ Adjusting nut to 70 Nm (52.0 lb ft). 6. Turn the adjusting nut counterclockwise until the nut is loose using the J 2222-C. 7. Turn the adjusting nut clockwise until the nut contacts the bearing cone. Torque on the nut must be zero to finger tight. 8. Insert the adjusting nut lock key into the keyway using one of the following procedures: ^ If the adjusting nut slot is in alignment with the keyway in the axle spindle, insert the adjusting nut lock key into the keyway in the axle spindle. IMPORTANT: Do not turn the adjusting nut more than one slot counterclockwise in order to align the adjusting nut slot with the keyway in the axle spindle. ^ If the adjusting nut slot is not aligned with the keyway in the axle spindle, turn the adjusting nut counterclockwise until the adjusting nut slot is in alignment with the keyway in the axle spindle and insert the adjusting nut lock key. Page 4657 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Micro-Pack 100W Connectors MICRO-PACK 100W CONNECTORS TOOLS REQUIRED J 38125-D Terminal Repair Kit REMOVAL PROCEDURE There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2)has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. IMPORTANT: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Page 4642 Electrical Symbols Part 13 Interior - Power Seat Switch Knobs Loose/Missing Power Seat Switch: All Technical Service Bulletins Interior - Power Seat Switch Knobs Loose/Missing Bulletin No.: 05-08-50-017 Date: December 14, 2005 TECHNICAL Subject: Power Front Seat (RPO AN3) Switch Knobs Loose or Missing (Replace Switch Knobs) Models: 2002-2006 Cadillac Escalade, Escalade EXT 2003-2006 Cadillac Escalade ESV 2002-2006 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2002-2006 GMC Sierra, Yukon, Yukon XL with Individual Front Seat Non-Bucket (RPO AN3) and Driver Front Seat Power Adjuster (AG1) and/or Passenger Front Seat Power Adjuster (AG2) Condition Some customers may comment that the power front seat adjuster switch knobs are loose and fall off or are missing. Correction Replace the front seat adjuster switch knob. These knobs were formerly available only as part of the power seat adjuster switch. DO NOT replace the switch if the knob only needs to be replaced. Parts Information Warranty Information Page 8517 Involved are certain 2003 and 2004 model year Cadillac Escalade, Escalade EXT and Escalade ESV; Chevrolet Silverado, Avalanche, Suburban, and Express; GMC Sierra, Yukon, Yukon XL, and Savana; and 2004 model year Chevrolet Tahoe vehicles built within the VIN breakpoints shown. IMPORTANT: Dealers should confirm vehicle eligibility through GMVIS (GM Vehicle Inquiry System) prior to beginning recall repairs. [Not all vehicles within the above breakpoints may be involved.] For U.S.: For dealers with involved vehicles, a Campaign Initiation Detail Report containing the complete Vehicle Identification Number, customer name and address data has been prepared and will be loaded to the GM DealerWorld, Recall Information website. The customer name and address data furnished will enable dealers to follow up with customers involved in this recall. For Canada & IPC: Computer listings containing the complete Vehicle Identification Number, customer name and address data of involved vehicles have Page 7631 Control Module: Diagrams Page 6840 7. Place an alignment mark between the pinion and the pinion yoke. 8. Remove the pinion gear bearing retainer bolts. 9. Remove the pinion gear bearing retainer and the pinion. 10. Remove the selective shim. 11. Measure the amount of torque required to rotate the pinion. Use an inch-pound torque wrench. Record this measurement for reassembly. 12. Install the J 8614-01 as shown. 13. Remove the pinion nut while holding the J 8614-01. 14. Remove the washer. 15. Install the J 8614-2 (2) and the J 8614-3 (1) into the J 8614-01 (3) as shown. 16. Remove the pinion yoke by turning the J 8614-3 (1) clockwise while holding the J 8614-01 (3). 17. Remove the pinion oil seal. Use a suitable seal removal tool. Do not damage the housing. 18. Remove the outer pinion bearing. Page 4932 Vehicle Speed Sensor: Service and Repair Manual Transmission - NV 4500 Vehicle Speed Sensor (VSS) Replacement Removal Procedure 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. Disconnect the vehicle speed sensor (VSS) electrical connector (3). 3. Remove the VSS and seal. Installation Procedure 1. Coat the NEW O-ring seal with a thin film of transmission fluid, use GM P/N 12346190 (Canadian P/N 10953477), or equivalent. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the VSS. ^ Tighten the VSS to 16 Nm (12 ft. lbs.). Page 13470 3. Connect the trailer wiring harness. Wiper Arm Blade Replacement Wiper Blade: Service and Repair Wiper Arm Blade Replacement WIPER ARM BLADE REPLACEMENT REMOVAL PROCEDURE 1. Turn the ignition switch to the ACCY position. 2. Set the wiper switch to the PULSE position. 3. Turn the ignition OFF when the wipers are in the innerwipe position and not moving. 4. Push in the button of the wiper blade clip and remove the wiper blade from the inside radius of the wiper arm. 5. Bring the wiper arm out through the opening in the wiper blade. INSTALLATION PROCEDURE 1. Insert the hook of the wiper arm through the opening in the wiper blade. Page 8378 6. Remove the rear cable mounting bracket bolt. 7. Remove the cable from the lever. 8. Remove the cable (2) from the rear brake cable mounting bracket (3) by depressing the locking tabs (1) on the brake cable. 9. Remove the cable from the guides and the body mounts. Installation Procedure A/T - 4L60-E/-4L65E No Shift/Slipping/Fluid Leaks Case: All Technical Service Bulletins A/T - 4L60-E/-4L65E No Shift/Slipping/Fluid Leaks Bulletin No.: 04-07-30-025A Date: July 27, 2004 TECHNICAL Subject: Transmission Fluid Leak, Inoperative 2nd/3rd/4th Gears, No Movement, Case Cracked or Broken at 2-4 Servo (Repair Transmission and Install New Retaining Ring) Models: 2004 Chevrolet Corvette 2004 Pontiac GTO 2004 Light Duty Trucks with 4L60-E and 4L65-E Automatic Transmission (RPOs M30 or M32) Supercede: This bulletin is being revised to add the Corvette and GTO models and to include the 4L65-E transmission. Please discard Corporate Bulletin Number 04-07-30-025 (Section 07 Transmission/Transaxle). Condition Some customers may comment on a transmission leak, inoperative 2nd/4th gear, slipping 3rd/4th gear or no movement due to excess fluid loss. Cause This condition normally occurs at low mileage, usually under 1,600 km (1,000 mi), and investigation may show that the servo cover is loose or that the transmission case is cracked or broken at the servo bore. This condition may be caused by a servo cover retaining ring that did not retain the servo cover. The servo retaining ring design was changed for the 2004 MY from round wire to wire with two flat faces. In mid-April, 2004, the retaining ring design did revert back to a round design in production. It is possible that the transmission case may crack at the servo cover area due to the retaining ring being incorrectly seated. Correction Important: ^ In mid-April, 2004, the retaining ring design did revert back to a round design in production. ^ If the transmission fluid level has lowered due to loss of fluid, it is possible that damaged 3/4 clutches will result. ^ A cracked or broken case may usually be repaired at a significantly lower cost than transmission assembly replacement by replacing the case and any damaged clutches or bands. 1. Raise and suitably support the vehicle. 2. Inspect the transmission case around the servo cover for signs of cracks or damage to the case. ^ If the transmission case is cracked or damaged, replace the transmission case. Refer to the appropriate SI Document for Transmission Case Replacement. ^ If the servo cover is leaking and the case is not damaged, continue with the next step. 3. Remove the front exhaust pipe assembly. Refer to the appropriate SI Document. 4. Remove the heat shield if equipped. Refer to the appropriate SI Document. 5. Clean the servo cover area with Brake Clean and shop air. Page 3807 If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Sir/SRS Wiring Repairs SIR/SRS WIRING REPAIRS TOOLS REQUIRED J 38125-D Terminal Repair Kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-D contains the following items: - Special sealed splices - in order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping tool - A heat torch - An instruction manual The sealed splices have the following 2 critical features: - A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-D also serves as a generic terminal repair kit. The kit contains the following items: - A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors Page 8232 place before removing the J 45101-100 and the lug nuts. Brake Rotor Assembled Lateral Runout (LRO) Correction - On-Vehicle Lathe Brake Rotor Assembled Lateral Runout (LRO) Correction - On-Vehicle Lathe ^ Tools Required J 45101-100Conical Brake Rotor Washers Caution: Refer to Brake Dust Caution in Service Precautions. Important: ^ Brake rotor thickness variation MUST be checked BEFORE checking for assembled lateral runout (LRO). Thickness variation exceeding the maximum acceptable level can cause brake pulsation. Refer to Brake Rotor Thickness Variation Measurement. ^ Brake rotor assembled lateral runout (LRO) exceeding the maximum allowable specification can cause thickness variation to develop in the brake rotor over time, usually between 4,800-11,300 km (3,000-7,000 mi). Refer to Brake Rotor Assembled Lateral Runout (LRO) Measurement. 1. Ensure that the caliper and caliper bracket that are already being supported, are clear from contacting any rotating components, such as the brake rotor. 2. Remove the J 45101-100 and the lug nuts that were installed during the assembled LRO measurement procedure and/or the indexing correction procedure. 3. Inspect the mounting surface of the hub/axle flange and the brake rotor to ensure that there are no foreign particles or debris remaining. 4. Set up the lathe, following the manufacturer's instructions. 5. Refinish the brake rotor, following the brake lathe manufacturer's instructions. 6. After each successive cut, inspect the brake rotor thickness. Refer to Brake Rotor Thickness Measurement. 7. If at any time the brake rotor exceeds the minimum allowable thickness after refinish specification, the brake rotor must be replaced. After replacing the rotor, proceed to step 10. 8. After refinishing the brake rotor, use the following procedure in order to obtain the desired non-directional finish: 1. Follow the brake lathe manufacturer's recommended speed setting for applying a non-directional finish 2. Using moderate pressure, apply the non-directional finish: ^ If the lathe is equipped with a non-directional finishing tool, apply the finish with 120 grit aluminum oxide sandpaper ^ If the lathe is not equipped with a non-directional finishing tool, apply the finish with a sanding block and 150 grit aluminum oxide sandpaper 3. After applying a non-directional finish, clean each friction surface of the brake rotor with denatured alcohol, or an equivalent approved brake cleaner 9. Remove the lathe from the vehicle. 10. Measure the assembled LRO of the brake rotor. Refer to Brake Rotor Assembled Lateral Runout (LRO) Measurement. 11. If the brake rotor assembled LRO measurement still exceeds the maximum allowable specification, refer to Brake Rotor Assembled Lateral Runout (LRO) Correction. 12. If the brake rotor assembled LRO is within specification, install the brake caliper and depress the brake pedal several times to secure the rotor in place before removing the J 45101-100 and the lug nuts. Brake Rotor Refinishing Brake Rotor Refinishing ^ Tools Required J 41013 Rotor Resurfacing Kit - J 42450-A Wheel Hub Resurfacing Kit Caution: Refer to Brake Dust Caution in Service Precautions. Important: ^ The disc brake rotors do not require refinishing as part of routine brake system service. New disc brake rotors do not require refinishing.Do not refinish disc brake rotors in an attempt to correct the following conditions: ^ Brake system noise - squeal, growl, groan ^ Uneven and/or premature disc brake pad wear ^ Superficial or cosmetic corrosion/rust of the disc brake rotor friction surface ^ Scoring of the disc brake rotor friction surface less than the maximum allowable specification ^ Before refinishing a brake rotor, the rotor MUST first be checked for adequate thickness to allow the rotor to be refinished and remain above the minimum allowable thickness after refinish specification. Refer to Brake Rotor Thickness Measurement. Disc brake rotors should only be refinished if they have adequate thickness to be refinished and if one or more of the following conditions exist: ^ Thickness variation in excess of the maximum allowable specification ^ Excessive corrosion/rust and/or pitting ^ Cracks and/or heat spots ^ Excessive blueing discoloration ^ Scoring of the disc brake rotor surface in excess of the maximum allowable specification ^ Disc brake rotors may need to be refinished as part of the process for correcting brake rotor assembled lateral runout (LRO) that exceeds the maximum allowable specification. 1. Important: Page 5567 Ignition Coil 7 Audio Amplifier Amplifier: Description and Operation Audio Amplifier AUDIO AMPLIFIER The audio amplifier is standard on some vehicle lines but is optional on most. The radio supplies low level audio signals to the audio amplifier in order to boost the signal sent to the speakers. The class 2 signal circuit allows the radio to recognize that an amplifier is present. Once the radio detects an audio amplifier, it will output low level audio signals. The audio amplifier is turned on when it receives a message via the class 2 serial data circuit indicating that the radio is on. Page 6818 10. Remove the inner pinion bearing using the J 22912-01 and a hydraulic press. 11. Remove the pinion position shim. Installation Procedure 1. Install the oil deflector into the inner pinion cup bore. 2. Install the inner pinion bearing cup using the J 45704 (2) and the J 8092 (1). 3. Install the outer pinion bearing cup using the J 7818 (2) and the J 8092 (1). 4. Determine the pinion position shim thickness and the pinion preload shim thickness for the drive pinion. 5. Install the differential assembly. 6. Fill the axle with lubricant. Use the proper fluid. 7. Lower the vehicle. Page 2671 Junction Block - I/P - C2 Part 2 Page 14355 High Temperature Conditions Tools Required J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency MEASURING FREQUENCY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage MEASURING VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop MEASURING VOLTAGE DROP NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Page 8158 Assembly Procedure 1. Notice: Refer to Fastener Notice in Service Precautions. Install the brake caliper bleed screw. ^ Tighten the brake caliper bleed screw to 12 Nm (106 inch lbs.). 2. Install the brake caliper bleed screw cap. 3. Lubricate the new piston seal and the brake caliper bore seal groove with brake fluid. 4. Install the new seal into the brake caliper bore seal groove. 5. Ensure that the seal is not twisted. 6. Lubricate the brake caliper bore and the piston with brake fluid. 7. Install the boot and piston. 1. Install the boot over the end of the piston so that the fold will face toward the brake caliper housing piston bore opening. 2. Seat the boot into the brake caliper bore groove. Slide the piston into the brake caliper bore. 3. Push down the piston to the bottom of the brake caliper bore. 4. Ensure that the boot is properly seats into the piston groove and into the groove in the brake caliper bore. 8. Install the brake caliper to the vehicle. Brake Caliper Bracket Replacement - Front Brake Caliper Bracket Replacement - Front Caution: Refer to Brake Dust Caution in Service Precautions. Removal Procedure 1. Notice: Support the brake caliper with heavy mechanic's wire, or equivalent, whenever it is separated from its mount and the hydraulic flexible brake hose is still connected. Failure to support the caliper in this manner will cause the flexible brake hose to bear the weight of the caliper, which may cause damage to the brake hose and in turn may cause a brake fluid leak. Remove the caliper from the mounting bracket and support the caliper with heavy mechanic's wire or equivalent. DO NOT disconnect the hydraulic brake flexible hose from the caliper. Refer to Brake Caliper Replacement Front. 2. Remove the brake pads. 3. Remove the anti-rattle clips from the brake caliper bracket. Page 5867 2. Connect the speed sensor electrical connector. 3. Lower the vehicle. Service and Repair Steering Wheel: Service and Repair Steering Wheel Replacement ^ Tools Required - J 1859-A Steering Wheel Puller - J 36541-A Steering Wheel Puller Adapter - J 42578 Steering Wheel Puller Legs Removal Procedure 1. Disable the supplemental inflatable restraint (SIR) system. 2. Remove the inflator module. Refer to Horn Switch Replacement in SIR. 3. Remove the horn switch. Refer to Horn Switch Replacement. 4. Make an alignment mark in order to note the relationship of the steering wheel to the steering shaft. 5. Remove the steering wheel nut. 6. Remove the steering wheel using: ^ J 1859-A (1) with ^ J 36541-A (2) or J 42578 (2) Installation Procedure 1. Align the marks made during the removal of the steering shaft and the steering wheel. 2. Install the steering wheel onto the steering shaft. 3. Notice: Refer to Fastener Notice in Service Precautions. Install the steering wheel nut to the steering shaft. ^ Tighten the nut to 40 Nm (29 ft. lbs.). 4. Install the horn switch. Refer to Horn Switch Replacement. 5. Install the inflator module. 6. Enable the SIR system. Page 4801 Fuel Level Sensor: Description and Operation Fuel System Description (Cab Chassis) FUEL LEVEL SENSOR The fuel level sensor is a part of the fuel sender assembly. The position of the float arm indicates the fuel level. The fuel level sensor contains a variable resistor which changes resistance in correspondence with the amount of fuel in the fuel tank. On models that are equipped with a single fuel tank, the fuel level sensor is wired directly to the instrument panel (IP) cluster. On models equipped with dual fuel tanks, both fuel level sensors are wired to the PCM. The PCM calculates the total fuel level in both tanks. The instrument panel (IP) fuel gage displays the total fuel level in both fuel tanks. Page 8926 Steps 5-7 The numbers below refer to the step numbers on the diagnostic table. 4. Lack of communication may be due to a partial malfunction of the class 2 serial data circuit or due to a total malfunction of the class 2 serial data circuit. The specified procedure will determine the particular condition. 5. The symptom list in Symptoms will determine the correct diagnostic procedure to use. 6. The presence of DTCs which begin with "U" indicate some other module is not communicating. The specified procedure will compile all the available information before tests are performed. Page 6278 Disclaimer Page 11521 31. Install the ring gear onto the differential case. 32. Install the ring gear bolts. Hand start each bolt to ensure that the ring gear is properly seated to the differential case. 33. Tighten the ring gear bolts. Tighten the ring gear bolts alternately and in stages, gradually pulling the ring gear onto the differential case. Tighten Tighten the ring gear bolts in sequence to 120 N.m (88 lb ft). 34. Install the differential side bearings by performing the following steps: 34.1. In order to protect the differential case, install the J 8107-2 in the case on the side opposite the bearing installation. 34.2. Install the J 22761(2) and the J 8092 (1) onto the differential case bearing as shown. 34.3. Drive the differential case bearing onto the case using the J 22761 and the J 8092. 35. Install the new differential case assembly into the carrier. 36. Clean the sealing surface of each half of the differential carrier case and the inner axle housing to differential carrier assembly. The surfaces must be clean of all grease and oil. 37. Apply a bead of sealer, P/N 1052942 (Canadian P/N 10953466), or equivalent, to one differential carrier case half sealing surface. 38. Install the right differential carrier case half. 39. Install the differential carrier case bolts Tighten Tighten the differential carrier case bolts to 47 N.m (35 lb ft). 40. Install the front drive axle clutch shaft to the differential carrier. 41. Install the left side inner axle shaft by doing the following steps: 41.1. Install the left side inner shaft into the differential carrier assembly until the inner shaft is seated against the differential side gear. 41.2. While holding the inner shaft against the differential side gear, turn the inner shaft in order to align the splines of the inner shaft with the splines on the differential side gear. 41.3. Drive the inner into the differential case side gear using a soft-faced mallet until the retaining ring on the inner shaft is fully seated within the groove in the differential case side gear. Pull back on the inner shaft to ensure that the inner shaft is properly retained in the differential case side gear. 42. Apply sealant, P/N 1052942 (Canadian P/N 10953466), or equivalent, to the inner axle housing to differential carrier sealing surface. Page 2681 Junction Block - Rear Lamps - C3 Page 9376 of the possible harness chafing/pinching. Also, on any of the above listed vehicles, the PCM wiring harness may be chafing against the precharge pump bracket or the battery tray. Correction On RPO AN3 vehicles, inspect the routing of the seat wiring harness. Reroute the seat wiring harness and attaching harness fastener (1) to the opposite side of the seat module bracket. Repair the harness as necessary. Refer to Wiring Repairs in the Wiring Systems sub-section of SI. The seat may have to be removed for ease of access and proper repair of the wiring harness. Inspect the routing of the PCM wiring harness at the precharge pump bracket and the battery tray. Repair the harness as necessary. Refer to Wiring Repairs in the Wiring Systems sub-section of SI. If any of the above conditions still remain after this repair, refer to SI for further diagnostic information. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Installation Refrigerant Filter: Service and Repair Installation AIR CONDITIONING (A/C) REFRIGERANT FILTER INSTALLATION TOOLS REQUIRED J 39400-A Halogen Leak Detector IMPORTANT: The A/C Refrigerant filter, ACDelco P/N 15-1696 must be installed to the A/C evaporator tube between the condenser and evaporator. The installation of this A/C refrigerant filter eliminates the need for flushing. 1. Remove the air cleaner. 2. Measure 50 mm (2 in) from the bend on the evaporator tube (2) near the expansion tube end and mark the location. 3. Measure 50.8 mm (2 in) from the mark on the evaporator tube (2) from the previous step. IMPORTANT: Do not allow metal burrs to enter the evaporator tube (2) during cutting or when removing the burrs. 4. Using a tubing cutter, cut the marked section of the evaporator tube (2). 5. Remove the burrs from the evaporator tube (2). 6. Remove the nuts (4), the ferrules (3), and the O-rings (2) from the A/C refrigerant filter (1). IMPORTANT: DO NOT install the O-rings (2) in this step. 7. Push the nuts (4) and ferrules (3) over each of the evaporator tube halves. 8. Install the ferrules (3) with the small end toward the nut (4). Page 14604 Front Passenger Seat (2 Of 2) (With RPO Code AN3) Lamp Switch Assembly Replacement-Front Fog Lamp and Cargo Lamp Fog/Driving Lamp Switch: Service and Repair Lamp Switch Assembly Replacement-Front Fog Lamp and Cargo Lamp LAMP SWITCH ASSEMBLY REPLACEMENT - FRONT FOG LAMP AND CARGO LAMP REMOVAL PROCEDURE 1. Remove the instrument cluster bezel. 2. Remove the fog lamp switch and cargo switch from the housing. 3. Disconnect the electrical connector(s) from the fog lamp switch. 4. Remove the fog lamp and cargo lamp switch from the housing. INSTALLATION PROCEDURE 1. Connect the electrical connector(s) to the fog lamp and cargo lamp switch. 2. Install the fog lamp switch into the housing. 3. Install the IP trim bezel to the instrument panel. TPMS System - Service And Re-Learning Sensor IDs Tire Pressure Sensor: Technical Service Bulletins TPMS System - Service And Re-Learning Sensor IDs INFORMATION Bulletin No.: 10-03-16-001 Date: July 19, 2010 Subject: TPMS System Service and Re-Learning Sensor IDs Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks 2010 and Prior HUMMER H2 2009 and Prior HUMMER H3 2010 and Prior Saturn Models 2009 and Prior Saab 9-7X with Wheel-Mounted Tire Pressure Sensors In the event that the spare tire, which is normally not equipped with a tire pressure monitor (TPM) sensor, is installed in place of one of the road tires and the vehicle is driven above 40 km/h (25 mph) for 20 minutes or more, the TPM indicator icon on the instrument panel cluster (IPC) will flash for approximately one minute and then remain on steady each time the ignition is turned ON, indicating a diagnostic trouble code (DTC) has been set. The driver information center (DIC), if equipped, will also display a SERVICE TIRE MONITOR type message. When the road tire is repaired and reinstalled in the original location, the TPM indicator icon illumination and DIC message may remain displayed until the DTC is cleared. To ensure that the TPM indicator and the DIC message are cleared after service, it is necessary to clear any TPM DTCs using a scan tool. If a scan tool is unavailable, performing the TPM relearn procedure using a TPM diagnostic tool will provide the same results. It is advised to perform the relearn procedure away from other vehicles to prevent picking up a stray sensor signal. If one or more of the TPM sensors are missing or damaged and have been replaced, then the relearn procedure must be performed. Disclaimer Specifications Idle Speed: Specifications Information not supplied by manufacturer. Service and Repair Steering Damper: Service and Repair Steering Damper Replacement ^ Tools Required J 24319-B Universal Steering Linkage Puller - J 29193 Steering Linkage Installer-12 mm Removal Procedure 1. Raise the vehicle. Support the vehicle with safety stands. Refer to Vehicle Lifting. 2. Remove the engine protection shield, if equipped. 3. Important: Do not reuse the nut. Remove the steering damper (2) ball stud nut (1). 4. Remove the steering damper ball stud from the relay rod using the J 24319-B. 5. Important: Do not reuse the nut. Remove the steering damper mounting bolt (5) and the nut (6). 6. Remove the steering damper (4) from the vehicle. 7. Inspect the following parts: Page 14110 Door Module: Connector Views Driver Door Module (DDM) - C1 (With RPO Code YE9) Page 10020 1. Position the idler arm (2) on the frame. 2. Notice: Refer to Fastener Notice in Service Precautions. Install the frame bolts (3) and the nuts (1) to the idler arm. ^ Tighten the frame bolts or nuts to 99 Nm (73 ft. lbs.). 3. Install the relay rod (9) to the idler arm ball stud (1). Ensure the seal is on the stud. 4. Use the J 29193 in order to seat the tapers. ^ Tighten the J 29193 or the J 29194 to 54 Nm (40 ft. lbs.) in order to seat the tapers. 5. Install the new idler arm ball stud prevailing torque nut to the idler arm ball stud. ^ Tighten the nut to 62 Nm (46 ft. lbs.). 6. Install the engine protection shield, if equipped. 7. Lower the vehicle. 8. Check the wheel alignment. Page 15884 Turn Signal Lamp: Service and Repair Tail/Turn Signal Lamp Replacement (Except Stepside) TAIL/TURN SIGNAL LAMP REPLACEMENT (EXCEPT STEPSIDE) REMOVAL PROCEDURE 1. Ensure that the headlamp switch is in the OFF position. 2. Lower the end gate. 3. Remove the 2 screws retaining the tail/turn signal lamp assembly to the body. 4. Identify the bulb in need of replacement. - The top bulb is a parking lamp and stop lamp - The center bulb is a turn indicator lamp - The lower bulb is a backup lamp 5. Turn the socket assembly. 6. Remove the socket assembly from the housing. INSTALLATION PROCEDURE 1. Turn the socket. 2. Lock the socket in place. 3. Install the tail/turn signal lamp assembly to the vehicle with the 2 screws. Page 13257 Page 8481 Service and Repair Rear Door Window Motor: Service and Repair Window Regulator Motor Replacement - Rear Door Removal Procedure 1. Raise the window. If the window motor is inoperable, remove the window to gain access to the window motor retaining screws. Refer to Window Replacement - Rear Door. 2. Remove the door trim panel. 3. Remove the water deflector. 4. Remove the door speaker. 5. Support the window. 6. Disconnect the wiring harness from the window regulator motor. 7. Remove the 3 bolts from the window motor located on the front side of the motor. Important: Do not allow the cable gear come out of the housing. A failure will result with the cable coming off the spool. 8. Separate the motor from the cable housing by wiggling the window motor. Observe the orientation of the window motor. 9. Remove the motor from the window regulator assembly. Installation Procedure 1. Install the motor to the cable housing by wiggling motor into place. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the 3 bolts to the window motor. Tighten the bolts to 5 N.m (44 lb in). 3. Install the window, if removed. 4. Connect the wiring harness to the window regulator motor. 5. Remove the window support. 6. Connect the wire connector to the switch to inspect the operation of the window. 7. Install the speaker. 8. Install the water deflector. 9. Install the door trim panel. Page 4370 Engine Coolant Temperature (ECT) Sensor Page 10258 Control Module References Part 1 Page 5673 Park Neutral Position (PNP) Switch C175 Page 8558 1. Install the gasket. 2. Install the booster assembly. 3. Install the 4 booster to bulkhead nuts. Tighten Tighten the nuts to 36 N.m (26 lb-ft). 4. Snap the stop lamp switch onto the pushrod to the power brake booster. 5. Install the stop lamp switch with the pushrod on the brake pedal pin. 6. Install the brake switch retainer. 7. Connect the electrical connector to the stop lamp switch. 8. Install the master cylinder to the booster. 9. Install the master cylinder mounting nuts. Tighten Tighten the nuts to 36 N.m (27 lb-ft). 10. Connect the power brake booster outlet hose, the steering gear inlet hose, and the power brake booster inlet hose. Tighten ^ Tighten the power brake booster inlet hose to 28 N.m (20 lb-ft). ^ Tighten the steering gear inlet hose to 28 N.m (20 lb-ft). Important: Maintain the fluid level throughout the bleed procedure. 11. Remove the pump reservoir cap. Important: Page 9828 Junction Block - I/P Wire Entry Part 2 Page 4457 Fuel Level Sensor: Service and Repair Fuel Level Sensor Replacement - 2 FUEL LEVEL SENSOR REPLACEMENT REMOVAL PROCEDURE 1. Remove the sending unit. 2. Disconnect the fuel pump electrical connector. 3. Remove the fuel level sensor electrical connector retaining clip. 4. Disconnect the fuel level sensor electrical connector. Drivetrain - Service 4WD Light/DTC C0374 Set Speed Sensor: All Technical Service Bulletins Drivetrain - Service 4WD Light/DTC C0374 Set TECHNICAL Bulletin No.: 05-04-21-003C Date: April 15, 2008 Subject: Service 4WD Light Illuminated, DTC C0374 Set (Inspect Wiring Harness to Transfer Case Speed Sensors,, Replace Wiring Harness) Models: 2004-2007 Buick Rainier 2003-2006 Chevrolet Avalanche, Suburban, Tahoe 2003-2007 Chevrolet Silverado Classic, TrailBlazer, TrailBlazer EXT 2003-2006 GMC Yukon, Yukon XL 2003-2007 GMC Envoy, Envoy XL, Sierra Classic 2003-2004 Oldsmobile Bravada 2005-2007 Saab 9-7X With Four Wheel Drive or All-Wheel Drive and Active All-Wheel Drive (RPO NP4) or Active Two-Speed (RPO NP8) Transfer Case Supercede: This bulletin is being revised to update the Model and Warranty Information. Please discard Corporate Bulletin Number 05-04-21-003B (Section 04 - Driveline/Axle). Condition Some customers may comment on intermittent illumination of the Service 4WD light. Upon investigation, the technician may find DTC C0374 set. The customer may also comment on intermittent erratic operation of the 4WD or AWD system after driving through rain/snow or simply going through a car wash. Cause The speed sensor signal may have become corrupted. Possible openings in the speed sensor wire insulation (twisted pairs) can allow water intrusion. Also wire connections contaminated by water may result in short circuits and erroneous speed sensor readings. This most often occurs on the rear speed sensor circuit. Correction Inspect the wiring harness to the transfer case speed sensors. On Rainier, TrailBlazer, Envoy and 9-7X models, fabricate a replacement speed sensor harness between the C101 connector and the speed sensors. Completely inspect and test all wiring. Refer to Speed Signal Front Axle Actuator and Indicators schematic in SI. Replace the affected twisted pairs. Do not over-twist the two wires in the replacement harness. Wires should be twisted at a rate of 9 revolutions per foot. Use service connector pack, P/N 88987993 at the speed sensor end and terminal, P/N 15326267, at C101. Terminal testing tools and service terminals can be found in Terminal Repair Kit J 38125. Terminals are available from SPX/Kent-Moore. The smaller transfer case harness splices into the larger chassis harness a few inches in front of the crossmember. The chassis harness routes along the left side of the frame under the driver door area. Use nylon tie straps to secure the fabricated harness to the main chassis harness between the transfer case and C101. On the full-size pickup and full-size utility models, replace the 2.2 m (88 in) pigtail harness that runs from the C151 connector under the hood to the transfer case. Use either harness P/N 15832722 or 15224663 depending on vehicle equipment. Refer to Propshaft Speed Sensors Front Axle Actuator and Transfer Case Shift Control Switch schematic in SI. Important: Technicians should verify the integrity of the splice joints after the repair. All splice joints and connections should seal properly against water or a repeat condition can occur. Locations Chassis And License Lamp Harnesses Drivetrain - Excessive Effort When Shift 2HI to 4HI Differential Fluid - M/T: Customer Interest Drivetrain - Excessive Effort When Shift 2HI to 4HI TECHNICAL Bulletin No.: 09-04-19-002A Date: February 17, 2011 Subject: 4WD System Shift Performance in Cold Ambient Temperatures (Use Synthetic Fluid in Light Duty Front Axles with 8.5" Ring Gears) Models: 1999-2011 Chevrolet Silverado 1500 Series Models 1999-2011 GMC Sierra 1500 Series Models Equipped with 4WD and 8.25" Front Axle Ring Gears (Transfer Case RPOs NP2, NQG) Attention: It is important to determine the RPO for the transfer case in GWM/IVH prior to applying this bulletin. This bulletin applies ONLY to vehicles equipped with 8.25" front axle ring gears, used in conjunction with a manual transfer case (RPOs NP2, NQG). Supercede: This bulletin is being revised to add the 2011 model year. Please discard Corporate Bulletin Number 09-04-19-002 (Section 04 - Driveline/Axle). Condition Some customers may comment about the effort required to shift from 2HI to 4HI in cold ambient temperatures at -6°C (20°F) or below. Cause This condition may be caused by the standard front axle being equipped with conventional mineral oil axle fluid. In cold ambient temperatures, prior to complete warm up, the fluid viscosity is thick. This may affect transfer case shift performance prior to full warm up. Correction Drain the front axle fluid and refill with GM SAE 75W-90 Synthetic Axle Fluid, P/N 89021677 (in Canada, 89021678). Refer to Front Axle Lubricant Replacement in SI. It is important to use synthetic fluid in this 8.25" axle to improve the performance of the 4WD system in cold ambient temperatures. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 1915 Page 12142 Important: This bulletin does NOT apply to 2006 vehicles built AFTER the VIN breakpoints listed above. Refer to applicable diagnostics in SI for those vehicles that exhibit this condition. Remove the OnStar(R) fuse from the fuse box, wait five minutes and reinstall the fuse. (For Saturn VUE vehicles, remove the "INT LTS" fuse from the I/P fuse block for five minutes, then reinstall the fuse.) If the OnStar(R) system DOES NOT return to normal functionality, then follow the diagnostics in SI for this condition. If the OnStar(R) system DOES return to normal functionality, perform the following steps: 1. Install the Tech 2(R) and determine what generation hardware and software ID is in the vehicle. 2. If the vehicle is equipped with Generation 5 hardware and a software version 146, the VCIM should have the B1000 reprogramming performed as described in Corporate Bulletin Number 04-08-46-004A. The system should be tested and if the concern returns, the VCIM should be replaced. 3. If Gen 5 with a software version OTHER than 146 or Gen 6 and above, the VCIM needs to be replaced and the system reconfigured. Refer to the current version of Corporate Bulletin 03-08-46-004 for details on how to order a new VCIM. Important: As with any OnStar(R) VCIM replacement, the OnStar(R) system must be reconfigured after replacement. Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use the table. Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table. Disclaimer With Full Floating 10.5 18. Inspect and add axle lubricant to the axle housing, if necessary. 19. Lower the vehicle. Page 12019 8.2. Remove the console (A) together with the OnStar(R) control modules. 8.3. Remove the connectors (B). Important: The optic cable must not be bent with a radius less than 25 mm (1 in). Important: Secure the wiring harness so that there is no risk of chafing and rattling. 8.4. Fold back the wiring harness and tape over the connectors (C). Fold back the wiring harness once more and secure with cable ties (D). Page 4977 Evaporative Emissions (EVAP) Canister Purge Solenoid Page 928 Door Control Module Diagram 3 Part 2 Recall - Brake Hydroboost Relief Valve Seal Defect Technical Service Bulletin # 04004 Date: 040601 Recall - Brake Hydroboost Relief Valve Seal Defect File In Section: Product Recalls Bulletin No.: 04004 Date: June 2004 F/CMVSS NONCOMPLIANCE RECALL SUBJECT: BRAKE HYDRO-BOOST RELIEF VALVE SEAL FRACTURE MODELS: 2003-2004 CADILLAC ESCALADE, ESCALADE EXT, ESCALADE ESV 2003-2004 CHEVROLET SILVERADO, AVALANCHE, SUBURBAN, EXPRESS 2004 CHEVROLET TAHOE 2003-2004 GMC SIERRA, YUKON, YUKON XL, SAVANA CONDITION General Motors has decided that certain 2003 and 2004 model year Cadillac Escalade, Escalade EXT and Escalade ESV; Chevrolet Silverado, Avalanche, Suburban, and Express; GMC Sierra, Yukon, Yukon XL, and Savana; and 2004 model year Chevrolet Tahoe vehicles fail to conform to either Federal/Canada Motor Vehicle Safety Standard 105, "Hydraulic and Electric Brake System", or Standard 135, "Light Vehicle Brake Systems". These vehicles may have a relief valve bore within the brake hydro-boost module that is not to specification. An out-of-specification bore could result in fracture of the relief valve 0-ring seal within the module. If this happens, during braking applications the driver may be able to hear an engine compartment noise similar to the sound that occurs when the steering wheel is turned to a full stop position. The driver could also experience a slight increase in steering efforts while braking and parking. Under certain driving conditions, a fractured seal may require a slight increase in the applied brake pedal effort to achieve the same vehicle deceleration rate as prior to the seal fracture. If this were to occur, it could result in a vehicle crash without prior warning. CORRECTION Dealers are to inspect the hydro-boost module, and replace the relief valve, if necessary. VEHICLES INVOLVED Page 13348 Important The following information MUST be documented on the repair order. Failure to do so may result in a chargeback. - Customer vehicle condition. - Was a Service Lamp or Service Message illuminated? If yes, specify which Service Lamp or Service Message. - Was a DTC(s) set? If yes, specify which DTC(s) were set. - After following the procedure contained within this bulletin, could the condition be duplicated? ‹› If the condition was not duplicated, then document the affected module/component connector name and number on the repair order. - If the condition was duplicated after the procedure contained within this bulletin was followed, and additional diagnosis led to the replacement of a module or component, the SI Document ID Number MUST be written on the repair order. Parts Information Alternate Distributor For All of North America Note NyoGel(R) 760G Lubricant* is equivalent to GMSPO P/N 12377900, and P/N 10953529 (Canada), specified for use to correct the condition in this bulletin. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to: Warranty Information (Saab Models) Page 12605 2. Click on the Analog-to-Digital Program link to start the ordering process. 3. To order a kit, you will need the information shown above. 4. After submitting the order, the "Terms and Conditions of Your OnStar(R) Service" page will display. This is your confirmation that the upgrade kit order has been created. U.S. Dealers will also receive an e-mail from Autocraft within several hours of ordering an upgrade kit (Canadian Dealers will receive an e-mail from MASS Electronics). 5. Print the "Terms and Conditions of Your OnStar(R) Service" page, and have the customer sign a copy. 6. A copy of this form should be stapled to the customer's copy of the Repair Order and one copy should be retained in the customer service folder. 7. If the kit you ordered is available, you will receive the upgrade kit within 4 business days of entering your order through the OnStar(R) Online Enrollment webpage. 8. To check on kit availability or the status of your order, U.S. Dealers can log onto the distributor's website at www.autocraft.com. Canadian dealers can call MASS Electronics at 877-410-6277. Upgrade Kit Installation 1. Skip to the next step if the vehicle to be upgraded is not shown above. Page 13157 7.2. Remove the console (A). 7.3. Disconnect the connector (B) from the OnStar(R) control module. Important: Secure the cable harness to prevent the risk of scraping and rattling. 7.4. Fold back the cable harness and tape down the connector (C). Fold back the cable harness again and secure with cable ties (D). 7.5. 5D: Assemble the right-hand cover for the luggage compartment floor. 8. Fit the ground cable on the battery's negative cable. Page 4914 7. Remove the transmission control lever from the manual shaft. 8. Remove the PNP switch bolts. 9. Remove the PNP switch from the manual shaft. If the PNP switch did not slide off the manual shaft, file the outer edge of the manual shaft in order to remove any burrs. Installation Procedure 1. Install the PNP switch to the transmission manual shaft by aligning the switch hub flats with the manual shaft flats. 2. Slide the PNP switch onto the transmission manual shaft until the switch mounting bracket contacts the mounting bosses on the transmission. 3. Important: If a NEW PNP switch is being installed, the switch will come with a positive assurance bracket. The positive assurance bracket aligns the new switch in its proper position for installation and the use of the park neutral switch aligner will not be necessary. Install the PNP switch bolts finger tight. 4. Install J 41364-A onto the PNP switch. Ensure that the two slots on the switch where the manual shaft is inserted are lined up with the lower two tabs on the tool. 5. Notice: Refer to Fastener Notice in Service Precautions. Rotate the tool until the upper locator pin on the tool is lined up with the slot on the top of the switch. ^ Tighten the bolts to 25 Nm (18 ft. lbs.). 6. Remove the J 41364-A from the switch. If installing a new switch, remove the positive assurance bracket at this time. 7. Install the transmission control lever to the manual shaft with the nut. ^ Tighten the nut to 25 Nm (18 ft. lbs.). Page 12498 Disclaimer Page 15769 Turn Signal Multifunction Switch - C2 Body - Revised Tailgate Latch Bezel Replacement Tailgate Latch: Technical Service Bulletins Body - Revised Tailgate Latch Bezel Replacement Bulletin No.: 05-08-66-005 Date: July 21, 2005 SERVICE MANUAL UPDATE Subject: SMU - Addition of Pickup Box End Gate Latch Handle Bezel Procedure Models: 2002-2005 Cadillac Escalade EXT 1999-2005 Chevrolet Silverado Pickup Models 2002-2005 Chevrolet Avalanche 1999-2005 GMC Sierra Pickup Models This bulletin is being issued to add the Pickup Box End Gate Latch Handle Bezel procedure to the Body Rear End sub-section of the Service Manual. Page 2308 Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 1883 8. Connect the PNP switch electrical connector (2). 9. If equipped with 4WD, install the front propeller shaft. 10. Lower the vehicle. 11. Check the switch for proper operation. The engine must start in the park (P) or neutral (N) positions only. If proper operation of the switch can not be obtained, replace the switch. Page 10141 Maintain the sensor position. Do not turn the sensor. Remove the rear wheel position sensor (2) from the steering gear. Installation Procedure 1. Important: Make sure the O-ring (1) is installed. Install the rear wheel position sensor (2) to the steering gear. 2. Important: Be careful to maintain the position of the replacement sensor. Remove the pin retaining the position of the new sensor and immediately install the sensor to the steering gear. 3. Notice: Refer to Fastener Notice in Service Precautions. Install the rear wheel position sensor retaining bolts. Apply LOCTITE 242 blue. ^ Tighten the bolts to 4 Nm (35 inch lbs.). 4. Install the rear wheel position sensor cover (4). 5. Connect the electrical connector (1). 6. Install the steering gear protection shield (1) and retaining bolts (3). ^ Tighten the steering gear protection shield retaining bolts to 180 Nm (132 ft. lbs.). Page 12804 DTC B2476 04: Cellular Phone Select Service Switch Open Circuit DTC B2476 59: Cellular Phone Select Service Switch Stuck Button DTC B2482 00: Cellular Phone Select Service Switch Range/Performance Circuit Short to Ground Open / High Resistance Short to Voltage Signal Performance Circuit/System Description The OnStar(R) button assembly consists of 3 buttons, Call/Answer, OnStar(R) Call Center, and OnStar(R) Emergency. The vehicle communication interface module (VCIM) supplies the OnStar(R) button assembly with 10 volts via the keypad supply voltage circuit. Each of the buttons, when pressed, completes the circuit across a resistor allowing a specific voltage to be returned to the VCIM over the keypad signal circuit. Depending upon the voltage range returned, the VCIM is able to identify which button has been activated. Conditions for Running the DTCs The ignition is ON. System voltage is between 9 - 16 volts. Conditions for Setting the DTCs B2476 04: The VCIM detects an open/high resistance on the keypad supply voltage circuit. B2482 and B2476 59: The VCIM detects a valid signal on the keypad signal circuit for more than 15 seconds. If one of the OnStar(R) buttons is held or stuck for 15 seconds or more, the VCIM will set these DTCs. Action Taken When the DTCs Set The OnStar(R) status LED turns red. No calls can be placed. The VCIM will ignore all inputs from the OnStar® button assembly. Conditions for Clearing the DTCs The condition responsible for setting the DTC no longer exists. A history DTC will clear once 100 consecutive malfunction-free ignition cycles have occurred. Specifications Valve Clearance: Specifications The manufacturer indicates that this vehicle has hydraulic lifters or adjusters and therefore does not require adjustment. Page 2327 3. Notice: Refer to Power Steering Hose Disconnected Notice in Service Precautions. Install a drain pan under the vehicle. 4. Remove the power steering gear inlet hose (3) from the power steering pump (1). 5. Remove the power steering gear inlet hose from the power steering gear. 6. Remove the power steering gear inlet hose from the vehicle. Installation Procedure 1. Notice: Refer to Installing Hoses Without Twists or Bends Notice in Service Precautions. Route the hose in the same position the hose occupied prior to removal. 2. Install the power steering gear inlet hose (3) to the power steering pump (1). Hand tighten only. 3. Notice: Refer to Fastener Notice in Service Precautions. Install the power steering gear inlet hose to the power steering gear. ^ Tighten both power steering gear inlet hose fittings to 28 Nm (20 ft. lbs.). 4. Remove the drain pan from under the vehicle. 5. Install the engine protection shield. 6. Lower the vehicle. 7. Bleed the power steering system. Refer to Bleeding the Power Steering System. Page 13229 ^ Audio amplifier ^ Driver door module (DDM) ^ Driver door switch assembly (DDSA) ^ Front passenger door module (FPDM) ^ Left rear door module (LRDM) ^ Memory seat module (MSM) ^ Radio antenna module (listed as remote function actuation in scan tool display) ^ Rear integration module (RIM) ^ Right rear door module (RRDM) ^ Theft deterrent module (TDM) ^ TV antenna module ^ Vehicle communication interface module (VCIM) The star has 4 splice packs: ^ SP200 located in the left side of the instrument panel, near the steering column , taped to the instrument panel harness ^ SP201 located in the center of the instrument panel, near the radio ^ SP300 located in the left side middle of the passenger compartment, taped to the body harness, near the carpet seam ^ SP303 located in the right rear of the passenger compartment, taped to the body harness, approximately 24 cm (9.5 in) from the fuse block - right rear. Refer to Data Communication Schematics in SI. The following modules, components, and splice packs are connected to the ring portion of the class 2 serial data circuit: ^ Dash integration module (DIM) ^ Electronic brake control module (EBCM) ^ Engine control module (ECM) ^ Inflatable restraint sensing and diagnostic module (SDM) ^ Instrument panel cluster (IPC) ^ HVAC control module ^ Radio ^ Rear integration module (RIM) ^ Vehicle communication interface module (VCIM) OR ^ Communication interface module (CIM) ^ SP200 ^ SP201 ^ SP300 Page 6024 Shift Solenoid: Diagrams Automatic Transmission - 4L80-E/4L85-E Service and Repair Rear Door Window Regulator: Service and Repair Window Regulator Replacement - Rear Door Removal Procedure 1. Raise and support the window glass. 2. Remove the trim panel. 3. Remove the water deflector. 4. Remove the 2 bolts that hold the window to the regulator. 5. Remove the bolts from the window regulator. 6. Remove the window regulator assembly from the door by folding both sides together. Installation Procedure 1. Install the regulator to the door. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the bolts to the window regulator. Tighten the bolts to 9 N.m (80 lb in). 3. Align the window glass to the regulator. 4. Install the bolts that hold the window to the regulator. Tighten the bolts to 9 N.m (80 lb in). 5. Install the water deflector. 6. Install the trim panel. 7. Lower the window. Inspect the operation. Page 14075 Door Module: Diagnostic Aids Basic Knowledge Required BASIC KNOWLEDGE REQUIRED Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the Service Data. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories CHECKING AFTERMARKET ACCESSORIES Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: - Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions INDUCING INTERMITTENT FAULT CONDITIONS In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: - Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. Tires/Wheels - Low Tire/Leaking Cast Aluminum Wheels Wheels: All Technical Service Bulletins Tires/Wheels - Low Tire/Leaking Cast Aluminum Wheels TECHNICAL Bulletin No.: 05-03-10-003F Date: April 27, 2010 Subject: Low Tire Pressure, Leaking Cast Aluminum Wheels (Repair with Adhesive Sealant) Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks (Including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X with Cast Aluminum Wheels Supercede: This bulletin is being revised to update the model years and the bulletin reference information. Please discard Corporate Bulletin Number 05-03-10-003E (Section 03 - Suspension). Condition Some customers may comment on a low tire pressure condition. Diagnosis of the low tire pressure condition indicates an air leak through the cast aluminum wheel. Cause Porosity in the cast aluminum wheel may be the cause. Notice This bulletin specifically addresses issues related to the wheel casting that may result in an air leak. For issues related to corrosion of the wheel in service, please refer to Corporate Bulletin Number 08-03-10-006C - Tire Slowly Goes Flat, Tire Air Loss, Low Tire Pressure Warning Light Illuminated, Aluminum Wheel Bead Seat Corrosion (Clean and Resurface Wheel Bead Seat). Correction 1. Remove the tire and wheel assembly from the vehicle. Refer to the appropriate service procedure in SI. 2. Locate the leaking area by inflating the tire to 276 kPa (40 psi) and dipping the tire/wheel assembly in a water bath, or use a spray bottle with soap and water to locate the specific leak location. Important - If the porosity leak is located in the bead area of the aluminum rim (where the tire meets the rim), the wheel should be replaced. - If two or more leaks are located on one wheel, the wheel should be replaced. 3. If air bubbles are observed, mark the location. - If the leak location is on the tire/rubber area, refer to Corporate Bulletin Number 04-03-10-001F Tire Puncture Repair Procedures for All Cars and Light Duty Trucks. - If the leak is located on the aluminum wheel area, continue with the next step. 4. Inscribe a mark on the tire at the valve stem in order to indicate the orientation of the tire to the wheel. 5. Dismount the tire from the wheel. Refer to Tire Mounting and Dismounting. 6. Remove the tire pressure sensor. Refer to Tire Pressure Sensor removal procedure in SI. 7. Scuff the INSIDE rim surface at the leak area with #80 grit paper and clean the area with general purpose cleaner, such as 3M(R) General Purpose Adhesive Cleaner, P/N 08984, or equivalent. 8. Apply a 3 mm (0.12 in) thick layer of Silicone - Adhesive/Sealant, P/N 12378478 (in Canada, use 88900041), or equivalent, to the leak area. 9. Allow for the adhesive/sealant to dry. Notice Caution must be used when mounting the tire so as not to damage the sealer. Damaging the repair area may result in an air leak. Page 352 Page 13135 Involved are certain vehicles within the VIN breakpoints shown above. PARTS INFORMATION -- Saab US Only Customer Notification General Motors will notify customers of this special coverage on their vehicles (see copy of typical customer letter shown in this bulletin - actual divisional letter may vary slightly). Page 15092 Front Door Weatherstrip: Service and Repair Weatherstrip Replacement - Front Door Weatherstrip Replacement - Front Door Removal Procedure 1. Open the door. 2. Remove the sill plate. 3. Remove the hinge pillar trim panel. 4. Remove the windshield pillar molding. 5. Remove the weatherstrip from the rear side door opening. Pull the unit away from channel, separating the weatherstrip from the pinchweld flange. Installation Procedure 1. Install the weatherstrip from the rear side door opening fully seating the weatherstrip into the channel. 2. Install the windshield pillar molding. 3. Install the hinge pillar trim panel. 4. Install the sill plate. 5. Check door closing effort and seal to door fit. Page 1813 Seat Sensor/Switch: Service and Repair INFLATABLE RESTRAINT SEAT POSITION SENSOR REPLACEMENT REMOVAL PROCEDURE 1. Remove the passenger or driver's seat from the vehicle. 2. Disconnect the electrical connector from the seat position sensor. CAUTION: Eye protection must be worn when drilling rivets to reduce the chance of personal injury. 3. Drill out the rivets that retain the seat position sensor (1) to the seat adjuster track bracket. 4. Remove the seat position sensor from the seat adjuster track bracket. INSTALLATION PROCEDURE 1. Install the seat position sensor to the seat adjuster bracket. 2. Install the rivets that retain the seat position sensor (1) to the seat adjuster track bracket. 3. Connect the electrical connector to the seat position sensor. 4. Install the passenger or driver's seat to the vehicle. Page 10319 2. Notice: Refer to Fastener Notice in Service Precautions. Install the bolts (2) retaining the lower ball joint (3) to the steering knuckle. ^ Tighten the bolts to 110 Nm (81 ft. lbs.). 3. Install the lower ball joint pinch bolt (1). ^ Tighten the bolt to 230 Nm (169 ft. lbs.). 4. Install the snap ring (2) to the lower ball joint. 5. Install the bolt (8) and nut (2) retaining the bracket to the axle. ^ Tighten the retaining bolt and nut to 25 Nm (18 ft. lbs.). 6. Install the tire and wheel. 7. Lower the vehicle. 8. Perform a four wheel alignment. Page 7566 6. With the output gear encoder assembly in hand, carefully align the casting and output gear timing marks (1). 7. At the same time, be sure to align the encoder phasing post (1) with the phasing slot (2) in the casting and insert the shaft into the bushing. 8. Verify that the output gear and idler are engaged properly. 9. Seat the harness wires on the casting channel. 10. Place the shim on the output shaft gear. 11. Press a NEW seal into the cover. Page 9302 Junction Block - I/P Wire Entry Part 3 Power Window Switch Replacement - Rear Door Power Window Switch: Service and Repair Power Window Switch Replacement - Rear Door POWER WINDOW SWITCH REPLACEMENT - REAR DOOR REMOVAL PROCEDURE 1. Use a small flat-bladed tool in order to carefully pry the door power window switch from the door trim panel. 2. Disconnect the electrical connector from the switch. INSTALLATION PROCEDURE 1. Connect the electrical connector to the switch. 2. Install the switch to the door trim panel by pressing the switch into place until fully seated. Page 5221 8. Install the new fuel cap, P/N 15225005, tether strap in the elongated hole in the fuel filler housing. 9. Install the fuel fill cap on the filler pipe and tighten until the cap clicks. Parts Information Warranty Information For vehicles repaired under warranty, use the table Disclaimer Body - TPO Fascia Cleaning Prior to Painting Paint: All Technical Service Bulletins Body - TPO Fascia Cleaning Prior to Painting INFORMATION Bulletin No.: 08-08-51-002 Date: March 12, 2008 Subject: New Primer For TPO Fascias and Affected Cleaning Process of Painting Operation Models: 2009 and Prior Passenger Cars and Trucks 2009 and Prior HUMMER H2, H3 The purpose of this bulletin is to inform the technician that General Motors has made a change in the primer it uses for TPO plastic for service parts. This new primer comes in several different colors from five different suppliers. This change affects the cleaning process of the painting operation. The new process is as follows. 1. Wash with soap and water. 2. Clean with a 50% mix of isopropyl alcohol and water (or a waterborne cleaner). Check with your paint supplier for product recommendations. 3. Scuff sand per your paint suppliers recommendations. Note: The use of a solvent-type cleaner will soften, or begin to dissolve the primer. Base coats do not have any affect on this primer. 4. Reclean with a 50% mix of isopropyl alcohol and water (or a waterborne cleaner). All fascias, with the exception of the Corvette, Camaro, and Cadillac XLR, are made of TPO. You may find other TPO parts with this primer. If the technician has a question as to the type of plastic they are painting, inspect the back of the part for the plastic symbol (TPO). Disclaimer Page 12003 Page 1127 Seat Front Vertical Position Sensor - Driver (With RPO Code AN3) Specifications Camshaft: Specifications Camshaft Retainer Bolts ...................................................................................................................... ..................................................... 25 Nm (18 ft. lbs.) Page 5797 Page 2159 7. Inspect the drive belt (1) for proper installation and alignment. 8. Align the arrow (2) at the throttle body end of the duct with the throttle body attaching stud (1). 9. Install the air cleaner outlet duct. 10. Connect the radiator inlet hose clip to the outlet duct. Notice: Refer to Fastener Notice in Service Precautions. 11. Tighten the air cleaner outlet duct clamp screws at the following locations: ^ The throttle body ^ The MAF/IAT sensor ^ Tighten the screws to 7 Nm (62 inch lbs.). Page 9071 Application Tabel Part 2 Location View Page 597 Memory Seat Module - C3 Part 1 Page 12209 Page 444 For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to refer to the table above. Disclaimer OnStar(R) - Generation 6 Service Procedures Technical Service Bulletin # 09-08-46-001 Date: 090409 OnStar(R) - Generation 6 Service Procedures INFORMATION Bulletin No.: 09-08-46-001 Date: April 09, 2009 Subject: Servicing Vehicles Upgraded to OnStar(R) Generation 6 Digital‐Capable System (Follow Information Below) Models Attention: This bulletin is being issued to provide dealer personnel with information and the procedures to diagnose an upgraded OnStar(R) Generation 6 Digital-Capable system. Program Overview Since it was launched in 1996, OnStar® has relied on an analog wireless network to provide communication to and from OnStar-equipped vehicles. As part of an industry wide change in the North American wireless telecommunications industry, wireless carriers are transitioning to digital technology and will no longer support the analog wireless network beginning early 2008. Effective January 1, 2008, OnStar(R) service in the United States and Canada will be available only through vehicles that are capable of operating on the digital network. Refer to Corporate Bulletin Number 05-08-46-006H for information about upgrading certain vehicles to digital service. Details were covered in both the November 2006 and December 2007 issues of TechLink, which are available in the Archives of the TechLink website. Vehicles eligible for an OnStar(R) hardware upgrade are listed in this bulletin. Vehicle upgradeability can also be determined by typing the VIN into the field entitled "Determine VIN Hardware Functionality" on the OnStar(R) Online Enrollment website, located in the sales or service workbench tab of GM GlobalConnect. Canadian Dealers can use a similar tool that is available within the OnStar(R) Canada Online Enrollment site that can be accessed from the OnStar(R) Brand Resources in GlobalConnect. Access to the sales and/or service workbench in the GM GlobalConnect website can be granted by the dealership's Partner Security Coordinator (PSC). Description and Operation Passenger Compartment Cross Beam: Description and Operation Magnesium Instrument Panel Support Instrument Panel Support The Instrument Panel Support is a one-piece component comprised of a magnesium steering column support (Fig. 1.21), which holds the instrumentation and steering column; a die-formed tube attaches to the passenger side and supports the dashboard. This assembly functions as a structural cross-vehicle beam, air-bag support, and instrument panel carrier, which consolidates many different steel and plastic components. The magnesium instrument panel support is designed to deform and absorb energy generated by a severe impact. NOTE: Under no circumstance is the magnesium support to be repaired in any way. If any of the following conditions are present after a collision, the magnesium support must be replaced: - Steering column capsules have released or column has collapsed. - The steel knee bolster brackets are bent. - The parts which attach to the magnesium support do not fit. Page 893 6. Use fingers to squeeze the 2 locking legs of the cover. 7. Apply pressure and gently rock the cover until one locking leg is unseated. 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. Page 9089 Junction Block - I/P Wire Entry Part 1 Page 13753 8. Install the new fuel cap, P/N 15225005, tether strap in the elongated hole in the fuel filler housing. 9. Install the fuel fill cap on the filler pipe and tighten until the cap clicks. Parts Information Warranty Information For vehicles repaired under warranty, use the table Disclaimer Fuel Level Sensor Replacement - 1 Fuel Level Sensor: Service and Repair Fuel Level Sensor Replacement - 1 FUEL LEVEL SENSOR REPLACEMENT REMOVAL PROCEDURE 1. Remove the sending unit. 2. Disconnect the fuel pump electrical connector. 3. Remove the fuel lever sensor electrical connector retaining clip. 4. Disconnect the fuel level sensor electrical connector. 5. Remove the fuel level sensor retaining clip. 6. Remove the fuel level sensor (1). INSTALLATION PROCEDURE 1. Install the fuel level sensor (1). 2. Install the fuel level sensor retaining clip. 3. Connect the fuel level sensor electrical connector. 4. Install the fuel lever sensor electrical connector retaining clip. 5. Connect the fuel pump electrical connector. 6. Install the sending unit. Page 15559 1. Notice: Refer to Fastener Notice in Service Precautions. Install the backup lamp switch. ^ Tighten the switch to 20 Nm (15 ft. lbs.). 2. If equipped with a 8.1L engine, connect the backup lamp switch electrical connector (4). 3. If equipped with a 6.6L engine, connect the backup lamp switch electrical connector (3). Lower the vehicle. Page 12357 Control Module References Part 6 A/C - HVAC Module External Seal Kit Availability Housing Assembly HVAC: Technical Service Bulletins A/C - HVAC Module External Seal Kit Availability Bulletin No.: 04-01-38-018 Date: November 30, 2004 INFORMATION Subject: HVAC Module External Seal Kit Now Available For Service Use Models: 2003-2005 Cadillac Escalade, Escalade ESV, Escalade EXT 2003-2005 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2003-2005 GMC Sierra, Yukon, Yukon XL with Air Conditioning (RPOS CJ2 and CJ3) The purpose of this bulletin is to inform dealer technicians that the external Heating, Ventilation and Air Conditioning (HVAC) module seals are now available for service use. The individual external module seals are not available separately. They are only available as part of the seal kit. The seal kit, P/N 89024877, consists of the following seven parts: ^ A/C Evaporator Case Drain Tube Seal ^ A/C Evaporator Seal ^ A/C Evaporator Tube Seal ^ Air Distribution Case Seal ^ Air Inlet Valve Seal ^ Heater and A/C Evaporator and Blower Module Seal ^ Heater Core Tube Seal Parts Information Parts are currently available from GMSPO. Disclaimer Page 3358 12. Install the following to the positive battery cable clip: ^ Engine wiring harness clip ^ Positive battery cable clip 13. Slide the channel pin in to the oil pan tab. 14. Install the battery cable channel bolt. ^ Tighten the bolt to 12 Nm (106 inch lbs.). Page 1598 Knock Sensor (KS) Interior - Heated Seats Intermittently Inoperative Seat Heater Control Module: All Technical Service Bulletins Interior - Heated Seats Intermittently Inoperative Bulletin No.: 05-08-05-008 Date: August 18, 2005 TECHNICAL Subject: Intermittent Heated Seats Inoperative, DTC B3941 Set (Reprogram Driver Seat Module) Models: 2003-2005 Cadillac Escalade, Escalade ESV, Escalade EXT 2003-2005 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2003-2005 GMC Sierra, Yukon, Yukon XL, Yukon Denali All with Seat FRT, Individual (Non BKT) (RPO AN3) 2003-2005 HUMMER H2 with Seat, Front Bucket Deluxe (RPO AR9) Condition Some customers may comment that occasionally the seat heater will not operate when activated. If the ignition key is cycled OFF and back ON again, the heated seat will operate correctly. Also, on some LB7 diesel engine vehicles, the seat heater may turn itself off during the first 10 minutes of operation. This occurs only with the first activation for the day and works correctly with subsequent activations immediately after the event. These conditions are intermiffent and DTC B3941 may be set. Correction Technicians are to reprogram the driver seat module with an updated software calibration. This new service calibration was released with TIS satellite data update version 6.5 available June 13, 2005. As always, make sure your Tech 2(R) is updated with the latest software version. Warranty Information Disclaimer Page 8714 Parts Information Place unused material on dealer shelf for future use. Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Electrical - MIL ON/DTC's Set By Various Control Modules Relay Module: Customer Interest Electrical - MIL ON/DTC's Set By Various Control Modules TECHNICAL Bulletin No.: 09-06-03-004D Date: December 08, 2010 Subject: Intermittent No Crank/No Start, No Module Communication, MIL, Warning Lights, Vehicle Messages or DTCs Set by Various Control Modules - Diagnosing and Repairing Fretting Corrosion (Disconnect Affected Connector and Apply Dielectric Lubricant) Models: 2011 and Prior GM Passenger Cars and Trucks Attention: This repair can be applied to ANY electrical connection including, but not limited to: lighting, body electrical, in-line connections, powertrain control sensors, etc. DO NOT over apply lubricant to the point where it prevents the full engagement of sealed connectors. A light coating on the terminal surfaces is sufficient to correct the condition. Supercede: This bulletin is being revised to update the Attention statement and add the 2011 model year. Please discard Corporate Bulletin Number 09-06-03-004C (Section 06 Engine/Propulsion System). Condition Some customers may comment on any of the following conditions: - An intermittent no crank/no start - Intermittent malfunction indicator lamp (MIL) illumination - Intermittent service lamp illumination - Intermittent service message(s) being displayed The technician may determine that he is unable to duplicate the intermittent condition. Cause This condition may be caused by a buildup of nonconductive insulating oxidized debris known as fretting corrosion, occurring between two electrical contact surfaces of the connection or connector. This may be caused by any of the following conditions: - Vibration - Thermal cycling - Poor connection/terminal retention - Micro motion - A connector, component or wiring harness not properly secured resulting in movement On low current signal circuits this condition may cause high resistance, resulting in intermittent connections. On high current power circuits this condition may cause permanent increases in the resistance and may cause a device to become inoperative. Representative List of Control Modules and Components The following is only a representative list of control modules and components that may be affected by this connection or connector condition and DOES NOT include every possible module or component for every vehicle. - Blower Control Module - Body Control Module (BCM) - Communication Interface Module (CIM) - Cooling Fan Control Module - Electronic Brake Control Module (EBCM) - Electronic Brake and Traction Control Module (EBTCM) - Electronic Suspension Control (ESC) Module - Engine Control Module (ECM) - Heating, Ventilation and Air Conditioning (HVAC) Control Module Page 478 High Temperature Conditions Tools Required J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency MEASURING FREQUENCY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage MEASURING VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop MEASURING VOLTAGE DROP NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Page 1111 4. Connect the electrical connectors. 5. Install the front door trim panel. 6. If equipped with camper mirrors program the door module. Refer to Service Programming System (SPS) in Programming. Switch Replacement - Door Lock and Side Window - Passenger SWITCH REPLACEMENT - DOOR LOCK AND SIDE WINDOW - PASSENGER REMOVAL PROCEDURE 1. Remove the front door trim panel. 2. Disconnect the electrical connectors. 3. Remove the screw that retains the switch panel bezel (1) from the front door panel. 4. Remove the switch panel bezel from the door panel using a flat-bladed tool. Page 6454 6. Important: DO NOT hold the transmission end (1) during this operation, this will result in a mis-adjusted cable. Release the transmission end (3) and allow the spring (2) to tension/adjust the cable system. 7. Pull the white cover (5) on the shifter end (1) back. 8. Push the natural colored lock button (4) down to engage the locking teeth on the transmission end (3). 9. Release the white cover (1). 10. Verify the white cover (1) conceals the natural colored lock (2). Page 13264 2. Disconnect the C2 32-way blue connector from the VIU and tape the connector to a secure location. Refer to Cellular Communications Connector End Views and related schematics in SI, if required. Important: DO NOT perform the OnStar(R) reconfiguration and/or programming procedure. 3. Secure the VIU in its original brackets and/or mounting locations and reinstall the VIU and interior components that were removed to gain access to the VIU. Refer to OnStar Vehicle Interface Unit Replacement in SI. 2002 Through 2006 Model Year Vehicles (Except Saab Vehicles) 2002 through 2006 Model Year Vehicles (Except Saab Vehicles) Important: The Tech 2 diagnostic tool must be updated with version 28.002 or later in order to successfully perform the VCIM setup procedure and disable the analog system. 1. Connect the Tech 2 to the data link connector (DLC), which is located under the instrument panel of the vehicle. 2. Turn the Tech 2 ON by pressing the power button. Important: Tech 2 screen navigation to get to the setup procedure depends on the year and make of the vehicle. The actual name of the setup procedure (Setup New OnStar or VCIM Setup) depends on model year and vehicle make as well. Example Tech 2 navigation to the setup procedure Tech 2 screen is provided below. ^ Diagnostics >> (2) 2002 >> Passenger Car >> Body >> C >> OnStar >> Special Functions >> Setup New OnStar >> ^ Diagnostics >> (5) 2005 >> Passenger Car >> (4) Buick >> C >> Body >> Vehicle Comm. Interface Module >> Module Setup >> VCIM Setup >> 3. Setup VCIM using the Tech 2. Follow on-screen instructions when you have reached the setup Tech 2 screen. 2000-2002 Saab 9-3 (9400) 4D/5D; 2000-2003 Saab 9-3 (9400) CV 2000-2002 Saab 9-3 (9400) 4D/5D; 2000-2003 Saab 9-3 (9400) CV 1. Remove the ground cable from the battery's negative terminal. 2. Apply the handbrake brake. 3. Detach the floor console. 4. Remove the switch and the floor console: 3.1. Twist loose the immobilizer unit (A), bayonet fitting. Unplug the unit's connector. 3.2. Remove the ignition switch cover (B) by first undoing the rear edge of the cover and then unhooking the front edge. Unplug the ignition A/C - Ticking Noise From Instrument Panel/DTC's Set Control Module HVAC: All Technical Service Bulletins A/C - Ticking Noise From Instrument Panel/DTC's Set Bulletin No.: 06-01-38-003 Date: April 27, 2006 TECHNICAL Subject: Intermittent Ticking Noise from I/P, Poor A/C Performance, HVAC DTCs B0229, B0414, B0424, B3770 (Reprogram HVAC Control Module) Models: 2004-2006 Cadillac Escalade Models 2004-2006 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2004-2006 GMC Sierra Models, Yukon Models with Air Conditioning (RPOs CJ2, CJ3) Condition Some customers may comment on one or more of the following concerns: ^ Intermittent ticking/clicking noise from the instrument panel. ^ Recirculation mode does not work or Air Conditioning (A/C) system performance is poor during high ambient temperatures. ^ Unable to control the driver side temperature. ^ Unable to control the passenger side temperature. ^ Unable to change the front system modes. Cause This condition may be caused by the Heating, Ventilation and Air Conditioning (HVAC) actuators that may hunt for the correct commanded position. This cycling may cause a clicking or ticking noise. An overtravel of the HVAC system control doors may cause one or more of the concerns listed above. If an overtravel occurs, a Diagnostic Trouble Code (DTC) will be set, and the door will go to a preset default position. When a system door defaults, that door will stay at the default position until the DTC is cleared. After the DTC is cleared, the door will operate properly until the overtravel condition re-occurs. The table lists the HVAC system doors and the DTC associated with it. Correction Technicians are to perform the normal diagnostic procedures in SI for these concerns. If diagnostics show that the HVAC system door(s) travel below 5 counts (out of the lower range) or above 250 counts (out of the upper range), then update the software calibrations in the HVAC control module. The new calibrations were made available to dealerships as part of TIS2000 incremental satellite update version 2.5, which was broadcast to dealers in February 2006. Page 8476 CLAIM INFORMATION CUSTOMER NOTIFICATION - For US and CANADA General Motors will notify customers of this recall on their vehicle (see copy of customer letter shown in this bulletin). CUSTOMER NOTIFICATION - For IPC Letters will be sent to known owners of record located within areas covered by the US National Traffic and Motor Vehicle Safety Act. For owners outside these areas, dealers should notify customers using the sample letter. DEALER RECALL RESPONSIBILITY - For US and IPC (US States, Territories, and Possessions) The US National Traffic and Motor Vehicle Safety Act provides that each vehicle that is subject to a recall of this type must be adequately repaired within a reasonable time after the customer has tendered it for repair. A failure to repair within sixty days after tender of a vehicle is prima facie evidence of failure to repair within a reasonable time. If the condition is not adequately repaired within a reasonable time, the customer may be entitled to an identical or reasonably equivalent vehicle at no charge or to a refund of the purchase price less a reasonable allowance for depreciation. To avoid having to provide these burdensome remedies, every effort must be made to promptly schedule an appointment with each customer and to repair their vehicle as soon as possible. In the recall notification letters, customers are told how to contact the US National Highway Traffic Safety Administration if the recall is not completed within a reasonable time. This bulletin is notice to you that the new motor vehicles included in this recall may not comply with the standard identified above. Under Title 49, Section 30112 of the United States Code, it is illegal for a dealer to sell a new motor vehicle which the dealer knows does not comply with an applicable Federal Motor Vehicle Safety Standard. As a consequence, if you sell any of these motor vehicles without first performing the recall correction, your dealership may be subject to a civil penalty for each such sale. DEALER RECALL RESPONSIBILITY - ALL All unsold new vehicles in dealers' possession and subject to this recall must be held and inspected/repaired per the service procedure of this recall bulletin before customers take possession of these vehicles. Dealers are to service all vehicles subject to this recall at no charge to customers, regardless of mileage, age of vehicle, or ownership, from this time forward. Customers who have recently purchased vehicles sold from your vehicle inventory, and for which there is no customer information indicated on the dealer listing, are to be contacted by the dealer. Arrangements are to be made to make the required correction according to the instructions contained in this bulletin. A copy of the customer letter is shown in this bulletin for your use in contacting customers. Recall follow-up cards should not be used for this purpose, since the customer may not as yet have received the notification letter. In summary, whenever a vehicle subject to this recall enters your vehicle inventory, or is in your dealership for service in the future, you must take the steps necessary to be sure the recall correction has been made before selling or releasing the vehicle. Disclaimer Service Procedure The following procedure provides instructions for inspecting, and if necessary, replacing the hydraulic brake booster relief valve. 1. Open the hood. Important You may notice that there is a blue epoxy-type material in the center of the relief valve described in the next step. This material will be found in both the original arid replacement relief valves. 2. Locate the relief valve (2) on the hydraulic brake booster. The valve is located in the front of the brake booster directly behind the master cylinder reservoir (1). ^ If the color of the relief valve is metallic yellow or has a brass appearance, then further action is required. Specifications Valve Clearance: Specifications The manufacturer indicates that this vehicle has hydraulic lifters or adjusters and therefore does not require adjustment. Page 4225 Ignition Cable: Service and Repair SPARK PLUG WIRE REPLACEMENT REMOVAL PROCEDURE 1. Remove the spark plug wire from the spark plug. 1.1. Twist the spark plug wire boot a 1/2 turn. 1.2. Pull only on the boot in order to remove the wire from the spark plug. 2. Remove the spark plug wire from the ignition coil. 2.1. Twist the spark plug wire boot a 1/2 turn. 2.2. Pull only on the boot in order to remove the wire from the ignition coil. IMPORTANT: The Melco(R) spark plug wires MUST be used only with the Melco(R) coils and bracket, like wise the Delphi(R) spark plug wires MUST be used only with Delphi(R) coils and bracket. The components are NOT interchangeable. 3. There are 2 different manufacturers for the spark plug wire, ignition coils and coil brackets. They are as follows: 4. The Melco(R) spark plug wire (1) will have a blue foil mark on it, and the wire is 145 mm (5.70 in) in length from cable seal to cable seal. 5. The Delphi(R) spark plug wire (2) will have a white foil mark on it, and the wire is 110 mm (4.30 in) in length cable seal to cable seal. Page 12864 7.2. Remove the console (A). 7.3. Disconnect the connector (B) from the OnStar(R) control module. Important: Secure the cable harness to prevent the risk of scraping and rattling. 7.4. Fold back the cable harness and tape down the connector (C). Fold back the cable harness again and secure with cable ties (D). 7.5. 5D: Assemble the right-hand cover for the luggage compartment floor. 8. Fit the ground cable on the battery's negative cable. Electrical - Trailer Brakes Apply With Headlamps ON Trailer Lighting Module: Customer Interest Electrical - Trailer Brakes Apply With Headlamps ON Bulletin No.: 02-05-22-004C Date: April 05, 2005 TECHNICAL Subject: Trailer Brakes Applied When Headlights/Park Lamps Are On, Brake Controller Illumination (Modify Brake Controller Wiring Harness) Models: 2002-2005 Cadillac Escalade, Escalade EXT 1999-2005 Chevrolet Silverado 2000-2005 Chevrolet Suburban, Tahoe 2002-2005 Chevrolet Avalanche 1999-2005 GMC Sierra 2000-2005 GMC Yukon, Yukon XL 2003-2005 HUMMER H2 Supercede: This bulletin is being revised to add additional model years. Please discard Corporate Bulletin Number 02-05-22-004B (Section 05 - Brakes). Condition Some customers may comment that when the headlamps or park lamps are on, the brakes on the trailer are always applied, or that the back lighting for the trailer brake controller only illuminates when the brakes are applied. Cause The cause of this condition may be due to wiring changes within the vehicle electrical system for the 2003 model year. Correction Inspect the brake controller wiring harness jumper that is plugged into the vehicle relay block-body. The relay block-body is located under the left side of the instrument panel near the left kick panel, behind a plastic cover. Page 13798 Disclaimer Specifications Valve Clearance: Specifications The manufacturer indicates that this vehicle has hydraulic lifters or adjusters and therefore does not require adjustment. Heated Seat Switch Replacement - Front Seat Heater Switch: Service and Repair Heated Seat Switch Replacement - Front HEATED SEAT SWITCH REPLACEMENT - FRONT REMOVAL PROCEDURE 1. Remove the front door trim panel. 2. Disconnect the electrical connector. 3. Release the retaining clips for the front seat heater switch assembly in order to remove the switch. 4. Remove the front seat heater switch assembly. INSTALLATION PROCEDURE 1. Install the front seat heater switch assembly to the front trim panel by pressing the switch into place until the switch is completely seated. 2. Connect the electrical connector to the front seat heater switch assembly. 3. Install the front trim panel. Page 6718 3. Discard the old clutch pilot bearing. Installation Procedure Important: The flywheel spacer (if applicable) must be removed prior to pilot bearing installation. 1. Install a 5/8 inch washer (1) onto the J 38836 or equivalent. 2. Install a NEW clutch pilot bearing (2) onto the tool. Page 10153 Looking at the FRONT of the sensor, align the sensor with the steering shaft and install into the adapter and bearing assembly. 24. Install the connector to the sensor. Page 4999 Important The new canister vent valve will be installed in a new location, outside of the frame. 7. Position and secure the new valve assembly to the frame bracket on the outside of the frame using the existing hole and mounting bolt. Tighten Tighten the bracket mounting bolt to 12 Nm (106 lb in). 8. Connect the vent valve pipe to the EVAP canister. 9. Install the two vent valve pipe clips into the existing underbody holes. 10. Connect the EVAP canister vent valve electrical connector, if equipped. 11. Attach bulk 5/8" heater hose to the vent valve port and secure using a clamp. Run a length as needed along the frame rail routing to the area above the transmission. 12. Cut the hose to determined length and install the supplied filter box. Secure using a clamp. 13. Remove the transmission support and lower the transmission assembly as necessary to allow for access to the new filter box location. 14. Secure the filter box to the transmission vent hose just forward of the hose tee-section using a tie strap. DO NOT pinch or restrict the transmission vent hose. The filter box opening should be pointing downward. 15. Raise the transmission and reinstall the transmission support. 16. Tie strap the hose as needed along the frame rail in order to keep the hose away from pinch-points and heat sources. 17. Lower the vehicle. 2004-2007 Model Year (Use Service Kit P/N 19152349) 1. Raise the vehicle. Suitably support the vehicle. 2. Disconnect the EVAP canister vent valve electrical connector. 3. Disconnect the canister pipe from the vent valve. 4. Push in the retainer and remove the existing canister vent valve from the fuel tank clip or mounting bracket. Discard the old valve. 5. Cut back the existing canister pipe approximately 51 mm (2 in) to remove the quick connect end. Crew Cab Short Box Shown Below, Other Configurations Similar Page 9833 Application Table Page 15149 Electrical Symbols Part 13 Page 2061 1. For vehicles equipped with a torsion bar suspension turn the bolt (1) that contacts the torsion arm clockwise to raise the and counterclockwise to lower the height adjustment. One revolution of the bolt (1) into the nut increases the Z height by approximately 6.0 mm (0.2 inch). 2. For vehicles without torsion bars, replace damaged or worn components as necessary. D Height Measurement Important: There are no specified trim heights specifications on leaf spring vehicles because it is not an adjustable feature. The height of the suspension will depend on the option content of the vehicle as well as the aftermarket equipment that is placed on the vehicle. The measurements are used for comparison only and should be within 15 mm with the vehicle at curb and no accessories. 1. With the vehicle on a flat surface, lift upward on the rear bumper 38 mm (1.5 inch). 2. Allow the vehicle to settle into position. 3. Important: Measure the metal to metal contact points of the rear axle to the frame on the inboard side of the leaf springs. Measure the D height by measuring the distance between the bumper bracket and the top of the rear axle tube. 4. Repeat the jouncing operation 2 more times for a total of 3 times. 5. Use the highest and lowest measurements to calculate the average height. 6. The true D height dimension number is the average of the highest and the lowest measurements. 7. If these measurements are out of specifications, inspect for the following conditions: ^ Sagging front suspension Refer to Front Coil Springs Replacement or Torsion Bar Replacement in Front Suspension. ^ Sagging rear leaf/coil springs Refer to Leaf Spring Replacement in Rear Suspension. ^ Worn rear suspension components, such as leaf spring bushings Refer to Spring Bushing Replacement in Rear Suspension. ^ Improper tire inflation Refer to Tire Inflation Pressure Specifications. ^ Improper weight distribution ^ Collision damage Mirrors - Heated Mirrors, Defrosting Time Heated Element: Technical Service Bulletins Mirrors - Heated Mirrors, Defrosting Time INFORMATION Bulletin No.: 08-08-64-011A Date: February 25, 2010 Subject: Information on Heated Electrochromatic Outside Rearview Mirror Performance Models: 2010 and Prior GM Passenger Cars and Light Duty Trucks (including Saturn) 2009 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X Supercede: This bulletin is being revised to update the model years. Please discard Corporate Bulletin Number 08-08-64-011 (Section 08 - Body and Accessories). Defrosting Time/Performance Concern The electrochromatic (auto-dimming) outside rearview mirror used on the driver's side of many GM vehicles is slower to defrost than the passenger side outside rearview mirror. This is a normal condition. The glass on the driver's side electrochromatic mirror is twice as thick as the traditional glass on the passenger side mirror. The heating elements for the mirrors on both sides draw the same wattage, therefore the driver's side mirror will take approximately twice as long to defrost as the passenger mirror (approximately four minutes versus two minutes). Should a customer indicate that the driver's side heated mirror is not functioning correctly, verify it's function based upon this information prior to replacing the mirror. Disclaimer Page 4361 Camshaft Position Sensor: Description and Operation CAMSHAFT POSITION (CMP) SENSOR The CMP sensor is also a magneto resistive sensor, with the same type of circuits as the CKP sensor. The CMP sensor signal is a digital ON/OFF pulse, output once per revolution of the camshaft. The CMP sensor information is used by the PCM to determine the position of the valve train relative to the CKP. Front Wheel Bearing Wheel Bearing: Service and Repair Front Wheel Bearing Front Wheel Hub, Bearing, and Seal Replacement (4WD) ^ Tools Required J 45859 Axle Remover Removal Procedure 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Remove the tire and wheel. 3. Remove the rotor. Refer to Brake Rotor Replacement - Front in Disc Brakes. 4. Remove the wheel speed sensor and brake hose mounting bracket bolt from the steering knuckle. 5. Remove the wheel drive shaft nut retaining cover. Page 4552 Page 13906 Rear Fender: Service and Repair Fender Replacement - Rear (Step Side) Fender Replacement - Rear (Step Side) Removal Procedure 1. Remove the front filler bolts. 2. Remove the step pad. 3. Remove the lower fender brace rod bolts. 4. Remove the fender step bolts. 5. Remove the fender molding push-pins. 6. Remove the tail lamp assembly. 7. Remove the fender to rear pillar retaining bolts through the tail lamp opening. 8. Remove the rear retaining screws. 9. Remove the top fender molding push-pin retainer. 10. Remove the top fender molding. 11. Use the following procedure in order to remove the fender from the vehicle: 1. Lift the fender up 90 degrees. 2. Slide the fender outward. Page 5297 Fuel Line Coupler: Service and Repair Quick Connect Fitting(S) Service (Plastic Collar) QUICK CONNECT FITTING(S) SERVICE (PLASTIC COLLAR) REMOVAL PROCEDURE IMPORTANT: There are several types of plastic fuel and evaporative emission (EVAP) quick connect fittings used on this vehicle. The following instructions apply to all types of plastic quick connect fittings except where indicated. 1. Relieve the fuel system pressure. Refer to Fuel Pressure Relief Procedure. CAUTION: Wear safety glasses when using compressed air in order to prevent eye injury. 2. Using compressed air, blow any dirt or debris from around the quick connect fitting. 3. Squeeze the plastic quick connect fitting release tabs together to disengage the quick connect fitting. (This step applies to Bartholomew style fittings ONLY) 4. Squeeze where indicated by the arrows on both sides of the plastic ring to disengage the quick connect fitting. Page 11195 Hose/Line HVAC: Service and Repair Suction Hose Replacement (W/ Denso) SUCTION HOSE REPLACEMENT (W/DENSO) TOOLS REQUIRED J 39400-A Halogen Leak Detector REMOVAL PROCEDURE 1. Recover the refrigerant. Refer to Refrigerant Recovery and Recharging. 2. Remove the suction hose mounting bolt from the A/C compressor. 3. Remove the suction hose (2) from the A/C compressor. 4. Remove the suction hose nut from the accumulator. 5. Remove the suction hose from the accumulator. 6. Remove the suction hose assembly from the vehicle. 7. Discard all of the used sealing washers. Cap the system openings. INSTALLATION PROCEDURE 1. Install the suction hose to the vehicle. Inflatable Restraint I/P Module Disable Switch (HD Model) Air Bag Deactivation Switch: Description and Operation Inflatable Restraint I/P Module Disable Switch (HD Model) INFLATABLE RESTRAINT I/P MODULE DISABLE SWITCH (HD MODEL PICKUPS) The instrument panel (I/P) module disable switch is a manual 2-position key switch. The I/P module disable switch allows the vehicle operator the ability to enable or disable the I/P module (passenger frontal air bag). The I/P module disable switch interfaces with the inflatable restraint sensing and diagnostic module (SDM) to request the enabling or disabling of the I/P module. The occupants are notified of the enabling or disabling of the I/P module via the I/P module disable switch ON/OFF indicators located on the I/P module disable switch. Page 16019 Rear Defogger: Diagnostic Aids Basic Knowledge Required BASIC KNOWLEDGE REQUIRED Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the Service Data. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories CHECKING AFTERMARKET ACCESSORIES Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: - Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions INDUCING INTERMITTENT FAULT CONDITIONS In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: - Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. Page 12598 7.2. Remove the console (A). 7.3. Disconnect the connector (B) from the OnStar(R) control module. Important: Secure the cable harness to prevent the risk of scraping and rattling. 7.4. Fold back the cable harness and tape down the connector (C). Fold back the cable harness again and secure with cable ties (D). 7.5. 5D: Assemble the right-hand cover for the luggage compartment floor. 8. Fit the ground cable on the battery's negative cable. Page 15027 Page 3531 Air Filter Element: Service and Repair AIR CLEANER ELEMENT REPLACEMENT REMOVAL PROCEDURE 1. Remove the air cleaner outlet duct. 2. Disconnect the mass air flow/intake air temperature (MAF/IAT) sensor electrical connector (4). 3. Loosen the air cleaner housing top screws. 4. Remove the air cleaner housing cover. 5. Remove the air filter element. INSTALLATION PROCEDURE Page 7155 Fluid - M/T: Fluid Type Specifications Transmission Fluid 5-SPEED WITH LOW GEAR (RPO MW3) Grade ............................................................................... .............................................................................................................................. GL-4 Synthetic Viscosity .............................................................................................................................................. ..................................................................... 75W-90 5-SPEED WITHOUT LOW GEAR (RPO MG5) Fluid Type ................................................................................................................................................. Synchromesh Transmission Fluid P/N 12345349 6-SPEED Fluid Type ....................................................................................................................... Synthetic Transmission Fluid approved for Allison Transmission NVG 246-NP8 Control Module: Service and Repair NVG 246-NP8 Transfer Case Control Module Reprogramming Transfer Case Control Module Reprogramming Set-up for Module Programming/Reprogramming Important: Ensure that the vehicle battery is fully charged and that a battery charger is no longer connected. If performing this procedure for module replacement, install new module before proceeding. Before reprogramming close the doors and wait two minutes to allow other modules to stop communicating via the class 2 data line. Failure to do so could result in a failed reprogramming procedure. ^ Turn OFF all accessories. ^ Turn ON the ignition, with the engine OFF. Remote Programming Feature 1. Connect the scan tool to the vehicle. 2. Power-up the scan tool and select the Service Programming feature. 3. Select the appropriate vehicle. 4. Press the Request Info button on the scan tool. 5. Disconnect the scan tool from the vehicle and connect the scan tool to the computer station. 6. Follow the menu select items for reprogramming and provide information as to what type of device you are programming and whether you are reprogramming or replacing the electronic control unit (ECU). 7. Select "vehicle" from the selection menu. 8. Select the module you wish to Program. 9. Select "Normal" for Programming Type. 10. Select the applicable software calibrations. 11. Transfer data file to the scan tool. 12. Reconnect the scan tool to the vehicle. 13. Turn ON the ignition, with the engine OFF. 14. Select the Service Programming feature on the scan tool. 15. Press the Program button on the scan tool. Programming Using Scan Tool Pass-Through Connection 1. Connect the scan tool to vehicle and power it up. 2. Connect the computer station to the scan tool. 3. Select "PC Using Scan Tool Connection" from the programming menu on the computer station. 4. Follow the menu select items for reprogramming and provide information as to what type of device you are programming and whether you are reprogramming or replacing the electronic control unit (ECU). 5. Select "vehicle" from the selection menu. 6. Select the module you wish to program. 7. Select "Normal" for Programming Type. 8. Select the applicable software calibrations. 9. Transfer data file to the scan tool. Transfer Case Shift Control Module Replacement Transfer Case Shift Control Module Replacement Removal Procedure Page 8259 9.1. Push the mud flap to make contact with the front side of the underbody cross sill and mark location of the hole (5) of the mud flap. 9.2. Center punch the marked location and drill a 5.159 mm (13/64 in) hole. 9.3. Install the screw. Tighten Tighten the screw to 4 N.m (35 lb in). 9.4. Repeat the above steps for hole location 6. 10. Repeat the above steps for the opposite side. Parts Information Parts are expected to be available from GMSPO on June 30, 2004. Warranty Information Please advise the customer that the mud flaps can be purchased as an accessory. Installation and/or cost of the mud flaps will not be covered under the vehicle's warranty. Disclaimer Drivetrain - Updated Transfer Case Speed Sensor Conn. Speed Sensor: All Technical Service Bulletins Drivetrain - Updated Transfer Case Speed Sensor Conn. Bulletin No.: 06-04-21-001 Date: May 17, 2006 INFORMATION Subject: Updated Transfer Case Connector Service Kit Now Available For Transfer Case Speed Sensor Wire Harness Connector that Comes Loose Or Connector Retainer Clip Breaks Models: 2007 and Prior GM Light Duty Trucks 2007 and Prior HUMMER H2, H3 2005-2007 Saab 9-7X with Four-Wheel Drive or All-Wheel Drive Technicians may find that when the transfer case speed sensor wire harness connector is removed, the connector lock flexes/bends and does not return to the original position. The transfer case speed sensor wire harness connector then has no locking device. On older vehicles, the plastic connector retainer becomes brittle and the clip may break as soon as it is flexed. In the past, the only service fix was to install a wire harness connector service pack, P/N 88987183. This repair procedure involved splicing a new service connector with an integral connector lock. This connector service kit is of the same design and was still prone to failure over time. A new connector service repair kit is now available, P/N 15306187, that is an updated design. This new kit should be used whenever the speed sensor wire harness connector requires replacement. Parts Information Disclaimer Page 12440 Wheels/Tires - Slow Tire Leak/Vibration Wheels: All Technical Service Bulletins Wheels/Tires - Slow Tire Leak/Vibration Bulletin No.: 03-03-10-001D Date: January 17, 2008 TECHNICAL Subject: Tire Slowly Goes Flat and/or Excessive wheel Vibration Caused By Bead Splits (Replace wheels with New Heavy Duty Rim Version) Models: 1999-2006 Chevrolet Silverado 1500 Series Pickup Models (Classic) 1999-2006 Chevrolet Express 1500 Series Vans 2000-2006 Chevrolet Suburban Tahoe 1999-2006 GMC Sierra 1500 Series Pickup Models (Classic) 1999-2006 GMC Savana 1500 Series Vans 2002-2006 GMC Yukon Yukon XL 2007 GMC Sierra Denali Crew Cab with 6-Bolt, 16 X 6.5 Full Face Steel wheel (Base and RPO PY2) Supercede: This bulletin is being revised to add the Express and Savana models and add information to the Correction section. Please discard Corporate Bulletin Number 03-03-10-001C (Section 03 Suspension). Implementation of this service bulletin by "GM of Canada" dealers requires prior District Service Manager approval. Condition Some customers may comment on a tire that slowly goes flat and/or excessive wheel vibration. This condition is more apparent on vehicles in which customer usage typically involves frequent severe conditions such as: High load (at or above gross vehicle weight) Rough road/off road usage Fleet/Commercial usage Cause The wheel may experience a crack or split in the outboard bead seat weld area. A weld attaches the rim and disc together on full-face wheels in this area. To identify this wheel it is offered in a silver painted version P/N 9593915 code "TZA" and a chrome-clad version, P/N 9593150 code "RSC" (these codes are stamped into the wheel's disc near the bolt holes). Correction Wheel replacement should only be done for air loss and/or vibration caused by bead splits. A new heavy-duty rim version of these wheels has been released for service. The new heavy-duty painted wheel is P/N 9595245 code "FFU" used as a road wheel and spare. The new heavy-duty chrome clad version is P/N 9595306 code "FFW" used as a road wheel only (these codes are stamped into the inboard rim flange balance weight area and are also on a sticker near the bolt holes). If a condition of a crack or split as described above occurs all (5) five of the original wheels on the vehicle should be replaced with the new heavy-duty wheels as follows: Replace road wheel P/N 9593915 with P/N 9595245. Replace road wheel PIN 9593150 with P/N 9595306. Replace the spare wheel with P/N 9595245 on all vehicles. Page 9103 Fuse Block: Service and Repair Body Wiring Harness Junction Block Replacement BODY WIRING HARNESS JUNCTION BLOCK REPLACEMENT REMOVAL PROCEDURE 1. Remove the cover retaining nut. 2. Remove the cover by pushing in the tabs. 3. Remove the harness from the front of the junction block. 4. Remove the junction block from the bracket by pressing to release the tabs. 5. Remove the junction block in order to gain access to the rear of the block to remove the retaining bolts. 6. Remove the retaining bolts. 7. Separate the wire harness block from the junction block by inserting a screw driver in between. 8. Remove the junction block from the vehicle. INSTALLATION PROCEDURE 1. Install the wire harness block to the junction block. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the retaining bolts. Tighten Tighten the bolts to 6 N.m (53 lb in). 3. Install the junction block to the bracket. Drivetrain - Excessive Effort When Shift 2HI to 4HI Differential Fluid - Transfer Case: Customer Interest Drivetrain - Excessive Effort When Shift 2HI to 4HI TECHNICAL Bulletin No.: 09-04-19-002A Date: February 17, 2011 Subject: 4WD System Shift Performance in Cold Ambient Temperatures (Use Synthetic Fluid in Light Duty Front Axles with 8.5" Ring Gears) Models: 1999-2011 Chevrolet Silverado 1500 Series Models 1999-2011 GMC Sierra 1500 Series Models Equipped with 4WD and 8.25" Front Axle Ring Gears (Transfer Case RPOs NP2, NQG) Attention: It is important to determine the RPO for the transfer case in GWM/IVH prior to applying this bulletin. This bulletin applies ONLY to vehicles equipped with 8.25" front axle ring gears, used in conjunction with a manual transfer case (RPOs NP2, NQG). Supercede: This bulletin is being revised to add the 2011 model year. Please discard Corporate Bulletin Number 09-04-19-002 (Section 04 - Driveline/Axle). Condition Some customers may comment about the effort required to shift from 2HI to 4HI in cold ambient temperatures at -6°C (20°F) or below. Cause This condition may be caused by the standard front axle being equipped with conventional mineral oil axle fluid. In cold ambient temperatures, prior to complete warm up, the fluid viscosity is thick. This may affect transfer case shift performance prior to full warm up. Correction Drain the front axle fluid and refill with GM SAE 75W-90 Synthetic Axle Fluid, P/N 89021677 (in Canada, 89021678). Refer to Front Axle Lubricant Replacement in SI. It is important to use synthetic fluid in this 8.25" axle to improve the performance of the 4WD system in cold ambient temperatures. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 13404 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors USING CONNECTOR TEST ADAPTERS IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-B Connector Test Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Page 14318 WA964L/29 - WA9792/39 Page 12356 Control Module References Part 5 Page 14945 9.1. Push the mud flap to make contact with the front side of the underbody cross sill and mark location of the hole (5) of the mud flap. 9.2. Center punch the marked location and drill a 5.159 mm (13/64 in) hole. 9.3. Install the screw. Tighten Tighten the screw to 4 N.m (35 lb in). 9.4. Repeat the above steps for hole location 6. 10. Repeat the above steps for the opposite side. Parts Information Parts are expected to be available from GMSPO on June 30, 2004. Warranty Information Please advise the customer that the mud flaps can be purchased as an accessory. Installation and/or cost of the mud flaps will not be covered under the vehicle's warranty. Disclaimer Page 6577 Page 14816 Seat Heater Switch: Service and Repair Heated Seat Switch Replacement - Rear HEATED SEAT SWITCH REPLACEMENT - REAR REMOVAL PROCEDURE 1. Remove the center console end panel. 2. Disconnect the electrical connector. 3. Remove the seat heater switch retaining screws. 4. Remove the switch from the vehicle. INSTALLATION PROCEDURE 1. Install the switch to the console panel. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the retaining screw. Tighten Tighten the screws to 1.6 N.m (14 lb in). 3. Connect the electrical connector. 4. Install the center console end panel. Engine, A/T - Shift/Driveability Concerns/MIL ON Air Filter Element: Customer Interest Engine, A/T - Shift/Driveability Concerns/MIL ON Bulletin No.: 04-07-30-013B Date: February 01, 2007 INFORMATION Subject: Automatic Transmission Shift, Engine Driveability Concerns or Service Engine Soon (SES) Light On as a Result of the Use of an Excessively/Over-Oiled Aftermarket, Reusable Air Filter Models: 2007 and Prior GM Cars and Light Duty Trucks 2007 and Prior Saturn Models 2003-2007 HUMMER H2 2006-2007 HUMMER H3 2005-2007 Saab 9-7X Supercede: This bulletin is being revised to add models and model years. Please discard Corporate Bulletin Number 04-07-30-013A (Section 07 - Transmission/Transaxle). The use of an excessively/over-oiled aftermarket, reusable air filter may result in: Service Engine Soon (SES) light on Transmission shift concerns, slipping and damaged clutch(es) or band(s) Engine driveability concerns, poor acceleration from a stop, limited engine RPM range The oil that is used on these air filter elements may be transferred onto the Mass Air Flow (MAF) sensor causing contamination of the sensor. As a result, the Grams per Second (GPS) signal from the MAF may be low and any or all of the concerns listed above may occur. When servicing a vehicle with any of these concerns, be sure to check for the presence of an aftermarket reusable, excessively/over-oiled air filter. The MAF, GPS reading should be compared to a like vehicle with an OEM air box and filter under the same driving conditions to verify the concern. The use of an aftermarket reusable air filter DOES NOT void the vehicle's warranty. If an aftermarket reusable air filter is used, technicians should inspect the MAF sensor element and the air induction hose for contamination of oil prior to making warranty repairs. Transmission or engine driveability concerns (related to the MAF sensor being contaminated with oil) that are the result of the use of an aftermarket reusable, excessively/over-oiled air filter are not considered to be warrantable repair items. Page 5623 Crankshaft Position Sensor: Service and Repair Crankshaft Position (CKP) Sensor Replacement CRANKSHAFT POSITION (CKP) SENSOR REPLACEMENT REMOVAL PROCEDURE IMPORTANT: Perform the CKP System Variation Learn Procedure whenever the crankshaft position sensor is removed or replaced. 1. Remove the starter. 2. Disconnect the crankshaft position (CKP) sensor electrical connector. 3. Clean the area around the CKP sensor before removal in order to avoid debris from entering the engine. 4. Remove the CKP sensor bolt. 5. Remove the CKP sensor. INSTALLATION PROCEDURE Page 12584 7.3. If equipped, connect the rear seat heater's connector and install the switch. 8. Install the floor console: 8.1. Install the floor console's retaining bolts (C) and retaining nuts (F). 8.2. Align the rear cover; make sure that the air duct connects firmly to the air nozzle. Screw in the cover (E). 8.3. Install the ashtray/cover (D). 8.4. Install the ignition switch cover (B). 8.5. Plug in the immobilizer unit (A) connector. Install the unit, bayonet fitting. 9. Remove the OnStar(R) control modules and secure the wiring: 9.1. Remove the right-hand rear luggage compartment trim in accordance with WIS - 8. Body - Interior equipment - Adjustment/Replacement. 9.2. Unplug the connectors (A) from the OnStar(R) control modules. 9.3. Remove the console (B) together with the OnStar(R) control modules. Page 14024 Scuff Plate: Service and Repair Door Sill Plate Replacement - Rear Door Sill Plate Replacement - Rear Removal Procedure 1. Use a flat-bladed tool in order to pry the door sill plate. 2. Remove the sill plate from the vehicle. Installation Procedure 1. Install the sill plate. 2. Push the sill plate down until the sill plate locks into place. Valve Rocker Arm Cover Replacement (Left) Valve Cover: Service and Repair Valve Rocker Arm Cover Replacement (Left) Valve Rocker Arm Cover Replacement - Left Removal Procedure 1. Remove the engine sight shield, if required. 2. Remove the connector position assurance (CPA) lock. 3. Disconnect the main electrical connector (2) to the ignition coil wire harness. 4. Remove the harness clips (1). 5. Reposition the engine harness, if necessary. 6. Remove the spark plug wires from the ignition coils. ^ Twist each plug wire 1/2 turn. ^ Pull only on the boot in order to remove the wire from the ignition coil. 7. Remove the ignition coil bracket studs. 8. Remove the ignition coil bracket. Page 828 Junction Block - I/P Wire Entry Part 2 Page 10835 1. Install the mode actuator as an assembly with the actuator cam. - Line up the heater/defroster valve lever with the mode actuator cam slot. - Line up the A/C valve lever with the mode actuator cam. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the mode actuator mounting screws to the HVAC module. Tighten Tighten the screws to 1.6 N.m (14 lb in). 3. Connect the electrical connection at the mode actuator (10). 4. Install the center console duct. 5. Install the screws to the center console duct. A/C - Defaults To Defrost Mode/Poor Control Wiring Harness HVAC: All Technical Service Bulletins A/C - Defaults To Defrost Mode/Poor Control Bulletin No.: 04-01-38-008 Date: June 17, 2004 TECHNICAL Subject: HVAC System Cannot be Controlled or Defaults to Defrost Mode (Repair HVAC Actuator Harness) Models: 2003-2005 Cadillac Escalade, Escalade ESV, Escalade EXT 2003-2005 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2003-2005 GMC Sierra, Yukon, Yukon XL Condition ^ Some customers may comment that they cannot control the HVAC (heating, ventilation and air conditioning) system. Others may comment that the HVAC system defaults to the Defrost mode. ^ Technicians may find that the following diagnostic trouble codes have set: ^ B0229 Recirculation Actuator ^ B0414 Left Air Temperature Actuator ^ B0424 Right Air Temperature Actuator ^ B3770 Mode Actuator Cause The HVAC actuator harness may contact a sharp edge on the instrument panel support brace, causing a rub through condition and a ground out of the actuator control and/or feedback circuits. Correction Locate the HVAC actuator harness contact point shown by the arrow in the above illustration. The illustration is of the instrument panel with the instrument panel compartment door opened and folded downward. The actuator harness is located in the left side of the opening in the instrument panel. Page 11919 8.2. Remove the console (A) together with the OnStar(R) control modules. 8.3. Remove the connectors (B). Important: The optic cable must not be bent with a radius less than 25 mm (1 in). Important: Secure the wiring harness so that there is no risk of chafing and rattling. 8.4. Fold back the wiring harness and tape over the connectors (C). Fold back the wiring harness once more and secure with cable ties (D). Page 6843 8. Install a new pinion oil seal using the J 44414. 9. Apply sealant, GM P/N 12346004 (Canadian P/N 10953480) or equivalent, to the splines of the pinion yoke. 10. Install the pinion yoke. Align the marks made during removal. 11. Seat the pinion yoke onto the pinion shaft by tapping it with a soft-faced hammer until a few pinion shaft threads show through the yoke. Notice: Do not hammer the pinion flange/yoke onto the pinion shaft. Pinion components may be damaged if the pinion flange/yoke is hammered onto the pinion shaft. 12. Install the washer and a new pinion nut. 13. Install the J 8614-01 onto the pinion yoke as shown. 14. Tighten the pinion nut while holding the J 8614-01. ^ Tighten the nut until the pinion end play is just taken up. Rotate the pinion while tightening the nut to seat the bearings. Notice: Refer to Fastener Notice in Service Precautions. Important: If the rotating torque is exceeded, the pinion will have to be removed and a new collapsible spacer installed. 15. Measure the rotating torque of the pinion. Compare this measurement with the rotating torque recorded during removal. ^ Tighten the nut in small increments, as needed, until the rotating torque is 0.40-0.57 Nm (3-5 inch lbs.) greater than the rotating torque recorded during removal. 16. Once the specified torque is obtained, rotate the pinion several times to ensure the bearings have seated. Recheck the rotating torque and adjust if necessary. Page 16303 5. Install the reinforcement panel with the 4 bolts. Tighten Tighten the 4 bolts to 9 N.m (80 lb in). 6. Install the air inlet grille panel. 7. Install the wiper arms. 8. Operate the wipers and inspect for proper operation. Page 10991 Blower Motor Resistor Assembly Page 9411 Electrical Symbols Part 10 I/P Fuse Block Fuse Block: Locations I/P Fuse Block Body Control Module (BCM) Page 8435 Parking Brake Shoe: Service and Repair Parking Brake Shoe Replacement (1500HD/25/35 Series) Parking Brake Shoe Replacement (1500HD/25/35 Series) Removal Procedure Caution: Avoid taking the following actions when you service wheel brake parts: - Do not grind brake linings. - Do not sand brake linings. - Do not clean wheel brake parts with a dry brush or with compressed air. Some models or aftermarket brake parts may contain asbestos fibers which can become airborne in dust. Breathing dust with asbestos fibers may cause serious bodily harm. Use a water-dampened cloth in order to remove any dust on brake parts. Equipment is available commercially in order to perform this washing function. These wet methods prevent fibers from becoming airborne. 1. For the 1500HD, relieve the tension from the park brake cable by pulling down on the park brake cable in front of the equalizer then removing the cable from the equalizer bar. 2. For the 25/35 series Disable the park brake cable automatic adjuster. Refer to Parking Brake Cable Adjuster Disabling See: Parking Brake Cable/Adjustments. 3. Raise and support the vehicle. 4. Remove the tire and the wheel. 5. Perform the following procedure to remove the cable (2) from the backing plate (4): 5.1. Compress the spring (3) by pushing towards the lever (1). 5.2. Depress the locking tabs. 5.3. Pull the cable housing out of the backing plate (4). 5.4. Remove the cable (2) through the slot in the backing plate. 6. Remove the park brake cable (2) from the lever (1). 7. Remove the rotor. Refer to Rear Brake Rotor Replacement in Disc Brakes See: Disc Brake System/Brake Rotor/Disc/Service and Repair. 8. Remove the rear axle shaft. Refer to Rear Axle Shaft Replacement in Rear Drive Axle . Page 13126 Page 5397 Fuel Filler Hose: Service and Repair Filler Tube Replacement (Cab/Chassis - Rear) FILLER TUBE REPLACEMENT (CAB/CHASSIS - REAR) REMOVAL PROCEDURE 1. Relieve the fuel system pressure. Refer to Fuel Pressure Relief Procedure. 2. Loosen the fuel fill pipe hose clamp (2) at the tank. 3. Loosen the fuel vent pipe hose clamp (1) at the tank. 4. Remove the fuel fill and vent hoses from the tank. INSTALLATION PROCEDURE 1. Install the fuel fill and vent hoses to the tank. 2. Tighten the fuel vent pipe hose clamp (1) at the tank. NOTE: Refer to Fastener Notice in Service Precautions. 3. Tighten the fuel fill pipe hose clamp (2) at the tank. Tighten Tighten the clamps to 2.5 N.m (22 lb in). Page 11901 Page 7088 SRS - Air Bag Lamp ON/DTC B0092 Set Seat Occupant Sensor: All Technical Service Bulletins SRS - Air Bag Lamp ON/DTC B0092 Set Bulletin No.: 02-09-41-002A Date: March 24, 2004 TECHNICAL Subject: Air Bag Lamp On, Passenger Air Bag Indicator Always Reads OFF, DTC B0092 Set (Repair Passenger Presence System (PPS) Sensor Harness) Models: 2003-2004 Cadillac Escalade, Escalade EXT 2003-2004 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2003-2004 GMC Sierra, Yukon, Yukon XL with Sensor Indicator Inflatable Restraint Front Passenger/Child Presence Detector (RPO ALO) Supercede: This bulletin is being revised to add the 2004 model year. Please discard Corporate Bulletin Number 02-09-41-002 (Section 09 - Restraints). Condition Some customers may comment that the Air Bag Lamp is on and the Passenger Air Bag indicator always reads OFF. Upon investigation, the technician may find DTC B0092 set. Cause The cause of this condition may be a shorted Passenger Presence System (PPS) sensor wire. The PPS sensor harness is located under the front passenger seat. This harness may be pinched between the seat frame and the track/riser. Correction Locate the PPS sensor (1) and inspect the harness for proper routing. If the harness is pinched between the seat frame and the track/riser, use the procedure listed below to repair wire(s). 1. Move the front passenger seat to the full rearward and full tilt up position. 2. Loosen the seat frame to track/riser nut and remove the harness. 3. Tighten the seat frame to track/riser nut. 4. Repair any damaged wires. Refer to Wiring Repairs in the Wiring Systems sub-section of the Service Manual. Warranty Information Page 2679 Junction Block - Rear Lamps - C1 Part 2 Page 1083 Lock Cylinder Switch: Description and Operation PASSLOCK(TM) SENSOR The Passlock(TM) sensor is inside the ignition cylinder lock housing. The Passlock(TM) sensor contains 2 hall effect sensors. The tamper hall effect sensor is on the top. The security hall effect sensor is under the tamper hall effect sensor. Both of the hall effect sensors monitor the magnet of the lock cylinder through an opening. The tamper hall effect sensor is physically placed on top of the security hall effect sensor. This arrangement enables the tamper hall effect sensor to engage first if an intruder attempts to bypass the Passlock(TM) sensor by placing a large magnet around that area of the steering column. There is a tamper resistor inside the Passlock(TM) sensor in order to help prevent tamper to the system. Passlock(TM) equipped vehicles have a selection of 10 different security resistors ranging from 0.5K ohms up to 13.6K ohms. Installing one of the security resistors inside the Passlock(TM) sensor will generate a unique Passlock(TM) code. All 10 combinations of the Passlock(TM) sensor have the same part number. However, you cannot simply replace the Passlock(TM) sensor and expect the system to operate properly. Always start by performing the Diagnostic System Check first and following the instructions. Page 10687 Refer to the Model Application Chart shown to verify usage. Supercede: This bulletin is being revised to include 2007 model year and calibration information. Please discard Corporate Bulletin Number 03-03-10-006E (Section 03 - Suspension). Tires GM has designed 20" wheels based on the Goodyear Eagle LS and LS2 P275/55R20 tire. The Goodyear Eagle LS tire has a Tire Performance Criteria spec # 1235 and the LS2 has a Tire Performance Criteria spec # 1245. These tires have been designed to GM's specific Tire Performance Criteria. GM's Tire Performance Criteria specifications meet or exceed all Federal safety guidelines. When mounting the tires, rubber lubricant, P/N 12345884 (in Canada, P/N 5728223), MUST be used. The vehicle should not be driven aggressively (hard acceleration or braking) for at least 6-8 hours after tire mounting to allow the lube to dry. Failure to do so may cause the tire to slip on the rim. This condition will affect wheel balance which could result in a vibration. Spare Tire A P265/75R16 or P265/70R17 tire should be used as a spare. Re-use the vehicle's original spare wheel to mount the spare tire. The spare tire should be used to drive the vehicle to a tire repair/replacement facility and is not intended for extended driving conditions. Tire Changers Dealers must have the correct level of tire changing equipment to perform tire changing services. GM requirements and recommendations for servicing glamour wheels are as follows: ^ Rim Clamp design ^ Runflat capable (preferred) ^ Side mounted bead breaking to reduce stress on the wheel and tire ^ No metal contact to the wheel at the clamping jaws Protective devices to prevent damage during mounting and dismounting operations Regulated air pressure to protect user and wheel assembly. Approved lubricant (P/N 12345884 [in Canada, P/N 5728223]) to avoid wheel slip and damage to the wheel For further information regarding equipment meeting the requirements for this program, call 1-800-GM-TOOLS. Balancing MC style coated weights are recommended and will provide the best balancing of the tire-wheel assembly. If stick-on weights are used, be sure to follow the manufacturers recommended installation procedure (SI Document ID # 664222) making sure the surface is clean and dry. Using the incorrect type of weights will result in improper fit, and such weights may fall off the wheel. Page 16261 Windshield Moulding / Trim: Service and Repair Windshield Upper Reveal Molding Replacement Windshield Upper Reveal Molding Replacement Tools Required * Urethane Adhesive Kit GM P/N 12346392 or Equivalent * Isopropyl Alcohol or Equivalent * Cartridge-type Caulking Gun * Plastic Paddle Removal Procedure 1. Remove both right and left sides of the reveal molding. Caution: Refer to Glass and Sheet Metal Handling Caution in Service Precautions. Important: The windshield reveal molding fills the cavities between the body and windshield. If the reveal molding is stretched or damaged it and cannot be reused it must be replaced. 2. Remove the upper windshield reveal molding. 1. Use a flat-bladed tool in order to carefully pry the end of the upper reveal molding out about 76 mm (3 in). 2. Grasp the corner of the windshield reveal molding by hand or use a suitable tool to slowly pull the reveal molding away from the windshield. 3. If the windshield reveal molding will not release, use a utility knife to aid in the releasing of the molding. Installation Procedure 1. Clean the top edge of the windshield surface with a 50/50 mixture of isopropyl alcohol and water by volume on a dampened lint - free cloth. 2. The new reveal molding should be fitted to the windshield prior to installation. Caution: Refer to Window Retention Caution in Service Precautions. 3. Verify all primers and urethane adhesive are within expiration dates. Important: Use care when applying the prep (clear #1) to the windshield. This primer dries almost instantly, and may stain the viewing area of the windshield if not applied evenly. 4. Use a new dauber in order to apply glass prep (clear #1) to the channel area approximately 13 mm (1/2 in) to the upper edge of the windshield. 5. Wipe the glass primed area immediately with a clean lint-free cloth. 6. Shake the glass primer (black #2) for at least one minute. Using a new dauber in order to apply glass primer (black #2) to the top edge of the windshield. Page 3973 5. Connect the fuel pump electrical connector. 6. Install the sending unit. Service and Repair Cabin Ventilation Grille: Service and Repair Pressure Relief Valve Replacement Removal Procedure Use a flat-bladed tool to pry the pressure release valve from the cab back panel. Remove the pressure relief valve from the vehicle. Installation Procedure Align the pressure relief valve into the opening of the rear cab. Press the Pressure Relief Valve into the Cab Back Panel until the locking tabs are fully seated. Page 528 Front Passenger Door Module (FPDM) - C5 (With RPO Code AN3) Part 2 Page 5289 Fuel Injector: Service and Repair Fuel Injector Replacement FUEL INJECTOR REPLACEMENT REMOVAL PROCEDURE NOTE: Use care in removing the fuel injectors in order to prevent damage to the fuel injector electrical connector pins or the fuel injector nozzles. Do not immerse the fuel injector in any type of cleaner. The fuel injector is an electrical component and may be damaged by this cleaning method. IMPORTANT: The engine oil may be contaminated with fuel if the fuel injectors are leaking. 1. Remove the fuel rail. 2. Remove and discard the fuel injector retainer clip (19). 3. Remove the fuel injector (17). 4. Remove and discard the fuel injector retainer clip (1). 5. Remove and discard the fuel injector O-ring seals (2, 4). INSTALLATION PROCEDURE IMPORTANT: When ordering new fuel injectors, you must order the correct injector for the application being serviced. Page 4036 Tighten Tighten to 8 Nm (71 lb in). Note The repair area MUST BE properly refinished to maintain a secure, stable and corrosion-free electrical ground. 12. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 13. Verify proper system operation. M8 Weld Nut Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M8 weld nut electrical ground location is accessible from both sides of the panel, a M8 conductive bolt and a M8 conductive nut may be used to secure the electrical ground wire terminal. Refer to the Parts Information section of this bulletin. 2. Select a location adjacent the M8 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the new electrical ground site. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the ground location and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 10 mm (0.40 in) diameter hole through the panel. 5. Remove paint and primer from the area surrounding the 10 mm (0.40 in) hole until bare metal is visible. 6. Select a M8 conductive bolt. Refer to the Parts Information section of this bulletin. 7. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M8 conductive bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 8. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 9. Install the electrical ground wire terminal and the M8 conductive bolt to the ground location. 10. Select a M8 conductive nut. Refer to the Parts Information section of this bulletin. 11. Install the M8 conductive nut to the bolt and: Tighten Tighten to 22 Nm (16 lb ft). Note The repair area MUST BE properly refinished to maintain a secure, stable and corrosion-free electrical ground. 12. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 13. Verify proper system operation. M8 Weld Nut Alternative Repair Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M8 weld nut electrical ground location is not accessible from both sides of the panel, a M6 conductive rivet stud and a M6 conductive nut may be used to secure the electrical ground wire terminal. 2. Select a location adjacent the damaged M8 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the M6 conductive rivet stud flange. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the repair site and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 10 mm (0.40 in) diameter hole through the panel. Page 9716 C149 Engine Harness To Coil Jumper Harness Page 15061 G. Apply an approved anti-corrosion material to all of the bare metal surfaces. 2. After completion of any repairs due to the use of aftermarket accessories, install new pickup box reinforcements using the following procedure and the applicable part numbers listed below. Pickup Box Reinforcement Installation Important: The reinforcements must be installed before adding a toolbox or ladder rack system. After the reinforcements have been installed, follow the instructions supplied with the toolbox/ladder rack system for installation onto the pickup box. Use the following service procedure to install the reinforcements. Use the applicable reinforcement kit part number listed below. Cross Toolbox and Rear Window Barrier Applications - Front Reinforcement Installation Important: The horizontal surfaces of the reinforcements must be flush to the horizontal surface of the pickup box top rail. Use a clamping tool when positioning the reinforcements onto the top rail to ensure flushness to the outer panel. 1. Place the front L-shaped reinforcements into position on the front top of the pickup box. For vehicles equipped with an over the rail bedliner, the bedliner should be removed with the aid of an assistant prior to installing these reinforcements. 2. Mark the holes necessary for drilling. 3. Remove the front reinforcements. Important: Use a block of wood and/or a drill stop in order to protect the back of the cab while drilling. 4. Drill two 13.5 mm (0.54 in) holes per side into the box section of the front panel. 5. Drill 7.5 mm (0.30 in) holes into the weld flange of the side outer panel. 6. Apply anti-corrosion material to the drilled holes as necessary per the GM4901M-D-2005 (English) or GM4901M-D-F 2005 (French) GM Approved Refinish Materials booklet. The information for the 2005 GM Approved Refinish Materials booklet will now be online at the GMGOODWRENCH WEB SITE ONLY. Printed books have been discontinued. Steps to the site are as follows: A. Go to www.gmgoodwrench.com. B. Click on GM Collision Parts. C. Click on GM Technical Repair Information. D. Click on Paint Shop. 7. Place the front reinforcements back onto the box, lining up the drilled holes. Page 13873 Page 14326 Paint: Service and Repair Basecoat/Clearcoat Paint Systems Caution: Exposure to isocyanates during paint preparation and application processes can cause severe breathing problems. Read and follow all of the instructions from the manufacturers of painting materials, equipment, and protective gear. Caution: Refer to Eye Protection Caution in Service Precautions. All paint finish repairs of rigid exterior surfaces must meet GM standards. The GM Approved Refinish Materials book GM P/N GM4901M-D identifies the paint systems you may use. Always refer to the latest revision of the 4901M-D book. All approved products, including volatile organic compound (VOC) compliant regulations are listed in the system approach recommended by the individual manufacturer. Refer to the manufacturer's instructions for the detailed procedures for materials used in the paint system in the painting repairs of rigid exterior surfaces. All components of an approved paint system have been engineered in order to ensure proper adhesion between layers. If necessary, spot repairs or color blending in an open panel can be done. However, do not blend clearcoat in an open panel. Always apply clearcoat to the next break point, body side molding, feature line, or the next panel. Do not mix paint systems or substitute a product of one manufacturer for another manufacturer's product. If incompatible products are used together the following problems may occur: * Lifting of primer coats caused by overly aggressive solvents in subsequent layers * Loss of adhesion between layers due to incompatibility of resin systems * Solvent popping or pinholing due to inappropriate solvent selection * Poor through-curing due to incompatible hardener resins or insufficient reactivity * Gloss reduction due to incompatible resins and/or solvents * Poor color accuracy due to pigment interactions with incompatible resins and/or solvents * Film defects, such as craters, blisters, orange peel loss of gloss, due to the use of inferior quality raw materials in incompatible products Page 6980 Seals and Gaskets: Service and Repair Rear Axle Hub, Bearing, Cup, and/or Seal Replacement Rear Axle Hub, Bearing, Cup, and/or Seal Replacement ^ Tools Required J 8092 Universal Driver Handle - 3/4 inch - 10 - J 2222-C Wheel Bearing Nut Wrench - J 24426 Wheel Bearing Race Installer - Outer - J 24427 Wheel Bearing Race Installer - Inner - J 44419 Hub Outer Bearing Race Installer - J 44420 Differential Bearing and Hub Seal Installer Removal Procedure 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Remove the tire and wheel assembly. 3. Remove the brake caliper. 4. Remove the axle shaft. 5. Remove the axle nut retaining ring. 6. Remove the key. 7. Remove the adjusting nut using the J 2222-C. Page 12979 Speaker Replacement Reference Speaker Replacement - Front Door SPEAKER REPLACEMENT - FRONT DOOR REMOVAL PROCEDURE 1. Remove the trim panel. 2. Remove the speaker by pushing down on the top retainer. 3. Disconnect the electrical connector. INSTALLATION PROCEDURE Page 10220 Electrical Symbols Part 4 Page 16003 Important: The first part of the test must be completed quickly before the entire surface of the back window becomes warm. 3.1.1. From outside the vehicle, place the heat sensitive paper (dull surface in contact with the glass) against the top driver side grid line. Start the engine and turn on the back window defogger. A distinct color change will take place at each conductive grid line. Repeat for the bottom grid lines until they have all been checked in the driver side zone. 3.1.2. Repeat the process for the passenger side and center area zones. 3.1.3. If no color change is noted for a grid line, place a crayon or china marker check mark beside it. Mark each grid line in the zone where it is non-conductive and, therefore, not heating up. More than one broken grid line may be found. 3.2. Method using portable infrared thermometer: 3.2.1. Start the engine and turn on the rear back window defogger. 3.2.2. From inside the vehicle, start at the top driver side grid line and slowly run the portable infrared thermometer vertically down the rear window contacting each grid line. You should be able to see a district variation in temperature readings. 3.2.3. Mark each grid line in the zone where it is non-conductive and, therefore, not heating up. More than one broken grid line may be found. 3.2.4. Repeat the process for the passenger side and center area zones. 4. Use Permatex(R) Quick Grid, GM P/N 12346001, or equivalent, to repair each broken grid line. Follow the manufacturer's instructions. 5. Wait 24 hours before turning the defogger on, or the repair can be fast cured using a heat gun, 260°C - 371°C (500°F - 700°F). Hold the heat gun within 25 - 51 mm (1-2 in) from the repair point for 2 to 3 minutes. 6. Recheck the grid line with the heat sensitive paper or portable infrared thermometer to ensure that the line is now functional and that the repair was successful. Disclaimer Page 9328 4. Push on the top part until it clicks in place. 5. Connect the harness to the front of the junction block. 6. Install the cover to the junction block until it clicks in place. 7. Hand tighten the retaining nut until seated. Page 9226 C277 Steering Wheel Module Coil To Steering Wheel Harness (With RPO Code UK3) Wheels - Plastic Wheel Nut Covers Loose/Missing Wheel Fastener: Customer Interest Wheels - Plastic Wheel Nut Covers Loose/Missing Bulletin No.: 01-03-10-009A Date: July 27, 2004 TECHNICAL Subject: Plastic Wheel Nut Covers Missing and/or Loose (Replace Missing Covers and Add Sealant to All Covers) Models: 2005 and All Prior Passenger Cars (Except All Cadillac Models and Pontiac GTO) with Plastic Wheel Nut Covers Supercede: This bulletin is being revised to add additional models years. Please discard Corporate Bulletin Number 01-03-10-009. Condition Some customers may comment that the plastic wheel nut covers are missing and/or loose. Correction Important: ^ DO NOT USE a silicone-based adhesive. ^ Do not apply the *permatex(R) around the threads in a circular pattern. ^ Apply a single bead across the threads approximately 10 mm (0.4 in) in length, 5 mm (0.2 in) in height and 5 mm (0.2 in) in width. Replace any missing plastic wheel nut covers with the appropriate covers and apply Permatex(R) # 2 Form A Gasket Sealant(R) to the threads of all the plastic wheel nut covers. Tighten finger tight plus a 1/4 turn with a hand wrench. *We believe this source and their products to be reliable. There may be additional manufacturers of such material. General Motors does not endorse, indicate any preference for or assume any responsibility for the products from this firm or for any other such items which may be available from other sources. Permatex(R) # 2 Form A Gasket Sealant(R) part numbers (available at your local parts supplier) ^ P/N 80009 (2A/2AR) - 44 ml (1.5 oz) tube boxed ^ P/N 80015 (2AR) - 44 ml (1.5 oz) tube carded ^ P/N 80010 (2B/2BR) - 89 ml (3 oz) tube boxed ^ P/N 80016 (2BR) - 89 ml (3 oz) tube carded ^ P/N 80011 (2C) - 325 ml (11 oz) tube boxed Warranty Information For vehicles repaired under warranty, use the table. SRS - Air Bag Lamp ON/DTC B0092 Set Seat Occupant Sensor: Customer Interest SRS - Air Bag Lamp ON/DTC B0092 Set Bulletin No.: 02-09-41-002A Date: March 24, 2004 TECHNICAL Subject: Air Bag Lamp On, Passenger Air Bag Indicator Always Reads OFF, DTC B0092 Set (Repair Passenger Presence System (PPS) Sensor Harness) Models: 2003-2004 Cadillac Escalade, Escalade EXT 2003-2004 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2003-2004 GMC Sierra, Yukon, Yukon XL with Sensor Indicator Inflatable Restraint Front Passenger/Child Presence Detector (RPO ALO) Supercede: This bulletin is being revised to add the 2004 model year. Please discard Corporate Bulletin Number 02-09-41-002 (Section 09 - Restraints). Condition Some customers may comment that the Air Bag Lamp is on and the Passenger Air Bag indicator always reads OFF. Upon investigation, the technician may find DTC B0092 set. Cause The cause of this condition may be a shorted Passenger Presence System (PPS) sensor wire. The PPS sensor harness is located under the front passenger seat. This harness may be pinched between the seat frame and the track/riser. Correction Locate the PPS sensor (1) and inspect the harness for proper routing. If the harness is pinched between the seat frame and the track/riser, use the procedure listed below to repair wire(s). 1. Move the front passenger seat to the full rearward and full tilt up position. 2. Loosen the seat frame to track/riser nut and remove the harness. 3. Tighten the seat frame to track/riser nut. 4. Repair any damaged wires. Refer to Wiring Repairs in the Wiring Systems sub-section of the Service Manual. Warranty Information Page 9621 Application Table Page 14093 Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses CIRCUIT PROTECTION - FUSES The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the Page 5578 Steps 1 - 3 Page 10978 ^ Reinstall the fuse and fuse panel cover. ^ Press the "Enter" button to perform the "Refresh" function. ^ "Test in Progress" will be displayed and the right front passenger door lock will cycle once. ^ The screen will display "Procedure Completed". ^ Press the "Exit" button as necessary to return to the main menu screen. 3. Using the switches in the right front passenger door, verify that the power window and power door lock located in that door function properly. Important: The calibrations required for performing SPS reprogram in the next step are based on the type of exterior rearview mirror the vehicle has. To determine the correct calibration, check the Service Parts Identification Label on the vehicle for the RPO code for exterior mirrors. 4. Follow normal Service Programming System (SPS) to reprogram the passenger door module with the current calibration available in TIS 2000. 5. After reprogramming is complete, using the switches in the right front passenger door, verify that the power window and power door lock located in that door function properly. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 5001 3. Disconnect the vent valve pipe quick connect from the canister. 4. Either cut the existing valve vent pipe and leave the remaining section of pipe in the vehicle or remove along with the valve. 5. Push in the retainer and remove the existing canister vent valve from the fuel tank clip or mounting bracket. 6. Cut back the existing canister pipe approximately 51 mm (2 in) and retain the pipe for use with new valve. 7. Connect the canister pipe quick connect to the canister. 2500 Crew Cab Short Box Shown Below, Other Configurations Similar 1500 Extended Cab Short Box Shown Below, Other Configurations Similar 8. Install the new canister vent valve solenoid to the fuel tank clip or mounting bracket as shown above. The valve port closest to the electrical connector must point towards the canister. 9. Cut bulk 5/8" heater hose to a length of approximately 76 mm (3 in). Install the hose between the solenoid and the canister pipe and secure using clamps. 10. Attach bulk 5/8" heater hose to the vent port and secure using a clamp. Run a length as needed along the frame rail routing to the passenger side area above the transmission. 11. Cut the hose to determined length and install the supplied filter box. Secure using a clamp. 12. Remove the transmission heat shield, if necessary. 13. Remove the transmission support and lower the transmission assembly as necessary to allow for access to the new filter box location. 14. Secure the filter box to the transmission vent hose just forward of the hose tee-section using a tie strap. DO NOT pinch or restrict the transmission vent hose. The filter box opening should be pointing downward. 15. Raise the transmission and reinstall the transmission support. 16. Reinstall the transmission heat shield. 17. Connect the EVAP canister vent valve electrical connector. 18. Tie strap the hose as needed along the frame rail in order to keep the hose away from pinch-points and heat sources. 19. Lower the vehicle. Parts Information Page 7878 Control Module: Locations NVG 263-NP1 Transfer Case Shift Control Module Transfer Case Shift Control Module 1 - I/P Harness 2 - Transfer Case Shift Control Module Connectors 3 - Transfer Case Shift Control Module 4 - Instrument Panel Page 12725 ^ For U.S. Saturn retailer claim submission, use Net Item code "M" and Case Type VW. Page 9320 Application Table Page 4321 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Page 475 Electrical Symbols Part 13 Page 14446 Disclaimer Page 12955 Speaker: Diagrams Speaker - LR Door Speaker - LR - Except Crew Cab Page 11486 Impact Sensor: Service and Repair Sensor Replacement Guidelines SENSOR REPLACEMENT GUIDELINES The SIR sensor replacement policy requires replacing sensors in the area of accident damage. The area of accident damage is defined as the portion of the vehicle which is crushed, bent, or damaged due to a collision. For example, a moderate collision where the front of the vehicle impacts a tree. If the vehicle has an SIR sensor mounted forward of the radiator, it must be replaced. - Replace the sensor whether or not the air bags have deployed. - Replace the sensor even if it appears to be undamaged. Sensor damage which is not visible, such as slight bending of the mounting bracket or cuts in the wire insulation, can cause improper operation of the SIR sensing system. Do not try to determine whether the sensor is undamaged, replace the sensor. Also, if you follow a Diagnostic Trouble Code (DTC) table and a malfunctioning sensor is indicated, replace the sensor. Service and Repair Rear Wheel Steering Switch: Service and Repair Rear Wheel Steering Mode Switch Replacement Removal Procedure 1. Remove the dash trim bezel. 2. Grasp the rear wheel steering mode switch housing (2) and pull outward to remove the switch assembly. 3. Disconnect the electrical connector (3) from the rear wheel steering mode switch. 4. Remove the rear wheel steering mode switch assembly (1) from the vehicle. Installation Procedure 1. Reconnect the rear wheel steering mode switch (3) electrical connectors. 2. Install the rear wheel steering mode switch (1) into the dash. 3. Reinstall the dash trim bezel. Page 14612 Power Seat Motor: Diagrams Seat Rear Vertical Motor Seat Rear Vertical Motor - Driver Page 2288 7. Reposition the inlet heater hose clamp (4) from the auxiliary water pump (1). 8. Remove the inlet heater hose (6) from the auxiliary water pump (1). INSTALLATION PROCEDURE 1. Install the inlet heater hose (6) to the auxiliary water pump (1). 2. Position the inlet heater hose clamp (4) to the auxiliary water pump (1). 3. Install the inlet heater hose to the engine. 4. Position the inlet heater hose clamp to the engine. IMPORTANT: Align the arrow at the throttle body end of the duct with the throttle body attaching stud. Page 15968 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-8 (12085115) crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-8 (12085115) until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes SPLICING INLINE HARNESS DIODES Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate Service Data wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. 9. Tape the diode to the harness or connector using electrical tape. Page 3645 6. Remove the inlet heater hose. INSTALLATION PROCEDURE 1. Install the inlet heater hose. 2. Install the inlet heater hose to the engine. 3. Connect the heater and surge tank hose to the heater core. Firmly push the quick connect onto the heater core pipe until you hear an audible click. 4. Install the heater and surge tank hose to the mounting clip. 5. Install the air intake tube. 6. Fill the cooling system. Refer to Draining and Filling Cooling System (with HP2)Draining and Filling Cooling System (without HP2) in Cooling System. A/T - Valve Body Reconditioning Valve Body: All Technical Service Bulletins A/T - Valve Body Reconditioning Bulletin No.: 07-07-30-024 Date: September 27, 2007 INFORMATION Subject: Information on 4L60-E M30 Rear Wheel Drive Automatic Transmission Valve Body Reconditioning, DTC P0741, P0756, P0894, Harsh 1-2 Shift Models The following new service information outlined in this bulletin will aid technicians in providing easy to follow valve body reconditioning instructions and new illustrations to simplify reassembly of the valve body. This service bulletin will also provide additional service information documents that are related to the 4L60-E transmission. Related Service Documents DTC P0741 - Torque Converter Clutch (TCC) System - Stuck Off. Refer to Service Bulletin 04-07-30-041. DTC P0756 - 2-3 Shift Solenoid Valve Performance - No First or Second Gear. Refer to Service Bulletin 01-07-30-036F. DTC P0894 - Transmission Component Slipping. Refer to Service Bulletin 06-07-30-007. Harsh 1-2 Shift. Refer to Bulletin PIP3170E. If valve body cleaning is not required, Do Not disassemble the bores unless it is necessary to verify movement of valves. Drivetrain - Updated Transfer Case Speed Sensor Conn. Speed Sensor: All Technical Service Bulletins Drivetrain - Updated Transfer Case Speed Sensor Conn. Bulletin No.: 06-04-21-001 Date: May 17, 2006 INFORMATION Subject: Updated Transfer Case Connector Service Kit Now Available For Transfer Case Speed Sensor Wire Harness Connector that Comes Loose Or Connector Retainer Clip Breaks Models: 2007 and Prior GM Light Duty Trucks 2007 and Prior HUMMER H2, H3 2005-2007 Saab 9-7X with Four-Wheel Drive or All-Wheel Drive Technicians may find that when the transfer case speed sensor wire harness connector is removed, the connector lock flexes/bends and does not return to the original position. The transfer case speed sensor wire harness connector then has no locking device. On older vehicles, the plastic connector retainer becomes brittle and the clip may break as soon as it is flexed. In the past, the only service fix was to install a wire harness connector service pack, P/N 88987183. This repair procedure involved splicing a new service connector with an integral connector lock. This connector service kit is of the same design and was still prone to failure over time. A new connector service repair kit is now available, P/N 15306187, that is an updated design. This new kit should be used whenever the speed sensor wire harness connector requires replacement. Parts Information Disclaimer Page 6989 Wheel Bearing: Testing and Inspection Wheel Bearings Diagnosis Test 1-7 Page 9599 Relay Block - I/P C4 Page 4685 Body Control Module (BCM) - C4 Part 1 Page 11104 A/C line and the A/C component. 5. Assemble the remaining A/C refrigerant components. Page 5490 Fuel Pump Relay: Locations Fuel Pump Relay Secondary - With Dual Tanks FUEL PUMP RELAY - SECONDARY (Vehicles with Dual Tanks Only) Fuel Pump Relay-Secondary-With Dual Tanks The Fuel Pump Relay - Secondary is attached to the Underhood Fuse Block Bracket. The Underhood Fuse Block is located at the left side of the engine compartment, to the rear of the battery. Page 15455 Door Switch: Description and Operation DOOR LATCH (DOOR JAMB) SWITCHES The theft deterrent system uses the door key switch as one method in order to activate the alarm. If the BCM detects any door opening before the BCM receives a disarm input, the alarm mode activates. DOOR KEY SWITCH The BCM monitors the door key switches in order to disarm the CTD system. When the lock cylinder turns in order to unlock the door, the switch grounds the disarm input to the BCM. Page 8620 of failure to repair within a reasonable time. If the condition is not adequately repaired within a reasonable time, the customer may be entitled to an identical or reasonably equivalent vehicle at no charge or to a refund of the purchase price less a reasonable allowance for depreciation. To avoid having to provide these burdensome remedies, every effort must be made to promptly schedule an appointment with each customer and to repair their vehicle as soon as possible. In the recall notification letters, customers are told how to contact the US National Highway Traffic Safety Administration if the recall is not completed within a reasonable time. Dealer Recall Responsibility -- All All unsold new vehicles in dealers' possession and subject to this recall MUST be held and inspected/repaired per the service procedure of this recall bulletin BEFORE customers take possession of these vehicles. Dealers are to service all vehicles subject to this recall at no charge to customers, regardless of mileage, age of vehicle, or ownership, from this time forward. Customers who have recently purchased vehicles sold from your vehicle inventory, and for which there is no customer information indicated on the dealer listing, are to be contacted by the dealer. Arrangements are to be made to make the required correction according to the instructions contained in this bulletin. A copy of the customer letter is shown in this bulletin for your use in contacting customers. Recall follow-up cards should not be used for this purpose, since the customer may not as yet have received the notification letter. In summary, whenever a vehicle subject to this recall enters your vehicle inventory, or is in your dealership for service in the future, please take the steps necessary to be sure the recall correction has been made before selling or releasing the vehicle. Disclaimer Service Procedure Inspection Tools Required CH 47950 Hydro-Boost Checking Tool 1. With the vehicle transmission in PARK or NEUTRAL, set the park brake. 2. With the engine OFF, make a minimum of five (5) high effort brake applies until the pedal feels hard. 3. Start the engine. Important: DO NOT depress the brake pedal until instructed. 4. Turn the steering wheel to the "steering lock" (fully turned) position. Hold at the steering lock position for 1 to 2 seconds and then release the steering wheel. Repeat a total of 3 times. 5. Turn the vehicle off being careful not to step on the brake pedal. 6. For Express/Savana only: A. Remove the remote power steering reservoir mounting nuts. B. Disconnect the reservoir outlet hose from the booster unit. Keeping the hose end higher than the reservoir, reposition the reservoir forward and down out of the way. 7. Using a clean, lint-free shop cloth, wipe any dirt away from the steering pump supply hose/tube connection area on the hydro-boost (this is the center hose/tube of the three). 8. Disconnect the power steering supply hose/tube from the hydro-boost unit and wrap a clean lint-free shop cloth around the end of the hose and secure it in the engine compartment. 9. Using a clean lint-free shop cloth, clean any dirt off of the inlet port adapter valve assembly. Before installing the inlet port adapter, place a shop Page 12514 If you are unsure who the PSC is, check with the Sales Manager. General Information 1. The first step is to verify if the OnStar(R) account is active or not. This can be done by pressing the blue OnStar(R) button and connecting to the OnStar(R) call center. Analog only accounts are no longer active. Only digital upgraded accounts will be active. On Gen 6 digital systems, a clear, or "dark" LED may indicate that the OnStar(R) system has been deactivated or may possibly have a no power/no communication condition. 2. If the account isn't active, the next step is to verify what version of OnStar(R) module is in the vehicle. This can be done via the Tech 2 (Body>VCIM>Module ID Information>Module Information 2) or by using www.onstarenrollment.com. 3. A Generation 5 or older analog module can be diagnosed by following the original electronic Service Information developed for the model year of the vehicle. Note: If the customer has an old analog module, the vehicle can be repaired by replacing the module, but the customer cannot have an active account without upgrading to a digital module. 4. Modules, antennas, brackets, and other equipment are in the same location, whether original analog production or digital upgrade. 5. An upgraded vehicle may also have a new vehicle communication interface module (VCIM) bracket. If it does, order the new bracket when replacing the bracket. Don't order the original bracket. The kit may also include a small wiring jumper cable. If it does, this jumper will be required for a new module replacement. Do not discard. 6. After replacing the VCIM, it is essential to configure the new OnStar(R) system. Failure to configure the system will result in an additional customer visit for repair. DO NOT press and hold the white dot or phone button on the keypad as it will not reset this version of the OnStar(R) system and may result in a DTC being set. Use of the TIS2WEB and SPS applications, along with the Tech2(R), are required in order to perform the VCIM configuration and setup procedure for this vehicle. The configuration and set-up procedure is now a two-step process which enables an automated activation by the OnStar(R) Center, without a button press by the technician to the OnStar(R) Call Center. Page 10713 8. Remove the adjusting nut. 9. Remove the hub from the axle housing. 10. Remove the rotor, if necessary. 11. Remove the oil seal from the wheel hub using a suitable seal removal tool. 12. Remove the inner hub bearing. 13. Remove the inner hub bearing cup using a brass drift and a hammer. Page 9757 C306 Infotainment Jumper Harness To Console Harness (Without RPO Code Y91) Part 2 Page 3478 1. Apply a 5 mm (0.20 inch) bead of sealant GM P/N 12378190, or equivalent 20 mm (0.80 inch) long to the oil pan to engine block junction. 2. Install the front cover gasket and cover. 3. Install the front cover bolts until snug. Do not overtighten. 4. Install the oil pan-to-front cover bolts until snug. Do not over tighten. 5. Install J 41476 to the front cover. 6. Align the tapered legs of the J 41476 with the machined alignment surfaces on the front cover. Notice: Refer to Fastener Notice in Service Precautions. 7. Install the crankshaft balancer bolt until snug. Do not overtighten. 1. Tighten the oil pan to front cover bolts to 25 Nm (18 ft. lbs.). 2. Tighten the engine front cover bolts to 25 Nm (18 ft. lbs.). 8. Remove the J 41476. 9. Install a NEW crankshaft front oil seal. 10. Install the water pump. Service and Repair Glove Box Lamp Switch: Service and Repair INSTRUMENT PANEL (I/P) COMPARTMENT LAMP SWITCH REPLACEMENT REMOVAL PROCEDURE 1. Lower the instrument panel storage compartment door by pressing in the tab. 2. With one hand holding the plunger of the switch, use a small screw driver to push in the tabs on each side while pulling outwards. 3. Pull the switch assembly from the I/P. 4. Disconnect the electrical connector. 5. Remove the bulb (1). INSTALLATION PROCEDURE OnStar(R) - No Power/Inoperative/No LED Emergency Contact Module: All Technical Service Bulletins OnStar(R) - No Power/Inoperative/No LED TECHNICAL Bulletin No.: 05-08-46-001D Date: May 02, 2008 Subject: OnStar(R) Generation 5 or 6 (Digital) System Inoperative/Has No Power, LED Light Not On (Remove/Reinstall OnStar(R) Fuse and Replace VCIM or Follow SI Diagnostics) Models Supercede: This bulletin is being revised to update the information on VCIM ordering instructions in step 3 of the Correction statement. Please discard Corporate Bulletin Number 05-08-46-001C (Section 08 - Body & Accessories). Condition Some customers may comment any or all of the following conditions: ^ The OnStar(R) system may be inoperative. ^ The OnStar(R) system may have no power. ^ The OnStar(R) LED light may not be on. The technician may also not be able to communicate with the OnStar(R) Vehicle Communication Interface Module (VCIM) with a Tech 2(R). Correction Notice: On 2006 Chevrolet Impala and Monte Carlo models, make sure the ignition is OFF and the vehicle has "RAP"ed out prior to removing the OnStar(R) fuse. Disconnecting power to the OnStar(R) module while the ignition is ON may discharge and permanently damage the OnStar(R) back-up battery. Page 3359 15. Connect the oil level sensor electrical connector (3). 16. Install the transmission cover and bolt. ^ Tighten the bolt to 12 Nm (106 inch lbs.). 17. Install the crossbar. 18. Install the crossbar bolts. ^ Tighten the bolts to 100 Nm (74 ft. lbs.). Page 1268 8. Remove the wheel speed sensor (WSS) mounting bolt. 9. NOTICE: Carefully remove the sensor by pulling it straight out of the bore. DO NOT use a screwdriver, or other device to pry the sensor out of the bore. Prying will cause the sensor body to break off in the bore. Remove the wheel speed sensor (5) from the hub/bearing assembly (4) shown on the 2500/3500 series. Installation Procedure 1. Plug the WSS bore to prevent debris from falling into the hub. 2. Using a wire brush or equivalent, clean the WSS mounting surface on the hub to remove any rust or corrosion. 3. Apply a thin layer of wheel bearing lubricant, GM P/N 01051344 to the hub surface and the sensor O-ring prior to sensor installation. 4. Install the WSS (5) into the hub/bearing assembly (4) shown on the 2500/3500 series. Ensure that the sensor is seated flat against the hub. Page 12345 SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-D. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: - The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair Tools Required J 38125-D Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-D. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Page 13431 Control Module References Part 2 Page 12203 Page 6256 4. Install the oil pan and NEW gasket. 5. Notice: Refer to Fastener Notice in Service Precautions. Install the oil pan bolts. ^ Tighten the bolts alternately and evenly to 11 Nm (97 inch lbs.). 6. If previously removed, install the range selector cable bracket and bolts. ^ Tighten the bolts to 25 Nm (18 ft. lbs.). 7. Apply a small amount of sealant GM P/N 12346004 (Canadian P/N 10953480), or equivalent to the threads of the oil pan drain plug, if equipped. 8. Install the oil pan drain plug, if equipped. ^ Tighten the plug to 18 Nm (13 ft. lbs.). 9. Lower the vehicle. 10. Fill the transmission to the proper level with DEXRON® III transmission fluid. 11. Check the COLD fluid level reading for initial fill only. 12. Inspect the oil pan gasket for leaks. Page 10311 Ball Joint: Testing and Inspection Ball Joint Inspection ^ Tools Required J 8001 Dial Indicator 1. Important: ^ The vehicle must rest on a level surface. ^ The vehicle must be stable. Do not rock the vehicle on the floor stands. ^ The upper control arm bumper must not contact the frame. Raise and support the vehicle. 2. Support the lower control arm with a floor stand or jack, as far outboard as possible. 3. Important: If a seal is cut or torn, replace the ball joint. Clean and inspect the ball joint seals for cuts or tears. If the ball joint seals are damaged, replace the ball joint. 4. Check the wheel bearing for looseness. If looseness in the wheel bearing is present, refer to Wheel Bearings Diagnosis. 5. Check the ball joints for horizontal looseness. 1. Position the J 8001 dial indicator against the lowest outboard point on the wheel rim. 2. Rock the wheel in and out while reading the dial indicator. This shows horizontal looseness in both joints. 3. The dial indicator reading should be no more than 2 mm (0.080 inch). If the reading is too high, check the lower ball joints for vertical looseness. 6. Notice: Do not pry between the lower arm and the wheel drive shaft boot or in such a manner that the ball joint seal is contacted. Damage to the wheel drive shaft boot will result (4WD). For 4WD vehicles, place a J 8001 dial indicator (1) against the spindle in order to show vertical movement. Locations Fog/Driving Lamp Switch: Locations Instrument Panel Switches-LH Page 13227 Check - Vehicle. The Diagnostic System Check will provide the following information: ^ The identification of the control modules which command the system ^ The ability of the control modules to communicate through the serial data circuit ^ The identification of any stored diagnostic trouble codes (DTCs) and their status The use of the Diagnostic System Check will identify the correct procedure for diagnosing the system and where the procedure is located. Visual/Physical Inspection Perform the following visual inspections; ^ Inspect for aftermarket devices which could affect the operation of the Radio/Audio System. Refer to Checking Aftermarket Accessories in SI. ^ Inspect the easily accessible and visible system components for obvious damage or conditions which could cause the symptom. Intermittent Conditions Faulty electrical connections or wiring may be the cause of intermittent conditions. Refer to Testing for Intermittent Conditions and Poor Connections in SI. Symptom List Page 15140 Electrical Symbols Part 3 Page 8895 circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links CIRCUIT PROTECTION - FUSIBLE LINKS Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Flat Wire Repairs FLAT WIRE REPAIRS NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Heated Oxygen Sensor (HO2S) Wiring Repairs HEATED OXYGEN SENSOR (HO2S) WIRING REPAIRS TOOLS REQUIRED J 38125-D Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: - Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-D. Repairing Damaged Wire Insulation REPAIRING DAMAGED WIRE INSULATION Page 11327 Radio (With RPO Code UB7,Y91 Shown, Others Similar) Page 7957 2. Connect the selector switch electrical connectors (2, 3). 3. Slide the selector switch into the housing until the switch snaps into place. Important: Make sure that the selector switch is seated properly in the housing before installing the I/P cluster bezel. 4. Install the I/P cluster bezel. Page 14103 Control Module References Part 1 Automatic Transmission - 4L60-E/4L65-E Transmission Speed Sensor: Locations Automatic Transmission - 4L60-E/4L65-E Automatic Transmission Electronic Component Views (M30/M32) Electronic Components Locations Fuel Composition Sensor Door Window Regulator Replacement (Manual) Front Door Window Regulator: Service and Repair Door Window Regulator Replacement (Manual) Window Regulator Replacement - Front Door Removal Procedure 1. Raise and support the window glass. 2. Remove the trim panel. 3. Remove the water deflector. 4. Remove the 2 bolts that hold the window to the regulator. 5. Remove the bolts from the window regulator. 6. Remove the window regulator assembly from the door by folding both sides together. Installation Procedure 1. Install the regulator to the door. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the bolts to the window regulator. Tighten the bolts to 9 N.m (80 lb in). 3. Align the window glass to the regulator. 4. Install the bolts that hold the window to the regulator. Tighten the bolts to 9 N.m (80 lb in). 5. Install the water deflector. 6. Install the trim panel. 7. Lower the window. Inspect the operation. Instruments - Service Tire Monitor Message is Displayed Fuse: Customer Interest Instruments - Service Tire Monitor Message is Displayed Bulletin No.: 05-08-49-018A Date: May 11, 2006 ADVANCE SERVICE INFORMATION RESOLUTION Subject: EI 05065 - Service Tire Monitor Message Displayed (Pull/Reinstall IPC Fuse or Verify Correct Passenger Door Module (PDM) and Tires) Models: 2004 Chevrolet Silverado 2004 GMC Sierra Supercede: This bulletin is being revised to provide correction action. Please discard Corporate Bulletin Number 05-08-49-018 (Section 08 - Body and Accessories). Condition Some customers may comment that the "SERVICE TIRE MONITOR" message is being displayed on the DIC. Correction DO NOT REPLACE THE INSTRUMENT PANEL CLUSTER. If the DIC is displaying the SERVICE TIRE MONITOR message: 1. Verify if the vehicle has an electronic aftermarket module spliced into the ALDL Class 2 data line (purple wire). 2. If the vehicle HAS an aftermarket module spliced into the Class 2 line, pull the IPC fuse (located underhood) for 25 seconds. Important: Due to the electronic aftermarket module, the SERVICE TIRE MONITOR message may reoccur. 3. Reinstall the IPC fuse. This will clear the SERVICE TIRE MONITOR message from the display. 4. If the vehicle DOES NOT have an aftermarket module spliced into the Class 2 line, verify the vehicle is equipped with the correct PDM (Passenger Door Module) and tires. Warrant Information This repair is not covered under the vehicle warranty due to the installation of an aftermarket module. Disclaimer Page 12805 Circuit/System Testing Component Testing Page 10902 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the cover up until the dress cover releases. Repeat this procedure for the other locking tab. 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. 5. If the connector has a nose piece, use a small flat-blade tool to remove the nose piece by inserting the blade into the slot on the front of the connector and prying up on the nose piece. IMPORTANT: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 6. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. IMPORTANT: Be careful not to angle or rock the J 38125-13A tool when inserting it into the connector or the tool may break. Engine Controls - MIL ON/Misfire/Misfire DTC's Set Engine Control Module: Customer Interest Engine Controls - MIL ON/Misfire/Misfire DTC's Set Bulletin No.: 06-06-04-046 Date: September 12, 2006 INFORMATION Subject: Information on Engine Misfire MIL/SES Light Illuminated or Flashing DTC P0300, P0301, P0302, P0303, P0304, P0305, P0306, P0307, P0308, P0420 or P0430 Models: 1999-2007 Cadillac, Chevrolet, GMC Full-Size Pickup and/or Utility Trucks with 4.8L, 5.3L, 5.7L, 6.0L or 6.2L VORTEC GEN III, GEN IV, V-8 Engine (VINs V, C, T, Z, B, 3, M, 0, J, R, U, N, Y, K, 8 - RPOs LR4, LY2, LM7, L59, L33, LC9, LH6, LMG, LY5, L31, LQ4, LQ9, L76, LY6, L92) with Active Fuel Management(TM) and E85 Flex Fuel If you encounter vehicles that exhibit the above conditions, refer to SI for the appropriate DTC(s) set. If no trouble is found, the cause may be due to an ECM ground terminal that has corroded with rust over time. Inspect the main engine wiring harness ground terminal (G103) for this condition. The wire terminal (G103) attaches either to the front or to the rear of the right side cylinder head, depending on the model year of the Full Size Pickup and/or Utility Trucks. If the ECM ground terminal has been found to be corroded, then follow the service procedure outlined in this bulletin to correct the corrosion issue. Remove either the nut or bolt securing the main engine wiring harness ground terminal (G103) to the right cylinder head. Refer to the above illustration to determine where the ground is located on the vehicle (1). Interior - Intermittent Seat Heater Operation Seat Heater Control Module: All Technical Service Bulletins Interior - Intermittent Seat Heater Operation Bulletin No.: 05-08-50-008 Date: August 19, 2005 TECHNICAL Subject: Intermittent Heated Seats Inoperative, DTC B3941 Set (Reprogram Driver Seat Module) Models: 2003-2005 Cadillac Escalade, Escalade ESV, Escalade EXT 2003-2005 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2003-2005 GMC Sierra, Yukon, Yukon XL, Yukon Denali All with Seat FRT, Individual (Non BKT) (RPO AN3) 2003-2005 HUMMER H2 with Seat, Front Bucket Deluxe (RPO AR9) Condition Some customers may comment that occasionally the seat heater will not operate when activated. If the ignition key is cycled OFF and back ON again, the heated seat will operate correctly. Also, on some LB7 diesel engine vehicles, the seat heater may turn itself off during the first 10 minutes of operation. This occurs only with the first activation for the day and works correctly with subsequent activations immediately after the event. These conditions are intermiffent and DTC B3941 may be set. Correction Technicians are to reprogram the driver seat module with an updated software calibration. This new service calibration was released with TIS satellite data update version 6.5 available June 13, 2005. As always, make sure your Tech 2(R) is updated with the latest software version. Warranty Information Drivetrain - Excessive Effort When Shift 2HI to 4HI Case: Customer Interest Drivetrain - Excessive Effort When Shift 2HI to 4HI TECHNICAL Bulletin No.: 09-04-19-002A Date: February 17, 2011 Subject: 4WD System Shift Performance in Cold Ambient Temperatures (Use Synthetic Fluid in Light Duty Front Axles with 8.5" Ring Gears) Models: 1999-2011 Chevrolet Silverado 1500 Series Models 1999-2011 GMC Sierra 1500 Series Models Equipped with 4WD and 8.25" Front Axle Ring Gears (Transfer Case RPOs NP2, NQG) Attention: It is important to determine the RPO for the transfer case in GWM/IVH prior to applying this bulletin. This bulletin applies ONLY to vehicles equipped with 8.25" front axle ring gears, used in conjunction with a manual transfer case (RPOs NP2, NQG). Supercede: This bulletin is being revised to add the 2011 model year. Please discard Corporate Bulletin Number 09-04-19-002 (Section 04 - Driveline/Axle). Condition Some customers may comment about the effort required to shift from 2HI to 4HI in cold ambient temperatures at -6°C (20°F) or below. Cause This condition may be caused by the standard front axle being equipped with conventional mineral oil axle fluid. In cold ambient temperatures, prior to complete warm up, the fluid viscosity is thick. This may affect transfer case shift performance prior to full warm up. Correction Drain the front axle fluid and refill with GM SAE 75W-90 Synthetic Axle Fluid, P/N 89021677 (in Canada, 89021678). Refer to Front Axle Lubricant Replacement in SI. It is important to use synthetic fluid in this 8.25" axle to improve the performance of the 4WD system in cold ambient temperatures. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 5581 Steps 7 - 9 Page 2867 Put unused material on the shelf for future use. Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Diagrams Engine Oil Level Switch Page 12874 ^ On 2002 Sevilles and DeVilles, the GPS jumper cable MUST be unclipped from the back seat cross brace, or unplugged from the VCIM first. DO NOT pull back on the mounting bracket until the GPS antenna jumper cable is unclipped from the back seat cross brace or unplugged from the VCIM. The short length of jumper cable does not allow the VCIM mounting bracket to be pulled back very far, and could lead to a break at the VCIM connector. ^ On 2000-2002 Bonnevilles and LeSabres and 2001-2002 Auroras you will need to follow these steps: 1. Remove the 4 nuts that secure the VCU/VIU bracket assembly to the rear seat back brace. Note: Save these nuts for later use. 2. Remove and discard the plastic VCU/VIU bracket assembly from the vehicle. 3. Remove the upper right stud (1) from the rear seat back brace and re-install in the middle lower slot (2) on the brace. Tighten the fastener to 4 Nm (36 lb in). 4. Position the new VCIM in the vehicle over the studs on the rear seat back brace. 5. Install two of the nuts saved from step (1). Tighten the nuts to 4 Nm (36 lb in). 6. Connect the new OnStar jumper harness supplied in the kit to the VCIM (two white connectors) and the body wiring harness (C345 connector). 7. Connect the small coaxial jumper cable supplied in the kit, to the VCIM, with the end that has a blue plastic housing connector. Plug the other end of this coaxial jumper cable to the OnStar Global Positioning Satellite (GPS) antenna coaxial cable at the right angle connector. Note: The GPS cable in the new OnStar jumper harness is not utilized. 8. Connect the cellular coaxial cable to the OnStar VCIM. On 2001 Impala and Monte Carlos you will need to follow these steps: 9. Remove the Vehicle Communications Unit (VCU) and Vehicle Interface Unit (VIU) following the procedures listed in SI. Save the bracket nuts for later use. Page 13564 Body Control Module (BCM) - C3 Part 2 Page 6005 Shift Interlock Solenoid: Service and Repair Automatic Transmission Shift Lock Actuator Replacement Removal Procedure 1. Caution: Refer to SIR Caution in Service Precautions. Disable the SIR system. 2. Remove the body control module (BCM). 3. Put the shift lever clevis into the neutral position. 4. Disconnect the electrical connector. 5. Using a small screwdriver, pry the automatic transmission shift lock control actuator away from the steering column jacket and the cable shift cam. 6. Remove the shift lock control actuator. Installation Procedure 1. Firmly install the shift lock control actuator onto the steering column jacket and the cable shift cam. 2. Connect the electrical connector. 3. Adjust the shift lock control actuator (with the shift lever clevis in the neutral position) in the following way: 1. Pull out the tab (1) on the adjuster block side (2) of the shift lock control actuator. 2. Press on the adjuster block (2) to compress the internal adjuster spring which disengages the adjuster teeth. Slide the adjuster block (2) as far away from the actuator as possible. 3. Lock the adjuster block (2) in place by pushing in on the tab (1). 4. Inspect the shift lock control actuator for the following items: Locations Mass Air Flow (MAF) Sensor: Locations Right Side Of The Engine Compartment Page 6281 Fluid Pan: Specifications Automatic Transmission - 4L80-E/4L85-E oil pan bolts ......................................................................................................................................... ..................................................... 24 Nm (18 ft. lbs.) Page 12180 Locations Fuel Pump And Sender Assembly Components Page 3679 Left Side Of Engine Page 13544 If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Sir/SRS Wiring Repairs SIR/SRS WIRING REPAIRS TOOLS REQUIRED J 38125-D Terminal Repair Kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-D contains the following items: - Special sealed splices - in order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping tool - A heat torch - An instruction manual The sealed splices have the following 2 critical features: - A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-D also serves as a generic terminal repair kit. The kit contains the following items: - A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors Page 14036 1. Ensure the bottom of the molding is seated in the slots on the I/P. 2. Align the molding retainers to the slots. 3. Press the moldings straight in till fully seated. Molding Replacement - Rear Window Lower Molding Replacement - Rear Window Lower Removal Procedure 1. Lightly pull the lower edge of the molding in order to release the clips. On extended cab fold the rear bench seat up. This will move the assembly forward so that the molding can be accessed. 2. Lift the molding up and away from the glass in order to release the upper retainers. Installation Procedure 1. Align the molding clips with the holes in the body panel along the back glass. 2. Snap the molding into place. Trim Panel Replacement - Hinge Pillar Trim Panel Replacement - Hinge Pillar Removal Procedure 1. Remove the door-sill plate. Page 3301 Notice: Refer to Fastener Notice in Service Precautions. 2. Install the oil filter to the engine block. ^ Tighten the oil filter to 30 Nm (22 ft. lbs.). 3. Install the oil drain plug to the engine block. ^ Tighten the oil pan drain plug to 25 Nm (18 ft. lbs.). 4. Lower the vehicle. 5. Fill the crankcase with the proper quantity and grade of engine oil. Refer to Capacities - Approximate Fluid and Fluid and Lubricant Recommendations. 6. Remove the oil level indicator. 7. Wipe the indicator with a clean cloth. 8. Install the oil level indicator. 9. Remove the oil level indicator in order to check the level. 10. Add oil if necessary. 11. Close the hood. Page 15242 Cigarette Lighter: Connector Views Cigar Lighter (With RPO Code Y91 Or UQ3/UQ5)) Page 7229 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground TESTING FOR SHORT TO GROUND NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting With A Digital Multimeter TROUBLESHOOTING WITH A DIGITAL MULTIMETER NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TROUBLESHOOTING WITH A TEST LAMP Page 16158 circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links CIRCUIT PROTECTION - FUSIBLE LINKS Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Flat Wire Repairs FLAT WIRE REPAIRS NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Heated Oxygen Sensor (HO2S) Wiring Repairs HEATED OXYGEN SENSOR (HO2S) WIRING REPAIRS TOOLS REQUIRED J 38125-D Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: - Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-D. Repairing Damaged Wire Insulation REPAIRING DAMAGED WIRE INSULATION Page 919 Body Control Module (BCM) - C4 Part 1 Page 2689 Relay Block - I/P C1 Part 7 Page 739 The new calibrations have been updated to compensate for the actuator overtravel condition, the actuator hunting and the ticking/clicking noises. The new calibrations effectively eliminate the codes listed above, the default position of the doors associated with the DTCs and opens up the feedback position value. The new calibrations should not be used unless the vehicle has one or more of the customer concerns listed above or a DTC listed above has been set. The new calibrations will not correct any other DTC or NC system performance concern. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer OnStar(R) - No Power/Inoperative/No LED Emergency Contact Module: Customer Interest OnStar(R) - No Power/Inoperative/No LED TECHNICAL Bulletin No.: 05-08-46-001D Date: May 02, 2008 Subject: OnStar(R) Generation 5 or 6 (Digital) System Inoperative/Has No Power, LED Light Not On (Remove/Reinstall OnStar(R) Fuse and Replace VCIM or Follow SI Diagnostics) Models Supercede: This bulletin is being revised to update the information on VCIM ordering instructions in step 3 of the Correction statement. Please discard Corporate Bulletin Number 05-08-46-001C (Section 08 - Body & Accessories). Condition Some customers may comment any or all of the following conditions: ^ The OnStar(R) system may be inoperative. ^ The OnStar(R) system may have no power. ^ The OnStar(R) LED light may not be on. The technician may also not be able to communicate with the OnStar(R) Vehicle Communication Interface Module (VCIM) with a Tech 2(R). Correction Notice: On 2006 Chevrolet Impala and Monte Carlo models, make sure the ignition is OFF and the vehicle has "RAP"ed out prior to removing the OnStar(R) fuse. Disconnecting power to the OnStar(R) module while the ignition is ON may discharge and permanently damage the OnStar(R) back-up battery. Page 9210 C214 Infotainment Harness To Headliner Harness (With RPO Code UE1) Page 7246 Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips SPLICING COPPER WIRE USING SPLICE CLIPS IMPORTANT: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. TOOLS REQUIRED J 38125-D Terminal Repair Kit 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-D in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. Page 3545 3.2. Reinstall any loose boot. Page 6047 A cracked 1-2 accumulator piston (56) that is allowing fluid to leak by. Mislocated/Missing valve body-to-spacer plate check balls (61). When attempting to correct a consistent harsh 1-2 shift, the four conditions listed above should be inspected as possible causes. It is important to also refer to the appropriate Service Manual for further possible causes of this condition. Page 9714 C127 Snowplow Harness To Forward Lamp Harness (With RPO Code VYU) Page 13572 Door Control Module Diagram 2 Part 2 Accessory Drive Belt: Service and Repair Accessory Drive Belt Replacement - Accessory (4.8L, 5.3L, and 6.0L Engines) Removal Procedure 1. Loosen the air cleaner outlet duct clamps at the following locations: ^ The throttle body ^ The mass airflow/intake air temperature (MAF/IAT) sensor 2. Disconnect the radiator inlet hose clip from the outlet duct. 3. Remove the air cleaner outlet duct. 4. Install a breaker bar with hex-head socket to the drive belt tensioner bolt. 5. Rotate the drive belt tensioner clockwise in order to relieve tension on the belt (1). 6. Remove the belt (1) from the pulleys and the drive belt tensioner. 7. Slowly release the tension on the drive belt tensioner. 8. Remove the breaker bar and socket and from the drive belt tensioner bolt. 9. Clean and inspect the belt surfaces of all the pulleys. Installation Procedure 1. Route the drive belt (1) around all the pulleys except the idler pulley. 2. Install the breaker bar with hex-head socket to the belt tensioner bolt. 3. Rotate the belt tensioner clockwise in order to relieve the tension on the tensioner. 4. Install the drive belt (1) under the idler pulley. 5. Slowly release the tension on the belt tensioner. 6. Remove the breaker bar and socket from the belt tensioner bolt. Page 12057 Important: This bulletin does NOT apply to 2006 vehicles built AFTER the VIN breakpoints listed above. Refer to applicable diagnostics in SI for those vehicles that exhibit this condition. Remove the OnStar(R) fuse from the fuse box, wait five minutes and reinstall the fuse. (For Saturn VUE vehicles, remove the "INT LTS" fuse from the I/P fuse block for five minutes, then reinstall the fuse.) If the OnStar(R) system DOES NOT return to normal functionality, then follow the diagnostics in SI for this condition. If the OnStar(R) system DOES return to normal functionality, perform the following steps: 1. Install the Tech 2(R) and determine what generation hardware and software ID is in the vehicle. 2. If the vehicle is equipped with Generation 5 hardware and a software version 146, the VCIM should have the B1000 reprogramming performed as described in Corporate Bulletin Number 04-08-46-004A. The system should be tested and if the concern returns, the VCIM should be replaced. 3. If Gen 5 with a software version OTHER than 146 or Gen 6 and above, the VCIM needs to be replaced and the system reconfigured. Refer to the current version of Corporate Bulletin 03-08-46-004 for details on how to order a new VCIM. Important: As with any OnStar(R) VCIM replacement, the OnStar(R) system must be reconfigured after replacement. Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use the table. Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table. Disclaimer Instruments - Service Tire Monitor Message is Displayed Low Tire Pressure Indicator: All Technical Service Bulletins Instruments - Service Tire Monitor Message is Displayed Bulletin No.: 05-08-49-018A Date: May 11, 2006 ADVANCE SERVICE INFORMATION RESOLUTION Subject: EI 05065 - Service Tire Monitor Message Displayed (Pull/Reinstall IPC Fuse or Verify Correct Passenger Door Module (PDM) and Tires) Models: 2004 Chevrolet Silverado 2004 GMC Sierra Supercede: This bulletin is being revised to provide correction action. Please discard Corporate Bulletin Number 05-08-49-018 (Section 08 - Body and Accessories). Condition Some customers may comment that the "SERVICE TIRE MONITOR" message is being displayed on the DIC. Correction DO NOT REPLACE THE INSTRUMENT PANEL CLUSTER. If the DIC is displaying the SERVICE TIRE MONITOR message: 1. Verify if the vehicle has an electronic aftermarket module spliced into the ALDL Class 2 data line (purple wire). 2. If the vehicle HAS an aftermarket module spliced into the Class 2 line, pull the IPC fuse (located underhood) for 25 seconds. Important: Due to the electronic aftermarket module, the SERVICE TIRE MONITOR message may reoccur. 3. Reinstall the IPC fuse. This will clear the SERVICE TIRE MONITOR message from the display. 4. If the vehicle DOES NOT have an aftermarket module spliced into the Class 2 line, verify the vehicle is equipped with the correct PDM (Passenger Door Module) and tires. Warrant Information This repair is not covered under the vehicle warranty due to the installation of an aftermarket module. Disclaimer Page 1498 Headlamp Alignment Switch: Service and Repair HEADLAMP LEVELING SWITCH REPLACEMENT REMOVAL PROCEDURE 1. Remove the instrument panel bezel. 2. Pull out the accessary switch housing. 3. Disconnect the electrical connectors. 4. Remove the head lamp leveling switch from the accessary switch housing. INSTALLATION PROCEDURE 1. Install the head lamp leveling switch into accessary switch housing. 2. Connect the electrical connectors. 3. Install the accessary switch housing. 4. Install the instrument panel bezel. Service and Repair Rear Engine Plate: Service and Repair Engine Rear Cover Replacement ^ Tools Required J 41476 Front and Rear Cover Alignment Tool Removal Procedure 1. Remove the engine flywheel. 2. Remove the oil pan-to-rear cover bolts (1). 3. Remove the rear cover bolts. 4. Remove the rear cover and gasket. 5. Discard the rear cover gasket. 6. If required, clean and inspect the rear cover. Installation Procedure Important: ^ Do not reuse the crankshaft oil seal or rear cover gasket. ^ Do not apply any type of sealant to the rear cover gasket (unless specified). ^ The special tool in this procedure is used to properly center the crankshaft rear oil seal. ^ The crankshaft rear oil seal will be installed after the rear cover has been installed and aligned.Install the rear cover without the crankshaft oil seal. ^ All gasket surfaces should be free of oil or other foreign material during assembly. ^ The crankshaft rear oil seal MUST be centered in relation to the crankshaft. ^ An improperly aligned rear cover may cause premature rear oil seal wear and/or engine assembly oil leaks. Service and Repair Oil Pressure Regulator Valve: Service and Repair Oil Filter Bypass Valve Replacement Removal Procedure 1. Drain the engine oil. 2. Remove the oil filter. 3. Remove the oil filter adapter (1). 4. Remove the oil filter bypass valve (2). Installation Procedure 1. Install the oil filter bypass valve (2). Notice: Refer to Fastener Notice in Service Precautions. 2. Install the oil filter adapter (1). ^ Tighten the oil filter adapter to 55 Nm (40 ft. lbs.). Page 7576 ^ Knock or Clunk Noise ^ Rear Drive Axle Noises (SI Document ID #700580) ^ Launch Shudder/Vibration on Acceleration (Replace Propeller Shaft and Install a New Pinion Flange/Seal), Bulletin # 02-04-17-001 ^ Information on 2-3 Upshift or 3-2 Downshift Clunk Noise, Bulletin # 01-07-30-042 ^ Driveline Clunk When Stopping (Reprogram Powertrain Control Module (PCM), Bulletin # 03-07-30-028 Correction Replace the rear drive shaft slip yoke with a new nickel-plated slip yoke. See the parts table below. Follow the service procedure below. 1. Raise the vehicle on a hoist. 2. Reference mark the propeller shaft to the pinion flange connection. Important: Do not pound on the propeller shaft yoke ears. Never pry or place any tool between a yoke and a universal joint. 3. Remove the bolts and the yoke retainers from the pinion flange. 4. Slide the propeller shaft forward and out of the rear pinion flange. 5. Lower the rear of the propeller shaft and pull the driveshaft out of the transfer case. Note: Never clamp propeller shaft tubing in a vise. Clamping could dent or deform the tube causing an imbalance or unsafe condition. Always clamp on one of the yokes and support the shaft horizontally. Avoid damaging the slip yoke sealing surface. Nicks may damage the bushing or cut the lip seal. 6. Support the propeller shaft in a line horizontal with the table of a press. Important: Remove the front slip yoke and the universal joint together. The new nickel-plated slip yoke comes with a new universal joint. 7. Disassemble the snap rings by pinching the ends together with a pair of pliers. 8. If the ring does not readily snap out of the groove in the yoke, tap the end of the cup lightly in order to relieve the pressure from the ring. 9. Place the universal joint so that the lower ear of the yoke is supported on a 30 mm (1-1/8 in) hex head socket or a 27 mm (1-1/16 in) socket. Page 533 Door Control Module Diagram 3 Part 2 OnStar(R) - Aftermarket Device Interference Information Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Aftermarket Device Interference Information INFORMATION Bulletin No.: 08-08-46-004 Date: August 14, 2008 Subject: Information on Aftermarket Device Interference with OnStar(R) Diagnostic Services Models: 2009 and Prior GM Passenger Car and Truck (including Saturn) 2009 and Prior HUMMER H2, H3 Models 2009 and Prior Saab 9-7X with OnStar(R) (RPO UE1) This bulletin is being issued to provide dealer service personnel with information regarding aftermarket devices connected to the Diagnostic Link Connector (DLC) and the impact to OnStar(R) diagnostic probes and Vehicle Diagnostic e-mails. Certain aftermarket devices, when connected to the Diagnostic Link Connector, such as, but not limited to, Scan Tools, Trip Computers, Fuel Economy Analyzers and Insurance Tracking Devices, interfere with OnStar's ability to perform a diagnostic probe when requested (via a blue button call) by a subscriber. These devices also prohibit the ability to gather diagnostic and tire pressure data for a subscriber's scheduled OnStar(R) Vehicle Diagnostic (OVD) e-mail. These aftermarket devices utilize the Vehicles serial data bus to perform data requests and/or information gathering. When these devices are requesting data, OnStar(R) is designed not to interfere with any data request being made by these devices as required by OBD II regulations. The OnStar(R) advisor is unable to definitively detect the presence of these devices and will only be able to inform the caller or requester of the unsuccessful or incomplete probe and may in some cases refer the subscriber/requester to take the vehicle to a dealer for diagnosis of the concern. When performing a diagnostic check for an unsuccessful or incomplete OnStar(R) diagnostic probe, or for concerns regarding completeness of the OnStar(R) Vehicle Diagnostic (OVD) e-mail, verify that an aftermarket device was not present at the time of the requested probe. Regarding the OVD e-mail, if an aftermarket device is interfering (including a Scan Tool of any type), the e-mail will consistently display a "yellow" indication in diagnostics section for all vehicle systems except the OnStar(R) System and Tire Pressure data (not available on all vehicles) will not be displayed (i.e. section is collapsed). Successful diagnostic probes and complete OVD e-mails will resume following the removal or disconnecting of the off-board device. Disclaimer Page 15851 The information shown is for the 1999-2002 wiring harnesses and for the 2003-05 wiring harness. To modify a 12171982, 15366255 or 15086884 harness for use in a 2003-05 vehicle, switch the wires in cavities "A" and "D". To modify a 15085418 harness for use in a 1999-2002 vehicle (see model list at the front of this bulletin for applicable models), switch the wires in cavities "A" and "D". Warranty Information When the correct wiring harness P/N is matched to the specific model year of the vehicle, everything works properly. Therefore, conversion of an incorrect wiring jumper to match the vehicle would not be considered a warrantable repair. Disclaimer Instruments - Odometer/Hour Meter Programming Procedure Odometer: All Technical Service Bulletins Instruments - Odometer/Hour Meter Programming Procedure INFORMATION Bulletin No.: 07-08-49-015D Date: May 04, 2010 Subject: Information on Instrument Panel Cluster (IPC) Odometer and Engine Hour Meter Set Up at Dealership After IPC Replacement Models: 2004-2007 Buick Rainier 2003-2006 Cadillac Escalade Models 2002-2009 Chevrolet TrailBlazer 2003-2006 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007 Chevrolet Silverado Classic (12th Digit of VIN 1 or 2) 2002-2009 GMC Envoy 2003-2006 GMC Sierra, Yukon Models 2007 GMC Sierra Classic (12th Digit of VIN 1 or 2) 2002-2004 Oldsmobile Bravada 2003-2007 HUMMER H2 2005-2009 Saab 9-7X Attention: The purpose of this bulletin is to inform dealership personnel that the Instrument Panel Cluster (IPC) odometer and engine hour meter (when applicable) setting will no longer be performed at an Electronic Service Center (ESC). Dealerships will now receive IPCs with the odometer and engine hour meter not programmed. The technician will be required to note the odometer reading and engine hour (when applicable) values of the original IPC, then use the SPS application to program these values into the new IPC. Supercede: This bulletin is being revised to update the text in Steps 1, 2, 3, 4, 5, 6 and 7. Please discard Corporate Bulletin Number 07-08-49-015C (Section 08 - Body and Accessories). Background Information Previous IPC replacement procedures specify that the odometer and engine hour values be communicated to and programmed by the Electronic Service Centers (ESC) into the replacement IPC at the time the replacement is ordered. This required the vehicle to be parked after the replacement IPC is ordered so that no additional mileage can be accumulated on the vehicle while the new IPC is in transit to the dealership. Improvements to the TIS2WEB SPS application will now allow IPC odometer and engine hour programming to be performed as an additional function of the IPC programming event. This new process will allow the vehicle to be returned to the customer, if necessary, and driven while waiting for the replacement IPC to arrive at the dealership. Odometer and engine hour values will no longer be communicated to the ESC for programming purposes but ESCs still need the odometer value for warranty reporting. Dealerships will now receive a replacement IPC with the odometer and engine hour values NOT programmed. The technician will be required to note the odometer and engine hour values of the original IPC, then use the TIS2WEB SPS application to program these values into the replacement IPC. The odometer and engine hour programming will now be included as a normal part of the IPC replacement procedure in SI. Odometer and Engine Hour Programming Procedure Information - If the original IPC odometer value cannot be obtained from the customer's vehicle, follow local and federal regulations regarding unknown odometer mileage situations. - Because the odometer and engine hour values can now be read from the original IPC and programmed into the replacement IPC during the same visit, the customer's vehicle will no longer need to be parked until the replacement IPC is received from an ESC. - Avalanche, Escalade, Sierra, Silverado, H2, Suburban, Tahoe and Yukon vehicles will also require the engine hour data to be recorded for transfer to the replacement IPC. The replacement IPC may already have engine hours showing. This does not affect the IPC Setup procedure. Bravada, Envoy, Rainier and TrailBlazer vehicles do not support the calculation or display of engine hour data. - Ensure that the correct odometer value is entered when prompted. Once programming is complete, the odometer and engine hour values, when applicable cannot be changed. - By default, the application odometer entry will be set to: miles. For metric units, click the button on the left next to: Kilometers. Service Procedure Important The replacement IPC requires IPC Setup procedures and SPS programming to be performed. Legacy Pass-Thru will no longer be Page 12560 Page 2686 Relay Block - I/P C1 Part 4 Page 11877 * Dealers using WINs: Add 0.2 hours to the labor time for administrative allowance for the module exchange. Dealers using GWM: Submit 0.2 hours administrative allowance under "Administration Time" for the module exchange. ** The $25 represents the additional net amount allowed for the module exchange. *** Dealers are to claim only administrative allowance of 0.2 hours when the module is replaced by Masscomp's Mobile Unit. Dealers using WINS should submit the 0.2 hours administrative allowance in labor time. Dealer using GWM should submit the 0.2 hours administrative allowance under Administrative Time. Customer Notification OnStar will notify customers of this program on their vehicle. Dealer Program Responsibility All unsold new vehicles in dealers'/retailers' possession and subject to this program must be held and inspected/repaired per the service procedure of this program bulletin before customers take possession of these vehicles. Dealers/retailers are to service all vehicles subject to this program at no charge to customers, regardless of mileage, age of vehicle, or ownership, through April 30, 2011. Customers who have recently purchased vehicles sold from your vehicle inventory, and for which there is no customer information indicated on the dealer/retailer listing, are to be contacted by the dealer/retailer. Arrangements are to be made to make the required correction according to the instructions contained in this bulletin. A copy of the customer letter is provided in this bulletin for your use in contacting customers. Program follow-up cards should not be used for this purpose, since the customer may not as yet have received the notification letter. Page 8892 9. Use J 38125-12A to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. REPAIR PROCEDURE The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. 1. Cut the wire as close to the terminal as possible. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. Page 16168 Control Module References Part 2 Page 9476 Page 3835 Door Control Module Diagram 2 Part 2 Page 861 Body Control Module: Locations Body Control Module (BCM) Page 13102 ^ An OnStar(R) Call Center button press WILL NOT connect the vehicle with OnStar(R). The vehicle must be upgraded to reactivate the account. The customer will hear a demo message stating that there is not a current OnStar(R) subscription for the vehicle. The message will also instruct the customer how to upgrade and reactivate services. ^ OnStar(R) personal calling (OPC) will not be available, as this feature requires the customer to have a current OnStar(R) account. Attempts to use this feature will result in cellular connection failure messages and the inability to connect to the number dialed. Note For deactivated vehicles, a no connect response should be considered normal system operation. Further diagnosis and subsequent repair is only necessary should the customer elect to become an active OnStar(R) subscriber and upgrade the account subscription. OnStar(R) Cellular, GPS, and Diagnostic Limitations The proper operation of the OnStar(R) System is dependent on several elements outside the components integrated into the vehicle. These include the National Cellular Network Infrastructure, the cellular telephone carriers within the network, and the GPS. The cellular operation of the OnStar(R) system may be inhibited by factors such as the users range from a digital cellular tower, the state of the cellular carrier's equipment, and the location where the call is placed. Making an OnStar(R) key press in areas that lack sufficient cellular coverage or have a temporary equipment failure will result in either the inability of a call to complete with a data transfer or the complete inability to connect to the OnStar(R) Call Center. The OnStar(R) system may also experience connection issues if the identification numbers for the module, station identification number (STID), electronic serial number (ESN) or manufacturers electronic ID (MEID), are not recognized by the cellular carriers local signal receiving towers. The satellites that orbit earth providing the OnStar system with GPS data have almost no failures associated with them. In the event of a no GPS concern, the failure will likely lie with the inability of the system to gain GPS signals because of its location, i.e. in a parking structure, hardware failure, or being mistaken with an OnStar(R) call which has reached the Call Center without vehicle data. During diagnostic testing of the OnStar(R) system, the technician should ensure the vehicle is located in an area that has a clear unobstructed view of the open sky, and preferably, an area where digital cellular calls have been successfully placed. These areas can be found by successfully making an OnStar(R) keypress in a known good OnStar(R) equipped vehicle and confirming success with the OnStar(R) Call Center advisor. Such places can be used as a permanent reference for future OnStar(R) testing. Mobile Identification Number and Mobile Directory Number The vehicle communication interface module (VCIM) utilizes 2 numbers for cellular device identification, call routing and connection. They are: ^ A mobile identification number (MIN) ^ A mobile directory number (MDN) Note The MIN represents the number used by the cellular carrier for call routing purposes. The MDN represents the number dialed to reach the cellular device. Diagnostic Information Symptoms - Cellular Communication The following steps must be completed before using the symptom table. 1. Perform the Diagnostic System Check - Vehicle, before using the Symptom Tables in order to verify that the following are true: ^ There are no DTCs set. ^ The control modules can communicate via the serial data link. 2. Review the system operation in order to familiarize yourself with the system functions. Refer to Radio/Audio System Description and Operation in SI. Diagnostic Starting Point - Displays and Gages Begin the displays and gages system diagnosis with Diagnostic System Check - Vehicle or the audible warning system diagnosis with Diagnostic System Page 13408 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground TESTING FOR SHORT TO GROUND NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting With A Digital Multimeter TROUBLESHOOTING WITH A DIGITAL MULTIMETER NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TROUBLESHOOTING WITH A TEST LAMP Campaign - Unwanted Repeat Calls to OnStar(R) Technical Service Bulletin # 10037 Date: 100420 Campaign - Unwanted Repeat Calls to OnStar(R) CUSTOMER SATISFACTION Bulletin No.: 10037 Date: April 20, 2010 Subject: 10037 - Unwanted Repeat Calls to OnStar(R) Models: 2003 Buick LeSabre 2004-2006 Buick Rendezvous 2005 Buick LeSabre, Terraza 2005-2006 Buick LaCrosse/Allure 2006-2008 Buick Lucerne 2008 Buick LaCrosse/Allure 2008-2009 Buick Enclave 2003 Cadillac CTS 2004 Cadillac Escalade 2004-2005 Cadillac CTS-V, Deville 2005 Cadillac Escalade ESV, SRX 2005-2006 Cadillac STS 2005-2008 Cadillac CTS 2006-2008 Cadillac DTS 2007 Cadillac Escalade, Escalade EXT 2007-2008 Cadillac Escalade ESV 2008 Cadillac SRX, STS 2002 Chevrolet Impala 2003-2008 Chevrolet Suburban 2003-2009 Chevrolet Silverado 2004-2008 Chevrolet Impala 2005 Chevrolet Colorado, Corvette, Malibu 2005-2006 Chevrolet Uplander 2005-2008 Chevrolet Avalanche, Tahoe, TrailBlazer 2006 Chevrolet HHR, Monte Carlo 2006-2008 Chevrolet Equinox 2007-2008 Chevrolet Corvette 2008 Chevrolet HHR 2008-2009 Chevrolet Cobalt, Colorado, Malibu, Uplander 2003 GMC Envoy XL, Sierra, Yukon XL 2004-2008 GMC Yukon 2005-2009 GMC Sierra 2005-2008 GMC Yukon XL 2006-2008 GMC Envoy 2007 GMC Canyon 2007-2009 GMC Acadia 2006 HUMMER H2 2006-2008 HUMMER H3 2008 HUMMER H2 2003 Oldsmobile Silhouette 2005 Montana SV6 2005-2008 Pontiac Grand Prix 2006 Pontiac G6, Vibe 2007 Pontiac Montana SV6 2007-2008 Pontiac Solstice 2008 Pontiac G6, Torrent 2008-2009 Pontiac G5, G8 2009 Pontiac G3, Montana SV6 2005-2007 Saturn ION 2006-2009Saturn VUE 2007-2008 Saturn AURA, OUTLOOK, SKY Equipped with OnStar(R) (RPO UE1) Page 4691 Door Control Module Diagram 2 Part 1 Page 5191 Flexible Fuel Sensor: Testing and Inspection Step 1 Steps 2 - 5 Page 16053 Control Module References Part 7 Page 9820 8. Install the left side end panel. Page 2604 Fuse: Locations I/P Fuse Block Body Control Module (BCM) Page 15238 Control Module References Part 4 Instruments - Service Tire Monitor Message is Displayed Low Tire Pressure Indicator: Customer Interest Instruments - Service Tire Monitor Message is Displayed Bulletin No.: 05-08-49-018A Date: May 11, 2006 ADVANCE SERVICE INFORMATION RESOLUTION Subject: EI 05065 - Service Tire Monitor Message Displayed (Pull/Reinstall IPC Fuse or Verify Correct Passenger Door Module (PDM) and Tires) Models: 2004 Chevrolet Silverado 2004 GMC Sierra Supercede: This bulletin is being revised to provide correction action. Please discard Corporate Bulletin Number 05-08-49-018 (Section 08 - Body and Accessories). Condition Some customers may comment that the "SERVICE TIRE MONITOR" message is being displayed on the DIC. Correction DO NOT REPLACE THE INSTRUMENT PANEL CLUSTER. If the DIC is displaying the SERVICE TIRE MONITOR message: 1. Verify if the vehicle has an electronic aftermarket module spliced into the ALDL Class 2 data line (purple wire). 2. If the vehicle HAS an aftermarket module spliced into the Class 2 line, pull the IPC fuse (located underhood) for 25 seconds. Important: Due to the electronic aftermarket module, the SERVICE TIRE MONITOR message may reoccur. 3. Reinstall the IPC fuse. This will clear the SERVICE TIRE MONITOR message from the display. 4. If the vehicle DOES NOT have an aftermarket module spliced into the Class 2 line, verify the vehicle is equipped with the correct PDM (Passenger Door Module) and tires. Warrant Information This repair is not covered under the vehicle warranty due to the installation of an aftermarket module. Disclaimer Page 10159 Maintain the sensor position. Do not turn the sensor. Remove the rear wheel position sensor (2) from the steering gear. Installation Procedure 1. Important: Make sure the O-ring (1) is installed. Install the rear wheel position sensor (2) to the steering gear. 2. Important: Be careful to maintain the position of the replacement sensor. Remove the pin retaining the position of the new sensor and immediately install the sensor to the steering gear. 3. Notice: Refer to Fastener Notice in Service Precautions. Install the rear wheel position sensor retaining bolts. Apply LOCTITE 242 blue. ^ Tighten the bolts to 4 Nm (35 inch lbs.). 4. Install the rear wheel position sensor cover (4). 5. Connect the electrical connector (1). 6. Install the steering gear protection shield (1) and retaining bolts (3). ^ Tighten the steering gear protection shield retaining bolts to 180 Nm (132 ft. lbs.). Page 476 Electrical Symbols Part 14 Page 4155 INSTALLATION PROCEDURE NOTE: Refer to Fastener Notice in Service Precautions. 1. If required, install the fuel composition sensor to the bracket and install the bolts. Tighten Tighten bolts to 10 N.m (89 lb in). 2. Install the fuel composition sensor. 3. Install the fuel composition sensor nuts. Tighten Tighten nuts to 17 N.m (13 lb ft). 4. Connect the fuel pipes to the fuel composition sensor. 5. Install the fuel line retainers (1). Page 13129 Page 4653 Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA and/or the secondary locks. Micro .64 Connectors MICRO .64 CONNECTORS TOOLS REQUIRED J 38125-D Terminal Repair Kit REMOVAL PROCEDURE Follow the steps below in order to remove terminals from Micro 64 connectors. 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. 2. Disconnect the connector from the component. Service and Repair Gear Sensor/Switch: Service and Repair Encoder Motor Sensor Replacement Removal Procedure Important: For ease of reassembly, shift the transfer case to 2HI prior to removing any components. 1. Remove the encoder motor. 2. Place the encoder motor on a clean work bench, 3. Remove the 2 screws (2) from the motor cover. 4. Remove the 2 screws (1) from the casting. 5. Remove the cover. 6. Remove and save the shim on the output gear. 7. Remove and discard the orange rubber seal from the cover. 8. Remove the output gear (1). Page 8373 Parking Brake Cable: Service and Repair Park Brake Cable Replacement - Left Rear (W/O NYS) Park Brake Cable Replacement - Left Rear (w/o NYS) Removal Procedure 1. Release the park brake. 2. Raise and support the vehicle. Refer Vehicle Lifting 3. For all 15 series vehicles, relieve the tension from the park brake cable by pulling down on the park brake cable in front of the equalizer and removing the left park brake cable from the equalizer bar. 4. For 25/35 series vehicles, disable the park brake cable automatic adjuster. Refer to Disabling the Park Brake Cable Automatic Adjuster. 5. For 25/35 series vehicles, disconnect the cable at the equalizer. Page 3295 - Support the GM Oil Life System, thereby minimizing the replacement of engine oil, before its life has been depleted. - Reduce the duplication of requirements for a large number of internal GM engine oil specifications. International Lubricants Standardization and Approval Committee (ILSAC) GF-5 Standard In addition to GM dexos 1(TM), a new International Lubricants Standardization and Approval Committee (ILSAC) standard called GF-5, was introduced in October 2010. - There will be a corresponding API category, called: SN Resource Conserving. The current GF-4 standard was put in place in 2004 and will become obsolete in October 2011. Similar to dexos 1(TM), the GF-5 standard will use a new fuel economy test, Sequence VID, which demands a statistically significant increase in fuel economy versus the Sequence VIB test that was used for GF-4. - It is expected that all dexos 1(TM) approved oils will be capable of meeting the GF-5 standard. However, not all GF-5 engine oils will be capable of meeting the dexos 1(TM) specification. - Like dexos(TM), the new ILSAC GF-5 standard will call for more sophisticated additives. The API will begin licensing marketers during October 2010, to produce and distribute GF-5 certified products, which are expected to include SAE 0W-20, 0W-30, 5W-20, 5W-30 and 10W-30 oils. Corporate Average Fuel Economy (CAFE) Requirements Effect on Fuel Economy Since CAFE standards were first introduced in 1974, the fuel economy of cars has more than doubled, while the fuel economy of light trucks has increased by more than 50 percent. Proposed CAFE standards call for a continuation of increased fuel economy in new cars and trucks. To meet these future requirements, all aspects of vehicle operation are being looked at more critically than ever before. New technology being introduced in GM vehicles designed to increase vehicle efficiency and fuel economy include direct injection, cam phasing, turbocharging and active fuel management (AFM). The demands of these new technologies on engine oil also are taken into consideration when determining new oil specifications. AFM for example can help to achieve improved fuel economy. However alternately deactivating and activating the cylinders by not allowing the intake and exhaust valves to open contributes to additional stress on the engine oil. Another industry trend for meeting tough fuel economy mandates has been a shift toward lower viscosity oils. dexos 1(TM) will eventually be offered in several viscosity grades in accordance with engine needs: SAE 0W-20, 5W-20, 0W-30 and 5W-30. Using the right viscosity grade oil is critical for proper engine performance. Always refer to the Maintenance section of a vehicle Owner Manual for the proper viscosity grade for the engine being serviced. GM Oil Life System in Conjunction With dexos (TM) Supports Extended Oil Change Intervals To help conserve oil while maintaining engine protection, many GM vehicles are equipped with the GM Oil Life System. This system can provide oil change intervals that exceed the traditional 3,000 mile (4,830 km) recommendation. The dexos (TM) specification, with its requirements for improved oil robustness, compliments the GM Oil Life System by supporting extended oil change intervals over the lifetime of a vehicle. If all GM customers with GM Oil Life System equipped vehicles would use the system as intended, GM estimates that more than 100 million gallons of oil could be saved annually. GM dexos 2(TM) Information Center Website Refer to the following General Motors website for dexos 2(TM) information about the different licensed brands that are currently available: http://www.gmdexos.com GM dexos 2(TM) Engine Oil Trademark and Icons Campaign - HVAC Blower Not Functional Runs Continuously Control Module HVAC: Recalls Campaign - HVAC Blower Not Functional Runs Continuously SPECIAL COVERAGE Bulletin No.: 11046 Date: April 07, 2011 Subject: 11046 - Special Coverage Adjustment - Heating, Ventilation, and Air Conditioning Blower Not Fully Functional on All Blower Speeds, Inoperative, or Runs Continuously with the Ignition Off Models: 2003-2006 Chevrolet Avalanche, Suburban, Tahoe 2003-2007 Chevrolet Silverado 2003-2006 GMC Yukon, Yukon XL 2003-2007 GMC Sierra Equipped with Manual HVAC (CJ3) or Heavy Duty Heater (C42) Due to part availability, owner letters will be released in phases starting with older model year first. Owners for model year vehicles not included in first phase owner mailing will receive an owner advisory letter. The letter will inform the customer that parts are not yet available and that another letter will be sent to them when parts become available. A copy of this letter will be attached to the dealer message announcing this bulletin. In the meantime, if a customer brings their vehicle to the dealership with the condition described in this bulletin, repair the vehicle using the parts called out in this bulletin. Condition On some 2003-2006 model year Chevrolet Avalanche, Suburban, Tahoe; GMC Yukon, Yukon XL; and 2003-2007 model year Chevrolet Silverado and GMC Sierra vehicles equipped with a manual heating, ventilation, and air conditioning (HVAC) system (CJ3) or heavy duty heater (C42), the interface between the electrical terminals of the relay resistor module and the wiring connector that powers the module may be incapable of conducting higher current levels for sustained periods of blower motor operation. In addition, moisture and other contaminants may enter the fresh air intake plenum and contact the internal circuit of the module or corrode the terminals. Either of the above may cause the relay resistor module or wiring connector to overheat, resulting in one or more of the following symptoms: - The HVAC blower may not function on certain or all blower speed settings - A burning plastic smell or smoke may be present in the vehicle - The HVAC blower may run continually with the ignition in the OFF position In very rare events, if the above symptoms are ignored, a fire could occur. Special Coverage Adjustment This special coverage covers the condition described above for a period of 10 years or 240,000 km, whichever occurs first, from the date the vehicle was originally placed in service, regardless of ownership. Dealers are to install a new blower motor resistor and resistor module connector. The repairs will be made at no charge to the customer. For vehicles covered by Vehicle Service Contracts, all eligible claims with repair orders on or after April 8, 2011 are covered by this special coverage and must be submitted using the labor operation codes provided with this bulletin. Claims with repair orders prior to April 8, 2011 must be submitted to the Service Contract provider. Vehicles Involved Involved are certain 2003-2006 model year Chevrolet Avalanche, Suburban, Tahoe; GMC Yukon, Yukon XL; and 2003-2007 model year Chevrolet Silverado and GMC Sierra vehicles equipped with a manual HVAC (CJ3) or heavy duty heater (C42). Important Dealers are to confirm vehicle eligibility prior to beginning repairs by using the Applicable Warranties section in the Global Warranty Management system. Parts Information Page 5823 Four Wheel Drive Selector Switch: Service and Repair Transfer Case - NVG 263-NP1 Transfer Case Shift Control Switch Replacement Removal Procedure 1. Remove the instrument panel (IP) cluster bezel. 2. Pull the tabs on the side of the transfer case driver control switch out. 3. Pull the transfer case driver control switch straight out from the panel. Installation Procedure 1. Important: Make sure that the transfer case control switch is seated properly in the instrument panel before installing the instrument panel trim bezel. Install the transfer case driver control switch into the instrument panel. 2. Install the IP cluster bezel. Page 11837 Technicians are to inspect the HVAC actuator harness for contact with the instrument panel support brace. Repair any damage to the actuator harness wiring and install protective plastic conduit over the harness. Install friction tape over the sharp edge of the instrument panel brace. Clear the diagnostic trouble codes and verify proper HVAC system operation. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 5670 Park Neutral Position (PNP) Switch C175 Page 11925 4.2. Release the back end of the connector (C) and remove from the contact rail (D). 4.3. M00-01: Disconnect pin 39, cut off the cable terminal and insulate the end using tape (E). Fold back the cable and secure using tape (F). 4.4. M02-04: Disconnect pin 58, cut off the cable terminal and insulate the end using tape (E). Fold back the cable and secure using tape (F). 4.5. Assemble the contact rail and end. 4.6. Connect connector (A) and secure the cable using a cable tie (B). 5. Assemble the gear shift housing (A). AUT: Connect connector (B). 6. Assemble the center console, see WIS - Body - Interior. 7. Remove the OnStar(R) control module and secure the cable harness: 7.1. 5D: Remove the right-hand cover from the luggage compartment floor. Page 10452 Torsion Bar: Service and Repair Torsion Bars Bushing Replacement Torsion Bars Bushing Replacement Removal Procedure 1. Raise and support the vehicle. Refer to Vehicle Lifting. Important: This procedure requires the removal of both torsion bars. 2. Remove the torsion bars. Refer to Torsion Bar Replacement. 3. Remove the bushing from the bracket utilizing a bushing driver or the equivalent. Installation Procedure 1. Install the bushing to the bracket utilizing a bushing driver or the equivalent. 2. Install the torsion bars. Refer to Torsion Bar Replacement. 3. Remove the safety stands. 4. Lower the vehicle. 5. Measure the Z height. Refer to Trim Height Inspection Procedure in Suspension General Diagnosis. 6. Turn the adjustment bolt clockwise to increase the Z height and counterclockwise to lower the Z height. Page 6239 Disclaimer Page 14320 WA994L/67 - WA994L/67 Page 7214 Electrical Symbols Part 5 Page 13115 High OR Low The above conditions are met for more than 3 seconds. Circuit/System Verification These DTCs cannot be retrieved with a current status. To diagnose use the Scan Tool Does Not Communicate with a Class 2 Device. Refer to SI. An intermittent condition is likely to be caused by a short on the Class 2 serial data circuit. To diagnose use the Scan Tool Does Not Communicate with a Class 2 Device. Refer to SI. DTC B2455 DTC Descriptors DTC B2455 01: Cellular Phone Microphone Circuit Short to Battery DTC B2455 02: Cellular Phone Microphone Circuit Short to Ground DTC B2455 04: Cellular Phone Microphone Circuit Open Circuit Circuit/System Description Without RPO UAV The vehicle communication interface module (VCIM) uses the cellular phone microphone to allow driver communication with OnStar(R). With RPO UAV The vehicle communication interface module (VCIM) and navigation radio use the cellular phone microphone to allow driver communication with OnStar(R), as well as to operate the voice recognition/voice guidance feature of the navigation radio. Conditions for Running the DTC The ignition is in RUN or ACC position. System voltage is between 9.5 - 15.5 volts. The above conditions are met for more than 10 seconds. Conditions for Setting the DTC B2455 01: A short to battery is detected on the cellular microphone signal circuit. B2455 02: A short to ground is detected on the cellular microphone signal circuit. B2455 04: An open circuit is detected on the cellular microphone signal circuit. Action Taken When the DTC Sets The VCIM and/or navigation radio (RPO UAV) will not receive any signal from the microphone. The OnStar(R) status LED turns red. Voice recognition will not function. Conditions for Clearing the DTC Page 11906 Page 9600 Relay Block - I/P C5 Part 1 Page 9549 Fuse Block - Underhood C1 Part 3 Page 14732 10. Install the pressure sensor (2) to the front passenger seat frame, if equipped with the Inflatable Restraint Passenger Presence System. 11. Connect the electrical connectors. NOTE: Refer to Fastener Notice in Service Precautions. 12. Install the front nuts (2) onto the studs on the underside of the cushion. Tighten Tighten the nuts to 21 N.m (15 lb ft). 13. Install the front seat trim panel. 14. Re-zero the Inflatable Restraint Passenger Presence System. Refer to Passenger Presence System Rezeroing Procedure in Restraint Systems. Seat Cushion Frame Replacement - Rear SEAT CUSHION FRAME REPLACEMENT - REAR REMOVAL PROCEDURE Page 3487 Steps 4 - 6 Page 11349 Ambient Air Temperature Sensor Page 14342 Electrical Symbols Part 2 Drivetrain - Updated Transfer Case Speed Sensor Conn. Speed Sensor: All Technical Service Bulletins Drivetrain - Updated Transfer Case Speed Sensor Conn. Bulletin No.: 06-04-21-001 Date: May 17, 2006 INFORMATION Subject: Updated Transfer Case Connector Service Kit Now Available For Transfer Case Speed Sensor Wire Harness Connector that Comes Loose Or Connector Retainer Clip Breaks Models: 2007 and Prior GM Light Duty Trucks 2007 and Prior HUMMER H2, H3 2005-2007 Saab 9-7X with Four-Wheel Drive or All-Wheel Drive Technicians may find that when the transfer case speed sensor wire harness connector is removed, the connector lock flexes/bends and does not return to the original position. The transfer case speed sensor wire harness connector then has no locking device. On older vehicles, the plastic connector retainer becomes brittle and the clip may break as soon as it is flexed. In the past, the only service fix was to install a wire harness connector service pack, P/N 88987183. This repair procedure involved splicing a new service connector with an integral connector lock. This connector service kit is of the same design and was still prone to failure over time. A new connector service repair kit is now available, P/N 15306187, that is an updated design. This new kit should be used whenever the speed sensor wire harness connector requires replacement. Parts Information Disclaimer Campaign - HVAC Blower Not Functional Runs Continuously Control Module HVAC: Recalls Campaign - HVAC Blower Not Functional Runs Continuously SPECIAL COVERAGE Bulletin No.: 11046 Date: April 07, 2011 Subject: 11046 - Special Coverage Adjustment - Heating, Ventilation, and Air Conditioning Blower Not Fully Functional on All Blower Speeds, Inoperative, or Runs Continuously with the Ignition Off Models: 2003-2006 Chevrolet Avalanche, Suburban, Tahoe 2003-2007 Chevrolet Silverado 2003-2006 GMC Yukon, Yukon XL 2003-2007 GMC Sierra Equipped with Manual HVAC (CJ3) or Heavy Duty Heater (C42) Due to part availability, owner letters will be released in phases starting with older model year first. Owners for model year vehicles not included in first phase owner mailing will receive an owner advisory letter. The letter will inform the customer that parts are not yet available and that another letter will be sent to them when parts become available. A copy of this letter will be attached to the dealer message announcing this bulletin. In the meantime, if a customer brings their vehicle to the dealership with the condition described in this bulletin, repair the vehicle using the parts called out in this bulletin. Condition On some 2003-2006 model year Chevrolet Avalanche, Suburban, Tahoe; GMC Yukon, Yukon XL; and 2003-2007 model year Chevrolet Silverado and GMC Sierra vehicles equipped with a manual heating, ventilation, and air conditioning (HVAC) system (CJ3) or heavy duty heater (C42), the interface between the electrical terminals of the relay resistor module and the wiring connector that powers the module may be incapable of conducting higher current levels for sustained periods of blower motor operation. In addition, moisture and other contaminants may enter the fresh air intake plenum and contact the internal circuit of the module or corrode the terminals. Either of the above may cause the relay resistor module or wiring connector to overheat, resulting in one or more of the following symptoms: - The HVAC blower may not function on certain or all blower speed settings - A burning plastic smell or smoke may be present in the vehicle - The HVAC blower may run continually with the ignition in the OFF position In very rare events, if the above symptoms are ignored, a fire could occur. Special Coverage Adjustment This special coverage covers the condition described above for a period of 10 years or 240,000 km, whichever occurs first, from the date the vehicle was originally placed in service, regardless of ownership. Dealers are to install a new blower motor resistor and resistor module connector. The repairs will be made at no charge to the customer. For vehicles covered by Vehicle Service Contracts, all eligible claims with repair orders on or after April 8, 2011 are covered by this special coverage and must be submitted using the labor operation codes provided with this bulletin. Claims with repair orders prior to April 8, 2011 must be submitted to the Service Contract provider. Vehicles Involved Involved are certain 2003-2006 model year Chevrolet Avalanche, Suburban, Tahoe; GMC Yukon, Yukon XL; and 2003-2007 model year Chevrolet Silverado and GMC Sierra vehicles equipped with a manual HVAC (CJ3) or heavy duty heater (C42). Important Dealers are to confirm vehicle eligibility prior to beginning repairs by using the Applicable Warranties section in the Global Warranty Management system. Parts Information Page 10749 Disclaimer Page 12832 Models The service procedure in this bulletin has been revised. Step 11 in the procedure for the 2004-2005 Saab 9-3 (9440) Convertible has been revised. Discard all copies of bulletin 08089B, issued September 2008. Condition In November 2002, the U.S. Federal Commissions (FCC) ruled that wireless carriers would no longer be required to support the analog wireless network beginning in 2008. As a result, On Star(R) is unable to continue analog service. OnStar(R) has deactivated most of the systems operating in the analog mode; however, there are some vehicles that OnStar(R) could not deactivate. Although the analog OnStar(R) hardware in these vehicles can no longer communicate with OnStar(R), the hardware in the vehicle is still active. If the OnStar(R) emergency button is pressed, or in the case of an airbag deployment, or near deployment, the customer may hear a recording that OnStar(R) is being contacted. However, since analog service is no longer available, the call will not connect to OnStar(R). To end the call, the customer must press the white phone or white dot button. If the call is not ended, the system will continue to try to connect to OnStar(R) until the vehicle battery is drained. Special Policy Adjustment At the customer's request, dealers/retailers are to deactivate the OnStar(R) system. The service will be made at no charge to the customer. This special coverage covers the condition described above until December 31, 2008 for all non-Saab vehicles; April 30, 2009 for all Saab vehicles. Vehicles Involved Page 11752 Accessory Delay Module: Symptom Related Diagnostic Procedures A Symptoms SYMPTOMS IMPORTANT: Review the system operation in order to familiarize yourself with the system functions. Refer to Retained Accessory Power (RAP) Description and Operation. Visual/Physical Inspection Inspect for aftermarket devices which could affect the operation of the RAP feature. - Inspect the easily accessible or visible system components for obvious damage or conditions which could cause the symptom. Intermittent Faulty electrical connections or wiring may be the cause of intermittent conditions. Symptom List Refer to a symptom diagnostic procedure from the following list in order to diagnose the symptom: - Retained Accessory Power (RAP) On After Timeout - Retained Accessory Power (RAP) Inoperative Steps 1-3 Page 6591 Vehicle Speed Sensor (VSS) Tow/Haul Switch Location Page 2065 average frame angle from the caster reading when making adjustments. 4. The caster and camber adjustments are made by rotating the offset cam bolt and the cam in the slotted frame bracket in order to reposition the control arm. Important: Before adjusting the caster and camber angles, jounce the front bumper three times to allow the vehicle to return to normal height. Measure and adjust the caster and the camber with the vehicle at curb height. The front suspension Z dimension is indicated in Trim Heights. Refer to Trim Height Inspection Procedure in Suspension General Diagnosis. For an accurate reading, do not push or pull on the tires during the alignment process. 5. Determine the caster angle (2). Be sure to compensate for frame angle where required. 6. Determine the positive camber (2) or negative camber (3) angle. 7. Remove the pinned adjusting cam insert. Do not reinstall the cam insert. 8. Loosen the upper control arm cam adjustment bolts. Notice: Refer to Fastener Notice in Service Precautions. 9. Adjust the caster and the camber angle by turning the cam bolts until the specifications have been met.When the adjustments are complete, hold the cam bolt head in order to ensure the cam bolt position does not change while tightening the nut. ^ Tighten the cam nuts to 190 Nm (140 ft. lbs.). 10. Verify that the caster and the camber are still within specifications. Refer to Wheel Alignment Specifications. When the caster and camber are within specifications, adjust the toe. Refer to Front Toe Adjustment. Front Toe Adjustment Front Toe Adjustment Fog Lamp Bulb Replacement - Front (Old Style) Fog/Driving Lamp Bulb: Service and Repair Fog Lamp Bulb Replacement - Front (Old Style) FOG LAMP BULB REPLACEMENT - FRONT (OLD STYLE) REMOVAL PROCEDURE 1. Remove the electrical connector. CAUTION: Refer to Halogen Bulb Caution in Service Precautions. 2. Remove the bulb from the fog lamp assembly by twisting the bulb counterclockwise and pulling the bulb out. INSTALLATION PROCEDURE 1. Install the bulb to the fog lamp assembly by inserting the bulb and twisting the bulb clockwise. 2. Install the electrical connector. Page 8619 Claim Information Refer to the General Motors WINS Claims Processing Manual for details on Product Recall Claim Submission. Customer Notification -- For US and Canada General Motors will notify customers of this recall on their vehicle (see copy of customer letter shown in this bulletin). Customer Notification -- For Letters will be sent to known owners of record located within areas covered by the US National Traffic and Motor Vehicle Safety Act. For owners outside these areas, dealers should notify customers using the sample letter. Dealer Recall Responsibility -- For US and Export (US States, Territories and Possessions) The US National Traffic and Motor Vehicle Safety Act provides that each vehicle which is subject to a recall of this type must be adequately repaired within a reasonable time after the customer has tendered it for repair. A failure to repair within sixty days after tender of a vehicle is prima facie evidence Page 9303 Junction Block - I/P Wire Entry Part 4 Page 9399 Multifunction Accessory Switch (HP2) Diagrams Power Door Lock Switch: Diagrams Door Lock Switch - Driver (Base Only) Campaign - ECM Software Upgrade PROM - Programmable Read Only Memory: Recalls Campaign - ECM Software Upgrade Bulletin No.: 06535 Date: August 09, 2006 SYSTEM SOFTWARE UPGRADE Subject: 06535-ON-BOARD DIAGNOSTIC (OBD) SYSTEM SOFTWARE UPGRADE - OBD SYSTEM IMPROVEMENTS (REPROGRAM POWERTRAIN CONTROL MODULE {PCM}) Models: 2004-05 CHEVROLET SILVERADO CHASSIS CAB, SUBURBAN, AVALANCHE 2004-05 GMC SIERRA CHASSIS CAB, YUKON XL EQUIPPED WITH DUAL FUEL TANKS Purpose This bulletin provides information about installing new Powertrain Control Module (PCM) software and calibration on certain involved 2004-05 Chevrolet Silverado chassis cab, Suburban, Avalanche; GMC Sierra chassis cab and Yukon XL model trucks, equipped with dual fuel tanks. The revised calibration includes OBD system improvements that affect the fuel level sender diagnostics that should be installed as soon as practical. Install the new calibration on all affected vehicles identified in this bulletin, including vehicles in new dealer inventory and any vehicles that return for service, for any reason, during the applicable 8 year / 80,000 mile (130,000 km) emission controller warranty coverage period. To verify if an updated calibration is required, refer to the following procedure in this bulletin. Parts Information Do not attempt to order the calibration number from GMSPO. The calibration numbers are programmed into Control Modules via a Techline Tech 2 scan tool and the Techline Information System (TIS) 2000 terminal with the calibration update. Use data version 8.0 for 2006 or later, broadcast to dealers on August 6, 2006 or TIS 2 Web version 8.0 for 2006 (website version of TIS); and on TIS DVD version 8.0 / 2006 or later, mailed to dealers beginning August 23, 2006. If you cannot access the calibration, call the Techline Customer Support Center and it will be provided. Service Procedure The "Required Field Actions" section of the GM Vehicle Inquiry System (GMVIS) must be checked to determine if a specific vehicle requires this action. If GMVIS indicates that System Software Upgrade 06535 remains 'open' and PCM reprogramming has not taken place otherwise after the TIS Broadcast or DVD availability dates identified in this bulletin, reprogram the PCM using a Tech 2 scan tool with the calibration update from Techline Information System (TIS) 2000. Tech 2(R) Remote Programming Method for PCM Note: Before reprogramming, please check the battery condition to prevent a reprogramming error of any of the modules due to battery discharge. Battery voltage must be between 12 and 16 volts during reprogramming. If the vehicle battery is not fully charged, use jumper cables from an additional battery. Be sure to turn off or disable any system that may put a load on the battery, such as automatic head lamps, daytime running lights, interior lights, heating, ventilation, and air conditioning (HVAC) system, radio, engine cooling fan, etc. A programming failure or control module damage may occur if battery voltage guidelines are not observed. The ignition switch must be in the proper position. The Tech 2(R) prompts you to turn ON the ignition, with the engine OFF. DO NOT change the position of the ignition switch during the programming procedure, unless instructed to do so. Make certain all tool connections are secure, including the following components and circuits: ^ The RS-232 communication cable port ^ The connection at the data link connector (DLC) ^ The voltage supply circuits DO NOT disturb the tool harnesses while programming. If an interruption occurs during the programming procedure, programming failure or control module damage may occur. DO NOT turn OFF the ignition if the programming procedure is interrupted or unsuccessful. Ensure that all control module and DLC connections Page 16150 7. Insert the J 38125-13A (GM P/N 12031876-1) tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the Terminal Repair Kit to ensure that the correct release tool is used. 8. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. REPAIR PROCEDURE Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. Page 12862 1. Remove the ground cable from the battery's negative cable. 2. Remove the center console, see WIS - Body - Interior. 3. Loosen the gear shift housing (A). AUT: Disconnect the 6-pin connector (B) to improve access to the gear shift housing screws. 4. Disconnect the signal cable from the SRS control module to the OnStar(R) control module and secure the cable. 4.1. Disconnect the connector (A) from the SRS control module and cut the cable tie (B). Page 7963 6. With the output gear encoder assembly in hand, carefully align the casting and output gear timing marks (1). 7. At the same time, be sure to align the encoder phasing post (1) with the phasing slot (2) in the casting and insert the shaft into the bushing. 8. Verify that the output gear and idler are engaged properly. 9. Seat the harness wires on the casting channel. 10. Place the shim on the output shaft gear. 11. Press a NEW seal into the cover. Connector Views Windshield Wiper Motor Module Page 15245 Cigar Lighter/Auxiliary Outlets Diagram 2 Page 5952 Park Neutral Position (PNP) Switch C175 Page 11676 Seat Belt Retractor: Service and Repair Rear (Crew Cab) SEAT BELT RETRACTOR REPLACEMENT - REAR (CREW CAB) CAUTION: To avoid personal injury to the occupants of the vehicle, observe the following precautions: - More than one supplier's seat belts are used, therefore, install ONLY the seat belt components specified in the GM parts catalog. - To verify that the correct seat belt components were installed, insert the seat belt latch in the seat belt buckle. The latch must be fully seated and be retained in the buckle until purposely released. REMOVAL PROCEDURE 1. Remove the rear seat, if required. 2. Remove the rear quarter trim panel. 3. Remove the rear seat belt to body bolts. 4. Remove the rear seat belt retractor to body bolt (1). 5. Remove the retractor from the vehicle. INSTALLATION PROCEDURE 1. Install the retractor to the vehicle. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the rear seat belt retractor to body bolt (1). Tighten A/C - Underhood Rattle Noise on Hard Acceleration Refrigerant Filter: All Technical Service Bulletins A/C - Underhood Rattle Noise on Hard Acceleration File In Section: 01 - HVAC Bulletin No.: 03-01-38~019A Date: September, 2004 TECHNICAL Subject: Underhood Rattle Noise Heard On Acceleration (Check A/C System Performance and Compressor Operation) Models: 2003-2004 Cadillac CTS 2002-2004 Cadillac Escalade, Escalade EXT 2003-2004 Cadillac Escalade ESV 2002-2004 Chevrolet Avalanche, Express, Silverado, Suburban, Tahoe 2002-2004 GMC Denali, Denali XL, Savana, Sierra, Yukon, Yukon XL 2002-2004 Commercial Upfitter Chassis Vehicles with Air Conditioning (A/C) This bulletin is being revised to update the service procedure and parts information. Please discard Corporate Bulletin Number 03-01-38-019 (Section 01 - HVAC). Condition Some customers may comment about an underhood rattle noise heard on acceleration or a sudden loss of A/C system performance. Cause This condition may be caused by liquid slugging of the A/C compressor. This condition may cause an internal failure in the A/C compressor. The serpentine belt tensioner and serpentine belt may also be damaged. Correction Technicians are to check the A/C system performance and compressor operation using the following repair procedure: 1. Open the hood and inspect the A/C compressor for damage and to see if the compressor is seized. Verify that the serpentine belt is not damaged or missing. If the A/C compressor is seized, proceed to Step 5. 2. Perform the A/C System Performance test. Refer to the Heating, Ventilation and Air Conditioning (HVAC) section of SI. Correct any performance concerns or refrigerant leaks that are found. 3. Inspect the vehicle for other possible sources of A/C compressor noise or performance concerns. Refer to Corporate Bulletin Number 01-01-38-013 for more information. 4. After all other possible sources of A/C compressor noise or performance concerns have been eliminated, only then should the A/C compressor be replaced. 5. Remove the A/C compressor. Refer to the A/C Compressor Replacement procedure in the HVAC section of SI. 6. Inspect the transmission cooler lines for damage due to contact from the serpentine belt. Replace the transmission cooler lines if necessary. 7. Install an inline A/C system filter. Refer to Corporate Bulletin Number 01-01-38-006C for more information about A/C system flushing and filter installation procedures. An A/C system flush is not to be done unless prior authorization is given by the GM Area Service Manager (in Canada, the District Service Manager). 8. Install an A/C Suction Screen. Refer to Corporate Bulletin Number 01-01-39-003A for more information about A/C suction screen repair recommendations and procedures. 9. Install a new A/C compressor. Refer to the Compressor Replacement procedure in the HVAC section of SI. 10. Install a new orifice tube for the front A/C system. Refer to the Expansion (Orifice) Tube Replacement procedure in SI. Page 8216 7. Install the caliper and caliper bracket assembly. 8. Perform the following procedure before installing the brake caliper bracket mounting bolts. 1. Remove all traces of the original adhesive patch. 2. Clean the threads of the bolt with brake parts cleaner or the equivalent and allow to dry. 3. Apply Threadlocker GM P/N 12345493 (Canadian P/N 10953488) to the threads of the bolt. 9. Notice: Refer to Fastener Notice in Service Precautions. Install the caliper bracket mounting bolts. ^ Tighten the brake caliper bracket mounting bolts to 175 Nm (121 ft. lbs.) (15 Series). ^ Tighten the brake caliper bracket mounting bolts to 300 Nm (221 ft. lbs.) (25 and 35 Series). 10. Install the front wheel hub extension (dual wheel vehicles only). 0. Insert a drift or large screwdriver through the brake caliper into one of the brake rotor vanes in order to prevent the rotor from turning. 1. Align and install the front wheel hub extension to the original position on the hub. 2. Important: Page 298 For vehicles repaired under warranty use, the table. Disclaimer Page 2023 Power Window Switch: Connector Views Window Switch - LR (Crew Cab Only) Page 13263 1. To receive credit, submit a claim with the information above. Disclaimer 2001 and Older Model Year Vehicles (Except Saab Vehicles) 2001 and Older Model Year Vehicles (Except Saab Vehicles) Important: 2001 and older model year vehicles require the removal of the battery power from the OnStar(R) vehicle interface unit (VIU) to eliminate the possibility of an inadvertent OnStar(R) or emergency/airbag call. 1. Locate and gain access to the OnStar® VIU. Refer to OnStar Vehicle Interface Unit Replacement in SI. Important: Complete removal of the VIU is usually not required. Perform only the steps required to gain access to the C2 32-way blue connector. Residing in the C2 connector are the battery positive (+) circuits. Removal of the C2 connector will deactivate the unit and eliminate the possibility of an inadvertent OnStar(R) or emergency/airbag call. Page 1659 Oxygen Sensor: Service and Repair Heated Oxygen Sensor (HO2S) Replacement Bank 2 Sensor 2 HEATED OXYGEN SENSOR (HO2S) REPLACEMENT BANK 2 SENSOR 2 REMOVAL PROCEDURE 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. Disconnect the connector position assurance (CPA) retainer. NOTE: Refer to Heated Oxygen and Oxygen Sensor Notice in Service Precautions. 3. Remove the heated oxygen sensor (HO2S) connector clip from the frame. 4. If equipped with a 4.8L or 5.3L engine, disconnect the HO2S electrical connector. Page 3238 Steps 1 - 13 Page 9515 Application Table Passlock Function Engine Control Module: Description and Operation Passlock Function VEHICLE/POWERTRAIN CONTROL MODULE The VCM/PCM communicates with the BCM over the Class 2 serial data line. When the BCM determines a no start condition, it sends a Class 2 serial data password to the VCM/PCM in order to disable the fuel injection system. If the BCM receives the expected voltage from the Passlock(TM) sensor, the BCM sends a class 2 serial data password to the VCM/PCM in order to enable the fuel injection system. The VCM/PCM then allows the vehicle to start correctly. If the Class 2 serial data password from the BCM to the VCM/PCM is not within the Vehicle Security Status Message, the fuel injectors will shut OFF during a start attempt. The SECURITY telltale will be illuminated for 10 minutes. If the VCM/PCM does not receive the same password from the BCM as the last learned one, the vehicle will start and then stalls due to the Fuel Lockout. Page 7003 18. Inspect and add axle lubricant to the axle housing, if necessary. 19. Lower the vehicle. Page 9468 Hybrid Control Module (HCM) - Part 1 Locations Instrument Panel Switches-LH Page 8901 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves SPLICING COPPER WIRE USING SPLICE SLEEVES TOOLS REQUIRED J 38125-D Terminal Repair Kit IMPORTANT: Use only GM splice sleeves, other splice sleeves may not protect the splice from moisture or a provide good electrical connection. Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. Page 370 8.5. Close the luggage compartment floor. 9. Fold down the left-hand rear side hatch in the luggage compartment. 10. M03: Replace the optic cable on the left-hand rear side: 10.1. Place the optic cable so that it is positioned behind the terminal housing on top of REC (A). 10.2. Remove the locking strip (B) on the 2-pin connector (H2-9) for the optic cable. 10.3. Open the terminal housing (C) with a screwdriver. Remove the secondary catch (D) on the connector and disconnect the optic cable coming from the OnStar(R) control modules. Page 13636 Tighten the door handle retaining bolts to 9 N.m (80 lb in). 4. Install the trim panel. Page 12344 If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Sir/SRS Wiring Repairs SIR/SRS WIRING REPAIRS TOOLS REQUIRED J 38125-D Terminal Repair Kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-D contains the following items: - Special sealed splices - in order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping tool - A heat torch - An instruction manual The sealed splices have the following 2 critical features: - A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-D also serves as a generic terminal repair kit. The kit contains the following items: - A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors Lamp Switch Assembly Replacement-Front Fog Lamp and Cargo Lamp Fog/Driving Lamp Switch: Service and Repair Lamp Switch Assembly Replacement-Front Fog Lamp and Cargo Lamp LAMP SWITCH ASSEMBLY REPLACEMENT - FRONT FOG LAMP AND CARGO LAMP REMOVAL PROCEDURE 1. Remove the instrument cluster bezel. 2. Remove the fog lamp switch and cargo switch from the housing. 3. Disconnect the electrical connector(s) from the fog lamp switch. 4. Remove the fog lamp and cargo lamp switch from the housing. INSTALLATION PROCEDURE 1. Connect the electrical connector(s) to the fog lamp and cargo lamp switch. 2. Install the fog lamp switch into the housing. 3. Install the IP trim bezel to the instrument panel. Page 10370 1. Tighten the bolts to 33 Nm (24 ft. lbs.), 15 series. 2. Tighten the bolts to 50 Nm (39 ft. lbs.), 25/35 series. Notice: Refer to Fastener Notice in Service Precautions. 4. Install the stabilizer links. Refer to Stabilizer Shaft Link Replacement. 5. Install the oil pan skid plate, if equipped. ^ Tighten the oil pan skid plate retaining bolts to 20 Nm (15 ft. lbs.). 6. Install the tire and wheel assembly. 7. Remove the safety stands. 8. Lower the vehicle. Navigation System - Replacement Navigation Discs Navigation System: All Technical Service Bulletins Navigation System - Replacement Navigation Discs Bulletin No.: 07-08-44-007 Date: April 17, 2007 INFORMATION Subject: Information on Obtaining Replacement Navigation Discs When Radios are Exchanged Order Replacement Navigation Disc Through Navigation Disc Center Models: 2007 and Prior GM Passenger Cars and Trucks (Including Saturn) 2007 and Prior HUMMER H2, H3 2007 and Prior Saab 9-7X with a Navigation Radio Attention: The purpose of this bulletin is to inform dealership personnel of a new procedure for obtaining a replacement navigation disc for radios that are sent to an ESC for exchange. This bulletin applies to U.S. and Canadian dealers only and is not intended for use by export dealers. When a navigation radio warranty exchange is performed, the customer must have a navigation disc to operate the new radio. If the customer's navigation disc was damaged or is stuck in the failed radio, the customer would have to wait for an excessive period of time for the disc to be returned or replaced. The Electronic Service Centers (ESC) are not authorized to remove stuck navigation discs from cores, as the cores must be returned to the supplier for analysis prior to any disassembly. The time it would take for the supplier to return the navigation disc would significantly delay the completion of the repair at the dealership. If the customer's navigation disc is damaged or cannot be removed from the radio, the dealership is to obtain an exchange radio through an ESC and a new navigation disc through the GM Navigation Disc Center. Both items can be shipped overnight to the dealership upon request. GM Navigation Disc Center Contact Information Via the web through gmnavdisc.com The GM Navigation Disc Center is also the center of expertise for navigation system questions. Warranty Information Include the part number and cost of the new navigation disc on the warranty claim for the navigation radio exchange. Disclaimer Page 466 Electrical Symbols Part 3 Page 15960 Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses CIRCUIT PROTECTION - FUSES The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the Page 7056 4. Install the propeller shaft (5) to the front axle pinion yoke (1). Align the reference marks made during removal. 5. Install the yoke retainers (7) and the bolts (6). ^ Tighten the yoke retainer bolts to 25 Nm (18 ft. lbs.). Notice: Refer to Fastener Notice in Service Precautions. 6. Install the boot onto the transfer case output shaft until the boot snaps into the groove on the output shaft. 7. Crimp the rear propeller shaft boot clamp using the J 43218 until the dimensions shown are obtained. 8. Install the transfer case shield, if equipped. 9. Lower the vehicle. Heater Core Replacement Heater Core: Service and Repair Heater Core Replacement HEATER CORE REPLACEMENT (HEAT ONLY) REMOVAL PROCEDURE 1. Remove the heater/vent module. See: 2. Remove the heater core cover screws. 3. Remove the heater core cover. 4. Remove the heater core. INSTALLATION PROCEDURE 1. Install the heater core. Diagrams Page 15202 Electrical Symbols Part 10 Page 10872 Ambient Temperature Sensor / Switch HVAC: Description and Operation AIR TEMPERATURE SENSORS The air temperature sensors are a 2-wire negative temperature co-efficient thermistor. The vehicle uses the following air temperature sensors: Ambient Air Temperature Sensor - Inside Air Temperature Sensor Assembly - Upper Left Air Temperature Sensor - Upper Right Air Temperature Sensor - Lower Left Air Temperature Sensor - Lower Right Air Temperature Sensor A signal and a low-reference circuit enables the sensor to operate. As the air temperature surrounding the sensor increases, the sensor resistance decreases. The sensor signal voltage decreases as the resistance decreases. The sensor operates within a temperature range between -40°C (-40°F) to 101°C (215°F). The sensor signal varies between 0.5 volts. The input of the duct air temperature sensors are different from the ambient and inside sensors. The HVAC control module converts the signal to a range between 0-255 counts. As the air temperature increases the count value will decrease. If the HVAC control module detects a malfunctioning sensor, then the control module software will use a defaulted air temperature value. The default value for the ambient and inside air temperature sensors will be displayed on the scan tool. The default value for the duct air temperature sensors will not be displayed on the scan tool. The scan tool parameter for the duct air temperature sensors are the actual state of the signal circuit. The default action ensures that the HVAC system can adjust the inside air temperature near the desired temperature until the condition is corrected. The ambient air temperature sensor mounts underhood and can be affected by city traffic, by idling, and by restarting a hot engine. Therefore, the HVAC control module filters the value of the ambient air temperature sensor for temperature display. The ambient air temperature value is updated under the above conditions. The scan tool has the ability to update the displayed ambient air temperature. To update the ambient air temperature display on the HVAC control module, perform the following procedure: Simultaneously press the MODE, FRONT DEFROST and REAR DEFROST switches. 1. Turn ON the ignition. 2. Simultaneously press the MODE, FRONT DEFROST and REAR DEFROST switches. Page 1837 until the sensor is seated into the adapter and bearing assembly. If installing a new sensor, it will come with a pin installed in the sensor. Do not remove the pin until the sensor is seated. If the new sensor did not come with a pin installed, you must reorder a new sensor. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install into the adapter and bearing assembly. 16. Install the connector to the sensor. 17. From the technicians point of view, the FRONT of the sensor will have: ^ A pin hole (2) for the centering pin. Note the location of the pin hole. ^ A flush rotor flange cuff (4) ^ An alignment mark (3) for installation 18. From the technicians point of view, the BACK of the sensor will have an alignment tab (1) for installation. This sensor does not have double D flats. 19. Important: If reusing the existing sensor, you must align the marks on the flush rotor flange cuff before installation. The alignment mark must stay aligned until the sensor is seated into the adapter and bearing assembly. If installing a new sensor, it will come with a pin installed in the sensor. Do not remove the pin until the sensor is seated. If the new sensor did not come with a pin installed, you must reorder a new sensor. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install into the adapter and bearing assembly. 20. Install the connector to the sensor. 21. From the technicians point of view, the FRONT of the sensor will have: ^ A pin hole (3) for the centering pin. Note location of the pin hole. ^ A flush rotor flange cuff (5) ^ An alignment mark (4) for installation ^ A foam ring (6) 22. From the technicians point of view, the BACK of the sensor will have: ^ Double D flats (1) ^ An alignment tab (2) for installing into the adapter and bearing assembly 23. Important: If reusing the existing sensor, you must align the marks on the flush rotor flange cuff before installation. The alignment mark must stay aligned until the sensor is seated into the adapter and bearing assembly. If installing a new sensor, it will come with a pin installed in the sensor. Do not remove the pin until the sensor is seated. If the new sensor did not come with a pin installed, you must reorder a new sensor. Page 4499 TOOLS REQUIRED J 34142-B 12 V Unpowered Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. When testing for voltage: 1. Attach 1 lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach 1 lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Using Connector Test Adapters USING CONNECTOR TEST ADAPTERS NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-B Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires USING FUSED JUMPER WIRES TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Connector Position Assurance Locks CONNECTOR POSITION ASSURANCE LOCKS The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Terminal Position Assurance Locks TERMINAL POSITION ASSURANCE LOCKS The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Push to Seat Connectors PUSH TO SEAT CONNECTORS TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Page 7234 7. Insert the J 38125-13A (GM P/N 12031876-1) tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the Terminal Repair Kit to ensure that the correct release tool is used. 8. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. REPAIR PROCEDURE Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. A/T - 2-3 Upshift or 3-2 Downshift Clunk Noise Output Shaft: Technical Service Bulletins A/T - 2-3 Upshift or 3-2 Downshift Clunk Noise INFORMATION Bulletin No.: 01-07-30-042F Date: February 05, 2010 Subject: Information on 2-3 Upshift or 3-2 Downshift Clunk Noise Models: 2010 and Prior GM Passenger Cars and Light Duty Trucks 2010 and Prior HUMMER H2, H3 2005-2009 Saab 9-7X with 4L60-E, 4L65-E or 4L70-E Automatic Transmission (RPOs M30, M32, M70) Supercede: This bulletin is being revised to add the 2010 model year and 4L70E transmission. Please discard Corporate Bulletin Number 01-07-30-042E (Section 07 - Transmission/Transaxle). Important For 2005 model year fullsize utilities and pickups, refer to Corporate Bulletin 05-07-30-012. Some vehicles may exhibit a clunk noise that can be heard on a 2-3 upshift or a 3-2 downshift. During a 2-3 upshift, the 2-4 band is released and the 3-4 clutch is applied. The timing of this shift can cause a momentary torque reversal of the output shaft that results in a clunk noise. This same torque reversal can also occur on a 3-2 downshift when the 3-4 clutch is released and the 2-4 band applied. This condition may be worse on a 4-wheel drive vehicle due to the additional tolerances in the transfer case. This is a normal condition. No repairs should be attempted. Disclaimer Page 13650 Tighten the hinge nuts (4) to 25 N.m (18 lb ft). 16. Clean and prepare all of the surfaces as necessary for refinishing. 17. Apply the sealers. Refinish the surfaces as necessary. 18. Install and align all of the related panels and the components. Page 15168 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. REPLACEMENT PROCEDURE After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Insure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the Terminal Removal Procedure. Repairing Connector Terminals REPAIRING CONNECTOR TERMINALS TOOLS REQUIRED J 38125-D Terminal Repair Kit Use the following repair procedures in order to repair the following: - Push to Seat terminals - Pull to Seat terminals - Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-D contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100 World terminals. Soldering Micro-Pack 100 World terminals may damage the terminal. Circuit Protection - Circuit Breakers CIRCUIT PROTECTION - CIRCUIT BREAKERS A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Page 8371 Parking Brake Cable: Service and Repair Park Brake Cable Replacement - Front Park Brake Cable Replacement - Front Removal Procedure 1. Release the park brake. 2. Remove the park brake pedal. Refer to Park Brake Pedal Assembly Replacement. 3. Roll the carpet back to access cable grommet. 4. Raise and support the vehicle. Refer Vehicle Lifting 5. Disengage the grommet and the cable from the floor pan. 6. Disconnect the front cable from the intermediate cable. 7. Remove the cable from the body mount by depressing the retaining tabs. 8. Remove the cable. Installation Procedure Page 6436 Vehicle Speed Sensor(VSS) Capacity Specifications Coolant: Capacity Specifications ENGINE COOLING SYSTEM A/T ....................................................................................................................................................... ....................................... 12.7 liters (13.4 quarts) A/T with Optional Air Conditioning ............................................................................................................................................ 14.1 liters (14.9 quarts) NOTE: ALL capacity specifications are approximate. When replacing or adding fluids, fill to the recommended level and recheck fluid level. Page 691 Page 13267 7.3. If equipped, connect the rear seat heater's connector and install the switch. 8. Install the floor console: 8.1. Install the floor console's retaining bolts (C) and retaining nuts (F). 8.2. Align the rear cover; make sure that the air duct connects firmly to the air nozzle. Screw in the cover (E). 8.3. Install the ashtray/cover (D). 8.4. Install the ignition switch cover (B). 8.5. Plug in the immobilizer unit (A) connector. Install the unit, bayonet fitting. 9. Remove the OnStar(R) control modules and secure the wiring: 9.1. Remove the right-hand rear luggage compartment trim in accordance with WIS - 8. Body - Interior equipment - Adjustment/Replacement. 9.2. Unplug the connectors (A) from the OnStar(R) control modules. 9.3. Remove the console (B) together with the OnStar(R) control modules. Page 15180 Control Module References Part 2 Page 3886 Engine Control Module: Description and Operation Powertrain Control Module (PCM) POWERTRAIN CONTROL MODULE (PCM) DESCRIPTION POWERTRAIN The powertrain has electronic controls to reduce exhaust emissions while maintaining excellent driveability and fuel economy. The powertrain control module (PCM) is the control center of this system. The PCM monitors numerous engine and vehicle functions. The PCM constantly looks at the information from various sensors and other inputs, and controls the systems that affect vehicle performance and emissions. The PCM also performs the diagnostic tests on various parts of the system. The PCM can recognize operational problems and alert the driver via the malfunction indicator lamp (MIL). When the PCM detects a malfunction, the PCM stores a diagnostic trouble code (DTC). The problem area is identified by the particular DTC that is set. The control module supplies a buffered voltage to various sensors and switches. Review the components and wiring diagrams in order to determine which systems are controlled by the PCM. The following are some of the functions that the PCM controls: The engine fueling - The ignition control (IC) - The knock sensor (KS) system - The evaporative emissions (EVAP) system - The secondary air injection (AIR) system (if equipped) - The exhaust gas recirculation (EGR) system - The automatic transmission functions - The generator - The A/C clutch control - The cooling fan control POWERTRAIN CONTROL MODULE FUNCTION The PCM constantly looks at the information from various sensors and other inputs and controls systems that affect vehicle performance and emissions. The PCM also performs diagnostic tests on various parts of the system. The PCM can recognize operational problems and alert the driver via the malfunction indicator lamp (MIL). When the PCM detects a malfunction, the PCM stores a diagnostic trouble code (DTC). The problem area is identified by the particular DTC that is set. The control module supplies a buffered voltage to various sensors and switches. The input and output devices in the PCM include analog-to-digital converters, signal buffers, counters, and output drivers. The output drivers are electronic switches that complete a ground or voltage circuit when turned on. Most PCM controlled components are operated via output drivers. The PCM monitors these driver circuits for proper operation and, in most cases, can set a DTC corresponding to the controlled device if a problem is detected. MALFUNCTION INDICATOR LAMP (MIL) OPERATION Page 5608 Steps 28 - 31 Page 14974 3. Install the endgate handle bezel. Notice: Refer to Fastener Notice in Service Precautions. 4. Install the fasteners (1) retaining the endgate handle bezel. Tighten the fasteners to 2.5 N.m (22 lb in). 5. Close the endgate. Page 1768 Inflatable Restraint Front End Sensor - Right Restraints - Driver/Passenger Seat Head Rest Information Head Restraint System: Technical Service Bulletins Restraints - Driver/Passenger Seat Head Rest Information INFORMATION Bulletin No.: 10-08-50-003A Date: March 24, 2011 Subject: Information on Driver or Passenger Seat Head Restraint Concerns with Comfort, Custom Upholstery or Other Comfort Enhancing Devices Models: 2012 and Prior GM Passenger Cars and Trucks Equipped with Adjustable Head Restraints Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 10-08-50-003 (Section 08 - Body and Accessories). Important ON A GM VEHICLE EQUIPPED WITH ADJUSTABLE HEAD RESTRAINTS, USE THE HEAD RESTRAINT COVERS, FOAM AND OTHER SEAT-RELATED EQUIPMENT AS RELEASED BY GM FOR THAT VEHICLE. DO NOT ALTER OR REPOSITION THE HEAD RESTRAINT SYSTEM. ANY ALTERATIONS TO HEAD RESTRAINTS DEFEATS THE INTENDED DESIGN OF THE SYSTEM. GM WILL NOT BE LIABLE FOR ANY PROBLEMS CAUSED BY USE OF SUCH IMPROPER DESIGN ALTERATIONS, INCLUDING ANY WARRANTY REPAIRS INCURRED. You may have a customer with a concern that the head restraint is uncomfortable or sits too far forward. The front driver and passenger seats are equipped with head restraints that have been designed to help minimize injuries while still providing comfort to the occupants. Each GM vehicle has its own specifically designed head restraint. The head restraints should only be used in the vehicle for which they were designed. The head restraint will not operate to its design intent if the original foam is replaced (1) by non-GM foam or head restraint, (2) by GM foam or head restraint designed for a different vehicle, (3) by GM foam or head restraint that has been altered by a trim shop or (4) if any object, such as an aftermarket comfort enhancing pad or device, is installed. Never modify the design of the head restraint or remove the head restraint from the vehicle as this may interfere with the operation of the seating and restraint systems and may prevent proper positioning of the passenger within the vehicle. Disclaimer Page 10706 9. Install the retaining ring. 10. Install the axle shaft. 11. Inspect the lubricant level and add, if necessary. 12. Lower the vehicle. Specifications Compression Check: Specifications The minimum compression in any one cylinder should not be less than 70 percent of the highest cylinder. No cylinder should read less than 690 kPa (100 psi). For example, if the highest pressure in any one cylinder is 1035 kPa (150 psi), the lowest allowable pressure for any other cylinder would be 725 kPa (105 psi). Multiply the highest cylinder pressure by 70 percent, 1035 kPa x 70 percent = 725 kPa (150 psi x 70 percent = 105 psi), in order to determine the lowest allowable pressure in any other cylinder. Page 9212 C220 I/P Harness To Infotainment Jumper Harness (With RPO Code UQ7 & Without RPO Code Y91) Part 1 Page 9385 5. Remove paint and primer from the area surrounding the 10 mm (0.40 in) until bare metal is visible. Important The M6 conductive rivet stud as shown, can accommodate a panel thickness range of 0.7-4.2 mm (0.03-0.17 in). If there are layers of sheet metal, they should be touching without any air gaps to ensure a good ground. 6. Select a M6 conductive rivet stud. Refer to the Parts Information section of this bulletin. Note Use the GE-50317 rivet stud tool kit. 7. Place the M6 conductive rivet stud (1) in the 10 mm (0.40 in) hole. Assemble the rivet stud tool (2) with the groove and flare side facing the rivet stud, then the washer and the M6 nut (3). 8. Using a wrench on the rivet stud tool, and a socket on the M6 nut, secure the M6 conductive rivet stud. 9. Ensure the new rivet stud is securely fastened, WITHOUT ANY detectable movement. 10. Completely wrap the threads of the rivet stud with painters tape or equivalent. Page 1315 Cabin Temperature Sensor / Switch: Service and Repair INSIDE AIR TEMPERATURE SENSOR ASSEMBLY REPLACEMENT REMOVAL PROCEDURE 1. Remove the left windshield garnish molding. 2. Remove the left center pillar assist handle. 3. Remove the left center pillar garnish molding. 4. Remove the left sunshade. 5. Gently pull down the headliner. 6. Disconnect the electrical connector from the inside air temperature sensor. 7. Partially remove the inside air temperature sensor from the headliner. 8. Remove the sensor grille from the inside air temperature sensor. 9. Remove the inside air temperature sensor from the headliner. INSTALLATION PROCEDURE 1. Install the new sensor grille to the headliner. Page 2736 Fuse Block: Service and Repair Body Wiring Harness Junction Block Replacement BODY WIRING HARNESS JUNCTION BLOCK REPLACEMENT REMOVAL PROCEDURE 1. Remove the cover retaining nut. 2. Remove the cover by pushing in the tabs. 3. Remove the harness from the front of the junction block. 4. Remove the junction block from the bracket by pressing to release the tabs. 5. Remove the junction block in order to gain access to the rear of the block to remove the retaining bolts. 6. Remove the retaining bolts. 7. Separate the wire harness block from the junction block by inserting a screw driver in between. 8. Remove the junction block from the vehicle. INSTALLATION PROCEDURE 1. Install the wire harness block to the junction block. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the retaining bolts. Tighten Tighten the bolts to 6 N.m (53 lb in). 3. Install the junction block to the bracket. Page 2360 Radiator Hose: Service and Repair Radiator Hose Quick Connect Fitting Radiator Hose Quick Connect Fitting Removal Procedure 1. Using a bent-tip screwdriver or equivalent, pull on one of the open ends of the retaining ring in order to rotate the retaining ring. 2. Rotate the retaining ring (3) around the quick connector until the retaining ring is out of position and can be completely removed. 3. Remove the radiator outlet hose (2) from the quick connector fitting at the radiator (1). Installation Procedure 1. Important: Do not install the retaining ring (3) onto the fitting by pushing the retaining ring down over the fitting. Hook one of the open ends of the retaining ring (3) in one of the slots in the quick connector. 2. Rotate the retaining ring (3) around the connector until the retaining ring is positioned with all 3 ears through the 3 slots. Page 11713 Seat Belt Switch - Front Passenger (With RPO Code AL0) Page 7327 Vehicle Speed Sensor (VSS) Tow/Haul Switch Location Page 4125 1. Coat a NEW O-ring seal with a thin film of Synchro-mesh transmission fluid GM P/N 12345349 (Canadian P/N 10953465), or equivalent. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the VSS and O-ring seal. ^ Tighten the VSS to 16 Nm (12 ft. lbs.). 3. Connect the VSS electrical connector (1). 4. Lower the vehicle. Page 15683 Upper Steering Column Service and Repair Child Seat Tether Attachment: Service and Repair CHILD RESTRAINT TETHER ANCHOR REPLACEMENT The child restraint tether anchors are welded to the seat back frame and cannot be serviced separately. Refer to Seat Back Frame Replacement - Front or Seat Back Frame Replacement Rear in Seats. Automatic Transmission - 4L60-E/4L65-E Transmission Position Switch/Sensor: Service and Repair Automatic Transmission 4L60-E/4L65-E Park/Neutral Position Switch Replacement ^ Tools Required J 41364-A Park Neutral Switch Aligner Removal Procedure 1. Apply the park brake. 2. Shift the transmission into neutral. 3. If equipped with 4-wheel drive (4WD), remove the front propeller shaft. 4. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 5. Disconnect the park/neutral position (PNP) switch electrical connector (2). 6. Remove the manual shaft lever nut. Procedures Power Door Lock Switch: Procedures Switch Replacement - Door Lock and Side Window - Driver SWITCH REPLACEMENT - DOOR LOCK AND SIDE WINDOW - DRIVER REMOVAL PROCEDURE 1. Remove the front door trim panel. 2. Disconnect the electrical connectors. 3. Remove the screw that retains the switch panel bezel (1) from the front door panel. 4. Remove the switch panel bezel from the door panel using a flat-bladed tool. 5. Using a wide plastic flat-bladed tool, release the retaining clips on both sides of the door module. Page 2483 1. Apply sealant GM P/N 12346004 (Canadian P/N 10953480), or equivalent to the oil drain and fill plug threads. 2. Notice: Refer to Fastener Notice in Service Precautions. Using J 36511 install the oil drain plug. ^ Tighten the plug to 30 Nm (22 ft. lbs.). 3. Remove and drain the drain pan used to catch the used transmission fluid. 4. Fill the transmission to just below the bottom of the fill plug hole. Interior - Seat Memory Feature Appears Inoperative Memory Positioning Module: Customer Interest Interior - Seat Memory Feature Appears Inoperative Bulletin No.: 04-08-50-003 Date: February 26, 2004 INFORMATION Subject: Enabling Memory Seat Feature via DIC If Feature Appears Inoperative Models: 2003-2004 Cadillac Escalade, Escalade ESV, Escalade EXT 2003-2004 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2003-2004 GMC Sierra, Yukon, Yukon Denali, Yukon Denali XL 2003-2004 HUMMER H2 with Steering Wheel Controls (RPO UK3) (standard on H2) If the memory seat feature appears inoperative, check the Driver Information Center (DIC). Many of the memory seat modules that were returned through the Warranty Parts Center for a condition of inoperative have shown No Trouble Found. The Driver Information Center (DIC), programmed for Seat Entry and Exit, is set to the default "Off" mode at the assembly plant. DO NOT REPLACE THE MEMORY SEAT MODULE. Perform the following procedure. Important: The following procedure will need to be completed for each Remote/Key selection. Using the DIC menu, do the following steps: 1. Set the "Seat Recall" to either "At Key In" or "On Remote" based on the customer's preference. 2. Set the "Exit Seat" to "On". 3. Adjust the following items: Memory Seat: 3.1. Driver's Seat (including the seat back, recliner, lumbar, and side wings) 3.2. Throttle and Brake Pedals (not available on H2 or Silverado and Sierra Trucks) 3.3. Outside Mirrors 3.4. Radio Station Presets 3.5. Last Chosen Climate Control System Settings (not available on Silverado or Sierra Trucks) 3.6. Press and hold the "1" or "2" (for driver 1 or 2) button of the memory control for three seconds. A double chime will sound to let you know that the position has been stored. Easy Exit Seat: 3.1. Press and release the 1 or 2 button or press the unlock button on the desired remote keyless entry transmitter. The seat will move to the stored memory position. 3.2. Adjust the seat to the desired exit position. 3.3. Press and hold the exit button of the memory control (located on the door) for three seconds. A double chime will sound to let you know that the position has been stored for the identified driver (1 or 2). Page 6756 Important The new canister vent valve will be installed in a new location, outside of the frame. 7. Position and secure the new valve assembly to the frame bracket on the outside of the frame using the existing hole and mounting bolt. Tighten Tighten the bracket mounting bolt to 12 Nm (106 lb in). 8. Connect the vent valve pipe to the EVAP canister. 9. Install the two vent valve pipe clips into the existing underbody holes. 10. Connect the EVAP canister vent valve electrical connector, if equipped. 11. Attach bulk 5/8" heater hose to the vent valve port and secure using a clamp. Run a length as needed along the frame rail routing to the area above the transmission. 12. Cut the hose to determined length and install the supplied filter box. Secure using a clamp. 13. Remove the transmission support and lower the transmission assembly as necessary to allow for access to the new filter box location. 14. Secure the filter box to the transmission vent hose just forward of the hose tee-section using a tie strap. DO NOT pinch or restrict the transmission vent hose. The filter box opening should be pointing downward. 15. Raise the transmission and reinstall the transmission support. 16. Tie strap the hose as needed along the frame rail in order to keep the hose away from pinch-points and heat sources. 17. Lower the vehicle. 2004-2007 Model Year (Use Service Kit P/N 19152349) 1. Raise the vehicle. Suitably support the vehicle. 2. Disconnect the EVAP canister vent valve electrical connector. 3. Disconnect the canister pipe from the vent valve. 4. Push in the retainer and remove the existing canister vent valve from the fuel tank clip or mounting bracket. Discard the old valve. 5. Cut back the existing canister pipe approximately 51 mm (2 in) to remove the quick connect end. Crew Cab Short Box Shown Below, Other Configurations Similar Tire/Wheel - Spare Tire Is Non-Matching To Other Tires Spare Tire: All Technical Service Bulletins Tire/Wheel - Spare Tire Is Non-Matching To Other Tires INFORMATION Bulletin No.: 02-03-10-001E Date: November 01, 2010 Subject: Spare Tire is a Different Size than Other Tires Models: 2002-2011 Cadillac Escalade Models 1999-2007 Chevrolet Silverado (Classic) 2000-2011 Chevrolet Suburban, Tahoe 2002-2011 Chevrolet Avalanche 1999-2007 GMC Sierra (Classic) 2001 GMC Sierra C3 2001-2011 GMC Yukon Models 2002-2011 GMC Sierra Denali Supercede: This bulletin is being revised to update the model years. Please discard Corporate Bulletin Number 02-03-10-001D (Section 03 - Suspension). This bulletin is being issued to supply additional information concerning the spare tire on the above vehicles. You or your customers may have noticed that the spare tire has a 16-inch diameter steel wheel or 17-inch diameter aluminum wheel while the road tires have a 17-inch, 18-inch, 20-inch or 22-inch diameter aluminum wheel. Although the spare tire has a different wheel diameter and may be a different brand, the rolling circumference is nearly identical to the road tires. The size difference will not cause a concern because the spare and the other tires will travel the same distance in one revolution. This combination of non-matching tires is used most often on full-size trucks. These vehicles use a road tire and wheel combination that may be too large to conveniently fit the storage compartment space of the vehicle. The customer may not be able to easily remove the spare tire/wheel from the storage area because of its size and/or weight. A steel spare wheel, rather than an aluminum one, may be used since the spare is stowed under the vehicle where it is exposed to road and weather elements. A steel wheel is less likely to incur cosmetic damage while in the stowed position for long periods of time. Please provide this information to your customers. Also, remind your customers of the importance of following the tire maintenance schedule as listed in their Owner Manual. Additional tire care information can be found by visiting www.gmtiresafety.com or contacting GM toll-free. Disclaimer Page 3109 ^ Dry or brittle ^ Compression set Installation Procedure 1. Clean all corrosion or contaminates from the steering knuckle bore and the hub and bearing assembly. 2. Lubricate the steering knuckle bore with wheel bearing grease or the equivalent. 3. Install the O-ring (7) to the steering knuckle, the 25/35 series. 4. Notice: Refer to Fastener Notice in Service Precautions. Install the wheel speed sensor mounting bolt to the wheel hub and bearing. ^ Tighten the sensor mounting bolt to 18 Nm (13 ft. lbs.). 5. Install the wheel hub and bearing and splash shield to the vehicle, 25/35 series. 6. Install the wheel hub and bearing (5) and splash shield (6) to the vehicle, 15 series. 7. Install the wheel hub and bearing mounting bolts, the 15 series. 8. Install the wheel hub and bearing mounting bolts, 25/35 series. ^ Tighten the wheel hub to knuckle bolts to 180 Nm (133 ft. lbs.). Diagrams Engine Oil Level Switch Page 7898 Fluid Pressure Sensor/Switch: Connector Locations Diagrams Door Latch Assembly (Key Cylinder Switch) - Driver C3 Page 12091 2007 Model Year Vehicles and Newer all have Digital OnStar(R) Modules. Part 1 OnStar(R) Description and Operation This OnStar(R) digital system consists of the following components: ^ Vehicle Communication Interface Module (VCIM) ^ OnStar(R) button assembly ^ Microphone ^ Cellular antenna ^ Navigation antenna Note This system also interfaces with the factory installed vehicle audio system. Vehicle Communication Interface Module (VCIM) The vehicle communication interface module (VCIM) is a cellular device that allows the user to communicate data and voice signals over the national cellular network. Power is provided by a dedicated, fused B+ circuit. Ground is provided through the vehicle wiring harness attached to the module. The ignition state is determined by the VCIM through serial data messaging. Dedicated circuits are used to connect the VCIM to a microphone, the button assembly, and to command the status LED. The VCIM communicates with the rest of the vehicle modules using the serial data bus. The module houses 2 technology systems, one to process GPS data, and another for cellular information. The cellular system connects the OnStar(R) system to the cellular carrier's communication system by interacting with the national cellular infrastructure. The module sends and receives all cellular communications over the cellular antenna and cellular antenna coax. GPS satellites orbiting earth are constantly transmitting signals of their current location. The OnStar(R) system uses the GPS signals to provide location on demand. The module also has the capability of activating the horn, initiating door lock/unlock, or activating the exterior lamps using the serial data circuits. These functions can be commanded by the OnStar(R) Call Center per: a customer request. OnStar(R) Button Assembly The OnStar(R) button assembly may be part of the rearview mirror, or a separate, stand alone unit. The button assembly is comprised of 3 buttons and a status LED. The buttons are defined as follows: ^ The answer/end call button, which is black with a white phone icon, allows the user to answer and end calls or initiate speech recognition. ^ The blue OnStar(R) call center button, which displays the OnStar(R) logo, allows the user to connect to the OnStar(R) call center. ^ The emergency button, which displays a white cross with a red background, sends a high priority emergency call to the OnStar(R) call center when pressed. The VCIM supplies 10 volts to the OnStar(R) button assembly on the keypad supply voltage circuit. When pressed, each button completes a circuit across a resistor allowing a specific voltage to be returned to the VCIM on the keypad signal circuit. Depending upon the voltage range returned the VCIM is able to identify which button has been pressed. The OnStar(R) status LED is located with the button assembly. The LED is green when the system is ON and operating normally. When the status LED is green and flashing, it is an indication that a call is in progress. When the LED is red, this indicates a system malfunction is present. In the event there is a system malfunction and the OnStar(R) system is still able to make a call, the LED will flash red during the call. If the LED does not illuminate, this may indicate that the customers OnStar(R) subscription is not active or has expired. Push the blue OnStar button to connect to an advisor who can then verify the account status. Each LED is controlled by the VCIM over dedicated LED signal circuits. Ground for the LED is provided by the wiring harness attached to the button assembly. Page 5194 6. Connect the fuel composition sensor electrical connector. 7. Lower the vehicle. 8. Use the following procedure in order to inspect for leaks: 8.1. Turn the ignition ON, with the engine OFF, for 2 seconds. 8.2. Turn the ignition OFF for 10 seconds. 8.3. Turn the ignition ON, with the engine OFF. 8.4. Inspect for fuel leaks. Page 12690 Circuit/System Testing Component Testing Page 11983 ^ I/O check Any faults detected during the initialization self-test shall generate a DTC. All nodes also continuously perform a self-test while in an active state. DTCs and their associated telltales will set as a result of unprogrammed or unlearned information. DTCs, which are defined for system configuration (e.g. Vehicle Option Content not programmed) do not support the history status bit (set =0). Warning indicator bit is also set, when applicable, while this DTC is present. Action Taken When the DTCs Sets The module suspends all message transmission. The module uses default values for all parameters received on the serial data circuits. The module inhibits the setting of all other communication DTCs. Conditions for Clearing the DTC A current DTC clears when the malfunction is no longer present. A history DTC clears when the module ignition cycle counter reaches the reset threshold of 50, without a repeat of the malfunction. Circuit/System Verification Refer to Data Link References to determine which serial data system is used for a specific module. The DTCs cannot be retrieved with a current status. Diagnosis is accomplished using the following symptom procedures: Scan Tool Does Not Communicate with High Speed GMLAN Device in SI. OR Scan Tool Does Not Communicate with Low Speed GMLAN Device in SI. DTC U1300, U1301, or U1305 Circuit Description Modules connected to the Class 2 serial data circuit monitor for serial data communications during normal vehicle operation. Operating information and commands are exchanged among the modules. In addition to this, Node Alive messages are transmitted by each module on the Class 2 serial data circuit about once every 2 seconds. When the module detects one of the following conditions on the Class 2 serial data circuit for approximately 3 seconds, the setting of all other Class 2 serial communication DTCs is inhibited and a DTC will set. Conditions for Running the DTCs Voltage supplied to the module is in the normal operating voltage range. The vehicle power mode requires serial data communication to occur. Conditions for Setting the DTCs No valid messages are detected on the Class 2 serial data circuit. The voltage level detected on the Class 2 serial data circuit is in one of the following conditions: Page 15649 Upper Steering Column Page 12238 6. See wiring diagram shown above for details. 5. Replace the OnStar(R) Vehicle Communication Interface Module (VCIM) in the vehicle with the provided Digitally-Capable VCIM. Refer to the Communication Interface Module Replacement procedure in the Cellular Communication section of SI. This kit may include a new VCIM bracket. If it does, use this new bracket on the vehicle and discard the original bracket. The kit may also include a small wiring jumper cable. If it does, plug the wiring jumper cable into the connector on the VCIM and the other end to the corresponding vehicle wiring harness connector. ^ For 2001, 2002 and 2003 Chevrolet Impala and Monte Carlo, do not reinstall the black plastic OnStar(R) module cover onto the vehicle after the VCIM and module bracket have been installed. This black plastic cover will no longer fit on the vehicle. ^ The upgrade kit for 2002 Sevilles and DeVilles, and some 2003 Sevilles and DeVilles, will contain a large bracket. To install the new VCIM into this bracket you'll need to carefully line up the notch in the VCIM with the tab in the bracket. Page 13527 Refer to the table as a guide in selecting the correct test adapter for frontprobing connectors: Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure SCAN TOOL SNAPSHOT PROCEDURE Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: - Snapshot - taken from the Snapshot menu choice - Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information Page 9018 Fuse Block - Underhood C3 Part 1 Linkage Replacement - Endgate Tailgate Shock / Support: Service and Repair Linkage Replacement - Endgate Linkage Replacement - Endgate Removal Procedure 1. Lower the endgate. 2. Loosen the endgate handle bolts. Refer to Handle Replacement Endgate. 3. Raise the endgate. 4. Remove the handle bezel by prying gently on the upper retainer tabs. 5. Lower and support the endgate. 6. Remove the endgate latch assembly. 7. Disengage the linkage rod from the latch assembly. 8. Remove the linkage rod (1) from the endgate handle assembly. Installation Procedure Page 6830 Pinion Flange: Service and Repair Rear Drive Axle All Except 9.75 Inch Axle Drive Pinion Flange/Yoke and/or Oil Seal Replacement (All Except 9.75 Inch Axle) ^ Tools Required J 8614-01 Flange/Pulley Holding Tool - J 22388 Rear Axle Pinion Oil Seal Installer - Rear (8.6 inch, 9.5 inch axle) - J 44414 Rear Axle Pinion Oil Seal Installer (10.5 inch, 11.5 inch axle) Removal Procedure 1. Important: Observe and mark the positions of all the driveline components, relative to the propeller shaft and the axles, prior to disassembly. These components include the propeller shafts, drive axles, pinion flanges, output shafts, etc. Reassemble all the components in the exact places in which you removed the parts. Follow any specifications, torque values, and any measurements made prior to disassembly. Raise the vehicle. Refer to Vehicle Lifting. 2. Remove the tire and wheel assemblies (8.6 inch, 9.5 inch axles). 3. Remove the rear brake calipers (8.6 inch, 9.5 inch axles). 4. Remove the brake rotors (8.6 inch, 9.5 inch axles). 5. Remove the axle shafts (10.5 inch, 11.5 inch axle). 6. Reference mark the rear propeller shaft (3) to the rear axle pinion yoke (4). 7. Disconnect the propeller shaft from the axle. Wrap the bearing caps with tape in order to prevent the loss of bearing rollers. Support the propeller shaft as necessary. 8. Measure the amount of torque required to rotate the pinion. Use an inch-pound torque wrench. Record this measurement for reassembly. This will give the combined preload for the following components: ^ The pinion bearings ^ The pinion pilot bearing (10.5 inch axle) ^ The pinion oil seal ^ The differential case bearings ^ The axle bearings (8.6 inch, 9.5 inch axles) ^ The axle seals (8.6 inch, 9.5 inch axles) Page 12599 9. Erase the diagnostic trouble codes. 10. Set the date and time, see WIS - 3. Electrical system - Information display (SID) - Technical description. Recall - Brake Booster Pressure Accumulator Cracking Technical Service Bulletin # 05006 Date: 050323 Recall - Brake Booster Pressure Accumulator Cracking Product Safety - Hydro-Boost Accumulator Over-Pressurization # 05006 - (Mar 23, 2005) Models: 2004 Chevrolet Kodiak 2004-2005 Chevrolet Avalanche, Express, Silverado, Suburban 2004 GMC TopKick 2004-2005 GMC Savana, Sierra, Yukon XL Condition General Motors has decided that a defect, which relates to motor vehicle safety, exists in certain 2004 Chevrolet Kodiak and GMC TopKick; 2004-2005 Chevrolet Avalanche, Express, Silverado, Suburban; GMC Savana, Sierra, Yukon XL vehicles. On some of these vehicles, the hydraulic brake booster's pressure accumulator may crack and/or separate from the Hydro-Boost(R) assembly during normal vehicle operating conditions. If a separation were to occur and the hood of the vehicle were open, fragments from the accumulator could cause injury to people in the immediate area. In addition, the presence of this crack or fractured surface could allow the hydraulic fluid to leak from the accumulator circuit of the booster assembly. The loss of fluid would cause increased steering and braking effort. Correction Dealers are to inspect the hydraulic brake booster, and replace it if necessary. Vehicles Involved Involved are certain 2004 Chevrolet Kodiak and GMC TopKick; 2004-2005 Chevrolet Avalanche, Express, Silverado, Suburban; GMC Savana, Sierra, Page 14392 Driver Door Module (DDM) - C3 (With RPO Code YE9) Part 1 Page 762 1. Install the blower motor control processor (2) to the HVAC module (1). NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the blower motor control processor retaining screws. Tighten Tighten the screws to 1.6 N.m (14 lb in). 3. Connect the electrical connector (4) to the blower motor control processor (2). 4. Connect the electrical connector at the blower motor. 5. If equipped, install the sound insulator panel. HVAC Control Module Replacement HVAC CONTROL MODULE REPLACEMENT REMOVAL PROCEDURE Electrical - Instrument Panel & General Wiring Repair Wiring Harness: All Technical Service Bulletins Electrical - Instrument Panel & General Wiring Repair Bulletin No.: 06-08-45-004 Date: May 02, 2006 INFORMATION Subject: Instrument Panel (I/P), Body and General Wiring Harness Repair Models: 2007 and Prior GM Cars and Trucks 2003-2007 HUMMER H2 2006-2007 HUMMER H3 Important: A part restriction has been implemented on all Body and I/P harnesses and is being administered by the PQC. If a body or I/P harness replacement is required, it can take 12-28 weeks for a harness to be built and delivered to a dealer. The dealer technician is expected to repair any harness damage as the first and best choice before replacing a harness. In an effort to standardize repair practices, General Motors is requiring that all wiring harnesses be repaired instead of replaced. If there is a question concerning which connector and/or terminal you are working on, refer to the information in the appropriate Connector End Views in SI. The Instruction Manual J 38125-620, which is sent with each new update of the J 38125 Terminal Repair Kit, also has terminal crimping and terminal remove information. Important: There are some parts in the J 38125 Terminal Repair Kit (i.e. SIR connector CPAs and heat shrink tube (used in high heat area pigtail replacement) and some TPAs that are not available from GMSPO. It is vitally important that each update to the J 38125 Terminal Repair Kit be done as soon as it arrives at the dealer. Utilize the Terminal Repair Kit (J 38125) to achieve an effective wiring repair. The Terminal Repair Kit has been an essential tool for all GM Dealers since 1987. Replacement terminals and tools for this kit are available through SPX/Kent Moore. Refer to Corporate Bulletin Number 06-08-45-001 for more information. The Instruction Manual J 38125-620, which is sent with each new update to the J 38125 Terminal Repair Kit, also has terminal crimping and terminal removal information. U.S. Dealers Only - Training courses (including Tech Assists, Emerging Issues, Web, IDL and Hands-on) are available through the GM Training website. Refer to Resources and then Training Materials for a complete list of available courses. Canadian Dealers Only - Refer to the Training section of GM infoNet for a complete list of available courses and a copy of the J 38125 Terminal Repair Kit Instruction Manual. Wiring repair information is also available in Service Information (SI). The Wiring Repair section contains information for the following types of wiring repairs: - Testing for intermittent conditions and poor conditions - Flat wire repairs - GMLAN wiring repairs - High temperature wiring repairs - Splicing copper wire using splice clips - Splicing copper wire using splice sleeves - Splicing twisted or shielded cable - Splicing inline harness diodes Page 7004 Wheel Bearing: Service and Repair With Rear Wheel Steering Wheel Hub and Bearing Replacement ^ Tools Required J 45859 Axle Remover Removal Procedure 1. Notice: Refer vehicle Lifting. Raise the vehicle. Refer to Vehicle Lifting. 2. Remove the tire and wheel. 3. Remove the brake rotor. 4. Remove the axle nut dust cover (4). 5. Remove the cotter pin (2) and retainer (3) from the wheel drive shaft nut. 6. Remove the wheel drive shaft retaining nut. 7. Remove the wheel hub and bearing retaining bolts. Page 360 switch lighting connector. 3.3. Undo the floor console's retaining bolts (C). 3.4. Take out the rear ashtray/cover (D). 3.5. Remove the screw (E) for the rear cover. 3.6. Remove the floor console's retaining nuts (E). 3.7. Detach the floor console (G) by pulling it straight back and lifting it slightly. 3.8. If required, detach the switch for the rear seat heater and unplug the connector. 4. Remove the switch and the floor console: 4.1. Detach the window lift module (A) by loosening it in the front edge (snap fastener). Unplug the window lift module's connector. 4.2. Detach the switch for the roof lighting (B) and unplug its connector. Lift away the floor console. 5. Pry out the signal line from the SRS control module to the OnStar(R) control module and secure it: 5.1. Unplug the SRS control module's connector (A). Memory Seat Calibration Procedure Memory Positioning Module: Service and Repair Memory Seat Calibration Procedure MEMORY SEAT CALIBRATION PROCEDURE The memory seat module uses position sensor inputs to establish soft stop locations for the adjuster motors several millimeters ahead of the physical limits of the adjuster assembly. After replacing a memory seat module or adjuster components, it may be necessary to reset the adjuster motor soft stop locations. When the repair procedure has been completed, operate the seat adjuster switch in every direction until the seat adjuster reaches its mechanical hard stop by repeatedly pressing and releasing the switch as necessary. Service and Repair Vacuum Pump: Service and Repair Brake Assist Pump Motor Replacement Removal Procedure 1. Remove the vacuum hose from the brake assist pump. 2. Disconnect the electrical connector. 3. Remove the brake assist pump nuts. 4. Remove the brake assist pump from the booster by pulling the inlet tube out of the grommet. Installation Procedure 1. Install the brake assist pump to the booster by pushing the inlet tube into the grommet and aligning the studs to the holes. 2. Notice: Refer to Fastener Notice in Service Precautions. Page 9280 Junction Block - I/P Wire Entry Part 4 Page 14069 Electrical Symbols Part 9 Page 16157 Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses CIRCUIT PROTECTION - FUSES The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the Automatic Transmission - 4L60-E/4L65-E Transmission Position Switch/Sensor: Adjustments Automatic Transmission - 4L60-E/4L65-E Park/Neutral Position Switch Adjustment Important: ^ The following procedure is for vehicles that have not had the park/neutral position (PNP) switch removed or replaced. If the PNP switch has been removed or replaced, refer to Park/Neutral Position Switch Replacement for the proper adjustment procedure. ^ Apply the park brake. ^ The engine must start in the park (P) or neutral (N) positions only. ^ Check the PNP switch for proper operation. If adjustment is required, proceed as follows: 1. Place the transmission range selector in the neutral (N) position. 2. With an assistant in the drivers seat, raise and suitably support the vehicle. Refer to Vehicle Lifting. 3. Loosen the park/neutral position (PNP) switch bolts. 4. With the vehicle in the neutral (N) position, rotate the switch while the assistant attempts to start the engine. 5. Following a successful start, turn the engine off. 6. Notice: Refer to Fastener Notice in Service Precautions. ^ Tighten the PNP switch bolts. ^ Tighten the bolts to 25 Nm (18 ft. lbs.). 7. Lower the vehicle. 8. Check the PNP switch for proper operation. The engine must start in the park (P) or neutral (N) positions only. 9. Replace the PNP switch if proper operation can not be achieved. Page 13584 Auxiliary Step / Running Board: Service and Repair Assist Step Replacement (Body Mount) Assist Step Replacement (Body Mount) Removal Procedure 1. Remove the following components from the vehicle: 1. The center body mount bolt (1) 2. The lock washer 3. The washer 2. Remove the center lower body-cushion assemblies (4). 3. Remove the following components from the assist step: 1. The center bolt (2) 2. The lock washer 3. The washer 4. Remove the assist step center bracket (5). 5. With an assistant, remove the following front components, and rear components: 1. The body mount bolts (1) 2. The lock washers (2) 3. The washers (3) 6. With an assistant, remove the assist step assembly from the vehicle. 7. Remove the lower body-mount cushion assemblies (4), front and rear, from the vehicle. Electrical - MIL ON/DTC's Set By Various Control Modules Wiring Harness: All Technical Service Bulletins Electrical - MIL ON/DTC's Set By Various Control Modules TECHNICAL Bulletin No.: 09-06-03-004D Date: December 08, 2010 Subject: Intermittent No Crank/No Start, No Module Communication, MIL, Warning Lights, Vehicle Messages or DTCs Set by Various Control Modules - Diagnosing and Repairing Fretting Corrosion (Disconnect Affected Connector and Apply Dielectric Lubricant) Models: 2011 and Prior GM Passenger Cars and Trucks Attention: This repair can be applied to ANY electrical connection including, but not limited to: lighting, body electrical, in-line connections, powertrain control sensors, etc. DO NOT over apply lubricant to the point where it prevents the full engagement of sealed connectors. A light coating on the terminal surfaces is sufficient to correct the condition. Supercede: This bulletin is being revised to update the Attention statement and add the 2011 model year. Please discard Corporate Bulletin Number 09-06-03-004C (Section 06 Engine/Propulsion System). Condition Some customers may comment on any of the following conditions: - An intermittent no crank/no start - Intermittent malfunction indicator lamp (MIL) illumination - Intermittent service lamp illumination - Intermittent service message(s) being displayed The technician may determine that he is unable to duplicate the intermittent condition. Cause This condition may be caused by a buildup of nonconductive insulating oxidized debris known as fretting corrosion, occurring between two electrical contact surfaces of the connection or connector. This may be caused by any of the following conditions: - Vibration - Thermal cycling - Poor connection/terminal retention - Micro motion - A connector, component or wiring harness not properly secured resulting in movement On low current signal circuits this condition may cause high resistance, resulting in intermittent connections. On high current power circuits this condition may cause permanent increases in the resistance and may cause a device to become inoperative. Representative List of Control Modules and Components The following is only a representative list of control modules and components that may be affected by this connection or connector condition and DOES NOT include every possible module or component for every vehicle. - Blower Control Module - Body Control Module (BCM) - Communication Interface Module (CIM) - Cooling Fan Control Module - Electronic Brake Control Module (EBCM) - Electronic Brake and Traction Control Module (EBTCM) - Electronic Suspension Control (ESC) Module - Engine Control Module (ECM) - Heating, Ventilation and Air Conditioning (HVAC) Control Module Page 4676 Control Module References Part 5 Page 13293 2. Connect the Techline Information System (TIS) terminal to the Tech2(R). 3. Scroll to the bottom of the Controller List, and select the "ONSA TIS2WEB Pass-Thru OnStar(R) Activation (Replaced/Upgraded Units Only)" option using the Service Programming System (SPS). Important: Do not use the clear DTC function. This will only temporarily turn the LED to green. 4. Upon completion of the OnStar(R) TIS2WEB step, disconnect the TIS terminal from the Tech2(R) and perform the VCIM/OnStar(R) Set-up Procedure using the Tech2(R). The set up procedure is located under the special function menu option. Important: Failure to perform the above steps will result in a red LED, DTC being set and limited or incomplete OnStar(R) services, and will require a customer return visit to the dealership. 5. The default language for the new VCIM will be English. To change to French or Spanish, access the special functions menu on the Tech 2(R), and follow the instructions accordingly. 7. Skip to the next step if the vehicle to be upgraded is not listed below: ^ 2002-2004 Cadillac DeVille ^ 2002-2004 Cadillac Seville ^ 2005 Cadillac STS Set up the Dash Integration Module (DIM) using the following procedure: 1. On the Tech2(R) select the correct Year, Make and Model. 2. Enter Dash Integration Module (DIM) > Special Functions > Set Options > Misc. Options 1 > and turn off phone (if the vehicle does not have the UV8 option). 3. Enter Nav Radio Present and set to "No Nav" (if the vehicle does not have a navigation radio). 4. Turn the ignition off and open the door to turn off the RAP. 5. Turn the ignition on and enter the Vehicle Comm. Interface Module > Special Functions > Set Up OnStar /VCIM. 6. When prompted select "No Phone" (if the vehicle does not have the UV8 phone) and "No Nav" (if the vehicle does not have a navigation radio). 7. Turn the ignition off and open the door to turn off the RAP. Important: OnStar(R) Emergency Services are immediately available after these steps, however, full configuration, including activation of Hands-Free Calling, may take up to 24 hours to complete. Processing the Module Exchange Processing the Module Exchange For this program, submitting a credit request for the removed OnStar(R) VCIM (the core) will be performed through a website. When this process is followed, the removed Analog / Digital-Ready VCIM, in most cases, will not be mailed back to the distributor, but can be scrapped by the dealership. U.S. Dealers 1. Return the removed Analog / Digital-Ready OnStar(R) VCIM to the Parts Manager. 2. The Parts Manager will log onto www.autocraft.com. 3. Select Account Maintenance. 4. Select Outstanding Cores. Page 3668 Radiator Hose: Service and Repair Radiator Vent Inlet Hose Replacement Radiator Vent Inlet Hose Replacement Removal Procedure 1. Drain the cooling system. 2. Reposition the vent inlet hose clamp from the radiator. 3. Remove the vent inlet hose from the radiator. 4. Reposition the vent inlet hose clamp from the surge tank. 5. Remove the vent inlet hose from the surge tank. Installation Procedure 1. Install the vent inlet hose to the surge tank. 2. Reposition the vent inlet hose clamp to the surge tank. 3. Install the vent inlet hose to the radiator. 4. Reposition the vent inlet hose clamp to the radiator. 5. Fill the cooling system. Page 10224 Electrical Symbols Part 9 Page 885 TOOLS REQUIRED J 34142-B 12 V Unpowered Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. When testing for voltage: 1. Attach 1 lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach 1 lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Using Connector Test Adapters USING CONNECTOR TEST ADAPTERS NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-B Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires USING FUSED JUMPER WIRES TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Connector Position Assurance Locks CONNECTOR POSITION ASSURANCE LOCKS The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Terminal Position Assurance Locks TERMINAL POSITION ASSURANCE LOCKS The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Push to Seat Connectors PUSH TO SEAT CONNECTORS TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Page 8774 Electrical Symbols Part 3 Page 15725 The 1999 though early 2003 wiring harness jumper that plugs into the relay block will have a reddish/brown 6-way connector and a tag with the last four digits of the wiring harness part number. Second design 2003-05 may have a white plastic connector with part number 5418 as well. ^ The 1999 jumper is/was P/N 12171982 with a pink/purple tag identifier of 1982. This number has been superseded to 15366255, with a pink/purple tag identifier of 6255. ^ The 2000 jumper harness is P/N 15366255. The pink/purple tag identifier is 6255. ^ The 2001-2002 jumper is P/N 15086884. The orange tag identifier is 6884. ^ The 2003-05 jumper is P/N 15085418. The orange tag identifier is 5418. When transferring the brake controller with the wiring jumper attached from a 2001-2002 vehicle to a 2003-05 vehicle, a change to the jumper harness connector must be performed. Page 5690 Vehicle Speed Sensor (VSS) Tow/Haul Switch Location Page 2062 Alignment: Service and Repair Measuring Wheel Alignment (W/Rear Wheel Steering) Measuring Wheel Alignment (w/Rear Wheel Steering) Learn Wheel Alignment After replacement of the handwheel position sensor, rear wheel position sensor, or rear wheel steering control module it is necessary to perform the learn wheel alignment procedure. Alignment Procedure Steering and vibration complaints are not always the result of improper alignment. One possible cause is wheel and tire imbalance. Another possibility is tire lead due to worn or improperly manufactured tires. Lead/pull is defined as follows: at a constant highway speed on a typical straight road, lead/pull is the amount of effort required at the steering wheel to maintain the vehicles straight path. Lead is the vehicle deviation from a straight path on a level road without pressure on the steering wheel. Refer to Radial Tire Lead/Pull Correction in Tires and Wheels in order to determine if the vehicle has a tire lead problem. Before performing any adjustment affecting wheel alignment, perform the following inspections and adjustments in order to ensure correct alignment readings: ^ Inspect the tires for the proper inflation and irregular tire wear. ^ Inspect the runout of the wheels and the tires. ^ Inspect the wheel bearings for backlash and excessive play. ^ Inspect the ball joints and tie rod ends for looseness or wear. ^ Inspect the control arms and stabilizer shaft for looseness or wear. ^ Inspect the steering gear for looseness at the frame. Refer to Fastener Tightening Specifications in Power Steering System. ^ Inspect the struts/shock absorbers for wear, leaks, and any noticeable noises. Refer to Struts or Shock Absorbers On-Vehicle Testing in Suspension General Diagnosis. ^ Inspect the vehicle trim height. Refer to Trim Height Inspection Procedure in Suspension General Diagnosis. ^ Inspect the steering wheel for excessive drag or poor return due to stiff or rusted linkage or suspension components. ^ Inspect the fuel level. The fuel tank should be full or the vehicle should have a compensating load added. Give consideration to excess loads, such as tool boxes, sample cases, etc. If normally carried in the vehicle, these items should remain in the vehicle during alignment adjustments. Give consideration also to the condition of the equipment being used for the alignment. Follow the equipment manufacturer's instructions. Satisfactory vehicle operation may occur over a wide range of alignment settings. However, if the setting exceeds the service allowable specifications, correct the alignment to the service preferred specifications. Refer to Wheel Alignment Specifications. Perform the following steps in order to measure the front and rear alignment angles: 1. Install the alignment equipment according to the manufacturer's instructions. 2. Jounce the front and the rear bumpers 3 times prior to checking the wheel alignment. 3. Measure the alignment angles and record the readings. 4. Important: When performing adjustments to vehicles requiring a 4-wheel alignment, set the rear wheel alignment angles first in order to obtain proper front alignment angles. Adjust alignment angles to vehicle specification, if necessary. Refer to Wheel Alignment Specifications then perform the learn alignment procedure. Learn Wheel Alignment Procedure 1. Turn ignition to ON position, with the engine ON. 2. Install the scan tool. 3. Center the steering wheel. 4. Lift the rear of the vehicle off the ground ensuring the rear wheels are centered. 5. Go to the Learn Alignment menu choice in the scan tool. Follow the prompts on the scan tool. Important: When prompted by the scan tool you must turn the steering wheel a full 90 degrees to the left and a full 90 degrees to the right and then to center and hold. If this step is not done properly then it is possible to cause a false DTC for the steering wheel position sensor. 6. Press the continue button. 7. Use the scan tool to clear all rear wheel steering DTCs. (W/O Rear Wheel Steering) Measuring Wheel Alignment (w/o Rear Wheel Steering) Emissions - MIL ON/DTC P0446 Stored In ECM Canister Purge Control Valve: All Technical Service Bulletins Emissions - MIL ON/DTC P0446 Stored In ECM TECHNICAL Bulletin No.: 02-06-04-037I Date: September 16, 2010 Subject: Check Engine Light On, Fuel Tank Hard to Fill, DTCs P0442, P0446, P0455 or P0449 Set (Replace Evaporative Emission (EVAP) Vent Valve Solenoid Assembly and Add/Relocate Filter Box Using Service Kit) Models: 1999-2007 Chevrolet Silverado (Classic) Models 1999-2007 GMC Sierra (Classic) Models 2007-2010 Chevrolet Silverado Models (Including Hybrid) 2007-2010 GMC Sierra Models (Including Hybrid) Supercede: This bulletin is being revised to add the 2010 model year and to include the Hybrid models. Please discard Corporate Bulletin Number 02-06-04-037H (Section 06 - Engine/Propulsion System). Condition Some customers may comment about the check engine light being illuminated. They may also comment that their vehicle is difficult to fill with fuel or when filling, the pump continuously shuts off before the tank is full. When checking the vehicle for DTCs, the ECM may report one or more of the following DTCs set as current or in history: P0442, P0446, P0449 or P0455. Cause The EVAP canister vent solenoid (CVS) valve draws fresh air into the system through a vent. Under certain operating conditions, dirt and dust intrusion into the EVAP CVS fresh air intake/venting system, may result in restricted air flow. Under certain operating conditions, water, if ingested into the EVAP CVS fresh air intake/venting system, may reach the CVS valve causing corrosion in the CVS valve, and may cause restrictions in the fresh air intake path, when the valve is in the closed position. Correction (1999-2007 Classic/Old Style Models) After following the published SI diagnostics and determining that the EVAP canister vent valve is the cause of the MIL light, replace the existing EVAP canister vent valve assembly with a new assembly. This new assembly is a sealed unit that is designed to be vented through a remote filter box. To ensure correct installation, follow the procedures below. Important DO NOT replace the EVAP canister assembly for this concern unless it fails the leak test. 1999-2003 Model Year (Use Service Kit P/N 19207762) 1. Raise the vehicle. Suitably support the vehicle. 2. Disconnect the EVAP canister vent valve electrical connector, if equipped. 3. Disengage the two vent valve pipe clips securing the pipe to the underbody. Remove the clips from the underbody and discard. 4. Disconnect the vent valve pipe at the EVAP canister. 5. Remove and retain the EVAP canister vent valve bracket mounting bolt. 6. Remove the complete EVAP canister vent valve assembly with bracket attached and discard. Page 10413 Do Not Replace coil-over shock absorbers displaying condition 1 or 2 levels of seepage. 1. Oil or fluid residue only on the bottom of the lower shock absorber tube or the coil-over shock absorber components and not originating from the shaft seal (located at the top of the coil-over shock tube). 2. Light film/residue on the shock absorber tube, but not on the spring seat and originating from the shaft seal. Replace coil-over shock absorbers displaying conditions 3 and 4 levels of leaks. 3. Oil drip or trail down the lower shock tube and originating from the shaft seal. 4. An extreme, wet film of oil covering the shock absorber tube and pooling in the spring seat and originating from the shaft seal. Struts Do Not Replace Struts displaying condition 1 or 2 levels of seepage. 1. Oil or fluid residue only on the bottom of the strut tube or on other strut components and not originating from the shaft seal. 2. Light film/residue on the strut tube, but not on the spring seat and originating from the shaft seal. Replace Struts displaying conditions 3 and 4 levels of leaks. 3. Oil drip or trail down the strut tube and originating from the shaft seal (located at the top of the strut tube). 4. Extreme wet film of oil covering the strut tube and pooling in the spring seat and originating from the shaft seal. Correction Use the information published in SI for diagnosis and repair. Use the applicable published labor operation. Disclaimer Page 9188 C148 Engine Harness To Coil Jumper Harness Page 3640 Tighten the screws to 2 N.m (18 lb in). 5. Install the HVAC module assembly. Page 3879 Page 4899 Vehicle Speed Sensor: Service and Repair Manual Transmission - ZF S6-650 Vehicle Speed Sensor (VSS) Replacement Removal Procedure 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. If equipped with the 6.6L engine, disconnect the vehicle speed sensor (VSS) electrical connector (4). 3. If equipped with the 8.1L engine, disconnect the VSS electrical connector (5). 4. Remove the VSS bolt, sensor and seal. Installation Procedure Page 8880 When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage TESTING FOR A SHORT TO VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity TESTING FOR CONTINUITY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents TESTING FOR ELECTRICAL INTERMITTENTS Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground - Testing for Continuity - Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 msRECORD and emits an audible tone (beep). Page 14126 Front Passenger Door Module (FPDM) - C5 (With RPO Code AN3) Part 2 Page 14322 Page 6869 - J 8608 Rear Pinion Bearing Race Installer - J 8614-01 Flange/Pulley Holding Tool Removal Procedure 1. Raise the vehicle. Refer to Vehicle Lifting. Important: Observe and mark the positions of all the driveline components, relative to the propeller shaft and the axles, prior to disassembly. These components include the propeller shafts, drive axles, pinion flanges, output shafts, etc. Reassemble all the components in the exact places in which you removed the parts. Follow any specifications, torque values, and any measurements made prior to disassembly. 2. Drain the axle lubricant. 3. Remove the axle shafts. 4. Reference mark the rear propeller shaft (3) to the rear axle pinion yoke (4). 5. Disconnect the propeller shaft from the axle. Wrap the bearing caps with tape in order to prevent the loss of bearing rollers. Support the propeller shaft as necessary. 6. Measure the amount of torque required to rotate the pinion and the ring gear. Use an inch-pound torque wrench. Record this measurement for reassembly. This will give the combined preload for the following components: ^ The pinion bearings ^ The pinion pilot bearing ^ The pinion oil seal ^ The differential case bearings 7. Place an alignment mark between the pinion and the pinion yoke. Procedures Power Door Lock Actuator: Procedures Lock Actuator Replacement - Front Door LOCK ACTUATOR REPLACEMENT - FRONT DOOR REMOVAL PROCEDURE 1. Raise the window glass. 2. Remove the door trim panel. 3. Remove the water deflector. 4. Disconnect the inside door lock rod from the handle retainer clip. 5. Disconnect the manual door lock rod from the door retainer clips. Page 7054 Drive/Propeller Shaft: Service and Repair Propeller Shaft Replacement - Front Propeller Shaft Replacement - Front ^ Tools Required J 43218 Clamp Pliers - Narrow Jaw Removal Procedure Important: Before disassembly, observe and accurately reference mark all driveline components relative to the propeller shaft and axles. These items include the following components: ^ The propeller shafts ^ The wheel drive shafts ^ The pinion flanges ^ The output shafts Assemble all components in the exact relationship to each other as they were prior to removal. Observe all published specifications and torque values, and any measurements obtained prior to disassembly. 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Remove the transfer case shield, if equipped. 3. Remove the rear propeller shaft boot clamp (4) by prying up the exposed end of the clamp with a flat-bladed tool. 4. Reference mark the relationship of the propeller shaft to the front axle pinion yoke. Specifications Wheel Bearing: Specifications Front Hub and Bearing Assembly to Steering Knuckle Bolts ............................................................................................................... 180 Nm (133 ft. lbs.) Page 4896 1. Coat a NEW O-ring seal with a thin film of Synchro-mesh transmission fluid GM P/N 12345349 (Canadian P/N 10953465), or equivalent. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the VSS and O-ring seal. ^ Tighten the VSS to 16 Nm (12 ft. lbs.). 3. Connect the VSS electrical connector (1). 4. Lower the vehicle. Page 9153 You MUST use a silver-bearing solder to make the solder joint. DO NOT attempt this repair with conventional tin/lead alloy solders. Most suppliers have this type of solder available and it is available nationally at Radio Shack(R)*. It is sold in several diameters and either are acceptable for this repair. 5. For this step, it is permitted that two technicians be used if required. Heat the new connector on the surface of the buss bar that is to be soldered. Long nose pliers are suggested to hold the electrical connector and the defroster tab in place. Keep the solder ready and begin flowing out the solder as soon as the melting temperature has been reached. Tip If a single technician is attempting this repair, it is beneficial to wrap one turn of the solder around the new contacts base. In this manner, as the melting point of the solder is reached, a layer is deposited on the bottom side of the contact. Important Try to align the new contact so that it is positioned with the same orientation as the original contact. 6. The above illustrates an ideal finished solder joint. Additional stray solder will not harm the performance of the bond; however, while it is unlikely that customers may refer to the appearance of the rear window defroster and its components as a positive styling feature of the vehicle interior, it is easy to elicit the opposite reaction due to a poor cosmetic application. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Parts Information Acrysol(TM) can be ordered directly from Kent Automotive at 1-800-654-6333 (in Canada, 1-800-563-1717). Radio Shack(R) products can be found nationally at retail locations, www.radioshack.com, or at 1-800-843-7422. All other parts can be ordered through GMSPO or SSPO. Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use: Warranty Information (Saab U.S. Models) Page 15556 Backup Lamp Switch: Service and Repair NV 4500 Backup Lamp Switch Replacement Removal Procedure 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. Disconnect the backup lamp switch electrical connector (1). 3. Remove the backup lamp switch and seal. Installation Procedure 1. Ensure the seal is installed on the switch. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the backup lamp switch. ^ Tighten the switch to 28 Nm (21 ft. lbs.). Page 2473 14. Important: It is not necessary to remove the selector cable from the bracket. Remove the transmission range selector cable bracket (2) bolts and bracket from the transmission. Reposition the bracket with cable. 15. Remove the oil pan bolts. 16. Important: The transmission oil pan gasket is reusable. Inspect the gasket and replace as needed. Remove the oil pan and gasket. 17. Remove the magnet from the bottom of the pan, if necessary. 18. Remove the oil filter. 19. Remove the filter neck seal. 20. Clean the transmission case and the oil pan gasket surfaces with solvent. Installation Procedure Page 2330 Power Steering Line/Hose: Service and Repair Power Brake Booster Inlet Hose Replacement Power Brake Booster Inlet Hose Replacement Removal Procedure 1. Notice: Refer to Power Steering Hose Disconnected Notice in Service Precautions. Install a drain pan under the vehicle. 2. Remove the brake booster inlet hose (1) from the brake booster (2). 3. Remove the brake booster inlet hose from the power steering pump. 4. Remove the brake booster inlet hose from the vehicle. Installation Procedure 1. Notice: Refer to Installing Hoses Without Twists or Bends Notice in Service Precautions. Route the hose in the same position the hose occupied prior to removal. 2. Install the brake booster inlet hose (1) to the brake booster (2). Hand tighten only. 3. Notice: Refer to Fastener Notice in Service Precautions. Install the brake booster inlet hose to the power steering pump. ^ Tighten the brake booster inlet hose fittings to 28 Nm (20 ft. lbs.). 4. Remove the drain pan from under the vehicle. 5. Bleed the power steering system. Refer to Bleeding the Power Steering System. Page 10920 Control Module References Part 1 Page 7770 Transfer Case Actuator: Service and Repair Transfer Case Encoder Motor Replacement Removal Procedure 1. Remove the transfer case shield, if equipped. 2. Remove the front propeller shaft. 3. Disconnect the encoder motor electrical connector. 4. Remove the encoder motor bolts. 5. Remove the encoder motor. 6. Remove the actuator insulator gasket. 7. If replacing the encoder motor, remove the locating pins from the old motor. Installation Procedure Important: ^ If the encoder motor is being replaced because it is defective, ensure that the transfer case is in the neutral position. Manually shift the unit at the shift shaft. Use a crescent wrench, if necessary. ^ If the encoder motor is being replaced, a new gasket will come with the encoder motor. DO NOT reuse the old gasket. ^ A NEW encoder motor does NOT come with locating pins. Page 1185 4. Press the button a second time, 2 light bars will glow indicating the MEDIUM temperature setting for the entire seat. 5. Press the button a third time, 1 light bar will glow indicating the LOW temperature setting for the entire seat. 6. Press the button a fourth time to turn the entire heated seat OFF. 7. To heat ONLY the seat back, press the vertical (LH) button one time. ^ An ON/OFF indicator light over the heated seat back symbol will glow to designate that ONLY the seat back is being heated. ^ All 3 light bars over the horizontal (RH) button will glow indicating the HIGH temperature setting for ONLY the seat back. 8. Press the button a second time, 2 light bars will glow indicating the MEDIUM temperature setting for ONLY the seat back. 9. Press the button a third time, 1 light bar will glow indicating the LOW temperature setting for ONLY the seat back. 10. Press the button a fourth time to turn the heated seat back OFF. Switch Diagnostics Important: In order to eliminate unnecessary part replacement and comeback repairs, it is essential that the appropriate diagnostic tables and aids found in the applicable manuals are followed. 1. Verify the condition prior to making any repairs. Refer to Seats and Seat Controls in the applicable Owners Manual or this bulletin for proper heated seat switch operation information. 2. If an improperly operating front heated seat condition exists, refer to the Diagnostic Information and Procedures in the Seats sub-section of the applicable Service Manual in order to diagnose the system accurately. 3. When measuring the resistance of the seat heater elements, ensure the values are within the updated range of 1.5-5.5 ohms. Refer to DTC B2425 or B2430-Clearing the DTC in the Diagnostic Information and Procedures in the Seats sub-section of the applicable Service Manual. Customer Information Some heated seat components from the above listed vehicles have been returned to the Warranty Parts Center (WPC) for heat function not operating properly. Analyses of these parts show 'no out of specification condition' or No Trouble Found (NTF). 1. Provide customers with the knowledge that if bumped, either one of the heated seat switches can be activated/deactivated accidentally. 2. Ensure customers have a thorough understanding of how the heated seat switches function. Disclaimer Page 13512 Electrical Symbols Part 2 Page 6085 6. Install the J 29714-A. 7. Compress the servo cover with J 29714-A. Important: Flat-faced servo cover retaining rings that have been removed when servicing a transmission for any reason should not be re-used. 8. Remove the servo cover retaining ring. 9. Install the new round wire servo cover ring, P/N 24232065. 10. Remove J 29714-A. 11. Clean the servo cover area with Brake Clean and shop air. 12. Lower the vehicle. 13. Fill the transmission to the proper level with DEXRON(R)III transmission fluid. Refer to the appropriate SI Document. Parts Information Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use the table. Page 11841 Keyless Entry Receiver: Service and Repair REMOTE CONTROL DOOR LOCK RECEIVER REPLACEMENT The remote control door lock module is incorporated into the passenger side window switch module. Page 2416 10. Place the J 9522-3 on the open horizontal bearing cups. Press the lower bearing cup out of the yoke ear. 11. If you do not completely remove the bearing cup, lift the cross and insert the J 9522-5 between the seal and the bearing cup you are removing. Continue pressing the bearing cup out of the yoke. 12. Rotate the propeller shaft. Press the opposite bearing cup out of the drive shaft yoke. 13. Remove the old slip yoke and universal joint. 14. Inspect the retaining ring grooves for dirt, corrosion, or pieces of the old ring. 15. Inspect the bearing cup bores for burrs or imperfections. 16. Clean the retaining ring grooves. Corrosion, dirt, rust, or pieces of the old retaining ring may prevent the bearing cups from pressing into place or prevent the bearing retainers from properly seating. 17. Install the new nickel-plated slip yoke and universal joint. See parts table below for parts information. 18. Remove the bearing cups from the universal joint. 19. Assemble one bearing cup part way into one side of the yoke. Turn the yoke ear toward the bottom. 20. Assemble the cross into the yoke so that the trunnion seats freely into the bearing cup. Page 599 Memory Seat Module - C3 Part 3 Page 9568 Fuse Block- I/P C1 Part 2 Page 7240 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. REPLACEMENT PROCEDURE After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Insure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the Terminal Removal Procedure. Repairing Connector Terminals REPAIRING CONNECTOR TERMINALS TOOLS REQUIRED J 38125-D Terminal Repair Kit Use the following repair procedures in order to repair the following: - Push to Seat terminals - Pull to Seat terminals - Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-D contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100 World terminals. Soldering Micro-Pack 100 World terminals may damage the terminal. Circuit Protection - Circuit Breakers CIRCUIT PROTECTION - CIRCUIT BREAKERS A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Page 7805 Park Neutral Position (PNP) Switch C175 Page 7377 Vehicle Speed Sensor (VSS) Tow/Haul Switch Location Page 7647 4. Inspect the rear output shaft bushing for scoring or wear. 5. Remove the rear output shaft bushing if required, using the J 45380. ^ Install the finger section of the J 45380 into the front of the bushing. ^ Install the tube and forcing screw to the finger section. Ensure the forcing screw is backed out. ^ Using a wrench on the forcing screw, remove the rear output shaft bushing. Installation Procedure 1. Using the J 45380, install a NEW rear output shaft bushing. ^ Install the bushing or the finger section of the J 45380. ^ Install the finger section to the main body of the J 45380. ^ Position the bushing and tool to the case. ^ Using a hammer and the J 45380, install the bushing. Page 15179 Control Module References Part 1 Page 7728 2. Connect the speed sensor electrical connector. 3. Lower the vehicle. Page 13644 4. Drill 3 mm (1/8 inch) pilot hole at each center punch location. 5. Using pilot hole as guide, drill a 115 mm (29/64 inch) hole through hinge pillar at stud locations. Must be exact drill size (Fig.1.14). 6. Clean and prepare all bare metal surfaces. IMPORTANT: Prior to refinishing, refer to GM P/N 4901.M-D Refinish Manual for recommended products. 7. Apply approved anti-corrosion primer. 8. Feed fish wire (such as GM part #15017229) through hinge stud hole and out conduit hole in the pillar (Fig.1.15). 9. Install stud (part #15017230) supplied with service hinge into wire end and pull the stud into position. Draw the studs tight through the pillar using nuts (part #11516746) supplied. Remove each service nut. 10. Apply a full-bodied caulk to the entire hinge mounting surface to ensure a proper seal. Page 2665 Fuse Block- I/P C1 Part 6 Page 12453 1. To receive credit, submit a claim with the information above. Disclaimer 2001 and Older Model Year Vehicles (Except Saab Vehicles) 2001 and Older Model Year Vehicles (Except Saab Vehicles) Important: 2001 and older model year vehicles require the removal of the battery power from the OnStar(R) vehicle interface unit (VIU) to eliminate the possibility of an inadvertent OnStar(R) or emergency/airbag call. 1. Locate and gain access to the OnStar® VIU. Refer to OnStar Vehicle Interface Unit Replacement in SI. Important: Complete removal of the VIU is usually not required. Perform only the steps required to gain access to the C2 32-way blue connector. Residing in the C2 connector are the battery positive (+) circuits. Removal of the C2 connector will deactivate the unit and eliminate the possibility of an inadvertent OnStar(R) or emergency/airbag call. Page 16170 Control Module References Part 4 Page 6529 2. Hook one of the open ends of the retaining ring in one of the slots in the quick connect fitting. 3. Rotate the retaining ring around the fitting until the retaining ring is positioned with all three ears through the three slots on the fitting. 4. Do not install the new retaining ring onto the fitting by pushing the retaining ring. 5. Ensure that the three retaining ring ears are seen from inside the fitting and that the retaining ring moves freely in the fitting slots. Service and Repair Window Handle: Service and Repair Window Handle Replacement Tools Required J 9886-01 Door Handle Clip Remover Removal Procedure 1. Open the door. 2. Remove the window crank handle using the J 9886-01. Be sure to retain the retainer clip on the back side of the handle. Installation Procedure 1. Install the window crank handle by pushing the handle into place. Ensure that the retainer engages. 2. Inspect the operation. Page 10236 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground TESTING FOR SHORT TO GROUND NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting With A Digital Multimeter TROUBLESHOOTING WITH A DIGITAL MULTIMETER NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TROUBLESHOOTING WITH A TEST LAMP Page 8936 Page 9733 C206 I/P Harness To Body Harness (With RPO Codes Y91/HP2) Part 2 Body - Vehicle Glass Distortion Information Back Window Glass: All Technical Service Bulletins Body - Vehicle Glass Distortion Information INFORMATION Bulletin No.: 00-08-48-005D Date: September 10, 2010 Subject: Distortion in Outer Surface of Vehicle Glass Models: 2011 and Prior GM Passenger Cars and Trucks 2009 and Prior HUMMER H2 2010 and Prior HUMMER H3 2005-2009 Saab 9-7X 2010 and Prior Saturn Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 00-08-48-005C (Section 08 - Body and Accessories). Distortion in the outer surface of the windshield glass, door glass or backlite glass may appear after the vehicle has: - Accumulated some mileage. - Been frequently washed in automatic car washes, particularly "touchless" car washes. This distortion may look like a subtle orange peel pattern, or may look like a drip or sag etched into the surface of the glass. Some car wash solutions contain a buffered solution of hydrofluoric acid which is used to clean the glass. This should not cause a problem if used in the correct concentration. However, if not used correctly, hydrofluoric acid will attack the glass, and over time, will cause visual distortion in the outer surface of the glass which cannot be removed by scraping or polishing. If this condition is suspected, look at the area of the windshield under the wipers or below the belt seal on the side glass. The area of the glass below the wipers or belt seal will not be affected and what looks like a drip or sag may be apparent at the edge of the wiper or belt seal. You may also see a line on the glass where the wiper blade or the belt seal contacts the glass. Important The repair will require replacing the affected glass and is not a result of a defect in material or workmanship. Therefore, is not covered by New Vehicle Warranty. Disclaimer Procedures Power Seat Switch: Procedures Lumbar Switch Replacement LUMBAR SWITCH REPLACEMENT REMOVAL PROCEDURE 1. Remove the power seat switch bezel containing the lumbar switch (1) from the seat. 2. Remove the lumbar switch screws from the power seat switch bezel. 3. Remove the lumbar switch. INSTALLATION PROCEDURE 1. Install the lumbar switch to the power seat switch bezel. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the lumbar switch screws. Tighten Tighten the screws to 2 N.m (18 lb in). 3. Install the power seat switch bezel (1) to the seat. Seat Switch Bezel Replacement SEAT SWITCH BEZEL REPLACEMENT REMOVAL PROCEDURE Page 12197 Models The service procedure in this bulletin has been revised. Step 11 in the procedure for the 2004-2005 Saab 9-3 (9440) Convertible has been revised. Discard all copies of bulletin 08089B, issued September 2008. Condition In November 2002, the U.S. Federal Commissions (FCC) ruled that wireless carriers would no longer be required to support the analog wireless network beginning in 2008. As a result, On Star(R) is unable to continue analog service. OnStar(R) has deactivated most of the systems operating in the analog mode; however, there are some vehicles that OnStar(R) could not deactivate. Although the analog OnStar(R) hardware in these vehicles can no longer communicate with OnStar(R), the hardware in the vehicle is still active. If the OnStar(R) emergency button is pressed, or in the case of an airbag deployment, or near deployment, the customer may hear a recording that OnStar(R) is being contacted. However, since analog service is no longer available, the call will not connect to OnStar(R). To end the call, the customer must press the white phone or white dot button. If the call is not ended, the system will continue to try to connect to OnStar(R) until the vehicle battery is drained. Special Policy Adjustment At the customer's request, dealers/retailers are to deactivate the OnStar(R) system. The service will be made at no charge to the customer. This special coverage covers the condition described above until December 31, 2008 for all non-Saab vehicles; April 30, 2009 for all Saab vehicles. Vehicles Involved Tires/Wheels - Tire Slowly Goes Flat/Warning Light ON Wheels: All Technical Service Bulletins Tires/Wheels - Tire Slowly Goes Flat/Warning Light ON TECHNICAL Bulletin No.: 08-03-10-006C Date: April 27, 2010 Subject: Tire Slowly Goes Flat, Tire Air Loss, Low Tire Pressure Warning Light Illuminated, Aluminum Wheel Bead Seat Corrosion (Clean and Resurface Wheel Bead Seat) Models: 2000-2011 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2009 HUMMER H2 2006-2010 HUMMER H3 2005-2009 Saab 9-7X Supercede: This bulletin is being revised to update the model years. Please discard Corporate Bulletin Number 08-03-10-006B (Section 03 - Suspension). Condition Some customers may comment on a tire that slowly loses air pressure over a period of days or weeks. Cause Abrasive elements in the environment may intrude between the tire and wheel at the bead seat. There is always some relative motion between the tire and wheel (when the vehicle is driven) and this motion may cause the abrasive particles to wear the wheel and tire materials. As the wear continues, there may also be intrusion at the tire/wheel interface by corrosive media from the environment. Eventually a path for air develops and a 'slow' leak may ensue. This corrosion may appear on the inboard or outboard bead seating surface of the wheel. This corrosion will not be visible until the tire is dismounted from the wheel. Notice This bulletin specifically addresses issues related to wheel bead seat corrosion that may result in an air leak. For issues related to porosity of the wheel casting that may result in an air leak, please refer to Corporate Bulletin Number 05-03-10-006F - Low Tire Pressure, Leaking Cast Aluminum Wheels (Repair with Adhesive Sealant) Correction In most cases, this type of air loss can be corrected by following the procedure below. Important DO NOT replace a wheel for slow air loss unless you have evaluated and/or tried to repair the wheel with the procedure below. Notice The repair is no longer advised or applicable for chromed aluminum wheels. 1. Remove the wheel and tire assembly for diagnosis. Refer to Tire and Wheel Removal and Installation in SI. 2. After a water dunk tank leak test, if you determine the source of the air leak to be around the bead seat of the wheel, dismount the tire to examine the bead seat. Shown below is a typical area of bead seat corrosion.Typical Location of Bead Seat Corrosion Page 8508 Page 14572 Memory/Heated Seat Switch - Driver (DDM C5) Part 2 Page 2561 perform the following steps: 1. Inspect the brake system for external leaks. 2. Pressure bleed the hydraulic brake system in order to purge any air that may still be trapped in the system. 22. Turn the ignition key ON, with the engine OFF. Check to see if the brake system warning lamp remains illuminated. 23. Important: If the brake system warning lamp remains illuminated, DO NOT allow the vehicle to be driven until it is diagnosed and repaired. If the brake system warning lamp remains illuminated, refer to Symptoms - Hydraulic Brakes. Page 13950 1. Press in the side grille retainers (1) into the fender (2). 2. Press the upper grille retainer (1) and lower grille retainer (2) to the vehicle. 3. Install the headlamp. 4. Install the upper air baffle. 5. Close the hood. Page 9855 4. Push on the top part until it clicks in place. 5. Connect the harness to the front of the junction block. 6. Install the cover to the junction block until it clicks in place. 7. Hand tighten the retaining nut until seated. Engine Controls - MIL ON/Rough Idle/Misfire/DTC's Set Oxygen Sensor: Customer Interest Engine Controls - MIL ON/Rough Idle/Misfire/DTC's Set Bulletin No.: 05-06-04-063 Date: October 12, 2005 TECHNICAL Subject: LM7, L59 or L33 Engines with Cold Start Rough or Incorrect Idle, Misfire, Malfunction Indicator Lamp (MIL) or Flashing Requiring 02 Sensor Replacement (Reprogram PCM) Models: 2004-2005 Cadillac Escalade 2004-2005 Chevrolet Avalanche, Silverado 1500, Suburban, Tahoe 2005 Chevrolet Silverado Hybrid (HP2) 2004-2005 GMC Sierra 1500, Yukon, Yukon XL 2005 GMC Sierra Hybrid (PH2) with Vortec 5300 5.3L V-8 Engine (VINs T, Z, B - RPOs LM7, L59, L33) Condition Some customers may comment on a Malfunction Indicator Lamp (MIL) On or that the MIL is flashing. An actual engine misfire may or may not be felt along with an incorrect idle speed. Typically this occurs during cold winter months, on cold engine starts. Some vehicles may have been previously serviced for the same condition. Technicians may also find the following DTCs stored with the Tech 2(R) P0131, P0133, P0134, P0137, P0138, P0140, P0151, P0153, P0154, P0157, P1133, which may be in conjunction with P0171, P0174, P0300 and P1138. Cause Water shock occurs when water droplets are present in the exhaust. The water in the exhaust contacts the sensor element inside the H02 sensor, causing the H02 sensor element to crack. Correction Upon diagnostic investigation, the technician may find that the H02 sensor requires replacement. In addition to replacing the affected H02 sensor, these vehicles should also be reflashed with the latest PCM calibration. An updated PCM calibration will be available to dealerships as part of TIS 2000 incremental satellite update 11.0 (NAO version 25.010) or greater. Always, make sure your Tech 2 is updated with the latest software version. Important: If a DTC P0420 or P0430 is stored along with DTC(s) P0300, the catalytic converter diagnostics in Service Information (SI) must be followed to determine if the catalytic converters are operating properly. Warranty Information For vehicles repaired under warranty, use the table. Page 1325 Air Temperature Sensor - Lower Left Page 11388 Low Pressure Sensor / Switch: Description and Operation A/C LOW PRESSURE SWITCH The A/C low pressure switch protects the A/C system from a low pressure condition that could damage the A/C compressor or cause evaporator icing. The HVAC control module applies 5 volts to the A/C low pressure switch signal circuit. The switch will open when the A/C low side pressure reaches 165-200 kPa (24-29 psi). This prevents the A/C compressor from operating. The switch will then close when A/C low pressure side reaches 275-310 kPa (40-45 psi). This enables the A/C compressor to turn back ON. The low pressure switch uses refrigerant pressure to open and close a set of electrical contacts. When A/C request is authorized, the switch is closed and shows normal status. During this state, the switch will show 0 volts on the A/C low pressure sensor signal circuit. When A/C request is denied due to a low pressure condition, the switch will be open. During this state, the switch will show 5 volts on the A/C low pressure sensor signal circuit. Page 15557 3. Connect the backup lamp switch electrical connector (1). 4. Lower the vehicle. Page 4072 Disclaimer Page 3783 Electrical Symbols Part 11 Description and Operation Pedal Positioning Switch: Description and Operation Brake Pedal Position Sensor Calibration Description and Operation Calibration Criteria The brake pedal position (BPP) sensor receives a low reference signal and a 5-volt reference signal from the electro-hydraulic power steering (EHPS). Whenever the brake pedal is applied, the brake pedal position sensor applies a variable voltage signal to the EHPS through the BPP sensor signal circuit. Brake pedal position sensor calibration must be performed after the brake pedal position sensor or EHPS system have been serviced. The calibration procedure will set brake pedal position sensor home value. This value is used by the EHPS to determine the brake pedal position and the brake pedal rate. These two outputs are provided to the hybrid control module (HCM) via GMLAN. Calibration Procedure 1. Install a scan tool. 2. Turn ON the ignition, with the engine OFF. 3. Important: Make sure the brake pedal is not depressed before sending BPP sensor calibration command. Navigate to the Special Functions screen on the scan tool and select BPP Sensor Calibration in order to perform the brake pedal position sensor calibration. OnStar(R) - System Inoperative/No LED Lamp ON Fuse: All Technical Service Bulletins OnStar(R) - System Inoperative/No LED Lamp ON Bulletin No.: 04-08-46-005 Date: December 21, 2004 TECHNICAL Subject: OnStar(R) Generation 6 (Digital) System Inoperative/Has No Power, LED Light Not On (Remove/Reinstall OnStar(R) Fuse and Replace VCIM or Follow SI Diagnostics) Models: 2004-2005 Buick Rainier, Rendezvous 2005 Buick Allure (Canada), LaCrosse, LeSabre, Terrazza 2004-2005 Cadillac Escalade, Escalade ESV, Escalade EXT 2005 Cadillac CTS, DeVille 2004-2005 Chevrolet Avalanche, Silverado, Suburban, Tahoe, TrailBlazer, TrailBlazer EXT 2005 Chevrolet Colorado, Express, Impala, Monte Carlo, Uplander 2004-2005 GMC Denali, Denali XL, Envoy, Envoy XL, Envoy XUV, Sierra, Yukon, Yukon XL 2005 GMC Canyon, Savana 2004-2005 Pontiac Aztek 2005 Pontiac Bonneville, Grand Prix, Montana SV6, Vibe with Digital Gen 6 OnStar(R) (RPO UE1) Condition Some customers may comment any or all of the following conditions: ^ The OnStar(R) system may be inoperative. ^ The OnStar(R) system may have no power. ^ The OnStar(R) LED light may not be on. The technician may also not be able to communicate with the OnStar(R) Vehicle Communication Interface Module VCIM) with a Tech 2(R). Correction Remove the OnStar(R) fuse from the fuse box, wait five minutes and reinstall the fuse. If the OnStar(R) system DOES NOT return to normal functionality, then follow the diagnostics in SI for this condition. If the OnStar(R) system DOES return to normal functionality, you will need to replace the VCIM. If the VCIM is not replaced, there is the possibility that the customer will return to the dealership with the same conditions at a later date. Please contact the GM Technical Assistance Center (TAC), to obtain a new VCIM. The TAC consultant will verify your diagnosis and, if appropriate, order a replacement part. Replacement parts are usually shipped out within 24 hours, and a pre-paid return package label will be included for returning the faulty part. By returning the faulty part, you will avoid a significant non-return core charge. After the VCIM has been replaced, press the blue OnStar(R) button and request a full reconfiguration. When contacting TAC regarding this concern, the availability of certain information from the vehicle will streamline the process for the dealership technician as well as minimize the time necessary for TAC to provide the correct diagnosis. Please refer to Corporate Bulletin Number 01-00-89-011B for further information concerning the information necessary before contacting TAC. Dealers in Canada should refer to GM Service Policies & Procedures Section 5.3.1 "DEALER REQUIREMENTS FOR ASSISTANCE". Warranty Information Page 1001 Steps 7 - 9 Page 10704 Wheel Bearing: Adjustments Rear Wheel Bearing Adjustment (With Full Floating 10.5" or 11.5" Ring Gear) IMPORTANT: Ensure the brakes are fully released and do not drag. ^ Pull or push the tire at the top back and forth in order to test the wheel bearing play. ^ Use a pry bar under the tire as an alternative. ^ If the wheel bearing adjustment is correct, the movement will be barely noticeable. ^ If the movement is excessive, adjust the bearings. Adjustment Procedure Tools Required J 2222-C Wheel Bearing Nut Wrench 1. Raise the vehicle. 2. Remove the axle shaft. 3. Remove the hub adjuster nut retaining ring. 4. Remove the adjuster nut lock key. Page 15161 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the cover up until the dress cover releases. Repeat this procedure for the other locking tab. 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. 5. If the connector has a nose piece, use a small flat-blade tool to remove the nose piece by inserting the blade into the slot on the front of the connector and prying up on the nose piece. IMPORTANT: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 6. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. IMPORTANT: Be careful not to angle or rock the J 38125-13A tool when inserting it into the connector or the tool may break. Page 13525 High Temperature Conditions Tools Required J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency MEASURING FREQUENCY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage MEASURING VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop MEASURING VOLTAGE DROP NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Page 3031 Balancing of the tire and wheel assembly must be performed on a computerized balancer, capable of static and dynamic wheel balance modes. Assemblies should be balanced to within 1/4 ounce on either rim flange. Proper cones and adapters should be used, free of nicks and burrs to ensure proper balancing. Center Cap Install the center cap onto the wheel after the tire has been mounted and balanced, but BEFORE the assembly is installed onto the vehicle. The preferred method for center cap installation is to push in by hand. As an alternate, use a nonmetallic object to push the center cap into place. Attempting to "hammer-on" the caps may result in damage to the cap. Wheel (Lug) Nuts ALUMINUM WHEELS REQUIRE SPECIAL WHEEL NUTS. Each wheel nut should be torqued in the appropriate torque sequence (refer to graphic) and to 190 N.m (140 lb ft). The torque should be re-checked after the first 160 km (100 mi). To help protect the wheels from theft, a wheel lock kit is also available. Incorrect wheel nuts or improperly tightened wheel nuts can cause the wheel to become loose and even come off. This could lead to an accident. Be sure to use the correct wheel nuts. Wheel Nut Caps Install the wheel nut caps after tightening the wheel nuts. Install the wheel nut caps finger tight, plus 1/2 turn. Jounce Bumper This modification is required on all 2WD vehicles EXCEPT the following: Excludes: 2006-2007 2WD Extended Cab - Short Box (model C15553) 2006-2007 2WD Crew Cab - Short Box with Enhanced Trailering (RPO NHT) (model C15543) 2006-2007 2WD Extended Cab - Standard Box with Enhanced Trailering (RPO NHT) (model C15753) It will be required to replace the existing front suspension spring/jounce bumper with Jounce Bumper kit, P/N 12499481. The following procedure should be followed: Raise and support the vehicle. Remove the nut from the spring bumper stud. Remove the spring bumper. Page 11466 Clockspring Assembly / Spiral Cable: Service and Repair INFLATABLE RESTRAINT STEERING WHEEL MODULE COIL REPLACEMENT REMOVAL PROCEDURE CAUTION: Refer to SIR Caution in Service Precautions. 1. Disable the SIR system. Refer to SIR Disabling and Enabling Zone 3. 2. Remove the steering column trim covers. 3. Remove the wire harness assembly (4) from the wire harness strap (5). 4. Remove the 2 wire harness straps (3) from the wire harness assembly. 5. Remove the wire harness strap (2) from the upper tilt head assembly (1). 6. Remove the retaining ring (1). 7. Remove the SIR coil (2). 8. Remove the wave washer (3) from the steering column upper shaft. INSTALLATION PROCEDURE Page 8883 TOOLS REQUIRED J 34142-B 12 V Unpowered Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. When testing for voltage: 1. Attach 1 lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach 1 lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Using Connector Test Adapters USING CONNECTOR TEST ADAPTERS NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-B Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires USING FUSED JUMPER WIRES TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Connector Position Assurance Locks CONNECTOR POSITION ASSURANCE LOCKS The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Terminal Position Assurance Locks TERMINAL POSITION ASSURANCE LOCKS The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Push to Seat Connectors PUSH TO SEAT CONNECTORS TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Page 12919 Audio Amplifier C1 - With RPO Code UQ7,Y91 - Part 3 Service and Repair Oil Pressure Sensor: Service and Repair Engine Oil Pressure Sensor and/or Switch Replacement ^ Tools Required J 41712 Oil Pressure Switch Socket Removal Procedure 1. If necessary, remove the engine sight shield. 2. Disconnect the oil pressure sensor electrical connector (1). 3. Using J 41712 or equivalent, remove the oil pressure sensor. Installation Procedure Page 4428 PCM Location Page 15967 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves SPLICING COPPER WIRE USING SPLICE SLEEVES TOOLS REQUIRED J 38125-D Terminal Repair Kit IMPORTANT: Use only GM splice sleeves, other splice sleeves may not protect the splice from moisture or a provide good electrical connection. Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. Page 12545 Page 728 - Proof of ownership at time of repair. - Original paid receipt confirming the amount of unreimbursed repair expense(s) (including Service Contract deductibles), a description of the repair, and the person or entity performing the repair. If the work was done by someone other than a GM dealership, the amount of reimbursement will be limited to the amount that the repair would have cost GM to have it completed by a GM dealership. Courtesy Transportation The General Motors Courtesy Transportation program is intended to minimize customer inconvenience when a vehicle requires a repair that is covered by the New Vehicle Limited Warranties. The availability of courtesy transportation to customers whose vehicles are within the warranty coverage period and involved in a product program is very important in maintaining customer satisfaction. Dealers are to ensure that these customers understand that shuttle service or some other form of courtesy transportation is available and will be provided at no charge. Dealers should refer to the General Motors Service Policies and Procedures Manual for Courtesy Transportation guidelines. Warranty Transaction Information Submit a transaction using the table below. * The amount identified in "Net Item" should represent the dollar amount reimbursed to the customer. Disclaimer Page 7899 Page 13737 Rear Door Window Glass Weatherstrip: Service and Repair Door Window Sealing Strip Sealing Strip Replacement - Rear Door Window Belt Outer Removal Procedure Important: The outer belt sealing strip seals between the inner and outer door panels and the window at the belt line. The outer sealing strip is replaceable. Do not remove the inner sealing strip, because the strip is attached to the glass run channel. 1. Lower the window. 2. Remove the outer sealing strip from the door. Installation Procedure 1. Align the sealing strip in place. Lower and press the strip into place. 2. Raise the window. Page 15956 Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. 1. Disconnect the connector from the component. 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. Page 11218 Disclaimer Locations Lower Left Of The I/P Service and Repair Thermostat Housing: Service and Repair Thermostat Housing Replacement (4.8L, 5.3L, and 6.0L Engines) Removal Procedure Important: The thermostat is not serviceable separately. The water pump inlet and thermostat must be replaced as an assembly. 1. Remove the radiator outlet hose. 2. Remove the water pump inlet bolts. 3. Remove the water pump inlet and thermostat from the water pump. Installation Procedure 1. Install the thermostat and thermostat housing to the water pump. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the thermostat housing bolts. Tighten the bolts to 15 Nm (11 ft. lbs.). 3. Install the radiator outlet hose. Page 12025 4.2. Release the back end of the connector (C) and remove from the contact rail (D). 4.3. M00-01: Disconnect pin 39, cut off the cable terminal and insulate the end using tape (E). Fold back the cable and secure using tape (F). 4.4. M02-04: Disconnect pin 58, cut off the cable terminal and insulate the end using tape (E). Fold back the cable and secure using tape (F). 4.5. Assemble the contact rail and end. 4.6. Connect connector (A) and secure the cable using a cable tie (B). 5. Assemble the gear shift housing (A). AUT: Connect connector (B). 6. Assemble the center console, see WIS - Body - Interior. 7. Remove the OnStar(R) control module and secure the cable harness: 7.1. 5D: Remove the right-hand cover from the luggage compartment floor. Page 16021 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors USING CONNECTOR TEST ADAPTERS IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-B Connector Test Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Page 14663 2. Install the recliner arm attachment bolts (2). Tighten Tighten the bolts to 53 N.m (39 lb ft). 3. Install the inboard pivot bolt (1). Tighten Tighten the bolt to 35 N.m (26 lb ft). 4. Install the seat belt retractor. 5. Install the lumbar assembly (or power lumbar/bolster assembly if equipped). 6. Install the seat back trim cover and pad. 7. Connect the lumbar cable (6) underneath the seat cushion (disconnect the wire harness if equipped with power lumbar). 8. Install the seat trim panel. 9. Install the head restraint and guides. 10. Install the seat into the vehicle. Driveline - Bump/Clunk/Squawking Noises Slip Yoke: All Technical Service Bulletins Driveline - Bump/Clunk/Squawking Noises Bulletin No.: 01-04-17-004B Date: January 05, 2005 TECHNICAL Subject: Clunk, Bump or Squawk when Vehicle Comes to Complete Stop or Accelerating from Complete Stop (Replace Rear Drive Shaft Nickel-Plated Slip Yoke) Models Supercede: This bulletin is being revised to add Cadillac Escalade (Old Style) to the Models section. Please discard Corporate Bulletin Number 01-04-17-004A (Section 04 - Driveline/Axle). Condition Some customers may comment on a clunk, bump or squawk noise when the vehicle comes to a stop or when accelerating from a complete stop. Cause A slip/stick condition between the transfer case output shaft and the driveshaft slip yoke may cause this condition. Diagnostic Tips There are several resources in the electronic Service Information System which can provide the technician with information on diagnosis and repair of clunk conditions, and fix the customer's vehicle right the first time without unnecessary parts replacement. Some of the documents available in SI include: ^ Symptoms - Propeller Shaft Page 2531 Notice: Refer to Fastener Notice in Service Precautions. 2. Install the oil filter to the engine block. ^ Tighten the oil filter to 30 Nm (22 ft. lbs.). 3. Install the oil drain plug to the engine block. ^ Tighten the oil pan drain plug to 25 Nm (18 ft. lbs.). 4. Lower the vehicle. 5. Fill the crankcase with the proper quantity and grade of engine oil. Refer to Capacities - Approximate Fluid and Fluid and Lubricant Recommendations. 6. Remove the oil level indicator. 7. Wipe the indicator with a clean cloth. 8. Install the oil level indicator. 9. Remove the oil level indicator in order to check the level. 10. Add oil if necessary. 11. Close the hood. Page 7311 Page 9570 Fuse Block- I/P C1 Part 4 Page 11200 7. Remove the push pin from the right side radiator air baffle. 8. Remove the bolts (2) from the starter/generator control module (SGCM) coolant pump (1). 9. Reposition the SGCM coolant pump. 10. Remove the right park/turn signal lamp. 11. Remove the grille from the vehicle. 12. Remove the evaporator tube nut from the condenser. 13. Remove the evaporator tube from the condenser. 14. Remove the front evaporator tube from the vehicle. Page 14931 Driver Door Module (DDM) - C5 (Memory/Heated Seat Switch) Part 2 Page 12537 Conditions for Running the DTC Ignition is in RUN or ACC position System voltage is between 9.5 - 15.5 volts. The above conditions are met for more than 1 second. Conditions for Setting the DTC The VCIM does not detect the presence of a cellular antenna for more than 1 second. Action Taken When the DTC Sets The vehicle is unable to connect to the OnStar(R) Call Center. The OnStar(R) status LED turns red. Conditions for Clearing the DTC The VCIM detects the presence of a cellular antenna. A history DTC clears after 50 malfunction-free ignition cycles. Circuit/System Testing Perform a visual inspection as shown above in order to verify that the cellular antenna and the cellular antenna coupling assembly are not damaged. If any components are damaged replace the assembly. DTC B2476 or B2482 DTC Descriptors Door Window Weatherstrip Rear Door Window Glass Weatherstrip: Service and Repair Door Window Weatherstrip Weatherstrip Replacement - Rear Door Window Removal Procedure 1. Remove the window. 2. Pull the weatherstrip from the front window run channel. 3. Pull the weatherstrip from the rear window run channel. 4. Pull the weatherstrip from the window frame flange. Installation Procedure 1. Align the weatherstrip in the window frame flange. 2. Press the weatherstrip into the window frame flange until fully seated. 3. Press the weatherstrip into the rear window run channel until fully seated. 4. Press the weatherstrip into the front window run channel until fully seated. 5. Install the window. Page 6856 5.5. Install the J 2619-01 (2) to the J 29369-1 or the J 2936-2. 5.6. Remove the inner axle shaft seal and/or the inner axle shaft bearing using the J 2619-01. Installation Procedure 1. Install the right side bearing with the square shoulder in using the J 36609 (1) and the J 8092 (2). Page 5764 Page 12550 Diagnostic Tips Review # 1 - Delphi Super Nav and Black Tie Nav Page 9266 Junction Block - I/P Wire Entry Part 4 Page 7682 6. With the output gear encoder assembly in hand, carefully align the casting and output gear timing marks (1). 7. At the same time, be sure to align the encoder phasing post (1) with the phasing slot (2) in the casting and insert the shaft into the bushing. 8. Verify that the output gear and idler are engaged properly. 9. Seat the harness wires on the casting channel. 10. Place the shim on the output shaft gear. 11. Press a NEW seal into the cover. Page 13440 Steering Mounted Controls Transmitter: Service and Repair Steering Wheel Control Switch Assembly Replacement Removal Procedure 1. Remove the steering wheel. 2. Remove the shroud retaining screws from the back of the steering wheel. 3. Remove the shroud from the steering wheel. 4. Position a blunt ended tool into the wire harness cavity (1) and apply moderate pressure in order to partially remove the steering wheel control switch from the steering wheel. 5. Disconnect the steering wheel control switch electrical connector. 6. Important: The bulbs in the steering wheel control switches are not serviceable. The switches should be replaced only as an assembly. Remove the steering wheel control switch from the steering wheel. Installation Procedure Wheels - Chrome Wheel Staining/Pitting/Corrosion Wheels: All Technical Service Bulletins Wheels - Chrome Wheel Staining/Pitting/Corrosion INFORMATION Bulletin No.: 00-03-10-002F Date: April 21, 2011 Subject: Chemical Staining, Pitting, Corrosion and/or Spotted Appearance of Chromed Aluminum Wheels Models: 2012 and Prior GM Cars and Trucks Supercede: This bulletin is being revised to update model years, suggest additional restorative products and add additional corrosion information. Please discard Corporate Bulletin Number 00-03-10-002E (Section 03 - Suspension). Important You may give a copy of this bulletin to the customer. What is Chemical Staining of Chrome Wheels? Figure 1 Chemical staining in most cases results from acid based cleaners (refer to Figure 1 for an example). These stains are frequently milky, black, or greenish in appearance. They result from using cleaning solutions that contain acids on chrome wheels. Soap and water is usually sufficient to clean wheels. If the customer insists on using a wheel cleaner they should only use one that specifically states that it is safe for chromed wheels and does not contain anything in the following list. (Dealers should also survey any products they use during prep or normal cleaning of stock units for these chemicals.) - Ammonium Bifluoride (fluoride source for dissolution of chrome) - Hydrofluoric Acid (directly dissolves chrome) - Hydrochloric Acid (directly dissolves chrome) - Sodium Dodecylbenzenesulfonic Acid - Sulfamic Acid - Phosphoric Acid - Hydroxyacetic Acid Notice Many wheel cleaner instructions advise to take care to avoid contact with painted surfaces. Most customers think of painted surfaces as the fenders, quarter panels and other exterior sheet metal. Many vehicles have painted brake calipers. Acidic wheel cleaners may craze, crack, or discolor the paint on the brake calipers. Damage from wheel cleaners is not covered under the vehicle new car warranty. Soap and water applied with a soft brush is usually all that is required to clean the calipers. Whenever any wheel cleaner is used, it must be THOROUGHLY rinsed off of the wheel with clean, clear water. Special care must be taken to rinse under the hub cap, balance weights, wheel nuts, lug nut caps, between the wheel cladding and off the back side of the wheel. Wheels returned to the Warranty Parts Center (WPC) that exhibit damage from wheel cleaners most often have the damage around and under the wheel weight where the cleaner was incompletely flushed away. Notice Locations Engine Oil Pressure (EOP) Sensor And CMP Sensor Page 8215 11. Remove the rotor. 12. If the rotor is difficult to remove due to corrosion in the hub area use the following procedure to remove the rotor, 25 and 35 series only. 1. Clean all the surface areas and the threaded holes of contamination. 2. Generously apply penetrating oil or the equivalent to the hub/rotor area. 3. Insert two M10 x 1.5 bolts or jack screws into the threaded holes of the rotor. 4. Tighten both bolts evenly to force the rotor from the hub. Installation Procedure 1. Important: Whenever the brake rotor has been separated from the hub/axle flange, any rust or contaminants should be cleaned from the hub/axle flange and the brake rotor mating surfaces. Failure to do this may result in excessive assembled lateral runout (LRO) of the brake rotor, which could lead to brake pulsation. Use the J 42450-A to clean all rust and contaminants from the mating surface of the hub flange. 2. Use the J 41013 to clean all rust and contaminants from the inside diameter of the hat section of the brake rotor to prevent any foreign material from getting between the brake rotor and the hub flange. 3. Inspect the mating surfaces of the hub/axle flange and the rotor to ensure that there are no foreign particles or debris remaining. 4. Important: If the rotor was removed using the jack screw method you must ensure that the hub flange is free of nicks or marks caused by this procedure. Remove all raised nicks or marks before installing the rotor. Align the rotor to its original position on the hub (if applicable) and install the rotor. 5. If the brake rotor was removed and installed as part of a brake system repair, measure the assembled lateral runout (LRO) of the brake rotor to ensure optimum performance of the disc brakes. Refer to Brake Rotor Assembled Lateral Runout (LRO) Measurement. 6. If the brake rotor assembled LRO measurement exceeds the specification, bring the LRO to within specifications. Refer to Brake Rotor Assembled Lateral Runout (LRO) Correction. Page 5568 Ignition Coil 8 Page 2620 Application Table Part 1 Page 8797 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Weather Pack Connectors WEATHER PACK CONNECTORS The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. Page 2675 Junction Block - I/P - C6 Page 9058 Relay Block - I/P C3 Part 2 Page 2511 Fluid - Transfer Case: Fluid Type Specifications NVG 149-NP3 ................................................................................................... Manual Transmission Fliod GM P/N 8861800 (Canadian P/N 88861801) NVG 246-NP8 ......................................................................................... Auto-Trak II, transfer case fluid, GM P/N 12378508 (Canadian P/N 10953626) NVG 261-NP2 ................................................................................................... Manual Transmission Fliod GM P/N 8861800 (Canadian P/N 88861801) NVG 263-NP1 ................................................................................................... Manual Transmission Fliod GM P/N 8861800 (Canadian P/N 88861801) Rear Wheel Steering Control Module Bracket Replacement Steering Control Module: Service and Repair Rear Wheel Steering Control Module Bracket Replacement Rear Wheel Steering Control Module Bracket Replacement Removal Procedure 1. Remove the rear wheel steering control module from the bracket. 2. Remove the bolts retaining the bracket (2) to the frame. 3. Remove the bracket (2) from the vehicle. Installation Procedure 1. Install the bracket (2) to the vehicle. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the bolts retaining the bracket (2) to the frame. ^ Tighten the bracket retaining bolts to 10 Nm (81 inch lbs.). 3. Install the rear wheel steering control module to the vehicle. Locations Mass Air Flow (MAF) Sensor: Locations Right Side Of The Engine Compartment Page 1413 Fuel Gauge Sender: Service and Repair Fuel Level Sensor Replacement - 2 FUEL LEVEL SENSOR REPLACEMENT REMOVAL PROCEDURE 1. Remove the sending unit. 2. Disconnect the fuel pump electrical connector. 3. Remove the fuel level sensor electrical connector retaining clip. 4. Disconnect the fuel level sensor electrical connector. Seat Bolster Motor/Position Sensor - Driver (With RPO Code AN3) Seat Bolster Motor/Position Sensor - Driver (With RPO Code AN3) Locations Mass Air Flow (MAF) Sensor: Locations Right Side Of The Engine Compartment Page 3390 Intake Manifold: Service and Repair Intake Manifold Replacement Removal Procedure 1. Important: The intake manifold, throttle body, fuel rail, and injectors may be removed as an assembly. If not servicing the individual components, remove the manifold as a complete assembly. Remove the throttle body. 2. Remove the fuel injectors. 3. Disconnect the following electrical connectors: ^ Manifold absolute pressure (MAP) sensor (1) ^ Knock sensor (2) 4. Remove the knock sensor harness electrical connector from the intake manifold. 5. Set the electrical harness aside. 6. If equipped with vacuum assisted brakes, remove the vacuum brake booster hose from the rear of the intake manifold. Page 14137 Each user will be required to accept the following agreement each time the KeyCode application is used. Key Code User Agreement - Key codes are proprietary information belonging to General Motors Corporation and to the vehicle owner. - Unauthorized access to, or use of, key code information is unlawful and may subject the user to criminal and civil penalties. - This information should be treated as strictly confidential and should not be disclosed to anyone unless authorized. I will ensure that the following information is obtained prior to releasing any Key Code information: 1. Government issued picture ID (Drivers License) 2. Registration or other proof of ownership. Registration should have normal markings from the Province that issued the registration and possibly the receipt for payment recorded as well. Important - GM takes this agreement seriously. Each user must be certain of vehicle ownership before giving out key codes. - When the ownership of the vehicle is in doubt, dealership personnel should not provide the information. Key code requests should never be received via a fax or the internet and key codes should never be provided to anyone in this manner. A face to face contact with the owner of the vehicle is the expected manner that dealers will use to release a key code or as otherwise stipulated in this bulletin or other materials. - Key codes should NEVER be sent via a fax or the internet. - Each Dealership should create a permanent file to document all KeyCode Look Up transactions. Requests should be filed by VIN and in each folder retain copies of the following: - Government issued picture ID (Drivers License) - Registration or other proof of ownership. - Copy of the paid customer receipt which has the name of the employee who cut and sold the key to the customer. - Do not put yourself or your Dealership in the position of needing to "explain" a KeyCode Look Up to either GM or law enforcement officials. - Dealership Management has the ability to review all KeyCode Look-Up transactions. - Dealership KeyCode documentation must be retained for two years. Frequently Asked Questions (FAQs) for GM of Canada Dealers How do I request a KeyCode for customer owned vehicle that is not registered? Scrapped, salvaged or stored vehicles that do not have a current registration should still have the ownership verified by requesting the vehicle title, current insurance policy and / or current lien holder information from the customers financing source. If you cannot determine if the customer is the owner of the vehicle, do not provide the key code information. In these cases, a short description of the vehicle (scrapped, salvaged, etc.) and the dealership location should be kept on file. Any clarifying explanation should be entered into the comments field. How do I document a KeyCode request for a vehicle that is being repossessed? The repossessor must document ownership of the vehicle by providing a court ordered repossession order and lien-holder documents prior to providing key code information. Copies of the repossessors Drivers License and a business card should be retained by the dealership for documentation. What do I do if the registration information is locked in the vehicle? Every effort should be made to obtain complete information for each request. Each Dealership will have to decide on a case by case basis if enough information is available to verify the customer's ownership of the vehicle. Other forms of documentation include vehicle title, insurance policy, and or current lien information from the customers financing source. Dealership Management must be involved in any request without complete information. If you cannot determine if the customer is the owner of the vehicle, do not provide the key code information. Can I get a print out of the information on the screen? It is important to note that the Key Code Look Up Search Results contain sensitive and/or proprietary information. For this reason GM recommends against printing it. If the Search Results must be printed, store and/or dispose of the printed copy properly to minimize the risk of improper or illegal use. Who in the dealership has access to the KeyCode application? Dealership Parts Manager (or assigned management) will determine, and control, who is authorized to access the KeyCode Look Up application. However, we anticipate that dealership parts and service management will be the primary users of the application. The KeyCode Look Up application automatically tracks each user activity session. Information tracked by the system includes: User name, User ID, all other entered data and the date/time of access. Page 3046 Wheel Bearing: Testing and Inspection Wheel Bearings Diagnosis Test 1-7 Page 14059 Front Passenger Door Page 13164 2. Click on the Analog-to-Digital Program link to start the ordering process. 3. To order a kit, you will need the information shown above. 4. After submitting the order, the "Terms and Conditions of Your OnStar(R) Service" page will display. This is your confirmation that the upgrade kit order has been created. U.S. Dealers will also receive an e-mail from Autocraft within several hours of ordering an upgrade kit (Canadian Dealers will receive an e-mail from MASS Electronics). 5. Print the "Terms and Conditions of Your OnStar(R) Service" page, and have the customer sign a copy. 6. A copy of this form should be stapled to the customer's copy of the Repair Order and one copy should be retained in the customer service folder. 7. If the kit you ordered is available, you will receive the upgrade kit within 4 business days of entering your order through the OnStar(R) Online Enrollment webpage. 8. To check on kit availability or the status of your order, U.S. Dealers can log onto the distributor's website at www.autocraft.com. Canadian dealers can call MASS Electronics at 877-410-6277. Upgrade Kit Installation 1. Skip to the next step if the vehicle to be upgraded is not shown above. Page 1715 Air Induction Components Page 1263 For vehicles repaired under warranty, use the table. Disclaimer Page 9197 C161 Roof Beacon Harness To Chassis Harness (With RPO Code 5Y0) Page 3463 Engine Oil Pressure (EOP) Sensor Page 5008 Page 684 Disclaimer Page 5971 Park Neutral Position (PNP) Switch C175 Automatic Transmission - 4L60-E/4L65-E Transmission Mount: Service and Repair Automatic Transmission - 4L60-E/4L65-E Transmission Mount Replacement Removal Procedure 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Support the transmission with a transmission jack. 3. Remove the transmission mount to the transmission support retaining nut or nuts. 4. Raise the transmission to take the weight off of the mount. 5. Remove the transmission mount to the transmission or transfer case adapter mounting bolts (1). 6. Raise the transmission just enough to remove the transmission mount. 7. Remove the transmission mount from the vehicle. Installation Procedure 1. Install the transmission mount to the vehicle. 2. Notice: Refer to Fastener Notice in Service Precautions. Install the transmission mount to the transmission or transfer case adapter mounting bolts (1). ^ Tighten the bolts to 50 Nm (37 ft. lbs.). Page 14405 Front Passenger Door Module (FPDM) - C5 (With RPO Code AN3) Part 2 Page 4189 Fuel Pressure: Testing and Inspection Fuel System Diagnosis FUEL SYSTEM DIAGNOSIS SYSTEM DESCRIPTION The control module enables the fuel pump relay when the ignition switch is turned ON. The control module will disable the fuel pump relay within two seconds unless the control module detects ignition reference pulses. The control module continues to enable the fuel pump relay as long as ignition reference pulses are detected. The control module disables the fuel pump relay within two seconds if ignition reference pulses cease to be detected and the ignition remains ON. The Fuel System is a returnless on-demand design. The fuel pressure regulator is a part of the fuel sender assembly, eliminating the need for a return pipe from the engine. A returnless fuel system reduces the internal temperature of the fuel tank by not returning hot fuel from the engine to the fuel tank. Reducing the internal temperature of the fuel tank results in lower evaporative emissions. The fuel tank stores the fuel supply. An electric turbine style fuel pump attaches to the fuel sender assembly inside the fuel tank. The fuel pump supplies high pressure fuel through the fuel filter and the fuel feed pipe to the fuel injection system. The fuel pump provides fuel at a higher rate of flow than is needed by the fuel injection system. The fuel pump also supplies fuel to a venturi pump located on the bottom of the fuel sender assembly. The function of the venturi pump is to fill the fuel sender assembly reservoir. The fuel pressure regulator, a part of the fuel sender assembly, maintains the correct fuel pressure to the fuel injection system. The fuel pump and sender assembly contains a reverse flow check valve. The check valve and the fuel pressure regulator maintain fuel pressure in the fuel feed pipe and the fuel rail in order to prevent long cranking times. TEST Steps 1 - 2 Fuel Pump Relay Fuel Pump Relay: Locations Fuel Pump Relay FUEL PUMP RELAY Fuse Block-Underhood Page 9180 C104 I/P Harness To Forward Lamp Harness (With Out RPO Code YE9) Page 9739 C220 I/P Harness To Infotainment Jumper Harness (With RPO Code UQ7 & Without RPO Code Y91) Part 1 Page 15590 Clearance Lamps - Roof (With RPo Code U01) Page 6827 ^ The axle bearings ^ The axle seals 10. Scribe an alignment line between the pinion shaft and the pinion yoke. 11. Install the J 8614-01 onto the pinion as shown. 12. Remove the pinion nut while holding the J 8614-01. 13. Install the J 8614-2 (2) and the J 8614-3 (3) into the J 8614-01 (1) as shown. 14. Remove the pinion yoke by turning the J 8614-3 (3) clockwise while holding the J 8614-01 (1). 15. Remove the oil seal using a suitable seal removal tool. Important: Carefully remove the oil seal from the bore. Do not distort or scratch the aluminum case. Installation Procedure Page 9295 4. Connect the wiring connectors to the fuse block. Refer to Electrical Center Identification Views to ensure the right connections are made. 5. Install the right side end panel. Page 10924 Control Module References Part 5 Page 15240 Control Module References Part 6 Page 15573 Stop Lamp Switch Part 2 Recall - Brake Booster Pressure Accumulator Cracking Technical Service Bulletin # 05006 Date: 050323 Recall - Brake Booster Pressure Accumulator Cracking Product Safety - Hydro-Boost Accumulator Over-Pressurization # 05006 - (Mar 23, 2005) Models: 2004 Chevrolet Kodiak 2004-2005 Chevrolet Avalanche, Express, Silverado, Suburban 2004 GMC TopKick 2004-2005 GMC Savana, Sierra, Yukon XL Condition General Motors has decided that a defect, which relates to motor vehicle safety, exists in certain 2004 Chevrolet Kodiak and GMC TopKick; 2004-2005 Chevrolet Avalanche, Express, Silverado, Suburban; GMC Savana, Sierra, Yukon XL vehicles. On some of these vehicles, the hydraulic brake booster's pressure accumulator may crack and/or separate from the Hydro-Boost(R) assembly during normal vehicle operating conditions. If a separation were to occur and the hood of the vehicle were open, fragments from the accumulator could cause injury to people in the immediate area. In addition, the presence of this crack or fractured surface could allow the hydraulic fluid to leak from the accumulator circuit of the booster assembly. The loss of fluid would cause increased steering and braking effort. Correction Dealers are to inspect the hydraulic brake booster, and replace it if necessary. Vehicles Involved Involved are certain 2004 Chevrolet Kodiak and GMC TopKick; 2004-2005 Chevrolet Avalanche, Express, Silverado, Suburban; GMC Savana, Sierra, Page 6232 Extension Housing: Service and Repair Automatic Transmission - 4L80-E/4L85-E Transmission Extension Housing Assembly Replacement Removal Procedure 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. Support the transmission with a transmission jack. 3. Place a drain pan under the vehicle. 4. Remove the propeller shaft. 5. Remove the transmission support and the transmission mount. 6. Remove the case extension bolts (3). 7. Remove the case extension (1). 8. Remove and discard the case extension O ring seal (2). Installation Procedure 1. Install a new case extension O ring seal (2). 2. Install the case extension (1). Notice: Refer to Fastener Notice in Service Precautions. 3. Install the case extension bolts (3). ^ Tighten the bolts (3) to 34 Nm (25 ft. lbs.). 4. Install the transmission support and the transmission mount. 5. Install the propeller shaft. 6. Remove the drain pan and the transmission jack. 7. Lower the vehicle. 8. Fill the transmission to the proper level with Dexron® III transmission fluid. Page 16173 Control Module References Part 7 Service and Repair Maintenance Indicator - A/T: Service and Repair This vehicle does not use a Trans Fluid Life index, and has no monitor to reset. Electrical - Trailer Brakes Apply With Headlamps ON Trailer Adapter Kit: Customer Interest Electrical - Trailer Brakes Apply With Headlamps ON Bulletin No.: 02-05-22-004C Date: April 05, 2005 TECHNICAL Subject: Trailer Brakes Applied When Headlights/Park Lamps Are On, Brake Controller Illumination (Modify Brake Controller Wiring Harness) Models: 2002-2005 Cadillac Escalade, Escalade EXT 1999-2005 Chevrolet Silverado 2000-2005 Chevrolet Suburban, Tahoe 2002-2005 Chevrolet Avalanche 1999-2005 GMC Sierra 2000-2005 GMC Yukon, Yukon XL 2003-2005 HUMMER H2 Supercede: This bulletin is being revised to add additional model years. Please discard Corporate Bulletin Number 02-05-22-004B (Section 05 - Brakes). Condition Some customers may comment that when the headlamps or park lamps are on, the brakes on the trailer are always applied, or that the back lighting for the trailer brake controller only illuminates when the brakes are applied. Cause The cause of this condition may be due to wiring changes within the vehicle electrical system for the 2003 model year. Correction Inspect the brake controller wiring harness jumper that is plugged into the vehicle relay block-body. The relay block-body is located under the left side of the instrument panel near the left kick panel, behind a plastic cover. Page 9566 Fuse Block - Underhood C9 Fuse Block- I/P C1 Page 13238 ^ I/O check Any faults detected during the initialization self-test shall generate a DTC. All nodes also continuously perform a self-test while in an active state. DTCs and their associated telltales will set as a result of unprogrammed or unlearned information. DTCs, which are defined for system configuration (e.g. Vehicle Option Content not programmed) do not support the history status bit (set =0). Warning indicator bit is also set, when applicable, while this DTC is present. Action Taken When the DTCs Sets The module suspends all message transmission. The module uses default values for all parameters received on the serial data circuits. The module inhibits the setting of all other communication DTCs. Conditions for Clearing the DTC A current DTC clears when the malfunction is no longer present. A history DTC clears when the module ignition cycle counter reaches the reset threshold of 50, without a repeat of the malfunction. Circuit/System Verification Refer to Data Link References to determine which serial data system is used for a specific module. The DTCs cannot be retrieved with a current status. Diagnosis is accomplished using the following symptom procedures: Scan Tool Does Not Communicate with High Speed GMLAN Device in SI. OR Scan Tool Does Not Communicate with Low Speed GMLAN Device in SI. DTC U1300, U1301, or U1305 Circuit Description Modules connected to the Class 2 serial data circuit monitor for serial data communications during normal vehicle operation. Operating information and commands are exchanged among the modules. In addition to this, Node Alive messages are transmitted by each module on the Class 2 serial data circuit about once every 2 seconds. When the module detects one of the following conditions on the Class 2 serial data circuit for approximately 3 seconds, the setting of all other Class 2 serial communication DTCs is inhibited and a DTC will set. Conditions for Running the DTCs Voltage supplied to the module is in the normal operating voltage range. The vehicle power mode requires serial data communication to occur. Conditions for Setting the DTCs No valid messages are detected on the Class 2 serial data circuit. The voltage level detected on the Class 2 serial data circuit is in one of the following conditions: Page 14808 Seat Heater Switch: Diagrams Driver Door Module (DDM) - C5 (Memory/Heated Seat Switch) Part 1 Page 1812 Inflatable Restraint Seat Position Switch - Right ((With RPO Code AL0) Drivetrain - Service 4WD Light/DTC C0374 Set Speed Sensor: Customer Interest Drivetrain - Service 4WD Light/DTC C0374 Set TECHNICAL Bulletin No.: 05-04-21-003C Date: April 15, 2008 Subject: Service 4WD Light Illuminated, DTC C0374 Set (Inspect Wiring Harness to Transfer Case Speed Sensors,, Replace Wiring Harness) Models: 2004-2007 Buick Rainier 2003-2006 Chevrolet Avalanche, Suburban, Tahoe 2003-2007 Chevrolet Silverado Classic, TrailBlazer, TrailBlazer EXT 2003-2006 GMC Yukon, Yukon XL 2003-2007 GMC Envoy, Envoy XL, Sierra Classic 2003-2004 Oldsmobile Bravada 2005-2007 Saab 9-7X With Four Wheel Drive or All-Wheel Drive and Active All-Wheel Drive (RPO NP4) or Active Two-Speed (RPO NP8) Transfer Case Supercede: This bulletin is being revised to update the Model and Warranty Information. Please discard Corporate Bulletin Number 05-04-21-003B (Section 04 - Driveline/Axle). Condition Some customers may comment on intermittent illumination of the Service 4WD light. Upon investigation, the technician may find DTC C0374 set. The customer may also comment on intermittent erratic operation of the 4WD or AWD system after driving through rain/snow or simply going through a car wash. Cause The speed sensor signal may have become corrupted. Possible openings in the speed sensor wire insulation (twisted pairs) can allow water intrusion. Also wire connections contaminated by water may result in short circuits and erroneous speed sensor readings. This most often occurs on the rear speed sensor circuit. Correction Inspect the wiring harness to the transfer case speed sensors. On Rainier, TrailBlazer, Envoy and 9-7X models, fabricate a replacement speed sensor harness between the C101 connector and the speed sensors. Completely inspect and test all wiring. Refer to Speed Signal Front Axle Actuator and Indicators schematic in SI. Replace the affected twisted pairs. Do not over-twist the two wires in the replacement harness. Wires should be twisted at a rate of 9 revolutions per foot. Use service connector pack, P/N 88987993 at the speed sensor end and terminal, P/N 15326267, at C101. Terminal testing tools and service terminals can be found in Terminal Repair Kit J 38125. Terminals are available from SPX/Kent-Moore. The smaller transfer case harness splices into the larger chassis harness a few inches in front of the crossmember. The chassis harness routes along the left side of the frame under the driver door area. Use nylon tie straps to secure the fabricated harness to the main chassis harness between the transfer case and C101. On the full-size pickup and full-size utility models, replace the 2.2 m (88 in) pigtail harness that runs from the C151 connector under the hood to the transfer case. Use either harness P/N 15832722 or 15224663 depending on vehicle equipment. Refer to Propshaft Speed Sensors Front Axle Actuator and Transfer Case Shift Control Switch schematic in SI. Important: Technicians should verify the integrity of the splice joints after the repair. All splice joints and connections should seal properly against water or a repeat condition can occur. Throttle Body Assembly Replacement Throttle Body: Service and Repair Throttle Body Assembly Replacement THROTTLE BODY ASSEMBLY REPLACEMENT REMOVAL PROCEDURE NOTE: Handle the electronic throttle control components carefully. Use cleanliness in order to prevent damage. Do not drop the electronic throttle control components. Do not roughly handle the electronic throttle control components. Do not immerse the electronic throttle control components in cleaning solvents of any type. IMPORTANT: DO NOT for any reason, insert a screwdriver or other small hand tools into the throttle body to hold open the throttle plate, as the wedge inside the throttle body could be damaged. - An 8-digit part identification number is stamped on the throttle body casting. Refer to this number if servicing, or part replacement is required. 1. Partially drain the cooling system in order to allow the hose at the throttle body to be removed. Refer to Draining and Filling Cooling System in Cooling System. 2. Remove the air cleaner outlet duct. 3. Remove the engine sight shield. 4. Disconnect the throttle actuator motor electrical connector (2). 5. Reposition the coolant air bleed hose clamp at the throttle body. 6. Remove the coolant air bleed hose from the throttle body. Page 8716 Wheel Speed Sensor: Diagrams ABS Connector End Views Wheel Speed Sensor (WSS) - LF Page 15078 Parts Information ^ P/N 15068208 contains the reinforcements necessary to install ladder rack systems and/or side-mounted toolboxes. ^ P/N 15068209 contains the reinforcements for cross toolbox and/or rear window barrier applications only. Disclaimer Page 8166 7. Remove the caliper pin boots (4) from the disc brake caliper mounting bracket (3). Installation Procedure 1. Lubricate the front brake caliper bushings, bolts and seals with high temperature silicone brake lubricant. 2. Install the caliper pin boots (4) to the disc brake caliper mounting bracket (3). 3. Install the disc brake pad retainers to the disc brake caliper mounting bracket. 4. Install the disc brake pads to the disc brake caliper mounting bracket. 5. Install the disc brake caliper to the caliper mounting bracket. Refer to Brake Caliper Replacement - Front. 6. With the engine OFF, gradually apply the brake pedal approximately 2/3 of its travel distance. 7. Slowly release the brake pedal. 8. Wait 15 seconds, then repeat steps 6-7 until a firm brake pedal is obtained. This will properly seat the brake caliper pistons and brake pads. Disc Brake Hardware Replacement - Rear Disc Brake Hardware Replacement - Rear Caution: Refer to Brake Dust Caution in Service Precautions. Removal Procedure 1. Raise and support the vehicle. Refer Vehicle Lifting 2. Remove the tire and wheel assembly. Page 6919 7. Place a brass drift against the CV joint cage (1). 8. Tap gently on the brass drift with a hammer in order to tilt the cage (1). 9. Install the first chrome alloy ball (2) when the CV joint cage (1) tilts. 10. Tilt the CV joint cage (1) in the opposite direction to install the opposing chrome alloy ball (2). 11. Repeat this process in order to install all six of the balls. Page 4454 Fuel Level Sensor: Description and Operation Fuel System Description (Cab Chassis) FUEL LEVEL SENSOR The fuel level sensor is a part of the fuel sender assembly. The position of the float arm indicates the fuel level. The fuel level sensor contains a variable resistor which changes resistance in correspondence with the amount of fuel in the fuel tank. On models that are equipped with a single fuel tank, the fuel level sensor is wired directly to the instrument panel (IP) cluster. On models equipped with dual fuel tanks, both fuel level sensors are wired to the PCM. The PCM calculates the total fuel level in both tanks. The instrument panel (IP) fuel gage displays the total fuel level in both fuel tanks. Page 11306 Parts required to complete this special coverage are to be obtained from General Motors Customer Care and Aftersales (GMCC&A;). Service Procedure Note The resistor module connector and blower motor resistor will need to be replaced if one or more of the symptoms below is present. - The HVAC blower may not function on certain or all blower speed settings - A burning plastic smell or smoke may be present in the vehicle - The HVAC blower may run continually with the ignition in the OFF position Determine if one or more of the above symptoms is present. If required refer to HVAC diagnostic information in SI. Refer to Resistor Module Connector and Blower Motor Resistor Replacement in this bulletin if one or more of the symptoms is present. Other HVAC repairs are NOT covered in this product safety special coverage bulletin. Resistor Module Connector and Blower Motor Resistor Replacement 1. Remove the blower fuses (Htr A/C & HVAC 1 fuses). 2. Lower the close-out panel enough to gain access to the resistor module connector. 3. Disconnect the connector from the resistor module. Note Connector replacement is required even if the connector was replaced on a previous service repair. 4. Remove the tape from the wiring harness to expose the wiring. 5. Cut the wires back far enough from the connector to eliminate any melted insulation on the wire. Note Use the old connector as a map for splicing the wires for the new connector. Be sure to use the correct crimping tool from the terminal repair kit J 38125. Use only Duraseal splice sleeves. Other splice sleeves may not protect the splice from moisture or provide a good electrical connection. 6. Install the new connector. Use the yellow splice sleeves provided with the connector. 7. Install the new blower motor resistor. 8. Reinstall the fuses. Test the blower motor to make sure all speeds are functional. 9. Reinstall the hush panel/close-out panel. Customer Reimbursement Customer requests for reimbursement of previously paid repairs to correct the condition described in this bulletin are to be submitted to the dealer prior to or by December 31, 2012. Repairs must have occurred within the 10 years of the date the vehicle was originally placed in service, or 240,000 kilometres, whichever occurs first. When a customer requests reimbursement, they must provide the following: Page 13586 5. With an assistant, raise the assist step to the vehicle. 6. With an assistant, install the following front components, and rear components: 1. The washers (3) 2. The lock washers (2) 3. The body mount bolts (1) Torque the bolts to 90 N.m (66 lb ft). 7. Install (5) the assist step center bracket. 8. Install (2) the following components to the assist step: 1. The washer 2. The lock washer 3. The center bolt Torque to 45 N.m (33 lb ft). 9. Install (1) the following components to the assist step: 1. The washer 2. The lock washer 3. The center body mount bolt Torque to 90 N.m (66 lb ft). Page 1904 1. Lubricate the output speed sensor seal with automatic transmission fluid. 2. Install the output speed sensor (2). Notice: Refer to Fastener Notice in Service Precautions. 3. Install the output speed sensor bolt. ^ Tighten the bolt to 11 Nm (96 inch lbs.). 4. Connect the output speed sensor (2) electrical connector. 5. Lower the vehicle. Page 3543 Ignition Cable: Service and Repair SPARK PLUG WIRE REPLACEMENT REMOVAL PROCEDURE 1. Remove the spark plug wire from the spark plug. 1.1. Twist the spark plug wire boot a 1/2 turn. 1.2. Pull only on the boot in order to remove the wire from the spark plug. 2. Remove the spark plug wire from the ignition coil. 2.1. Twist the spark plug wire boot a 1/2 turn. 2.2. Pull only on the boot in order to remove the wire from the ignition coil. IMPORTANT: The Melco(R) spark plug wires MUST be used only with the Melco(R) coils and bracket, like wise the Delphi(R) spark plug wires MUST be used only with Delphi(R) coils and bracket. The components are NOT interchangeable. 3. There are 2 different manufacturers for the spark plug wire, ignition coils and coil brackets. They are as follows: 4. The Melco(R) spark plug wire (1) will have a blue foil mark on it, and the wire is 145 mm (5.70 in) in length from cable seal to cable seal. 5. The Delphi(R) spark plug wire (2) will have a white foil mark on it, and the wire is 110 mm (4.30 in) in length cable seal to cable seal. Page 11221 Refrigerant: Fluid Type Specifications Air Conditioning Refrigerant ....................................................................................................................... R134a P/N 12356150 U.S. (10953485 Canada) Page 2674 Junction Block - I/P - C5 Page 15635 Accessory Switch Housing Page 12122 10. Disconnect and remove the OnStar(R) jumper harness. Note: You will need to remove the short GPS cable from this jumper harness. 11. Untape the cell antenna coax from the body harness in the trunk. This will be necessary to provide adequate length to connect to the new VCIM. 12. Fasten three retainer clips (1) from the kit to the new bracket that is included in the kit, and position the VCIM to the bracket (2). 13. Install the three bolts from the kit. Tighten the bolts to 10 Nm (89 lb in). 14. Connect the new OnStar(R) jumper harness supplied in the kit to the VCIM (two white connectors on module). 15. Connect small GPS coax cable jumper harness supplied in the kit (end with blue plastic housing) to VCIM GPS connector. 16. Position the VCIM / bracket assembly to the studs. 17. Install the bracket nuts saved from the Removal Procedure above to the VCIM / bracket assembly mounting studs. Tighten the nuts to 4 Nm (35 lb in). 18. Connect the new OnStar(R) jumper harness to the body wiring harness (C410 connector). 19. Connect small coax cable jumper from VCIM to the OnStar(R) Global Positioning Satellite (GPS) antenna coaxial cable at the connector previously left in the vehicle (short jumper removed from old harness in step 5.10). 20. Connect the cellular coaxial cable previously left in vehicle to the OnStar(R) VCIM. 21. Verify that all harnesses are properly secured in vehicle. 6. After replacing the VCIM, it is essential to configure the new OnStar(R) system. Failure to configure the system will result in an additional customer visit for repair. DO NOT press and hold the white dot or phone button on the keypad as it will not reset this version of the OnStar(R) system and may result in a DTC being set. Use of the TIS2WEB and SPS applications, along with the Tech2(R), are required in order to perform the VCIM configuration and setup procedure for this vehicle. The configuration and set-up procedure is now a two-step process which enables an automated activation by the OnStar(R) Center, without a button press by the technician to the OnStar(R) Call Center. 1. Connect the Tech2(R) to the vehicle. Page 3569 7. Install the outlet hose to the water pump. 8. Position the outlet hose clamp at the water pump. 9. Install the accessory drive belt. Replacement - Accessory (4.8L, 5.3L, and 6.0L Engines) Drive Belt Replacement - Accessory (5.3L Engine w/RPO HP2) in Engine Mechanical - 4.8L, 5.3L, and 6.0L. 10. Install the fan blade. 11. Install the inlet hose to the water pump. 12. Position the inlet hose clamp at the water pump. 13. Install the engine vent inlet hose to the radiator hose clips. 14. If necessary, install the engine sight shield. 15. Important: Align the arrow at the throttle body end of the duct with the throttle body attaching stud. Install the air cleaner outlet duct. Page 1139 For vehicles repaired under warranty, use the table. Disclaimer Page 1559 Engine Coolant Temperature (ECT) Sensor Page 7210 Electrical Symbols ELECTRICAL SYMBOLS Electrical Symbols Part 1 Page 14475 Memory Seat Module - C3 Part 2 Page 4638 Electrical Symbols Part 9 Page 5399 5. Remove the fuel tank fill pipe ground wire bolt. 6. Remove the fuel tank fill pipe ground wire from the frame. 7. Loosen the fuel tank fill pipe clamp (1) at the fuel tank. 8. Disconnect the recirculation line quick connect fitting at the tank. 9. Remove the fuel tank fill pipe. 10. Cap the opening on the fuel tank in order to prevent possible system contamination. INSTALLATION PROCEDURE 1. Remove the cap from the opening on the fuel tank. 2. Install the fuel tank fill pipe. 3. Connect the recirculation line quick connect fitting at the tank. NOTE: Refer to Fastener Notice in Service Precautions. 4. Tighten the fuel tank fill pipe clamp (1) at the fuel tank. Tighten Tighten the clamp to 2.5 N.m (22 lb in). Page 14004 Drink Holders: Service and Repair Cupholder Replacement (Pro) Cupholder Replacement (Pro) Removal Procedure 1. Insert a flat bladed tool between the cupholder and console in order to pry the cupholder assembly out. 2. Lift the cupholder assembly slightly in order to disconnect the electrical connectors. 3. Remove the cupholder from the console. 4. Remove the switches from the cupholder assembly. 5. Remove the screws retaining the beverage-mate to the cupholder. 6. Remove the beverage-mate. Installation Procedure 1. Install the beverage-mate to the cupholder. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the retaining screws. Tighten the retaining screws to 1.6 N.m (14 lb in). 3. Install the switches to the cupholder assembly. 4. Connect the wire connectors to the switches. 5. Install the cupholder assembly to the console by pressing downwards until fully seated. Page 10882 Electrical Symbols Part 4 Page 8931 Starter/Generator Control Module (SGCM) Page 12098 ^ SP303 The following modules, components, and splice pack are connected to the star portion of the class 2 serial data circuit: ^ SP300 ^ Audio amplifier ^ Driver door module (DDM) ^ Driver door switch assembly (DDSA) ^ Memory seat module (MSM) ^ Left rear door module (LRDM) AND ^ SP303 ^ Antenna module ^ Front passenger door module (FPDM) ^ Rear integration module (RIM) ^ Right rear door module (RRDM) ^ Theft deterrent module (TDM) ^ Vehicle communication interface module (VCIM). Refer to Data Communication Schematics and Data Link Communications Description and Operation in SI. Part 2 Conditions for Running the DTC Voltage supplied to the module is in the normal operating voltage range of 9 - 16 volts. DTCs B1327, B1328, U1300, U1301, U1305 are not set as current. The vehicle power mode requires serial data communication to occur. Conditions for Setting the DTC A message containing a critical operating parameter has not been received within the last 5 seconds after establishing class 2 serial data communication. Action Taken When the DTC Sets The module uses a default value for the missing parameter. Conditions for Clearing the DTC A current DTC clears when the malfunction is no longer present. A history DTC clears when the module ignition cycle counter reaches the reset threshold, without a repeat of the malfunction. Diagnostic Aids When a malfunction such as an open fuse to a module occurs while modules are communicating, a DTC U1001-1254 Loss of XXX Communications is set current. When the modules stop communicating the current DTC U1001-1254 Loss of XXX Communications is cleared but the history DTC remains. When the modules begin to communicate again, the module with the open fuse will not be learned by the other modules so U1000 or U1255 is set current by the other modules. If the malfunction occurs when the modules are not communicating, only U1000 or U1255 is set. Page 14303 WA8555/41 - WA8555/41 Page 2624 Location View Locations Instrument Panel Switches-LH Page 10471 Wheel Bearing: Service and Repair With Rear Wheel Steering Wheel Hub and Bearing Replacement ^ Tools Required J 45859 Axle Remover Removal Procedure 1. Notice: Refer vehicle Lifting. Raise the vehicle. Refer to Vehicle Lifting. 2. Remove the tire and wheel. 3. Remove the brake rotor. 4. Remove the axle nut dust cover (4). 5. Remove the cotter pin (2) and retainer (3) from the wheel drive shaft nut. 6. Remove the wheel drive shaft retaining nut. 7. Remove the wheel hub and bearing retaining bolts. OnStar(R) - Analog/Digital System Information Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Analog/Digital System Information INFORMATION Bulletin No.: 06-08-46-008C Date: September 18, 2008 Subject: Information on OnStar(R) Dual-Mode (Analog/Digital) Systems Models Supercede: This bulletin is being revised to correct the model year range for the Chevrolet Impala and Monte Carlo and update the reference to GM Dealerworld. Please discard Corporate Bulletin Number 06-08-46-008B (Section 08 - Body and Accessories). All 2000-2003 model year vehicles equipped with OnStar® from the list above were built with Analog/Digital-Ready OnStar(R) Hardware. Some of these vehicles may have been upgraded to Dual-Mode (Analog/Digital). Certain 2004-2005 model year vehicles equipped with OnStar(R) from the list above may have been either: ^ Originally built at the factory with Dual-Mode (Analog/Digital) OnStar(R) Hardware with Dual-Mode (Analog/Digital) OnStar(R) Hardware OR ^ Upgraded to Dual-Mode (Analog/Digital) Hardware All 2006 model year and newer vehicles equipped with OnStar(R) were built at the factory with Dual-Mode (Analog/Digital) OnStar(R) Hardware. If a vehicle has Dual-Mode (Analog/Digital) OnStar(R) Hardware, then the system is capable of operating on both the analog and digital cellular Page 12591 8.2. Remove the console (A) together with the OnStar(R) control modules. 8.3. Remove the connectors (B). Important: The optic cable must not be bent with a radius less than 25 mm (1 in). Important: Secure the wiring harness so that there is no risk of chafing and rattling. 8.4. Fold back the wiring harness and tape over the connectors (C). Fold back the wiring harness once more and secure with cable ties (D). Page 5374 3. If vehicle is a regular cab, install the fuel feed, EVAP, and return pipe assembly nuts. Tighten Tighten the nuts to 12 N.m (106 lb in). 4. Remove the caps from the fuel pipes at the fuel tank. 5. Connect the fuel feed and return pipes at the fuel tank. 6. If equipped with 4WD, install the torsion bar bracket. 7. Install the EHCU (1). 8. Install the bolts (4) attaching the EHCU bracket to the frame (5). Tighten Tighten the bolts to 25 N.m (18 lb ft). Page 7052 1. Install the front propeller shaft by sliding the front propeller shaft into the transmission or the transfer case, w/o RPO MW3 or M74. 2. Install the front propeller shaft to the transmission pinion yoke, w/ RPO MW3 or M74. 3. Install the yoke retainers and the bolts, w/ RPO MW3 or M74. Important: ^ Align the reference marks made during removal. ^ Tighten the bolts until snug. Do not torque the bolts at this time. 4. Install the center bearing support (2). 5. Install the center bearing support nuts. ^ Tighten the bearing support nuts to 40 Nm (30 ft. lbs.). Notice: Refer to Fastener Notice in Service Precautions. 6. Tighten the yoke retainer bolts, w/ RPO MW3 or M74. ^ Tighten the yoke retainer bolts to 25 Nm (18 ft. lbs.). 7. Inspect the splines of the front propeller shaft stub shaft for a sufficient coating of grease. If the splines of the stub shaft does not have a sufficient coating of grease, lubricate the shaft with chassis grease (GM P/N 12377985 or equivalent). Page 4937 5. Connect the VSS electrical connector (2). 6. Lower the vehicle. 7. Refill the fluid as required. Page 1914 Page 12369 Garage Door Opener Transmitter: Service and Repair Garage Door Opener Programming Universal GARAGE DOOR OPENER PROGRAMMING - UNIVERSAL GARAGE DOOR OPENER PROGRAMMING IMPORTANT: Do not use the garage door opener (GDO) with any garage door opener that does not have the stop and reverse safety feature. This includes any garage door opener model manufactured before April 1, 1982. Be sure that people and objects are clear of the garage door you are programming. The GDO is programmed by using the customer's hand-held transmitter(s). Turn the ignition OFF while programming the GDO transmitter. Follow these steps to program up to 3 channels: 1. If you have previously programmed a transmitter, proceed to Step 2. Otherwise, hold down the 2 outside buttons on the GDO transmitter for approximately 20 seconds, until the light on the GDO transmitter begins to flash rapidly. Then release the buttons. This procedure erases any previous settings and initializes the memory for all 3 channels. 2. Decide which of the 3 channels you want to program to the transmitter you have. 3. Hold the end of the hand-held transmitter against the front surface of the GDO (less than 1 inch) so you can still see the light. 4. Using both hands, press the hand-held transmitter button and the desired button on the GDO transmitter. Continue to hold both buttons through Step 5. IMPORTANT: The GDO is compatible with most, but not all, types and brands of transmitters. If the GDO light does not flash rapidly after 90 seconds, there may be a compatibility conflict with the transmitter used to program the GDO. Call HomeLink(tm) at 1-800-355-3515 in order to address this problem. 5. Hold down the buttons on both transmitters until you see the light on the GDO transmitter flash slowly and then rapidly. The rapid flashing, which could take up to 90 seconds, indicates that the GDO transmitter has been programmed. Release the buttons on both transmitters when the light starts to flash rapidly. TRAINING THE GDO FOR ROLLING CODE RECEIVERS This procedure is for training the customer's rolling code garage door openers to their GDO transmitter. The GDO must already be programmed to its hand-held transmitter. The training process below must be completed within 30 seconds or it must be repeated. 1. Locate the train button on the garage door opener receiver. Refer to the operator's manual for the garage door opener (or call HomeLink(tm) at 1-800-355-3515 for assistance). Follow instructions for the garage door opener in order to determine when the unit is in train mode. 2. Return to the GDO transmitter in the vehicle, and press the button that you want trained for rolling codes 3 times, for 1 second each time. If not successfully programmed, try 2-5 seconds each time. 3. Press the button used again in order to verify that the GDO transmitter has been programmed. You may use either the hand-held transmitter or the GDO to open the garage door. The GDO is compatible with most, but not all, types and brands of transmitters. If the GDO light does not flash rapidly after 90 seconds, there may be a compatibility conflict with the transmitter used to program the GDO. Call HomeLink(TM) at 1-800-355-3515 in order to address compatibility concerns. ERASING CHANNELS To erase programmed channels, hold down the 2 outside buttons until the light on the GDO transmitter begins to flash. Individual channels cannot be erased, but can be reprogrammed using the Garage Door Opener Programming and the Training GDO for Rolling Code Receivers procedures. Memory Seat Calibration Procedure Memory Positioning Module: Service and Repair Memory Seat Calibration Procedure MEMORY SEAT CALIBRATION PROCEDURE The memory seat module uses position sensor inputs to establish soft stop locations for the adjuster motors several millimeters ahead of the physical limits of the adjuster assembly. After replacing a memory seat module or adjuster components, it may be necessary to reset the adjuster motor soft stop locations. When the repair procedure has been completed, operate the seat adjuster switch in every direction until the seat adjuster reaches its mechanical hard stop by repeatedly pressing and releasing the switch as necessary. Page 15619 Door Switch: Diagrams Door Latch Assembly (Door Jamb Switch) - RR C2 (Crew Cab Only) Door Latch Assembly (Door Jamb Switch) - RR C2 (Crew Cab Only) Page 15868 Turn Signal Multifunction Switch - C2 Page 15375 Page 9773 C326 Heated Seat Jumper Harness To Passenger Seat Harness (With RPO Code KA1) Page 16059 Electrical Symbols ELECTRICAL SYMBOLS Electrical Symbols Part 1 Engine, A/T - Shift/Driveability Concerns/MIL ON Air Filter Element: Customer Interest Engine, A/T - Shift/Driveability Concerns/MIL ON Bulletin No.: 04-07-30-013B Date: February 01, 2007 INFORMATION Subject: Automatic Transmission Shift, Engine Driveability Concerns or Service Engine Soon (SES) Light On as a Result of the Use of an Excessively/Over-Oiled Aftermarket, Reusable Air Filter Models: 2007 and Prior GM Cars and Light Duty Trucks 2007 and Prior Saturn Models 2003-2007 HUMMER H2 2006-2007 HUMMER H3 2005-2007 Saab 9-7X Supercede: This bulletin is being revised to add models and model years. Please discard Corporate Bulletin Number 04-07-30-013A (Section 07 - Transmission/Transaxle). The use of an excessively/over-oiled aftermarket, reusable air filter may result in: Service Engine Soon (SES) light on Transmission shift concerns, slipping and damaged clutch(es) or band(s) Engine driveability concerns, poor acceleration from a stop, limited engine RPM range The oil that is used on these air filter elements may be transferred onto the Mass Air Flow (MAF) sensor causing contamination of the sensor. As a result, the Grams per Second (GPS) signal from the MAF may be low and any or all of the concerns listed above may occur. When servicing a vehicle with any of these concerns, be sure to check for the presence of an aftermarket reusable, excessively/over-oiled air filter. The MAF, GPS reading should be compared to a like vehicle with an OEM air box and filter under the same driving conditions to verify the concern. The use of an aftermarket reusable air filter DOES NOT void the vehicle's warranty. If an aftermarket reusable air filter is used, technicians should inspect the MAF sensor element and the air induction hose for contamination of oil prior to making warranty repairs. Transmission or engine driveability concerns (related to the MAF sensor being contaminated with oil) that are the result of the use of an aftermarket reusable, excessively/over-oiled air filter are not considered to be warrantable repair items. Page 3648 5. Install the air cleaner outlet duct. 6. Install the radiator inlet hose clip to the outlet duct. NOTE: Refer to Fastener Notice in Service Precautions. 7. Tighten the air cleaner outlet duct clamps at the following locations: - Throttle body - MAF/IAT sensor Tighten Tighten the screws to 7 N.m (62 lb in). 8. Fill the cooling system. Refer to Draining and Filling Cooling System (with HP2)Draining and Filling Cooling System (without HP2) in Cooling System. Page 6657 ^ Reinstall the fuse and fuse panel cover. ^ Press the "Enter" button to perform the "Refresh" function. ^ "Test in Progress" will be displayed and the right front passenger door lock will cycle once. ^ The screen will display "Procedure Completed". ^ Press the "Exit" button as necessary to return to the main menu screen. 3. Using the switches in the right front passenger door, verify that the power window and power door lock located in that door function properly. Important: The calibrations required for performing SPS reprogram in the next step are based on the type of exterior rearview mirror the vehicle has. To determine the correct calibration, check the Service Parts Identification Label on the vehicle for the RPO code for exterior mirrors. 4. Follow normal Service Programming System (SPS) to reprogram the passenger door module with the current calibration available in TIS 2000. 5. After reprogramming is complete, using the switches in the right front passenger door, verify that the power window and power door lock located in that door function properly. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 5827 9. Disassemble the harness connector (1) from the encoder. 10. Remove the encoder from the output shaft using a flat tip screwdriver. Installation Procedure 1. Assemble the harness to the NEW encoder with the connector legend "TOP" (1) and the encoder part number facing up. 2. Assemble the output shaft into the encoder, being sure to align the encoder tab with the groove on the shaft. 3. Ensure the encoder is seating properly on the output gear. 4. Place the output shaft encoder on the casting. 5. Place the grommet harness on the casting slot, the flat area on the grommet will be facing up. Service and Repair Starter Heat Shield: Service and Repair STARTER SHIELD REPLACEMENT REMOVAL PROCEDURE 1. Remove the starter motor. 2. If equipped with a 4.8L, 5.3L, or 6.0L engine, remove the starter heat shield. 3. If equipped with a 8.1L engine, remove the starter heat shield bolts, and nut. 4. Remove the starter heat shield. INSTALLATION PROCEDURE A/C - Hiss Noise From Instrument Panel Hose/Line HVAC: All Technical Service Bulletins A/C - Hiss Noise From Instrument Panel Bulletin No.: 06-01-38-002 Date: March 17, 2006 TECHNICAL Subject: A/C System Refrigerant Hiss Noise (Replace Liquid Line) Models: 2003-2006 Cadillac Escalade Models 2003-2006 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2003-2006 GMC Sierra, Yukon Models with 4.3L, 4.8L, 5.3L, 6.0L or 8.1L Engine (VINs X, V, T, Z, B, U, N, G - RPOs LU3, LR4, LM7, L59, L33, LQ4, LQ9, L18) and Air Conditioning (RPOs CJ2, CJ3 and C69) Condition Some customers may comment on a hiss noise coming from the instrument panel. The noise has also been described as sounding like a gurgle or water spattering. The noise occurs when the Air Conditioning (A/C) compressor engages and may continue for 5 to 10 seconds after the compressor disengages or the A/C system is turned off. The noise is most noticeable when the vehicle is at idle or is being driven at low speeds. The noise is undetectable after about one minute when the A/C system has been turned off or the vehicle has been turned off. Cause This condition may be caused by the expanding refrigerant as it passes through the orifice tube. Correction Technicians are to verify that the customer concern is only as described in the condition statement above. If the customer concern is a refrigerant hiss noise, then technicians are to perform the normal diagnostic procedures for an A/C system concern. The ACR2000 should be used to check the A/C system performance, charge level and discharge temperatures. This will eliminate the possibility that another condition is contributing to this customer concern. If the A/C system is performing properly, and all other possible sources of this noise are eliminated, then technicians are to replace the A/C liquid line. Use the proper part number as described in the parts information box below. Verify that the noise has been eliminated and that the A/C system operates normally. Parts Information Important: The trucks affected by this bulletin that have rear air conditioning were built with two different length condensers. The short condenser is 762 mm (30.0 in) long. The long condenser is 914 mm (36.0 in) long. Be sure to measure the length of the condenser before ordering one of the tubes listed below for vehicles with rear air conditioning. Page 16175 Window Switch - RR (Crew Cab Only) Part 1 Page 1303 1. Apply sealant GM P/N 12346004, (Canadian P/N 10953480), or equivalent, to the threads of the oil pressure sensor. Notice: Refer to Fastener Notice in Service Precautions. 2. Using J 41712 or equivalent, install the oil pressure sensor. ^ Tighten the oil pressure sensor to 30 Nm (22 ft. lbs.). 3. Connect the oil pressure sensor electrical connector (1). 4. If necessary, install the engine sight shield. Page 14122 Front Passenger Door Module (FPDM) - C3 (With RPO Code YE9) Part 1 Page 7598 Steering - Power Steering Pump Replacement Tips Power Steering Motor: Technical Service Bulletins Steering - Power Steering Pump Replacement Tips INFORMATION Bulletin No.: 06-02-32-013B Date: August 07, 2009 Subject: Diagnostic Tips/Recommendations When Power Steering Pump Replacement is Necessary Models: 1997-2010 GM Passenger Cars and Light Duty Trucks (including Saturn) 2010 and Prior HUMMER H2, H3 2005-2009 Saab 9-7X Supercede: This bulletin is being revised to add model years and update the information. Please discard Corporate Bulletin Number 06-02-32-013A (Section 02 - Steering). A recently completed analysis of returned power steering (PS) pumps that had been replaced for noise, no power assist, no or low pressure and leaking conditions has indicated a high number of "No Trouble Found" results. Corporate Bulletin Number 01-02-32-004 indicates that when attempting to repair a power steering concern, the steering system analyzer should be utilized to assist the technician in a successful diagnosis. Note- Saturn ASTRA does not utilize the Power Steering System Analyzer. In addition, extensive warranty analysis has shown that the following situations are all significant root causes of PS pump failures: - Improper pulley installation - Re-using the O-rings - Using fluid other than the OE-specified steering fluid - Failure to flush the PS system In order to help improve customer satisfaction and reduce comebacks, GM recommends the following tips for replacing a PS pump: 1. Low or no pressure from the PS pump may be the results of dirty or contaminated fluid, which could cause the pressure relief valve to stop functioning. Using the proper tools, flush and bleed the PS system. Any residual contaminants will result in pump failure. 2. When removing the pulley, use the proper special tools. Because the pulley alignment is critical, distorting the pulley may damage bearings on the new PS pump. Note Some new PS pumps may not include a new O-ring. Please refer to the appropriate Parts Catalog. Saturn retailers should refer to the appropriate model year Parts & Illustration Catalog for the vehicle. 3. Be sure to use only the new O-rings included with the PS pump. The new reservoir O-ring must be lubricated with OE-specific PS fluid prior to installation. Also make sure that the control valve O-ring is in its exact groove position and is NOT covering the pressure bypass hole. 4. Bleed the PS system according to the procedures/recommendations in SI. Following these procedures and using the correct tools and fluids should help ensure that the new PS pump operates properly. Skipping steps may cost you time and trouble later. Disclaimer Locations Knock Sensors Page 10094 Power Steering Pump: Service and Repair Power Steering Pump Bracket Replacement Power Steering Pump Bracket Replacement Removal Procedure 1. Remove the power steering pump from the bracket (3). 2. Remove the positive battery junction block bracket retaining bolts (2) from the power steering pump bracket. 3. Remove the bolts retaining the power steering pump bracket (3) to the engine. 4. Remove the power steering pump bracket from the vehicle. Installation Procedure Page 1690 1. Coat a NEW O-ring seal with a thin film of Synchro-mesh transmission fluid GM P/N 12345349 (Canadian P/N 10953465), or equivalent. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the VSS and O-ring seal. ^ Tighten the VSS to 16 Nm (12 ft. lbs.). 3. Connect the VSS electrical connector (1). 4. Lower the vehicle. Locations Vehicle Speed Sensor (VSS) - 4 Wheel Drive Manual Transmission Locations Instrument Panel Switches-LH Keyless Entry - Inoperative Keyless Entry Module: All Technical Service Bulletins Keyless Entry - Inoperative Bulletin No.: 04-08-52-005 Date: June 15, 2004 TECHNICAL Subject: Remote Keyless Entry (RKE) System Inoperative (Reprogram Passenger Door Module (PDM)) Models: 2004 Cadillac Escalade, Escalade ESV, Escalade EXT 2004 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2004 GMC Sierra, Yukon, Yukon XL Condition Some customers may comment on any of the following conditions: ^ The RKE key fob does not function. ^ The "Service Tire Pressure Monitoring System" message is displayed, if equipped. ^ The passenger door will not unlock from the passenger's or driver's door switches. ^ The passenger door window is inoperative. Correction Reprogram the PDM with the Tech 2(R). Currently the Tech 2(R) software is not available for the 2004 model year. Engineering is aware of this and are working to release a new service calibration. In the meantime, build the Tech 2(R) as a 2003 model year and perform the reprogram using the procedure listed below. 1. Turn the ignition switch to the ON position. 2. Connect the Tech 2(R) to the vehicle's diagnostic link connector (DLC), power it up and press enter. ^ Select: Diagnostics. ^ Select model year: 2003. ^ Select: Light truck. ^ Select: Body. ^ Select the proper Product line. ^ Select the proper HVAC Type. ^ Select the proper Radio System type. ^ Select: Passenger Door Module. ^ Select: Special Functions. ^ Select: Refresh. Important: You must remove the described fuse in the next step for the "Refresh" program to be performed. If you do not remove the fuse for five seconds, the Tech 2 will continue to display "Test in Progress" and the program will not complete. ^ Remove the PDM fuse for 5 seconds from the fuse center located behind the panel on the left end of the instrument panel. Capacity Specifications Refrigerant: Capacity Specifications Refrigerant Charge .............................................................................................................................. ........................................................... 0.7 kg (1.6 lbs) Refrigerant Charge with Front and Rear A/C ................................................................................................................................................ 1.13 kg (2.5 lb) Page 3532 1. Install a NEW air filter element. 2. Install the air cleaner housing cover. 3. Tighten the air cleaner housing top screws until snug. 4. Connect the MAF/IAT sensor electrical connector (4). 5. Install the air cleaner outlet duct. Page 3219 16. If equipped with RPO HP2, position the auxiliary heater water pump and install it onto the studs. 17. Install the auxiliary heater water pump bracket nuts (4). ^ Tighten the bolts to 15 Nm (11 ft. lbs.). 18. Install the heater hose bracket and nut. ^ Tighten the nut to 9 Nm (80 inch lbs.). 19. Position the surge tank/heater hoses to the heater hose bracket. Locations Instrument Panel Switches-LH AWD/4WD - AWD/4WD Lamps/System Inop./DTC C0550 Control Module: Customer Interest AWD/4WD - AWD/4WD Lamps/System Inop./DTC C0550 Bulletin No.: 02-04-21-006E Date: July 20, 2006 TECHNICAL Subject: Inoperative 4WD/AWD Lamps, Inoperative 4WD/AWD System, DTC C0550 Set, No Communication with TCCM (Reprogram Transfer Case Control Module) Models: 2004 Buick Rainier 2002-2004 Chevrolet TrailBlazer, TrailBlazer EXT 2003-2004 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2002-2004 GMC Envoy, Envoy XL 2003-2004 GMC Sierra, Yukon, Yukon XL 2004 GMC Envoy XUV 2002-2004 Oldsmobile Bravada with Electronic Shift or Active Transfer Case (RPOs NP1, NP4 or NP8) Supercede: This bulletin is being revised to add Subject information and change the labor operation. This bulletin cancels and supersedes Bulletin Number 03-04-21-006. Please discard Corporate Bulletin Numbers 02-04-21-006D and 03-04-21-006 (Section 04 - Driveline/Axle). Condition Some customers may comment that the 4WD/AWD indicator lights on the selector switch do not work, or the 4WD/AWD system may be inoperative and/or the service 4WD light is illuminated. The condition is typically intermittent and always occurs at key-up. Upon investigation, the technician may find DTC C0550 set. Cause The Transfer Case Control Module (TCCM) has not received the wake-up call during key-up and has remained in the "sleep mode". When the TCCM is in the "sleep mode", it will not communicate with the class II bus or the Tech 2(R). Correction 1. Try to communicate with the TCCM. If no communication, go to step 2. If communication is possible, go to step 5. 2. Remove the underhood (ATCM or TREC) TCCM fuse. 3. Wait 30 seconds. 4. Reinstall the fuse. The module should wake up and communicate with the Tech 2(R). 5. Check for codes in the TCCM. If a C0550 is found current or in history with or without other codes, replace the module and go to step 6. 6. Reprogram the TCCM with the latest TIS software using normal SPS procedures. 7. Verify operation and that no codes are present. Important: For the 2002 model year, the TCCM must be replaced and reprogrammed. Warranty Information Page 8502 Use clean, new power steering fluid only. 12. Fill the pump reservoir with fluid to the FULL COLD level. 13. Attach J 43485, Power Steering Bleeder Adapter, to J 35555, Metal Mityvac, or equivalent. 14. Place J 43485 on or in the pump reservoir filler neck. 15. Apply a vacuum of 68 kPa (20 in Hg) maximum. 16. Wait 1 minute. 17. Remove J 43485 and J 35555. 18. Reinstall the pump reservoir cap. 19. Start the engine. Allow the engine to idle. 20. Turn the steering wheel 180-360 degrees in both directions 5 times. 21. Switch the ignition off 22. Verify the fluid level. 23. Release the park brake and unblock the wheels. Hydro-Boost(R) Replacement -- Kodiak, TopKick Tools Required ^ J 35555 Metal Mityvac ^ J 43485 Power Steering Bleeder Adapter Removal 1. Block the wheels. 2. Disconnect the electrical connectors from the electrohydraulic pump and the flow switch. Page 2447 For vehicles repaired under warranty, use the table. Disclaimer Engine Controls - MIL ON/Misfire/Misfire DTC's Set Ground Strap: Customer Interest Engine Controls - MIL ON/Misfire/Misfire DTC's Set Bulletin No.: 06-06-04-046 Date: September 12, 2006 INFORMATION Subject: Information on Engine Misfire MIL/SES Light Illuminated or Flashing DTC P0300, P0301, P0302, P0303, P0304, P0305, P0306, P0307, P0308, P0420 or P0430 Models: 1999-2007 Cadillac, Chevrolet, GMC Full-Size Pickup and/or Utility Trucks with 4.8L, 5.3L, 5.7L, 6.0L or 6.2L VORTEC GEN III, GEN IV, V-8 Engine (VINs V, C, T, Z, B, 3, M, 0, J, R, U, N, Y, K, 8 - RPOs LR4, LY2, LM7, L59, L33, LC9, LH6, LMG, LY5, L31, LQ4, LQ9, L76, LY6, L92) with Active Fuel Management(TM) and E85 Flex Fuel If you encounter vehicles that exhibit the above conditions, refer to SI for the appropriate DTC(s) set. If no trouble is found, the cause may be due to an ECM ground terminal that has corroded with rust over time. Inspect the main engine wiring harness ground terminal (G103) for this condition. The wire terminal (G103) attaches either to the front or to the rear of the right side cylinder head, depending on the model year of the Full Size Pickup and/or Utility Trucks. If the ECM ground terminal has been found to be corroded, then follow the service procedure outlined in this bulletin to correct the corrosion issue. Remove either the nut or bolt securing the main engine wiring harness ground terminal (G103) to the right cylinder head. Refer to the above illustration to determine where the ground is located on the vehicle (1). Page 903 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves SPLICING COPPER WIRE USING SPLICE SLEEVES TOOLS REQUIRED J 38125-D Terminal Repair Kit IMPORTANT: Use only GM splice sleeves, other splice sleeves may not protect the splice from moisture or a provide good electrical connection. Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. Service and Repair Idler Arm: Service and Repair Idler Arm Replacement ^ Tools Required J 24319-B Universal Steering Linkage Puller - J 29193 Steering Linkage Installer (12 mm) - J 29194 Steering Linkage Installer (14 mm) Removal Procedure Notice: Do not attempt to free the ball stud by using a pickle fork or wedge type tool, because seal or bushing damage could result. Use the proper tool to separate all ball joints. 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Remove the engine protection shield, if equipped. 3. Remove the idler arm ball stud nut (10).Do not reuse the idler arm ball stud nut. 4. Remove the idler arm from the relay rod using the J 24319-B. 5. Remove the idler arm frame bolts (3) and the nuts (1). 6. Remove the idler arm (2) from the vehicle. Installation Procedure Page 1151 1. Set the front wheels in the straight ahead position. Notice: On the 2002 and later model year vehicles the steering column LOCK was removed from the steering column. It is critical that the J 42640 - Steering column Anti-Rotation Pin is used when servicing steering columns on 2002 and later model year vehicles. Failure to use the J 42640 may result in damage to the SIR coil. 2. Set the steering wheel in the LOCK position on 2001 and prior model year vehicles. 3. For 2002 and later vehicles install the J 42640 in the steering column lower access hole. 4. From under the hood remove the lower bolt that connects the upper intermediate shaft to the steering gear coupling shaft. 5. Slide the shaft towards the dash in order to disengage the shaft from the steering gear coupling shaft. 6. For vehicles equipped with adjustable foot pedals perform the following steps: 1. Reposition the carpet away from the accelerator pedal position (APP) sensor. 2. Remove the two nuts retaining the accelerator pedal to the bulkhead. 3. Reposition the accelerator pedal out of the way so the intermediate shaft can be removed. Service and Repair Tailgate Hinge: Service and Repair Hinge Replacement - Endgate Removal Procedure 1. Remove the endgate. 2. Remove the endgate hinge bolts. 3. Remove the hinge. 4. Remove the body side hinge bolts. 5. Remove the hinge from the vehicle. Installation Procedure 1. Install the body side hinge to the vehicle. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the body side hinge bolts. Tighten the bolts to 25 N.m (18 lb ft). Page 15493 Ambient Air Temperature Sensor - Outside Page 4526 Control Module References Part 7 Page 8044 7. Disconnect the BPMV electrical connector from the EBCM. 8. Clean the BPMV to EBCM mounting surfaces with a clean cloth. Installation Procedure Important: ^ Do not reuse the old mounting screws. Always install new mounting screws with the new EBCM. ^ Do not use RTV or any other type of sealant on the EBCM gasket or mating surfaces. 1. Connect the BPMV electrical connector to the EBCM. Page 587 Disclaimer Page 13559 Body Control Module: Connector Views Body Control Module (BCM) - C1 Locations Below Driver Seat - Restraint Systems Wiring Page 11869 * Dealers using WINs: Add 0.2 hours to the labor time for administrative allowance for the module exchange. Dealers using GWM: Submit 0.2 hours administrative allowance under "Administration Time" for the module exchange. ** The $25 represents the additional net amount allowed for the module exchange. *** Dealers are to claim only administrative allowance of 0.2 hours when the module is replaced by Masscomp's Mobile Unit. Dealers using WINS should submit the 0.2 hours administrative allowance in labor time. Dealer using GWM should submit the 0.2 hours administrative allowance under Administrative Time. Customer Notification OnStar will notify customers of this program on their vehicle. Dealer Program Responsibility All unsold new vehicles in dealers'/retailers' possession and subject to this program must be held and inspected/repaired per the service procedure of this program bulletin before customers take possession of these vehicles. Dealers/retailers are to service all vehicles subject to this program at no charge to customers, regardless of mileage, age of vehicle, or ownership, through April 30, 2011. Customers who have recently purchased vehicles sold from your vehicle inventory, and for which there is no customer information indicated on the dealer/retailer listing, are to be contacted by the dealer/retailer. Arrangements are to be made to make the required correction according to the instructions contained in this bulletin. A copy of the customer letter is provided in this bulletin for your use in contacting customers. Program follow-up cards should not be used for this purpose, since the customer may not as yet have received the notification letter. Page 6741 Replace the side bearing adjuster lock ring and refer to SI for adjustment. When replacing the side bearing adjuster lock ring, inspect the old locking ring and make sure there are vertical lines in the outer and inner diameter of the ring (1). Next inspect and make sure there is tension when the locking rings are installed. If the locking ring rotates freely around the adjuster, do not use the locking ring. Replace with a new locking ring and make the same inspection. Oversize Lock Rings-Do Not Use The new lock rings will not have any vertical lines (inner or outer). They are imprinted during install. If vertical lines are shown (1), DO NOT USE. Parts Information Refer to GM Parts Catalog. Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Page 8583 3. Remove the master cylinder nuts. Do not remove the pipes from the master cylinder. Position the master cylinder away from the booster head. Secure the master cylinder in an upright position. 4. Disconnect the power brake booster inlet hose, the steering gear inlet hose, and the power brake booster outlet hose from the booster assembly. 5. Remove the booster pump rod retainer from the lever. 6. Remove the stop lamp switch from the lever. 7. Remove the booster pump rod from the lever. 8. Remove the nuts at the booster. 9. Remove the booster assembly. Installation 1. Install the booster assembly to the vehicle. 2. Install the nuts at the booster. Page 6514 12. Inspect the TCC solenoid and wiring harness for the following defects: ^ Damage ^ Cracked connectors ^ Exposed wires ^ Loose pins Installation Procedure 1. Install the wiring harness and TCC solenoid with a new O-ring seal to the transmission. 2. Install the pass-through electrical connector to the transmission case. 3. Notice: Refer to Fastener Notice in Service Precautions. Install the valve body bolts which retain the internal wiring harness and install the TCC solenoid bolts. ^ Tighten the control valve body bolts to 11 Nm (97 inch lbs.). ^ Tighten the TCC solenoid bolts to 11 Nm (97 inch lbs.). Page 8090 8. Remove the wheel speed sensor (WSS) mounting bolt. 9. NOTICE: Carefully remove the sensor by pulling it straight out of the bore. DO NOT use a screwdriver, or other device to pry the sensor out of the bore. Prying will cause the sensor body to break off in the bore. Remove the wheel speed sensor (5) from the hub/bearing assembly (4) shown on the 2500/3500 series. Installation Procedure 1. Plug the WSS bore to prevent debris from falling into the hub. 2. Using a wire brush or equivalent, clean the WSS mounting surface on the hub to remove any rust or corrosion. 3. Apply a thin layer of wheel bearing lubricant, GM P/N 01051344 to the hub surface and the sensor O-ring prior to sensor installation. 4. Install the WSS (5) into the hub/bearing assembly (4) shown on the 2500/3500 series. Ensure that the sensor is seated flat against the hub. Page 12187 High OR Low The above conditions are met for more than 3 seconds. Circuit/System Verification These DTCs cannot be retrieved with a current status. To diagnose use the Scan Tool Does Not Communicate with a Class 2 Device. Refer to SI. An intermittent condition is likely to be caused by a short on the Class 2 serial data circuit. To diagnose use the Scan Tool Does Not Communicate with a Class 2 Device. Refer to SI. DTC B2455 DTC Descriptors DTC B2455 01: Cellular Phone Microphone Circuit Short to Battery DTC B2455 02: Cellular Phone Microphone Circuit Short to Ground DTC B2455 04: Cellular Phone Microphone Circuit Open Circuit Circuit/System Description Without RPO UAV The vehicle communication interface module (VCIM) uses the cellular phone microphone to allow driver communication with OnStar(R). With RPO UAV The vehicle communication interface module (VCIM) and navigation radio use the cellular phone microphone to allow driver communication with OnStar(R), as well as to operate the voice recognition/voice guidance feature of the navigation radio. Conditions for Running the DTC The ignition is in RUN or ACC position. System voltage is between 9.5 - 15.5 volts. The above conditions are met for more than 10 seconds. Conditions for Setting the DTC B2455 01: A short to battery is detected on the cellular microphone signal circuit. B2455 02: A short to ground is detected on the cellular microphone signal circuit. B2455 04: An open circuit is detected on the cellular microphone signal circuit. Action Taken When the DTC Sets The VCIM and/or navigation radio (RPO UAV) will not receive any signal from the microphone. The OnStar(R) status LED turns red. Voice recognition will not function. Conditions for Clearing the DTC Page 2651 Fuse Block - Underhood C3 Part 1 Page 10148 Steering Column Position Sensor: Service and Repair Steering Wheel Position Sensor Centering Steering Wheel Position Sensor Centering Removal Procedure 1. Important: Identify the type of steering wheel position sensor from the illustrations shown BEFORE removing the sensor from the steering column. Once you have identified the steering wheel position sensor, follow the instructions listed in the removal procedure. Verify the type of steering wheel position sensor. 2. From the technicians point of view, the FRONT of the sensor (1) connector will be on the right. 3. Important: If reusing the existing sensor, you do not have to align the sensor before removal. Centering is not required when it is time to reinstall. Remove the connector from the sensor. 4. Remove the sensor (1) from the adapter and bearing assembly. 5. To install the sensor, proceed to step 1 in the installation section. 6. From the technicians point of view, the FRONT of the sensor will have: ^ A foam ring (2) ^ A pin hole (1) for centering the pin. Note the location of the pin hole. ^ A flush rotor flange cuff (4) 7. Important: If reusing the existing sensor, you must make an alignment mark on the rotor flange cuff (3) before removing the sensor. Failure to do so will cause misalignment when installing the sensor. A new sensor will be required if misaligned. Make an alignment mark on the flush rotor flange cuff (3). 8. Remove the connector from the sensor. 9. Remove the sensor from the adapter and bearing assembly. 10. To install the sensor, proceed to step 5 in the installation procedure. Page 4823 Top Of Engine Page 9221 C249 Console Harness To Bezel Harness (With RPO Code Y91) Page 13006 THIS PROGRAM IS IN EFFECT UNTIL APRIL 30, 2011. Condition Certain 2002-2009 model year vehicles equipped with OnStar(R) may have a condition in which the vehicle's OnStar(R) system repeatedly makes incomplete calls to OnStar(R) without the vehicle's occupant(s) input or knowledge. Customer initiated Blue Button call, Emergency calls, and Automatic Crash Notification calls will also fail to establish a data connection with the OnStar(R) Call Center. Eventually, the customer's call will connect as a voice only line and the customer will be able to talk with an OnStar(R) advisor; however, the advisor will not get crucial customer data such as vehicle identification and location. Correction Dealers/retailers are to replace the OnStar(R) module (VCIM). Vehicles Involved Involved are certain 2002-2009 model year vehicles equipped with OnStar(R), and built within these VIN breakpoints: Note: Some model years/models have only one vehicle involved. Important Dealers/retailers are to confirm vehicle eligibility prior to beginning repairs by using GMVIS (dealers/retailers using WINS) or the Investigate Vehicle History link (dealers/retailers using GWM). Not all vehicles within the above breakpoints may be involved. For dealers/retailers with involved vehicles, a listing with involved vehicles containing the complete vehicle identification number, customer name, and address information has been prepared and will be provided to dealers/retailers through the GM GlobalConnect Recall Reports. Dealers/retailers will not have a report available if they have no involved vehicles currently assigned. The listing may contain customer names and addresses obtained from Motor Vehicle Registration Records. The use of such motor vehicle registration data for any purpose other than follow-up necessary to complete this program is a violation of law in several states/provinces/countries. Accordingly, you are urged to limit the use of this report to the follow-up necessary to complete this program. Parts Information US: OnStar(R) modules required for this program are to be obtained by contacting Autocraft Electronics via the web at www.autocraft.com, and selecting the catalog item that contains bulletin number 10037 (or PIC 4893B), or by calling 1-800-336-3998. Dealer must provide the VIN, R.O. number, and the current vehicle mileage. Canada: OnStar(R) modules required for this program are to be obtained by contacting MASS Electronics at 1-877-410-6277. Dealer must provide the VIN, R.O. number, and the current vehicle mileage. DO NOT ORDER ONSTAR(R) MODULES FROM GENERAL MOTORS CUSTOMER CARE AND AFTERSALES (GMCC&A;), SATURN SERVICE PARTS OPERATION (SSPO), OR THE TECHNICAL ASSISTANCE CENTER (TAC). Courtesy Transportation The General Motors Courtesy Transportation program is intended to minimize customer inconvenience when a vehicle requires a repair that is covered by the New Vehicle Limited Warranties. The availability of courtesy transportation to customers whose vehicles are within the warranty coverage period and involved in a product program is very important in maintaining customer satisfaction. Dealers/retailers are to ensure that these customers understand that shuttle service or some other form of courtesy transportation is available and will be provided at no charge. Dealers should refer to the General Motors Service Policies and Procedures Manual for Courtesy Transportation guidelines. Claim Information 1. Submit a claim using the table below. 2. Courtesy Transportation - For dealers/retailers using WINS, submit using normal labor code; for dealers/retailers using GWM - submit as Net Item under the repair labor code. Service and Repair Hood Latch Release Cable: Service and Repair Hood Latch Release Cable Replacement Removal Procedure Important: If the cable is broken, release the hood by pressing the latch tab on the left side of the lock assembly. Use a rod to press the latch tab. 1. Lift the hood. 2. Remove the left hinge pillar trim panel. 3. Remove the electrical center cover by removing the center retaining nut, and releasing the retaining clips (1) on both sides. 4. In order to gain access to the hood release cable, it is necessary to move the electrical center by releasing the retaining clips (1) on both sides, and lifting out of the retaining grooves (2). Page 6945 25. Position the CV joint end (outboard end) of the halfshaft assembly in the bottom half of the J 36652-1 or J 36652-2. 26. Align the following during this procedure: - The CV joint boot (3) - The CV joint assembly (1) - The swage ring (2) 27. Install the top half of J 36652-1 or J 36652-2 onto the lower half of the tool, over the the CV joint boot (3) and the CV joint assembly (1). 28. Align the swage ring (2) and the swage ring clamp. 29. Insert the bolts onto J 36652-1 or J 36652-2. Hand tighten the bolts until the bolts are snug. Tighten each bolt 180 degrees at a time. Alternate between the bolts until both side of the top half of the tool touch the bottom half of the tool. 30. Loosen the bolts and remove the halfshaft assembly from the tool. 31. Install the wheel drive shaft seal cover, if applicable. 32. Install the wheel drive shaft. Page 11514 Disclaimer Page 13638 1. Position the door handle bezel in the door trim panel. 2. Install the door handle bezel to the door panel by pressing the bezel into place until the bezel is completely seated. Page 4502 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the cover up until the dress cover releases. Repeat this procedure for the other locking tab. 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. 5. If the connector has a nose piece, use a small flat-blade tool to remove the nose piece by inserting the blade into the slot on the front of the connector and prying up on the nose piece. IMPORTANT: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 6. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. IMPORTANT: Be careful not to angle or rock the J 38125-13A tool when inserting it into the connector or the tool may break. Page 6265 The torque specification has changed for the fittings to case. The torque has changed from 38 Nm (28 lb ft) to 32 Nm (23 lb ft). Tighten Tighten the new cooler fittings to 32 Nm (23 lb ft). The converter drain back check ball (420C) has been removed from the cooler line fitting and is now located in the channel plate. If you get a concern of no movement in the morning or after sitting for several hours, the cooler check ball should be inspected. The best way to determine where the check ball is located is to look at the cooler line fittings. The old fittings are different sizes (3/8-18 NPSF & 1/4-18 NPSF) and would contain the cooler check ball. The new fittings are the same size as each other (9/16-18 UNF) and do not have a cooler check ball. Parts Information Disclaimer Page 2732 Fuse Block: Service and Repair I/P Electrical Center or Junction Block Replacement - Left INSTRUMENT PANEL ELECTRICAL CENTER OR JUNCTION BLOCK REPLACEMENT - LEFT REMOVAL PROCEDURE 1. Remove the left side end panel. 2. Remove the knee bolster. 3. Disconnect all the wiring connectors from the fuse block. 4. Remove all the fuses. 5. Remove the turn signal relay from the back of the fuse block. 6. From behind the fuse block, remove the retaining bolt. 7. Insert a screw driver between the fuse block and the wire harness block to separate. 8. Push on the retainers in order to remove the fuse block. 9. Remove the fuse block from the vehicle. INSTALLATION PROCEDURE 1. Install the fuse block onto the I/P assembly until it clicks in place. 2. Install the wire harness block to the back of the fuse block. NOTE: Refer to Fastener Notice in Service Precautions. 3. Install the bolt. Tighten Tighten the bolt to 6 N.m (53 lb in). 4. Install the turn signal relay to the back of the fuse block. 5. Using the wiring diagram on the cover of the fuse panel, install the fuses. 6. Install the electrical connectors. 7. Install the knee bolster. Page 11743 Seat Sensor/Switch: Service and Repair INFLATABLE RESTRAINT SEAT POSITION SENSOR REPLACEMENT REMOVAL PROCEDURE 1. Remove the passenger or driver's seat from the vehicle. 2. Disconnect the electrical connector from the seat position sensor. CAUTION: Eye protection must be worn when drilling rivets to reduce the chance of personal injury. 3. Drill out the rivets that retain the seat position sensor (1) to the seat adjuster track bracket. 4. Remove the seat position sensor from the seat adjuster track bracket. INSTALLATION PROCEDURE 1. Install the seat position sensor to the seat adjuster bracket. 2. Install the rivets that retain the seat position sensor (1) to the seat adjuster track bracket. 3. Connect the electrical connector to the seat position sensor. 4. Install the passenger or driver's seat to the vehicle. Page 7947 Service and Repair Steering Angle Sensor: Service and Repair Rear Position Sensor Replacement Removal Procedure 1. Notice: Refer vehicle Lifting. Raise the vehicle. Refer to Vehicle Lifting. 2. Remove the steering gear protection shield (1) retaining bolts (3). 3. Disconnect the electrical connector (1). 4. Notice: When removing the rear position cover from the steering gear be careful not to damage to the rear position sensor. Remove the rear wheel position sensor cover (4) from the steering gear by prying on the cover using the slot. 5. Remove the rear wheel position sensor retaining bolts (3). 6. Important: Check the inner tie rod boot for wear or damage. If the boots are damaged replace the steering gear actuator. 7. Important: Page 2662 Fuse Block- I/P C1 Part 3 Page 6197 interchangeable. Important: The wear plate (640) and input thrust washer (660) are not required with the new sprag. Use of the thrust washer and wear plate with the new sprag assembly will cause a misbuild (correct end play cannot be obtained). Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 5641 Spark Plug: Service and Repair SPARK PLUG REPLACEMENT REMOVAL PROCEDURE 1. Remove the spark plug wire. 2. Loosen the spark plug 1 or 2 turns. 3. Brush or using compressed air, blow away any dirt from around the spark plug. 4. Remove the spark plug. If removing more than one plug, place each plug in a tray marked with the corresponding cylinder number. INSTALLATION PROCEDURE 1. Correctly position the spark plug washer. 2. Inspect the spark plug gap. Adjust the gap as needed. Specification Spark plug gap: 1.01 mm (0.040 in) 3. Hand start the spark plug in the corresponding cylinder. NOTE: Refer to Fastener Notice in Service Precautions. 4. Tighten the spark plug. Tighten Tighten the plug to 15 N.m (11 lb ft) for used heads. - Tighten the plug to 20 N.m (15 lb ft) for NEW heads. 1. Install the spark plug wire. Locations Driver Door Component Locations Torque Converter Clutch Solenoid: Component Locations Automatic Transmission - 4L60-E/4L65-E Automatic Transmission Electronic Component Views (M30/M32) Electronic Components Page 14410 Door Control Module Diagram 3 Part 2 Page 14689 The GM Vehicle Care Odor Eliminator product is an effective odor elimination product when used properly. It must come into direct contact with the odor source. It should be used in conjunction with diagnostic procedures to first eliminate the root cause of the odor. Some procedures for use after odor root cause correction are: STEP TWO: ^ Use the trigger spray head. ^ Put a drop of dish soap the size of a quarter in the bottom of a bottle. ^ Add 8 oz. of GM Vehicle Care Odor Eliminator (1 cup) to the dish soap and top off the bottle with tap water. ^ This formula should be used on hard surfaces (dash, interior plastic molding, and floor pan) STEP THREE: The third step to neutralizing the vehicle is a light to medium treatment of all carpeting and upholstered seats with the GM Vehicle Care Odor Eliminator formula and a wide fan spray setting (at full strength) (i.e.: carpeting on the driver's side requires 4-5 triggers pulls for coverage). The headliner and trunk should be sprayed next. Lightly brushing the formula into the carpeting and upholstery is a recommended step for deep odor problems. The dash and all hard surfaces should be sprayed with dish soap/water mixture. Let stand for 1-2 minutes then wipe off the surface. STEP FOUR: (vehicle ventilation system treatment) The ventilation system is generally the last step in the treatment of the vehicle. a. Spray the GM Vehicle Care Odor Eliminator formula into all dash vents. (1-2 trigger pulls per vent). b. Start the vehicle and turn the vehicle fan on high cool (not A/C setting). c. Spray the formula (10 trigger pulls) into the outside fresh air intake vent (cowl at base of windshield) d. Enter the vehicle after 1 minute and wipe off the excess formula spurting out of the dash vents. e. Smell the air coming from the dash vents. If odors are still present, spray another 5 triggers into the cowl, wait another minute and smell the results. Once you have obtained a fresh, clean smell coming from the vents, turn the system to the A/C re-circulation setting. Roll up the windows, spray 3-5 pumps into the right lower IP area and let the vehicle run with the fan set on high for 5-7 minutes. Please follow this diagnosis process thoroughly and complete each step. If the condition exhibited is resolved without completing every step, the remaining steps do not need to be performed. If these steps do not resolve the condition, please contact GM TAC for further diagnostic assistance. Additional Suggestions to Increase Customer Satisfaction Here are some additional ideas to benefit your dealership and to generate greater customer enthusiasm for this product. ^ Keep this product on-hand for both the Service Department and the Used Car lot. Add value to your used car trades; treat loaner and demo cars during service and at final sale to eliminate smoke, pet, and other common odors offensive to customers. Make deodorizing a vehicle part of your normal vehicle detailing service. ^ Consider including GM Vehicle Care Odor Eliminator as a give-away item with new vehicle purchases. Many dealers give away as "gifts" various cleaning supplies at time of delivery. GM Odor Eliminator is one of a few products GM offers that has as many uses in the home as in the vehicle. Customers may find this product can be used for a host of recreational activities associated with their new vehicle, such as deodorizing a boat they tow, or a camper. ^ GM Odor Eliminator and many of the GM Vehicle Care products offer you the chance to increase dealership traffic as these superior quality products cannot be purchased in stores. Many Dealerships have product displays at the parts counter. Consider additional displays in the Customer Service Lounge, the Showroom and at the Service Desk or Cashier Window. Many customers who purchase vehicles and receive regular maintenance at your dealership may never visit the parts counter, and subsequently are not exposed to the variety and value that these products offer. Parts Information Page 7896 Vehicle Speed Sensor (VSS) Tow/Haul Switch Location Page 9017 Fuse Block - Underhood C2 Part 6 Page 314 If you are unsure who the PSC is, check with the Sales Manager. General Information 1. The first step is to verify if the OnStar(R) account is active or not. This can be done by pressing the blue OnStar(R) button and connecting to the OnStar(R) call center. Analog only accounts are no longer active. Only digital upgraded accounts will be active. On Gen 6 digital systems, a clear, or "dark" LED may indicate that the OnStar(R) system has been deactivated or may possibly have a no power/no communication condition. 2. If the account isn't active, the next step is to verify what version of OnStar(R) module is in the vehicle. This can be done via the Tech 2 (Body>VCIM>Module ID Information>Module Information 2) or by using www.onstarenrollment.com. 3. A Generation 5 or older analog module can be diagnosed by following the original electronic Service Information developed for the model year of the vehicle. Note: If the customer has an old analog module, the vehicle can be repaired by replacing the module, but the customer cannot have an active account without upgrading to a digital module. 4. Modules, antennas, brackets, and other equipment are in the same location, whether original analog production or digital upgrade. 5. An upgraded vehicle may also have a new vehicle communication interface module (VCIM) bracket. If it does, order the new bracket when replacing the bracket. Don't order the original bracket. The kit may also include a small wiring jumper cable. If it does, this jumper will be required for a new module replacement. Do not discard. 6. After replacing the VCIM, it is essential to configure the new OnStar(R) system. Failure to configure the system will result in an additional customer visit for repair. DO NOT press and hold the white dot or phone button on the keypad as it will not reset this version of the OnStar(R) system and may result in a DTC being set. Use of the TIS2WEB and SPS applications, along with the Tech2(R), are required in order to perform the VCIM configuration and setup procedure for this vehicle. The configuration and set-up procedure is now a two-step process which enables an automated activation by the OnStar(R) Center, without a button press by the technician to the OnStar(R) Call Center. Page 1975 Electrical Symbols ELECTRICAL SYMBOLS Electrical Symbols Part 1 Page 5752 1. If a NEW control module is being installed, program the new module. 2. Install the shift control module to the bracket. 3. Connect the shift control module electrical connectors. 4. Start the engine and test the automatic transfer case system for proper shift operation. Transfer Case Control Module Reprogramming Transfer Case Control Module Reprogramming Set-up for Module Programming/Reprogramming Important: Ensure that the vehicle battery is fully charged and that a battery charger is no longer connected. If performing this procedure for module replacement, install a new module before proceeding. Before reprogramming, close the doors and wait two minutes to allow other modules to stop communicating via the class 2 data line. Failure to do so could result in a failed reprogramming procedure. ^ Turn OFF all accessories. ^ Turn ON the ignition, with the engine OFF. Navigation - Report Missing/Inaccurate Nav. Map Info Navigation System: All Technical Service Bulletins Navigation - Report Missing/Inaccurate Nav. Map Info INFORMATION Bulletin No.: 10-08-44-006 Date: October 11, 2010 Subject: Reporting Missing or Inaccurate Navigation Radio Map Disc Information - Complete and Submit Feedback Form at GM Navigation Disc Center Website Models: 2011 and Prior GM Passenger Cars and Trucks Equipped with Navigation Radio Some customers may notice that some navigation radio map discs may have missing or incorrect information. The following list contains some examples: - Missing or incorrect roads, road names or road shapes - Missing or incorrect addresses - Missing or incorrect highway labeling - Missing or incorrect highway exit numbers - Missing or incorrect traffic restrictions - Missing points of interest (POI) or incorrect details, such as location, category or phone number General Motors uses a map database from two different suppliers. The two map suppliers are consistently updating their map database and will gladly accept any input regarding missing or incorrect information on the navigation radio map disc. To report any missing or incorrect information, please access the GM Navigation Disc Center at the following web site: http://www.gmnavdisc.com. At the GM Navigation Disc Center home page, select the tab: Your Feedback. In the Navigation Data Feedback form, fill in the appropriate information as required and then select: Submit, to send the form. Disclaimer Page 3893 1. Install the PCM. Ensure that the mounting tabs are engaged. 2. Secure the spring latch to the PCM. 3. Connect the PCM electrical connectors. NOTE: Refer to Fastener Notice in Service Precautions. 4. Tighten the PCM electrical connector bolts (2). Page 11198 2. Install the evaporator tube nut to the condenser. Tighten Tighten the nut to 16 N.m (12 lb ft). 3. Install the grille to the vehicle. 4. Install the right park/turn signal lamp. 5. Install the evaporator tube to the evaporator. 6. Install the evaporator tube nut to the evaporator. Tighten Tighten the nut to 16 N.m (12 lb ft). 7. Evacuate and recharge the A/C system. Refer to Refrigerant Recovery and Recharging. 8. Leak test the fittings of the components using the J 39400-A. OnStar(R) - Number Incorrect/Incorrectly Assigned Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Number Incorrect/Incorrectly Assigned INFORMATION Bulletin No.: 05-08-46-004C Date: December 23, 2010 Subject: OnStar(R) Phone Number Concerns (Phone Number Incorrect/Assigned to Another Vehicle/Phone) That Occur During Diagnosis of OnStar(R) System Models: 2000-2011 GM Passenger Cars and Trucks Equipped with OnStar(R) (RPO UE1) Supercede: This bulletin is being revised to update model years up to 2011. Please discard Corporate Bulletin Number 05-08-46-004B (Section 08 - Body and Accessories). During diagnosis of an OnStar(R) concern, the technician may be told that the OnStar(R) phone number is incorrect or tied to another vehicle and/or phone of some kind. To resolve these concerns, the Tech 2(R) with software version 22.005 (or higher), has the capability to change the OnStar(R) phone number. Service Procedure 1. With the Tech 2(R), build the vehicle to specifications within the Diagnostics area of the Tech 2(R). 2. For vehicles with physical-based diagnostics - under Body, go to the OnStar(R) section. Then select the Special Functions menu. For vehicles with functional-based diagnostics - under Body and Accessories, go to the Cellular Communication section. Select Module Setup and then Vehicle Communication Interface Module. 3. Locate the Program Phone Number prompt and select it. The original phone number will be displayed on the Tech 2(R) screen. 4. Contact the OnStar(R) team at the GM Technical Assistance Center (TAC) to obtain a new phone number. 5. Highlight the digits of the phone number one at a time and enter the new phone number using the number keys on the Tech 2(R). 6. Press the Soft key at the base of the screen for Done once these numbers have been changed on the screen. 7. Press the Soft key for Done again. The area code or new phone number has now been programmed into the phone. 8. Cycle the ignition to Off and open the driver's door. 9. Press the blue OnStar(R) button to make sure that a normal connection can be made to the OnStar(R) call center. If applicable, make sure the Hands-Free Calling (HFC) works properly by making a phone call. 10. If the system is working properly, fax or voicemail a case closing into the OnStar(R) team at TAC with the results. Dealers in Canada should submit case closing information through the GM infoNET. Please follow this diagnostic process thoroughly and complete each step. If the condition exhibited is resolved WITHOUT completing every step, the remaining steps do not need to be performed. If the procedure above does not resolve the condition, you must contact TAC for further assistance. This diagnostic approach was developed specifically for this condition and should not automatically be used for other vehicles with similar symptoms. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use: Warranty Information (Saab Models) For vehicles repaired under warranty, use the table. Page 10839 3. Remove the recirculation actuator retaining screws. 4. Remove the recirculation actuator. INSTALLATION PROCEDURE 1. Install the recirculation actuator. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the recirculation actuator retaining screws. Tighten Tighten the screws to 1.6 N.m (14 lb in). Page 4859 Oxygen Sensor: Service and Repair Heated Oxygen Sensor (HO2S) Replacement Bank 1 Sensor 2 HEATED OXYGEN SENSOR (HO2S) REPLACEMENT BANK 1 SENSOR 2 REMOVAL PROCEDURE 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. If equipped, disconnect the fuel composition sensor electrical connector. 3. Disconnect the connector position assurance (CPA) retainer. NOTE: Refer to Heated Oxygen and Oxygen Sensor Notice in Service Precautions. 4. If equipped with a fuel composition sensor, remove the heated oxygen sensor (HO2S) electrical connector from the fuel line clip. 5. If equipped with a 4.8L or 5.3L engine, disconnect the HO2S electrical connector (2). 6. If equipped with a 6.0L engine, disconnect the HO2S electrical connector (2). Page 14081 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground TESTING FOR SHORT TO GROUND NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting With A Digital Multimeter TROUBLESHOOTING WITH A DIGITAL MULTIMETER NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TROUBLESHOOTING WITH A TEST LAMP Page 8586 Page 5343 9. Remove the fuel line clip(s) from the bracket(s) on the transmission. 10. If equipped with 4-wheel drive (4WD), remove the fuel line clip from the bracket on the transfer case. 11. Remove the clip from the bracket on the frame. 12. Remove the transfer case harness from the clip bracket. IMPORTANT: The area around the electro-hydraulic control unit (EHCU) MUST be free from loose dirt to prevent contamination of disassembled anti-lock brake (ABS) components. 13. Thoroughly wash all contaminants from around the EHCU. 14. Disconnect the chassis electrical harness connectors from the electronic brake control module (EBCM). IMPORTANT: Make sure the brake lines are tagged and kept in order for proper reassembly. 15. Disconnect the brake lines from the brake pressure modulator valve (BPMV). 16. Remove the bolts (4) attaching the EHCU bracket to the frame (5). 17. Remove the EHCU (1). Page 7353 Install the parking lock bracket bolts. ^ Tighten the bolts to 24 Nm (18 ft. lbs.). 13. Install the PNP switch. 14. Install the transmission filter. 15. Fill the transmission to the proper level with Dexron® III transmission fluid. Page 15620 Door Latch Assembly (Door Jamb Switch) - RR - C2 (Crew Cab Only) Connector Views Daytime Running Lamp: Connector Views Daytime Running Lamp (DRL) - Left (Domestic) Page 15234 IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. Splicing Twisted or Shielded Cable SPLICING TWISTED OR SHIELDED CABLE Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. - Rewrap the conductors with the mylar tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with mylar tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Control Module References Page 11673 Seat Belt Retractor: Service and Repair Rear (Extended Cab) SEAT BELT RETRACTOR REPLACEMENT - REAR (EXTENDED CAB) CAUTION: To avoid personal injury to the occupants of the vehicle, observe the following precautions: - More than one supplier's seat belts are used, therefore, install ONLY the seat belt components specified in the GM parts catalog. - To verify that the correct seat belt components were installed, insert the seat belt latch in the seat belt buckle. The latch must be fully seated and be retained in the buckle until purposely released. REMOVAL PROCEDURE 1. Remove the rear seat. 2. Remove the seat belt guide cover (1). 3. Remove the rear seat belt to body bolts (2). 4. Remove the rear quarter trim panel. 5. Remove the rear seat belt retractor to body bolt (1). 6. Remove the retractor from the vehicle. INSTALLATION PROCEDURE 1. Install the retractor to the vehicle. NOTE: Refer to Fastener Notice in Service Precautions. Page 14085 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the cover up until the dress cover releases. Repeat this procedure for the other locking tab. 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. 5. If the connector has a nose piece, use a small flat-blade tool to remove the nose piece by inserting the blade into the slot on the front of the connector and prying up on the nose piece. IMPORTANT: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 6. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. IMPORTANT: Be careful not to angle or rock the J 38125-13A tool when inserting it into the connector or the tool may break. Page 5206 Fuel: Technical Service Bulletins Fuel - Top Tier Detergent Gasoline Information Bulletin No.: 04-06-00-047 Date: June 24, 2004 ADVANCED SERVICE INFORMATION Subject: Top Tier Detergent Gasoline (Deposits, Fuel Economy, No Start, Power, Performance, Stall Concerns) Models: 2005 and Prior All General Motors Passenger Cars and Trucks (U.S. Only) A new class of gasoline, called Top Tier Detergent Gasoline, will be appearing at retail stations of some fuel marketers. This gasoline meets detergency standards developed by four automotive companies. A description of the concept and benefits of Top Tier is provided in the following question and answer section. What is Top Tier Detergent Gasoline? Top Tier Detergent Gasoline is a new class of gasoline with enhanced detergency. It meets new, voluntary deposit control standards developed by four automotive companies that exceed the detergent requirements imposed by the EPA. Who developed Top Tier Detergent Gasoline standards? Top Tier Detergent Gasoline standards were developed by four automotive companies: BMW, General Motors, Honda and Toyota. Why was Top Tier Detergent Gasoline developed? Top Tier Detergent Gasoline was developed to increase the level of detergent additive in gasoline. The EPA requires that all gasoline sold in the U.S. contain a detergent additive. However, the requirement is minimal and in many cases, is not sufficient to keep engines clean. In order to meet Top Tier Detergent Gasoline standards, a higher level of detergent is needed than what is required by the EPA. Also, Top Tier was developed to give fuel marketers the opportunity to differentiate their product. Why did the four automotive companies join together to develop Top Tier? All four corporations recognized the benefits to both the vehicle and the consumer. Also, joining together emphasized that low detergency is an issue of concern to several automotive companies. What are the benefits of Top Tier Detergent Gasoline? Top Tier Detergent Gasoline will help keep engines cleaner than gasoline containing the "Lowest Additive Concentration" set by the EPA. Clean engines help provide optimal fuel economy and performance and reduced emissions. Also, use of Top Tier Detergent Gasoline will help reduce deposit related concerns. Who should use Top Tier Detergent Gasoline? All vehicles will benefit from using Top Tier Detergent Gasoline over gasoline containing the "Lowest Additive Concentration" set by the EPA. Those vehicles that have experienced deposit related concerns may especially benefit from use of Top Tier Detergent Gasoline. Where can Top Tier Detergent Gasoline be purchased? The Top Tier program began on May 3, 2004. Some fuel marketers have already joined and are making plans to introduce Top Tier Detergent Gasoline. This is a voluntary program and not all fuel marketers will offer this product. Once fuel marketers make public announcements, a list of all fuel marketers meeting Top Tier standards will be made available. For now, look for the "Top Tier" designation at the gas pump. Disclaimer Page 3741 Heat Shield: Service and Repair Exhaust Heat Shield Replacement - Dash Panel Exhaust Heat Shield Replacement - Dash Panel Removal Procedure 1. Raise and suitably support the vehicle. 2. Remove the exhaust heat shield nuts. 3. Remove the exhaust heat shield (1, 3) from the dash panel studs. 4. If removing the heat shield (3), remove the shield out thru the passenger side wheelwell. Installation Procedure 1. If installing the heat shield (3), install the shield thru the passenger side wheelwell. 2. Install the exhaust heat shield (1, 3) to the dash panel studs. Notice: Refer to Fastener Notice in Service Precautions. 3. Install the exhaust heat shield nuts. Tighten the nuts to 9 Nm (80 inch lbs.). 4. Lower the vehicle. Page 2185 Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 12167 If you are unsure who the PSC is, check with the Sales Manager. General Information 1. The first step is to verify if the OnStar(R) account is active or not. This can be done by pressing the blue OnStar(R) button and connecting to the OnStar(R) call center. Analog only accounts are no longer active. Only digital upgraded accounts will be active. On Gen 6 digital systems, a clear, or "dark" LED may indicate that the OnStar(R) system has been deactivated or may possibly have a no power/no communication condition. 2. If the account isn't active, the next step is to verify what version of OnStar(R) module is in the vehicle. This can be done via the Tech 2 (Body>VCIM>Module ID Information>Module Information 2) or by using www.onstarenrollment.com. 3. A Generation 5 or older analog module can be diagnosed by following the original electronic Service Information developed for the model year of the vehicle. Note: If the customer has an old analog module, the vehicle can be repaired by replacing the module, but the customer cannot have an active account without upgrading to a digital module. 4. Modules, antennas, brackets, and other equipment are in the same location, whether original analog production or digital upgrade. 5. An upgraded vehicle may also have a new vehicle communication interface module (VCIM) bracket. If it does, order the new bracket when replacing the bracket. Don't order the original bracket. The kit may also include a small wiring jumper cable. If it does, this jumper will be required for a new module replacement. Do not discard. 6. After replacing the VCIM, it is essential to configure the new OnStar(R) system. Failure to configure the system will result in an additional customer visit for repair. DO NOT press and hold the white dot or phone button on the keypad as it will not reset this version of the OnStar(R) system and may result in a DTC being set. Use of the TIS2WEB and SPS applications, along with the Tech2(R), are required in order to perform the VCIM configuration and setup procedure for this vehicle. The configuration and set-up procedure is now a two-step process which enables an automated activation by the OnStar(R) Center, without a button press by the technician to the OnStar(R) Call Center. Page 9838 Junction Block - Rear Lamps - C4 Page 7083 21. With the trunnion seated in the bearing cup, press the bearing cup into the yoke until the bearing cup is flush with the yoke ear. 22. Install the opposite bearing cup part way into the yoke ear. 23. Ensure that the trunnions start straight and true into both bearing cups. 24. Press the opposite bearing cup into the yoke ear while working the cross all the time in order to inspect for free unbinding movement of the trunnions in the bearing cups. Important: If there seems to be a hang up or binding, stop pressing. Inspect the needle bearings for misalignment in the bearing cup. 25. Press the bearing cup into the yoke until the bearing cup retainer groove is visible over the top of the bearing cup. 26. Assemble the bearing retainer in the retainer groove. 27. Continue pressing until both retainers can be snapped into place. 28. If the retainer is difficult to seat, the yoke can be sprung slightly with a firm blow from a soft-faced dead blow hammer. 29. It may be necessary to lubricate the snap ring with a slight amount of chassis grease so that the snap ring seats in the bearing cup groove. 30. Install the slip yoke onto the output shaft in the transfer case. 31. Align the reference marks on the pinion flange and the propeller shaft. 32. Install the yoke retainers and bolts. Tighten Tighten the yoke retainer bolts to 25 N.m (19 lb ft). 33. Lower the vehicle. Page 1673 7. Remove the transmission control lever from the manual shaft. 8. Remove the PNP switch bolts. 9. Remove the PNP switch from the manual shaft. If the PNP switch did not slide off the manual shaft, file the outer edge of the manual shaft in order to remove any burrs. Installation Procedure 1. Install the PNP switch to the transmission manual shaft by aligning the switch hub flats with the manual shaft flats. 2. Slide the PNP switch onto the transmission manual shaft until the switch mounting bracket contacts the mounting bosses on the transmission. 3. Important: If a NEW PNP switch is being installed, the switch will come with a positive assurance bracket. The positive assurance bracket aligns the new switch in its proper position for installation and the use of the park neutral switch aligner will not be necessary. Install the PNP switch bolts finger tight. 4. Install J 41364-A onto the PNP switch. Ensure that the two slots on the switch where the manual shaft is inserted are lined up with the lower two tabs on the tool. 5. Notice: Refer to Fastener Notice in Service Precautions. Rotate the tool until the upper locator pin on the tool is lined up with the slot on the top of the switch. ^ Tighten the bolts to 25 Nm (18 ft. lbs.). 6. Remove the J 41364-A from the switch. If installing a new switch, remove the positive assurance bracket at this time. 7. Install the transmission control lever to the manual shaft with the nut. ^ Tighten the nut to 25 Nm (18 ft. lbs.). Page 4602 7. Remove the HO2S. INSTALLATION PROCEDURE IMPORTANT: A special anti-seize compound is used on the HO2S threads. The compound consists of liquid graphite and glass beads. The graphite tends to burn away, but the glass beads remain, making the sensor easier to remove. New, or service replacement sensors already have the compound applied to the threads. If the sensor is removed from an exhaust component and if for any reason the sensor is to be reinstalled, the threads must have anti-seize compound applied before the reinstallation. 1. If reinstalling the old sensor, coat the threads with anti-seize compound GM P/N 12377953, or equivalent. NOTE: Refer to Component Fastener Tightening Notice in Service Precautions. 2. Install the HO2S. Tighten Tighten the sensor to 42 N.m (31 lb ft). Page 6365 6. Remove the transmission crossmember bolts/nuts. 7. Remove the transmission crossmember. 8. Loosen the left exhaust pipe nuts. 9. Loosen the right exhaust pipe nuts. 10. Remove the insulator nuts and insulator from the bracket. 11. Remove the exhaust pipe hanger bracket bolts and bracket. 12. Lower the transmission slightly. Page 8844 Disclaimer Page 8821 Generator - (Without RPO Code SBA) Page 8227 2. Perform the following procedure before installing the backing plate bolts (15 Series only). 1. Remove all traces of the original adhesive patch. 2. Clean the threads of the bolt with brake parts cleaner or the equivalent and allow to dry. 3. Apply Threadlocker GM P/N 12345493 (Canadian P/N 10953488) to the threads of the bolt. 3. Notice: Refer to Fastener Notice in Service Precautions. Install the backing plate bolts. ^ Tighten the backing plate bolts to 135 Nm (100 ft. lbs.). 4. Install the park brake shoe. 5. Install the axle shaft. 6. Adjust the park brake shoe. Refer to Park Brake Adjustment. 7. Install the rotor. 8. Install the park brake cable to the lever. 9. Perform the following procedure to install the cable to the backing plate: 1. Compress the spring by pushing towards the lever. 2. Route the cable through the slot in the backing plate. 3. Push the cable housing into the backing plate until the locking tabs snap into place. 10. Notice: Refer to Fastener Notice in Service Precautions. ^ Tighten the nut to the intermediate cable at the equalizer. ^ Tighten the nut to 3.5 Nm (31 inch lbs.). 11. Install the tire and wheel assembly. 12. Remove the safety stands. Page 12723 2. Connect the Techline Information System (TIS) terminal to the Tech2(R). 3. Scroll to the bottom of the Controller List, and select the "ONSA TIS2WEB Pass-Thru OnStar(R) Activation (Replaced/Upgraded Units Only)" option using the Service Programming System (SPS). Important: Do not use the clear DTC function. This will only temporarily turn the LED to green. 4. Upon completion of the OnStar(R) TIS2WEB step, disconnect the TIS terminal from the Tech2(R) and perform the VCIM/OnStar(R) Set-up Procedure using the Tech2(R). The set up procedure is located under the special function menu option. Important: Failure to perform the above steps will result in a red LED, DTC being set and limited or incomplete OnStar(R) services, and will require a customer return visit to the dealership. 5. The default language for the new VCIM will be English. To change to French or Spanish, access the special functions menu on the Tech 2(R), and follow the instructions accordingly. 7. Skip to the next step if the vehicle to be upgraded is not listed below: ^ 2002-2004 Cadillac DeVille ^ 2002-2004 Cadillac Seville ^ 2005 Cadillac STS Set up the Dash Integration Module (DIM) using the following procedure: 1. On the Tech2(R) select the correct Year, Make and Model. 2. Enter Dash Integration Module (DIM) > Special Functions > Set Options > Misc. Options 1 > and turn off phone (if the vehicle does not have the UV8 option). 3. Enter Nav Radio Present and set to "No Nav" (if the vehicle does not have a navigation radio). 4. Turn the ignition off and open the door to turn off the RAP. 5. Turn the ignition on and enter the Vehicle Comm. Interface Module > Special Functions > Set Up OnStar /VCIM. 6. When prompted select "No Phone" (if the vehicle does not have the UV8 phone) and "No Nav" (if the vehicle does not have a navigation radio). 7. Turn the ignition off and open the door to turn off the RAP. Important: OnStar(R) Emergency Services are immediately available after these steps, however, full configuration, including activation of Hands-Free Calling, may take up to 24 hours to complete. Processing the Module Exchange Processing the Module Exchange For this program, submitting a credit request for the removed OnStar(R) VCIM (the core) will be performed through a website. When this process is followed, the removed Analog / Digital-Ready VCIM, in most cases, will not be mailed back to the distributor, but can be scrapped by the dealership. U.S. Dealers 1. Return the removed Analog / Digital-Ready OnStar(R) VCIM to the Parts Manager. 2. The Parts Manager will log onto www.autocraft.com. 3. Select Account Maintenance. 4. Select Outstanding Cores. Page 1364 Door Latch Assembly (Door Jamb Switch) - LR - C2 (Crew Cab Only) Page 1542 1. Locate the air flow direction arrow (2) on the MAF/IAT sensor. 2. Install the MAF/IAT sensor to the air cleaner assembly. NOTE: Refer to Fastener Notice in Service Precautions. 3. Tighten the MAF/IAT clamp. Tighten Tighten the clamp to 7 N.m (62 lb in). 4. Connect the MAF/IAT sensor electrical connector (4). 5. Push in the gray CPA retainer. 6. Install the air cleaner outlet duct. Page 12208 Page 4529 Data Link Connector (DLC) Diagram 2 Part 1 Page 10672 longer. Important Whenever a wheel is refinished, the mounting surface and the wheel nut contact surfaces must not be painted or clearcoated. Coating these surfaces could affect the wheel nut torque. When re-mounting a tire on an aluminum wheel, coated balance weights must be used in order to reduce the chance of future cosmetic damage. Disclaimer Page 3265 Drive Belt Tensioner: Service and Repair Air Conditioning Drive Belt Tensioner Replacement - Air Conditioning Removal Procedure 1. Remove the air conditioning (A/C) drive belt. 2. Remove the A/C belt tensioner bolts. 3. Remove the A/C belt tensioner. Installation Procedure 1. Install the A/C belt tensioner. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the A/C belt tensioner bolts. ^ Tighten the A/C belt tensioner bolts to 50 Nm (37 ft. lbs.). 3. Install the A/C drive belt. Page 13380 3. Notice: Refer to Fastener Notice in Service Precautions. Install a new 4 mm bolt (1), with LOCTITETM , to the brake pedal position sensor. ^ Tighten the bolt to 9 Nm (80 inch lbs.). 4. Calibrate the brake pedal position sensor. Page 5121 7. Install the EHCU (1). 8. Install the bolts (4) attaching the EHCU bracket to the frame (5). Tighten Tighten the bolts to 25 N.m (18 lb ft). 9. Connect the brake lines to the BPMV. Tighten Tighten the fittings to 25 N.m (18 lb ft). 10. Connect the chassis electrical harness connectors to the EBCM. 11. Install the transfer case harness to the clip bracket. 12. Install the clip to the bracket on the frame. 13. Install the fuel line clip to the bracket on the transfer case, if equipped with 4WD. Locations Passenger Presence Components - Under Front Passenger Seat Page 12342 Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses CIRCUIT PROTECTION - FUSES The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the Page 7880 Page 3800 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Micro-Pack 100W Connectors MICRO-PACK 100W CONNECTORS TOOLS REQUIRED J 38125-D Terminal Repair Kit REMOVAL PROCEDURE There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2)has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. IMPORTANT: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Page 13838 5. Remove all adhesive from the endgate panel surface and the back of the emblem/nameplate using 3M(TM) scotch brite molding adhesive remover disk 3M(TM) P/N 07501 or equivalent. 6. Clean the endgate surface using varnish makers and painters (VMP) naptha. Installation Procedure 1. If the location of the emblem/nameplate has not been marked apply tape. 2. Warm the endgate surface with a heat gun J 25070 152 mm (6.0 in) from the surface to a minimum of 21°C (70°F). Important: Do not touch the adhesive backing of the emblem/nameplate. 3. Remove the backing from the front end of the emblem/nameplate. 4. Press the emblem/nameplate to the endgate panel surface while continuing to remove the backing. 5. Hand roll the emblem/nameplate to the endgate panel to ensure proper adhesion. 6. Inspect the emblem/nameplate for bonding. 7. Remove the tape from the area around the endgate emblem. Emblem/Nameplate Replacement - Pickup Box Emblem/Nameplate Replacement - Pickup Box Tools Required J 25070 Heat Gun Removal Procedure Important: Use the tape for protection and alignment marks for alignment of the new emblem. 1. Apply tape to the area around the pickup box emblem. 2. Heat the emblem/nameplate, using a heat gun J 25070 152 mm (6.0 in) from the surface. 3. Apply the heat using a circular motion for about 30 seconds. Notice: Refer to Exterior Trim Emblem Removal Notice in Service Precautions. 4. Remove the emblem/nameplate from the pickup box surface using a plastic, flat-bladed tool. Page 10317 3. Install the nut (1) retaining the upper ball joint to the steering knuckle. Use the J 44664 (2) in order to tighten the joint. ^ Tighten the upper ball joint to the steering knuckle nut to 200 Nm (147 ft. lbs.). 4. Install the bracket (7) to the axle. 5. Install the bolt (8) and nut (2) retaining the bracket to the axle. ^ Tighten the bolt and nut to 25 Nm (18 ft. lbs.). 6. Install the bolt (4) retaining the brake hose bracket (3) to the axle. ^ Tighten the brake hose bracket retaining bolt to 12 Nm (106 inch lbs.). 7. Install the tire and wheel. 8. Lower the vehicle. 9. Perform a four wheel alignment. Lower Ball Joint Replacement Lower Ball Joint Replacement Removal Procedure 1. Notice: Refer vehicle Lifting. Raise the vehicle. Refer to Vehicle Lifting. 2. Remove the tire and wheel. 3. Remove the bolt (8) and nut (2) retaining the bracket to gain access to the pinch bolt. Page 3815 Control Module References Part 1 Page 9772 C325 Heated Seat Jumper Harness To Seat Jumper Harness (With RPO Code KA1) Page 11513 43. Install the right inner axle shaft housing assembly to the differential carrier assembly. 44. Install the inner axle shaft housing bolts. Tighten Tighten the inner axle shaft housing bolts to 40 N.m (30 lb ft). 45. Install the inner axle shaft housing washers and nuts to the bracket. Tighten Tighten the inner axle shaft housing nuts to 100 N.m (75 lb ft). 46. Connect the wheel drive shaft inboard flange to the inner axle shaft. 47. Install the wheel drive shaft inboard flange to the inner axle shaft bolts. Tighten Tighten the wheel drive shaft inboard flange to the inner axle shaft bolts to 79 N.m (58 lb ft). 48. Connect the wire harness to the inner axle shaft housing and differential carrier. 49. Connect the electrical connector to the front axle actuator. 50. Fill the differential carrier assembly with axle lubricant. Use the proper fluid. Refer to Lubricant Replacement - Front Drive Axle in the Front Axle sub-section of the Service Manual. 51. Install the front engine protection shield. Refer to Engine Protection Shield Replacement in the Frame and Underbody sub-section of the service manual. 52. Lower the vehicle. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Page 3352 15. If equipped with the 4L60-E automatic transmission, remove the transmission bolt and stud on the right side. 16. Remove the bottom bolt on the left side. 17. If equipped with the 4L80-E automatic transmission, remove the transmission converter cover bolts. 18. If equipped with a manual transmission, remove the two bottom bellhousing bolts. Page 14613 Seat Rear Vertical Motor - Front Passenger Page 5333 3. Install the fuel rail. 4. Apply a 5 mm (0.020 in) band of threadlock, GM P/N 12345382 (Canadian P/N 10953489), or equivalent, to the threads of the fuel rail bolts. NOTE: Refer to the Fastener Notice in Service Precautions. 5. Install the fuel rail bolts. Tighten Tighten the bolts to 10 N.m (89 lb in). 6. Connect the fuel pressure regulator vacuum line. 7. Connect the fuel feed and return pipes (1, 2) to the fuel rail. Page 4191 Steps 4 - 6 Page 4852 Heated Oxygen Sensor (HO2S) Bank 1 Sensor 2 Page 6468 15. Remove the cable clip on the transfer case, if equipped. 16. Remove the range selector cable end (2) from the transmission range selector lever ball stud (1). 17. Depress the tangs and remove the cable from the bracket. 18. Lower the vehicle and ensure that the steering column shift lever is still in the park position. Installation Procedure 1. Ensure that the transmission manual shaft lever is in the mechanical park position. 2. Align and install the cable to the bracket. 3. Install the range selector cable end (2) to the transmission range selector lever ball stud (1). 4. Install the cable clip on the transfer case, if equipped. 5. Install the retainer that secures the cable to the bracket. 6. Install the clips on the cable to the floor panel reinforcement. Page 13462 The information shown is for the 1999-2002 wiring harnesses and for the 2003-05 wiring harness. To modify a 12171982, 15366255 or 15086884 harness for use in a 2003-05 vehicle, switch the wires in cavities "A" and "D". To modify a 15085418 harness for use in a 1999-2002 vehicle (see model list at the front of this bulletin for applicable models), switch the wires in cavities "A" and "D". Warranty Information When the correct wiring harness P/N is matched to the specific model year of the vehicle, everything works properly. Therefore, conversion of an incorrect wiring jumper to match the vehicle would not be considered a warrantable repair. Disclaimer Page 4795 1. Install the CKP sensor. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the CKP sensor bolt. Tighten Tighten the bolt to 25 N.m (18 lb ft). 3. Connect the CKP sensor electrical connector. 4. Install the starter. 5. Perform the CKP system variation learn procedure. See: Testing and Inspection/Programming and Relearning Page 4539 Steps 3 - 6 Page 4214 1. Install a NEW air filter element. 2. Install the air cleaner housing cover. 3. Tighten the air cleaner housing top screws until snug. 4. Connect the MAF/IAT sensor electrical connector (4). 5. Install the air cleaner outlet duct. Page 8292 Brake Caliper Overhaul - Front Brake Caliper Overhaul - Front ^ Tools Required J 45515 Brake Caliper Piston Boot Seal Installer Caution: Refer to Brake Dust Caution in Service Precautions. Caution: Refer to Brake Fluid Irritant Caution in Service Precautions. Notice: Refer to Brake Fluid Effects on Paint and Electrical Components Notice in Service Precautions. 1. Replace all the components included in the repair kits used to service this brake caliper. 2. Lubricate the rubber parts with new Delco Supreme 11®, GM P/N 12377967 (Canadian P/N 992667) or equivalent DOT-3 brake fluid to make assembly easier. 3. If any hydraulic component is removed or disconnected, it may be necessary to bleed all or part of the brake system. 4. The torque values specified are for dry, non-lubricated fasteners. 5. Perform the service operations on a clean bench, free from all mineral oil materials. 6. Remove the brake caliper from vehicle. Refer to Brake Caliper Replacement - Front. 7. Drain the brake fluid from the brake caliper. 8. Caution: Do not place your fingers in front of the piston in order to catch or protect the piston while applying compressed air. This could result in serious injury. Notice: Use clean cloths to pad interior of caliper housing during piston removal. Use just enough air to ease the pistons out of the bores. If the pistons are blown out, even with the padding provided, it may be damaged. Place a 25 mm (1 inch) block of wood between the caliper and the piston. 9. Install a large C-clamp over the body of the brake caliper with the C-clamp ends against the rear of the caliper body and against the block of wood. 10. Carefully remove the brake caliper piston by directing low pressure compressed air into the brake caliper inlet hole. 11. Remove the C-clamp form the caliper. 12. Remove the block of wood from the caliper. 13. Install clean cloths to pad the interior of the caliper housing between the remaining caliper piston and the caliper body. 14. To cover the open caliper bore place a 25 mm (1 inch) block of wood between the caliper body and the brake caliper dust boot seal. 15. Install a large C-clamp over the body of the brake caliper with the C-clamp ends against the rear of the caliper body and against the block of wood. 16. Carefully remove the brake caliper piston by directing low pressure compressed air into the brake caliper inlet hole. 17. Remove the C-clamp form the caliper. 18. Remove the block of wood from the caliper. Page 9919 Disclaimer Page 13378 Pedal Positioning Switch: Service and Repair Brake Pedal Position Sensor Replacement Removal Procedure 1. Important: Once the Brake Pedal Position Sensor bolt is removed for any reason, a new 4 mm bolt, with fresh LOCTITETM will need to be installed. Remove the brake pedal position sensor bolt (1). 2. Remove the brake pedal position sensor (2) from the mounting bracket. 3. Disconnect the brake pedal position sensor electrical connector (1). 4. Remove the brake pedal position sensor (2) from the vehicle Installation Procedure Page 14180 7. Connect the manual door lock to the door retainer clips. 8. Connect the inside door handle control rod to the lock assembly. 9. Connect the inside door lock rod to the handle retainer clip. 10. Install the water deflector. 11. Install the door trim panel. 12. Inspect the operation of all the related components. Lock Actuator Replacement - Rear Door LOCK ACTUATOR REPLACEMENT - REAR DOOR REMOVAL PROCEDURE HVAC System - Manual A/C Low Pressure Switch Page 7329 Fluid Pressure Sensor/Switch: Connector Locations Page 16090 Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses CIRCUIT PROTECTION - FUSES The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the Page 7761 1. Notice: Refer to Fastener Notice in Service Precautions. Install the left rear speed sensor. ^ Tighten the speed sensor to 15 Nm (11 ft. lbs.). 2. Connect the left rear speed sensor electrical connector (4) 3. Lower the vehicle. Transfer Case Speed Sensor Replacement - Right Rear Transfer Case Speed Sensor Replacement - Right Rear Removal Procedure 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. Disconnect the right rear speed sensor electrical connector (3). Page 7544 3. Install the fill plug. ^ Tighten the plug to 20 Nm (15 ft. lbs.). 4. Install the transfer case shield, if equipped. 5. Lower the vehicle. Page 2321 14. Install the evaporator tube nut to the evaporator. Tighten Tighten the nut to 16 N.m (12 lb ft). 15. Evacuate and recharge the A/C system. Refer to Refrigerant Recovery and Recharging. 16. Leak test the fittings of the components using the J 39400-A. Page 4495 Refer to the table as a guide in selecting the correct test adapter for frontprobing connectors: Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure SCAN TOOL SNAPSHOT PROCEDURE Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: - Snapshot - taken from the Snapshot menu choice - Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information Page 6250 8. Install the transmission support. 9. Install the transmission support side bracket and bolts. 10. Install the transmission support bolts and nuts. ^ Tighten the bolts/nuts to 95 Nm (70 ft. lbs.). 11. Install the transmission mount nuts. ^ Tighten the nuts to 40 Nm (30 ft. lbs.). 12. Remove the transmission jack. 13. Lower the vehicle. 14. Fill the transmission to the proper level with DEXRON® III transmission fluid. Page 13554 Control Module References Part 3 Page 11781 Antenna, Navigation: Service and Repair ANTENNA ASSEMBLY REPLACEMENT - CELLULAR AND NAVIGATION REMOVAL PROCEDURE 1. Lower the headliner. Refer to Headliner Replacement in Interior Trim 2. Disconnect the cables from the antenna. 3. Loosen the retaining nut until the antenna assembly can be pulled from the top of the roof. INSTALLATION PROCEDURE 1. Place the antenna assembly on the roof opening. NOTE: Refer to Fastener Notice in Service Precautions. 2. Tighten the retaining nut. Tighten Tighten the nut to 6 N.m (53 lb in). 3. Connect the antenna cables. 4. Install the headliner. Page 5103 Evaporative Emissions Hose: Service and Repair EVAP System Hoses/Pipes Replacement (1500 Crew Cab) EVAPORATIVE EMISSION (EVAP) SYSTEM HOSES/PIPES REPLACEMENT (1500 CREW CAB) REMOVAL PROCEDURE IMPORTANT: Clean the evaporative emission (EVAP) line connections and surrounding areas prior to disconnecting the fittings in order to avoid possible fuel system contamination. 1. Remove the fuel tank. 2. Disconnect and remove the EVAP rear line (2) from the sending unit and retaining clips. 3. Disconnect and remove the EVAP line (3) from the sending unit and retaining clips. 4. Cap the fuel feed/return, and EVAP lines in order to prevent possible fuel/EVAP system contamination. INSTALLATION PROCEDURE 1. Remove the caps from the fuel feed/return, and EVAP lines. 2. Install and connect the EVAP line (3) to the sending unit and retaining clips. 3. Install and connect the EVAP rear line (2) to the sending unit and retaining clips. 4. Install the fuel tank. Page 14132 Door Module: Service and Repair DOOR CONTROL MODULE PROGRAMMING AND SETUP Driver Door Module After replacing the driver door module (DDM), perform the programing procedure. Refer to Service Programming System (SPS). See: Testing and Inspection/Programming and Relearning Passenger Door Module After replacing the passenger door module (PDM), perform the following programing and setup procedures: ‹› Service Programming System (SPS). See: Testing and Inspection/Programming and Relearning ‹› Transmitter Programming. See: Testing and Inspection/Programming and Relearning ‹› Control Module Setup. See: Testing and Inspection/Programming and Relearning Page 4665 SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-D. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: - The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair Tools Required J 38125-D Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-D. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Intermediate Steering Shaft Replacement - Upper Steering Shaft: Service and Repair Intermediate Steering Shaft Replacement - Upper Intermediate Steering Shaft Replacement - Upper ^ Tools Required J 42640 Steering Column Anti-Rotation Pin Removal Procedure 1. Notice: The wheels of the vehicle must be straight ahead and the steering column in the LOCK position before disconnecting the steering column or intermediate shaft from the steering gear. Failure to do so will cause the SIR coil assembly to become uncentered, which may cause damage to the coil assembly. Install the J 42640 in the steering column lower access hole. 2. Important: Mark the relationship of the intermediate shaft components in order to assure proper installation. Mark the relationships of the following components: ^ Mark the relationship of the bolt and clamp at both ends of the upper intermediate shaft. ^ Mark the relationship of the upper intermediate shaft to the lower intermediate shaft. 3. Remove the nut and bolt from the lower shaft to upper shaft connection. 4. Remove the nut and bolt (1) from the upper shaft (2) to steering column connection. 5. Slide the intermediate shaft down, out of the steering column connection. Page 1016 Inflatable Restraint Sensing And Diagnostic Module: Service and Repair INFLATABLE RESTRAINT SENSING AND DIAGNOSTIC MODULE REPLACEMENT REMOVAL PROCEDURE CAUTION: Do not strike or jolt the inflatable restraint sensing and diagnostic module (SDM). Before applying power to the SDM, make sure that it is securely fastened with the arrow facing toward the front of the vehicle. Failure to observe the correct installation procedure could cause SIR deployment, personal injury, or unnecessary SIR system repairs. - Refer to SIR Caution in Service Precautions. 1. Disable the SIR system. Refer to SIR Disabling and Enabling Zone 7. 2. Remove the drivers seat. 3. Remove the driver side door sill plate. 4. Fold back the carpet to access the inflatable restraint sensing and diagnostic module (SDM). 5. Remove the connector position assurance (CPA) (1) from the inflatable restraint sensing and diagnostic module (SDM) wiring harness connector (2). 6. Push down the flex lock button (3) and slide the connector locking cover (4) to the open position. Page 12123 2. Connect the Techline Information System (TIS) terminal to the Tech2(R). 3. Scroll to the bottom of the Controller List, and select the "ONSA TIS2WEB Pass-Thru OnStar(R) Activation (Replaced/Upgraded Units Only)" option using the Service Programming System (SPS). Important: Do not use the clear DTC function. This will only temporarily turn the LED to green. 4. Upon completion of the OnStar(R) TIS2WEB step, disconnect the TIS terminal from the Tech2(R) and perform the VCIM/OnStar(R) Set-up Procedure using the Tech2(R). The set up procedure is located under the special function menu option. Important: Failure to perform the above steps will result in a red LED, DTC being set and limited or incomplete OnStar(R) services, and will require a customer return visit to the dealership. 5. The default language for the new VCIM will be English. To change to French or Spanish, access the special functions menu on the Tech 2(R), and follow the instructions accordingly. 7. Skip to the next step if the vehicle to be upgraded is not listed below: ^ 2002-2004 Cadillac DeVille ^ 2002-2004 Cadillac Seville ^ 2005 Cadillac STS Set up the Dash Integration Module (DIM) using the following procedure: 1. On the Tech2(R) select the correct Year, Make and Model. 2. Enter Dash Integration Module (DIM) > Special Functions > Set Options > Misc. Options 1 > and turn off phone (if the vehicle does not have the UV8 option). 3. Enter Nav Radio Present and set to "No Nav" (if the vehicle does not have a navigation radio). 4. Turn the ignition off and open the door to turn off the RAP. 5. Turn the ignition on and enter the Vehicle Comm. Interface Module > Special Functions > Set Up OnStar /VCIM. 6. When prompted select "No Phone" (if the vehicle does not have the UV8 phone) and "No Nav" (if the vehicle does not have a navigation radio). 7. Turn the ignition off and open the door to turn off the RAP. Important: OnStar(R) Emergency Services are immediately available after these steps, however, full configuration, including activation of Hands-Free Calling, may take up to 24 hours to complete. Processing the Module Exchange Processing the Module Exchange For this program, submitting a credit request for the removed OnStar(R) VCIM (the core) will be performed through a website. When this process is followed, the removed Analog / Digital-Ready VCIM, in most cases, will not be mailed back to the distributor, but can be scrapped by the dealership. U.S. Dealers 1. Return the removed Analog / Digital-Ready OnStar(R) VCIM to the Parts Manager. 2. The Parts Manager will log onto www.autocraft.com. 3. Select Account Maintenance. 4. Select Outstanding Cores. Page 14019 Passenger Assist Handle: Service and Repair Instrument Panel (I/P) Assist Handle Replacement Instrument Panel (I/P) Assist Handle Replacement Removal Procedure 1. Remove both the passenger side air deflector louvers. 2. From the air deflector louver opening, press the release tabs on the instrument panel assist handle retainers on both sides. 3. Pull the assist handle from the instrument panel. Installation Procedure 1. Install the instrument panel assist handle by pushing until it locks into place. 2. Install both the passenger side air deflector louvers. Page 13242 Conditions for Running the DTC Ignition is in RUN or ACC position System voltage is between 9.5 - 15.5 volts. The above conditions are met for more than 1 second. Conditions for Setting the DTC The VCIM does not detect the presence of a cellular antenna for more than 1 second. Action Taken When the DTC Sets The vehicle is unable to connect to the OnStar(R) Call Center. The OnStar(R) status LED turns red. Conditions for Clearing the DTC The VCIM detects the presence of a cellular antenna. A history DTC clears after 50 malfunction-free ignition cycles. Circuit/System Testing Perform a visual inspection as shown above in order to verify that the cellular antenna and the cellular antenna coupling assembly are not damaged. If any components are damaged replace the assembly. DTC B2476 or B2482 DTC Descriptors A/C - Broken Rear Window Defogger Grid Detection Rear Defogger: Technical Service Bulletins A/C - Broken Rear Window Defogger Grid Detection Bulletin No.: 04-08-48-001B Date: June 28, 2005 INFORMATION Subject: Rear Window Defogger - Broken Heating Grid Detection Method Models: 2006 and Prior Passenger Cars and Light Duty Trucks (Including Saturn) 2003-2006 HUMMER H2 2006 HUMMER H3 Supercede: This bulletin is being revised to add the 2006 model year and additional models. Please discard Corporate Bulletin Number 04-08-48-001A (Section 08 - Body and Accessories). The addition of vertical grid lines to the heated back window defogger circuits has made it difficult to detect broken defogger grid lines. In the past, it was a simple matter to use a voltmeter to check the continuity of each grid line in order to locate a non-functional line. Some new design back windows have two vertical grid lines that connect all of the horizontal grid lines together, thereby providing alternate routes for the electrical current to follow. This makes the old test method ineffective. If the vehicle does not have the vertical lines, the old (line-by-line) test methods can be used. Materials Required ^ Permatex(R) Quick Grid, GM P/N 12346001, or equivalent ^ A small ball of fine steel wool Type 00, or ^ Optional - A strip of liquid crystal heat sensitive paper, 51 mm x 305 mm (2 in x 12 in) or similar size (Contact Edmund Scientific at 800-728-6999 for part number CR30723-70 or go to www.scientificsonline.com), or ^ Optional-A portable infrared thermometer, GE-46819, available from Kent-Moore (1-800-345-2233), or equivalent. Correction There are three distinct zones across the back window that must be checked. They are: ^ the driver's side outboard of the two vertical lines ^ the passenger side outboard of the two vertical lines ^ the central zone that falls between the two vertical lines To detect a broken grid line in any of the above three zones and to isolate the exact location of the break, perform the following steps: Caution: ^ Approved safety glasses and gloves should be worn when performing this procedure to reduce the chance of personal injury. ^ Cover the rear shelf area to prevent damage to the interior trim material. 1. Start the engine and turn on the back window defogger. 2. Take the ball of fine steel wool and twist one end to a point. Move the point slowly across each grid line. Be sure to start at the far side of the zone and move it to the opposite side of the zone. When you bridge the grid line break with the steel wool, you will see a small spark. Repeat the test over the same area to be sure you have accurately located the break. Mark the exact location of the grid line break. Repeat this portion of the test for each grid line. If you do not see a spark at any point, it is possible that there are two breaks in the same line and zone. Close visual inspection using a magnifying glass may be the only way to locate breaks in this case. 3. The following are provided as an alternative way to detect a non-functional grid line. If available, use in addition to the steel wool. 3.1. Method using liquid crystal heat sensitive paper: Page 14656 2. Install the power seat switch bezel to the seat. Page 11169 Heater Hose: Service and Repair Heater Hose Replacement - Inlet (With RPO Code HP2 Front) HEATER HOSE REPLACEMENT - INLET (W/ HP2 FRONT) REMOVAL PROCEDURE 1. Drain the cooling system. Refer to Draining and Filling Cooling System (with HP2)Draining and Filling Cooling System (without HP2) in Cooling System. 2. Loosen the air cleaner outlet duct clamps at the following locations: - Throttle body - Mass airflow/intake air temperature (MAF/IAT) sensor 3. Remove the radiator inlet hose clip from the outlet duct. 4. Remove the air cleaner outlet duct. 5. Reposition the inlet heater hose clamp from the engine. 6. Remove the inlet heater hose from the engine. Body - Pick Up Box Damaged by Aftermarket Accessories Technical Service Bulletin # 01-08-66-014B Date: 050208 Body - Pick Up Box Damaged by Aftermarket Accessories Pickup Box Sheet Metal Fracture/Damage with Aftermarket Accessories Installed (Repair Pickup Box Damage and Install Pickup Box Reinforcements) # 01-08-66-014B - (Feb 8, 2005) Models: 1999-2003 Chevrolet Silverado (New Body Style) 1999-2003 GMC Sierra New Body Style) with Steel Fleetside Pickup Box (RPO E63) 2004-2005 Chevrolet Silverado 1500 Series Crew Cab with 5'8" Pickup Box 2004-2005 GMC Sierra 1500 Series Crew Cab with 5'8" Pickup Box Except Dual Rear Wheel (RPO R05), Stepside (RPO E62) and Inner Composite (RPO E37) Pickup Boxes This bulletin is being revised to add the 2004-2005 1500 Series Crew Cab with 5'8" pickup box and change equipment weight capacity information. Please discard Corporate Bulletin Number 01-08-66-014A (Section 08--Body and Accessories). Built Prior to the VIN Breakpoints shown. Important: Implementation of this Service Bulletin by "GM of Canada" dealers requires prior District Service Manager approval. Condition Some customers may comment about pickup box sheet metal fractures/damage when using aftermarket accessories such as tool boxes, window barrier and ladder racks. Page 376 7.2. Remove the console (A). 7.3. Disconnect the connector (B) from the OnStar(R) control module. Important: Secure the cable harness to prevent the risk of scraping and rattling. 7.4. Fold back the cable harness and tape down the connector (C). Fold back the cable harness again and secure with cable ties (D). 7.5. 5D: Assemble the right-hand cover for the luggage compartment floor. 8. Fit the ground cable on the battery's negative cable. Page 12445 Page 10468 4. Drive the bearing cup into the wheel hub using the J 44419 (2) and the J 8092 (1). 5. Install the retaining ring into the groove. Make sure the retaining ring is fully and evenly seated in the groove. 6. Install the inner bearing cup. 7. Drive the inner bearing cup into the wheel hub using the J 24427 (2) and the J 8092 (1). A/C - Underhood Rattle Noise on Hard Acceleration Refrigerant Filter: All Technical Service Bulletins A/C - Underhood Rattle Noise on Hard Acceleration File In Section: 01 - HVAC Bulletin No.: 03-01-38~019A Date: September, 2004 TECHNICAL Subject: Underhood Rattle Noise Heard On Acceleration (Check A/C System Performance and Compressor Operation) Models: 2003-2004 Cadillac CTS 2002-2004 Cadillac Escalade, Escalade EXT 2003-2004 Cadillac Escalade ESV 2002-2004 Chevrolet Avalanche, Express, Silverado, Suburban, Tahoe 2002-2004 GMC Denali, Denali XL, Savana, Sierra, Yukon, Yukon XL 2002-2004 Commercial Upfitter Chassis Vehicles with Air Conditioning (A/C) This bulletin is being revised to update the service procedure and parts information. Please discard Corporate Bulletin Number 03-01-38-019 (Section 01 - HVAC). Condition Some customers may comment about an underhood rattle noise heard on acceleration or a sudden loss of A/C system performance. Cause This condition may be caused by liquid slugging of the A/C compressor. This condition may cause an internal failure in the A/C compressor. The serpentine belt tensioner and serpentine belt may also be damaged. Correction Technicians are to check the A/C system performance and compressor operation using the following repair procedure: 1. Open the hood and inspect the A/C compressor for damage and to see if the compressor is seized. Verify that the serpentine belt is not damaged or missing. If the A/C compressor is seized, proceed to Step 5. 2. Perform the A/C System Performance test. Refer to the Heating, Ventilation and Air Conditioning (HVAC) section of SI. Correct any performance concerns or refrigerant leaks that are found. 3. Inspect the vehicle for other possible sources of A/C compressor noise or performance concerns. Refer to Corporate Bulletin Number 01-01-38-013 for more information. 4. After all other possible sources of A/C compressor noise or performance concerns have been eliminated, only then should the A/C compressor be replaced. 5. Remove the A/C compressor. Refer to the A/C Compressor Replacement procedure in the HVAC section of SI. 6. Inspect the transmission cooler lines for damage due to contact from the serpentine belt. Replace the transmission cooler lines if necessary. 7. Install an inline A/C system filter. Refer to Corporate Bulletin Number 01-01-38-006C for more information about A/C system flushing and filter installation procedures. An A/C system flush is not to be done unless prior authorization is given by the GM Area Service Manager (in Canada, the District Service Manager). 8. Install an A/C Suction Screen. Refer to Corporate Bulletin Number 01-01-39-003A for more information about A/C suction screen repair recommendations and procedures. 9. Install a new A/C compressor. Refer to the Compressor Replacement procedure in the HVAC section of SI. 10. Install a new orifice tube for the front A/C system. Refer to the Expansion (Orifice) Tube Replacement procedure in SI. Testing and Inspection Engine Mount: Testing and Inspection Engine Mount Inspection Notice: Broken or deteriorated mounts can cause misalignment and destruction of certain drive train components. When a single mount breaks, the remaining mounts are subjected to abnormally high stresses. Notice: When raising or supporting the engine for any reason, do not use a jack under the oil pan, any sheet metal, or the crankshaft pulley. Due to the small clearance between the oil pan and the oil pump screen, jacking against the oil pan may cause the pan to be bent against the pump screen. This will result in a damaged oil pickup unit. 1. Measure the engine movement at the engine mount in order to check for damage to the rubber portions of the mount. 1. Apply the park brake. 2. Start the engine. 3. Firmly apply and hold the primary brakes. 4. Have an assistant stand to the side of the vehicle in order to observe for engine movement. 5. Slightly load the engine shifting from drive to reverse a few times. 6. If the engine moves more than 24 mm (0.945 inch) from the at rest position, in either direction, check for loose engine mount bolts. 2. If the engine mount bolt torque is within specifications, check the condition of the engine mount. 3. Replace the engine mount if any of the following conditions exist: ^ Heat check cracks cover the rubber cushion surface. ^ The rubber cushion is separated from the metal plate of the mount. ^ There is a split through the rubber cushion. Page 3979 Fuel Tank Pressure Sensor: Service and Repair FUEL TANK PRESSURE SENSOR REPLACEMENT REMOVAL PROCEDURE 1. Remove the fuel tank. 2. Using a slight rocking motion, while pulling straight up, remove the fuel tank pressure sensor (1). INSTALLATION PROCEDURE 1. Install the fuel tank pressure sensor (1). 2. Install the fuel tank. Page 4532 Data Link Connector (DLC) Diagram 4 Page 7182 Shifter M/T: Service and Repair NV 4500 Shift Lever Assembly Replacement Removal Procedure Important: ^ Ensure that the control lever is positioned into the mechanical third or fourth gear prior to removal of the shift lever from the transmission. The transmission must remain in this state when the shift lever is removed. ^ Do not disassemble the transmission shift lever. Internal parts for this shift lever are not available. Opening the shift housing lever voids the warranty. ^ When removing the shift lever from the transmission, use the exposed bolts on the base of the lever. 1. Remove the control lever and boot. 2. Remove the transmission support. 3. Lower the transmission slightly to access to insulator. 4. Cut one side of the insulator in order to remove it. Remove the insulator. 5. Remove the shift lever and seal. Installation Procedure Front Seat Belt Buckle: Service and Repair Front SEAT BELT BUCKLE REPLACEMENT - FRONT CAUTION: To avoid personal injury to the occupants of the vehicle, observe the following precautions: - More than one supplier's seat belts are used, therefore, install ONLY the seat belt components specified in the GM parts catalog. - To verify that the correct seat belt components were installed, insert the seat belt latch in the seat belt buckle. The latch must be fully seated and be retained in the buckle until purposely released. REMOVAL PROCEDURE 1. Remove the front seat belt buckle nut (1). Disconnect the electrical connection (2). The right seat buckle is shown, the left is similar. 2. Remove the seat belt buckle from the vehicle. INSTALLATION PROCEDURE 1. Install the seat belt buckle in the vehicle. 2. Connect the electrical connection (2). NOTE: Refer to Fastener Notice in Service Precautions. 3. Install the front seat belt buckle nut (1). Tighten Tighten the nut to 53 N.m (39 lb ft). Page 2722 Junction Block - I/P Wire Entry Part 1 Audio - Inadvertent Steering Wheel Button Activation Remote Switch: Technical Service Bulletins Audio - Inadvertent Steering Wheel Button Activation INFORMATION Bulletin No.: 08-08-44-028 Date: August 28, 2008 Subject: Information On Inadvertent Steering Wheel Control (SWC) Button Press Causing Radio Anomalies Models: 2009 and Prior GM Passenger Cars and Trucks (Including Saturn) 2009 and Prior HUMMER H2, H3 Models 2009 and Prior Saab 9-7X All Vehicles with Steering Wheel Controls This bulletin is being issued to provide a recommendation for vehicles with a customer concern of the radio station tuning changing by itself, volume changing by itself, radio changing by itself, or radio muting or going silent when driving and turning the steering wheel. The switches on the right hand side of the steering wheel are easily pressed and may inadvertently be pressed when turning the steering wheel. These concerns may be affected by the location of the steering wheel controls. Recommendation Do Not Replace The Radio 1. Please determine that the switch controls on the steering wheel are functioning correctly. 2. Ask the customer if their hand was in close proximity to the steering wheel controls when the condition happened. Explain to the customer that bumping the controls would have caused this undesired action. Explain to the customer the proper use and function of the steering wheel controls. Disclaimer Page 8402 2. Install the park brake cable (2) to the lever (1). 3. Perform the following procedure to install the cable (2) to the backing plate (4): 1. Compress the spring (3) by pushing towards the lever (1). 2. Route the cable (2) through the slot in the backing plate. 3. Push the cable housing into the backing plate (4) until the locking tabs snap into place. 4. Install the cable to the mounting bracket until the locking tabs snap into place. 5. Notice: Refer to Fastener Notice in Service Precautions. Bolt the cable to the differential (clips). ^ Tighten the bolt to 25 Nm (18 ft. lbs.). 6. Important: Page 16009 Electrical Symbols Part 4 Page 3624 6. Remove the fan shroud retainers. 7. Remove the fan shroud bolts 8. Remove the upper fan shroud. Installation Procedure 1. Install the upper fan shroud. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the fan shroud bolts. Tighten the bolts to 9 Nm (80 inch lbs.). Page 11334 HVAC Control Module - C2 Part 1 Page 8437 5. Install the park brake shoe return spring (6). 6. Adjust the park brake shoe. Refer to Park Brake Adjustment See: Adjustments. 7. Install the rear axle shaft. Refer to Rear Axle Shaft Replacement in Rear Drive Axle . 8. Install the rotor. Refer to Rear Brake Rotor Replacement in Disc Brakes See: Disc Brake System/Brake Rotor/Disc/Service and Repair. 9. Install the park brake cable (2) to the lever (1). 10. Perform the following procedure to install the cable (2) to the backing plate (4): 10.1. Compress the spring (3) by pushing towards the lever (1). 10.2. Route the cable (2) through the slot in the backing plate. 10.3. Push the cable housing into the backing plate (4) until the locking tabs snap into place. 11. Install the tire and wheel. 12. Remove the safety stands. 13. Lower the vehicle. 14. Enable the park brake cable automatic adjuster. Refer to Parking Brake Cable Adjuster Enabling See: Parking Brake Cable/Adjustments. 15. For the 1500HD, install the park brake cable to the equalizer by pulling down on the park brake cable in front of the equalizer then installing the cable to the equalizer bar. Page 2735 4. Connect the wiring connectors to the fuse block. Refer to Electrical Center Identification Views to ensure the right connections are made. 5. Install the right side end panel. Page 1534 Accelerator Pedal Position Sensor: Service and Repair ACCELERATOR PEDAL POSITION (APP) SENSOR REPLACEMENT REMOVAL PROCEDURE NOTE: Handle the electronic throttle control components carefully. Use cleanliness in order to prevent damage. Do not drop the electronic throttle control components. Do not roughly handle the electronic throttle control components. Do not immerse the electronic throttle control components in cleaning solvents of any type. 1. Remove the connector position assurance (CPA) retainer. 2. Disconnect the accelerator pedal position (APP) sensor electrical connector. 3. Reposition the carpet to access the lower nut. 4. Remove the accelerator pedal nuts. 5. Remove the accelerator pedal assembly. INSTALLATION PROCEDURE Locations Driver Door Page 12207 Involved are certain vehicles within the VIN breakpoints shown above. PARTS INFORMATION -- Saab US Only Customer Notification General Motors will notify customers of this special coverage on their vehicles (see copy of typical customer letter shown in this bulletin - actual divisional letter may vary slightly). Page 5566 Ignition Coil 6 Page 8881 IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections TESTING FOR INTERMITTENT AND POOR CONNECTIONS TOOLS REQUIRED - J 35616-C GM-Approved Terminal Test Kit - J 38125-D Terminal Repair Kit - J 42675 Flat-Wire Probe Adapter Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector. - Poor terminal to wire connection - Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. - Wire insulation which is rubbed through - This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. - Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. Testing For Proper Terminal Contact It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-D or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-D, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. Underhood Electrical Center or Junction Block Replacement Fuse Block: Service and Repair Underhood Electrical Center or Junction Block Replacement UNDERHOOD ELECTRICAL CENTER OR JUNCTION BLOCK REPLACEMENT REMOVAL PROCEDURE 1. Disconnect the negative battery cable. 2. Remove the left fender upper brace. 3. Remove the electrical center brace cover assemble by lifting the cover (3) outwards to clear the tabs. 4. Remove all fuses and relays. Stationary Window Reveal Molding Repair Windshield Moulding / Trim: Service and Repair Stationary Window Reveal Molding Repair Stationary Window Reveal Molding Repair Removal Procedure Caution: Refer to Glass and Sheet Metal Handling Caution in Service Precautions. Important: The window reveal molding fills the cavity between the body and window. If the reveal molding is stretched or damaged, it cannot be reused and it must be replaced. 1. Lift up on the loose area of the reveal molding. 2. Clean the top edge of the window surface and the reveal molding with a 50/50 mixture of isopropyl alcohol and water by volume on a dampened lint-free cloth. Installation Procedure Caution: Refer to Window Retention Caution in Service Precautions. 1. Verify all primers and urethane adhesive are within expiration dates. Important: Use care when applying the prep, clear #1, to the window. This primer dries almost instantly, and may stain the viewing area of the window if not applied evenly. 2. Use a new dauber in order to apply glass prep, clear #1, to the channel area approximately 13 mm (1/2 in) to the upper edge of the window. 3. Wipe the glass primed area immediately with a clean lint-free cloth. 4. Shake the glass primer, black #2, for at least 1 minute. 5. Use a new dauber in order to apply glass primer, black #2, to the top edge of the window. 6. Apply a small bead of urethane adhesive (2) between the window (1) and the pinch-weld. Page 5629 Knock Sensor: Description and Operation KNOCK SENSOR (KS) SYSTEM DESCRIPTION PURPOSE The knock sensor (KS) system enables the control module to control the ignition timing for the best possible performance while protecting the engine from potentially damaging levels of detonation. The control module uses the KS system to test for abnormal engine noise that may indicate detonation, also known as spark knock. SENSOR DESCRIPTION This KS system uses one or two broadband one-wire sensors. The sensor uses piezo-electric crystal technology that produces an AC voltage signal of varying amplitude and frequency based on the engine vibration, or noise, level. The amplitude and frequency are dependant upon the level of knock that the KS detects. The control module receives the KS signal through a signal circuit. The KS ground is supplied by the engine block through the sensor housing. One way the control module monitors the system is by output of a bias voltage on the KS signal wire. The bias voltage creates a voltage drop that the control module monitors and uses to help diagnose KS faults. The KS noise signal rides along this bias voltage, and due to the constantly fluctuating frequency and amplitude of the signal, will always be outside of the bias voltage parameters. Another way the control module monitors the system is by learning the average normal noise output from the KS. The control module learns a minimum noise level, or background noise, at idle from the KS and uses calibrated values for the rest of the RPM range. The control module uses the minimum noise level to calculate a noise channel. The control module uses this noise channel, and the KS signal that rides along the noise channel, in much the same way as the bias voltage type does. As engine speed and load change, the noise channel upper and lower parameters will change to accommodate the normal KS signal. In order to determine which cylinders are knocking, the control module only uses KS signal information when each cylinder is near top dead center (TDC) of the firing stroke. If the control module has determined that knock is present, it will retard the ignition timing to attempt to eliminate the knock. The control module will always try to work back to a zero compensation level, or no spark retard. An abnormal KS signal will fall within the noise channel or will not be present. KS diagnostics are calibrated to detect faults with the KS circuitry inside the control module, the KS wiring, or the KS voltage output. Page 2329 Removal Procedure Notice: Refer to Power Steering Hose Disconnected Notice in Service Precautions. 1. Remove the power steering outlet hose (4) from the power steering gear (3). 2. Remove the power steering outlet hose (4) from the power steering cooler (5). Installation Procedure 1. Connect the power steering outlet hose (4) to the power steering cooler (5). 2. Connect the power steering outlet hose (4) to the power steering gear (3). Hand tighten only. 3. Notice: Refer to Fastener Notice in Service Precautions. Connect the power steering outlet hose (2) to the power steering pump (1). ^ Tighten both hose connections to 28 Nm (20 ft. lbs.). 4. Bleed the power steering system. Refer to Bleeding the Power Steering System. 5. Inspect all the hose connections for leaks. Page 4313 9. Use J 38125-12A to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. REPAIR PROCEDURE The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. 1. Cut the wire as close to the terminal as possible. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. Page 9214 C221 I/P Harness To Body Harness (With Single Stage Air Bag) Page 10698 Wheels: Service and Repair Tire and Wheel Removal and Installation Tire and Wheel Removal and Installation ^ Tools Required J 39544-KIT Complete Torque Socket Set Caution: If penetrating oil gets on the vertical surfaces between the wheel and the rotor or drum it could cause the wheel to work loose as the vehicle is driven, resulting in loss of control and an injury accident. Notice: Never use heat to loosen a tight wheel. It can shorten the life of the wheel, studs, or hub and bearing assemblies. Wheel nuts must be tightened in sequence and to the specified torque to avoid bending the wheel or rotor. Notice: Improperly tightened wheel nuts can lead to brake pulsation and rotor damage. In order to avoid expensive brake repairs, evenly tighten the wheel nuts to the proper torque specification. Important: Removing wheels can be difficult because of foreign material or a tight fit between the wheel center hole and the hub or rotor. Excessive force, such as hammering on the wheel or tire, can cause damage. Slightly tapping the tire side wall with a rubber mallet is acceptable. 1. ^ Tighten all wheel nuts on the affected wheel. 2. Loosen each wheel nut 2 turns. 3. Rock the vehicle from side to side in order to loosen the wheel. If this does not loosen the wheel, rock the vehicle front to back applying quick hard jabs to the brake pedal to loosen the wheel. 4. Repeat this procedure if the wheel does not break free. Removal Procedure 1. Raise the vehicle. Support the vehicle with suitable safety stands. Refer to Vehicle Lifting. 2. Remove the wheel center cap. 3. Remove the wheel nuts from the tire and wheel. 4. Mark the location of the tire and wheel to the hub assembly. 5. Remove the tire and wheel from the vehicle. 6. Clean the wheel nuts, studs and the wheel and rotor mounting surfaces. Installation Procedure Caution: Before installing the wheels, remove any buildup of corrosion on the wheel mounting surface and brake drum or disc mounting surface by scraping and wire brushing. Installing wheels with poor metal-to-metal contact at the mounting surfaces can cause wheel nuts to loosen. This can cause a wheel to come off when the vehicle is moving, causing loss of control and possibly personal injury. Notice: A torque wrench or J 39544 must be used to ensure that wheel nuts are tightened to specification. Never use lubricants or penetrating fluids on wheel stud, nuts, or mounting surfaces, as this can raise the actual torque on the nut without a corresponding torque reading on the torque wrench. Wheel nuts, studs, and mounting surfaces must be clean and dry. Failure to follow these instructions could result in wheel, nut, and/or stud damage. Page 3567 11. Reposition the outlet hose clamp at the water pump. 12. Remove the outlet hose from the water pump. 13. Reposition the surge tank outlet hose clamp at the water pump. 14. Remove the surge tank outlet hose from the water pump. 15. Reposition the heater inlet hose clamp at the water pump. 16. Remove the heater inlet hose from the water pump. 17. Remove the water pump bolts. 18. Remove the water pump and gaskets. 19. Discard the water pump gaskets. Installation Procedure Page 11672 3. Install the retractor tower cover. 4. Install the retractor tower cover retaining screw. Tighten Tighten the screw to 2 N.m (18 lb in). 5. Install the retractor. 6. Install the retractor bolt. Tighten Tighten the bolt to 53 N.m (39 lb ft). 7. Install the rear cardboard panel retainers. 8. Install the seat back cover and pad. 9. Move the seat to its original position. Page 10709 6. Important: Do not reuse the nut. A new nut must be used when installing the wheel drive shaft. Remove the wheel driveshaft assembly retaining nut (2) and washer (3) from the wheel driveshaft. 7. Disengage the wheel drive shaft from the wheel hub and bearing using J 45859 or equivalent. Page 933 1. Slide the BCM onto the bracket. 2. Connect all the connectors (1) except the brown connector. 3. Connect the brown connector. 4. Install the knee bolster. 5. Connect the negative battery cable(s). 6. Reprogram the BCM. Refer to Body Control Module (BCM) Programming/RPO Configuration. 7. Perform the Passlock Learn Procedure. See: Testing and Inspection/Programming and Relearning Page 7597 Diagrams Door Latch Assembly (Key Cylinder Switch) - Driver C3 Page 1742 Crankshaft Position Sensor: Description and Operation CRANKSHAFT POSITION (CKP) SENSOR The crankshaft position (CKP) sensor is a three wire sensor based on the magneto resistive principle. A magneto resistive sensor uses two magnetic pickups between a permanent magnet. As an element such as a reluctor wheel passes the magnets the resulting change in the magnetic field is used by the sensor electronics to produce a digital output pulse. The PCM supplies a 12-volt, low reference, and signal circuit to the CKP sensor. The sensor returns a digital ON/OFF pulse 24 times per crankshaft revolution. Page 5252 For vehicles repaired under warranty, use the table. Disclaimer Page 12087 If you are unsure who the PSC is, check with the Sales Manager. General Information 1. The first step is to verify if the OnStar(R) account is active or not. This can be done by pressing the blue OnStar(R) button and connecting to the OnStar(R) call center. Analog only accounts are no longer active. Only digital upgraded accounts will be active. On Gen 6 digital systems, a clear, or "dark" LED may indicate that the OnStar(R) system has been deactivated or may possibly have a no power/no communication condition. 2. If the account isn't active, the next step is to verify what version of OnStar(R) module is in the vehicle. This can be done via the Tech 2 (Body>VCIM>Module ID Information>Module Information 2) or by using www.onstarenrollment.com. 3. A Generation 5 or older analog module can be diagnosed by following the original electronic Service Information developed for the model year of the vehicle. Note: If the customer has an old analog module, the vehicle can be repaired by replacing the module, but the customer cannot have an active account without upgrading to a digital module. 4. Modules, antennas, brackets, and other equipment are in the same location, whether original analog production or digital upgrade. 5. An upgraded vehicle may also have a new vehicle communication interface module (VCIM) bracket. If it does, order the new bracket when replacing the bracket. Don't order the original bracket. The kit may also include a small wiring jumper cable. If it does, this jumper will be required for a new module replacement. Do not discard. 6. After replacing the VCIM, it is essential to configure the new OnStar(R) system. Failure to configure the system will result in an additional customer visit for repair. DO NOT press and hold the white dot or phone button on the keypad as it will not reset this version of the OnStar(R) system and may result in a DTC being set. Use of the TIS2WEB and SPS applications, along with the Tech2(R), are required in order to perform the VCIM configuration and setup procedure for this vehicle. The configuration and set-up procedure is now a two-step process which enables an automated activation by the OnStar(R) Center, without a button press by the technician to the OnStar(R) Call Center. Page 2613 Fuse Block - Underhood - Secondary Wire Entry (With RPO Code HP2) Part 3 Page 7651 7. Insert a flat-tipped screwdriver or a small pry bar in the space between the outer race of the seal and the transfer case. 8. Remove the outer part of the seal. Installation Procedure Page 9059 Relay Block - I/P C4 Page 11193 1. Install the discharge hose (1) to the vehicle. 2. Connect the electrical connector to the A/C recirculation switch. 3. Install the discharge hose to the condenser using new sealing washers. NOTE: Refer to Fastener Notice in Service Precautions. 4. Install the discharge hose nut to the condenser. Tighten Tighten the nut to 16 N.m (12 lb ft). 5. Install the upper air baffle. Service and Repair Wheel Seal: Service and Repair Wheel Hub, Bearing, and Seal Replacement (4WD) ^ Tools Required J 45859 Axle Remover Removal Procedure 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Remove the tire and wheel. 3. Remove the rotor. Refer to Brake Rotor Replacement - Front in Disc Brakes. 4. Remove the wheel speed sensor and brake hose mounting bracket bolt from the steering knuckle. 5. Remove the wheel drive shaft nut retaining cover. 6. Important: Page 14564 Memory Positioning Module: Service and Repair Memory Seat Control Module Replacement MEMORY SEAT CONTROL MODULE REPLACEMENT REMOVAL PROCEDURE 1. Remove the seat cushion. 2. Disconnect the upper electrical harness connectors (3). 3. Remove the module (2) retaining screws (1). 4. Slide the module to the right to disengage the lower retainers. 5. Disconnect the lower electrical harness connectors (2). 6. Remove the module from the vehicle. INSTALLATION PROCEDURE Page 11474 Impact Sensor: Diagrams Inflatable Restraint Front End Sensor - Left Page 12944 Steering Wheel Audio Controls - Right (With RPO Code YE9) Page 15227 If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Sir/SRS Wiring Repairs SIR/SRS WIRING REPAIRS TOOLS REQUIRED J 38125-D Terminal Repair Kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-D contains the following items: - Special sealed splices - in order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping tool - A heat torch - An instruction manual The sealed splices have the following 2 critical features: - A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-D also serves as a generic terminal repair kit. The kit contains the following items: - A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors Page 11059 - Proof of ownership at time of repair. - Original paid receipt confirming the amount of unreimbursed repair expense(s) (including Service Contract deductibles), a description of the repair, and the person or entity performing the repair. If the work was done by someone other than a GM dealership, the amount of reimbursement will be limited to the amount that the repair would have cost GM to have it completed by a GM dealership. Courtesy Transportation The General Motors Courtesy Transportation program is intended to minimize customer inconvenience when a vehicle requires a repair that is covered by the New Vehicle Limited Warranties. The availability of courtesy transportation to customers whose vehicles are within the warranty coverage period and involved in a product program is very important in maintaining customer satisfaction. Dealers are to ensure that these customers understand that shuttle service or some other form of courtesy transportation is available and will be provided at no charge. Dealers should refer to the General Motors Service Policies and Procedures Manual for Courtesy Transportation guidelines. Warranty Transaction Information Submit a transaction using the table below. * The amount identified in "Net Item" should represent the dollar amount reimbursed to the customer. Disclaimer Page 6922 25. Align the following during this procedure: ^ The CV joint boot (3) ^ The CV joint assembly (1) ^ The swage ring (2) 26. Install the top half of J 36652 onto the lower half of the tool, over the CV joint boot (3) and the CV joint assembly (1). 27. Align the swage ring (2) and the swage ring clamp. 28. Insert the bolts into J 36652. Hand tighten the bolts until the bolts are snug. ^ Tighten each bolt 180 degrees at a time. Alternate between the bolts until both sides of the top half of J 36652 touch the bottom half of the tool. 29. Loosen the bolts and remove the halfshaft assembly from J 36652. Marker Lamp Bulb Replacement - Roof (Outer) Marker Lamp Bulb: Service and Repair Marker Lamp Bulb Replacement - Roof (Outer) MARKER LAMP BULB REPLACEMENT - ROOF (OUTER) REMOVAL PROCEDURE 1. Remove the screws from the roof marker lamp lens. 2. Remove the roof marker lamp lens. 3. Remove the bulb. INSTALLATION PROCEDURE 1. In order to install the bulb, push in the bulb until the bulb is seated. 2. Install the roof marker lamp lens. NOTE: Refer to Fastener Notice in Service Precautions. 3. Install the screws to the roof marker lamp lens. Tighten Tighten the screws to 1.9 N.m (17 lb ft). Page 6523 Transmission Cooler: Technical Service Bulletins A/T - Water Or Coolant Contamination Information INFORMATION Bulletin No.: 08-07-30-035B Date: November 01, 2010 Subject: Information on Water or Ethylene Glycol in Transmission Fluid Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks with Automatic Transmission Supercede: This bulletin is being revised to update model years. Please discard Corporate Bulletin Number 08-07-30-035A (Section 07 - Transmission/Transaxle). Water or ethylene glycol in automatic transmission fluid (ATF) is harmful to internal transmission components and will have a negative effect on reliability and durability of these parts. Water or ethylene glycol in ATF will also change the friction of the clutches, frequently resulting in shudder during engagement or gear changes, especially during torque converter clutch engagement. Indications of water in the ATF may include: - ATF blowing out of the transmission vent tube. - ATF may appear cloudy or, in cases of extreme contamination, have the appearance of a strawberry milkshake. - Visible water in the oil pan. - A milky white substance inside the pan area. - Spacer plate gaskets that appear to be glued to the valve body face or case. - Spacer plate gaskets that appear to be swollen or wrinkled in areas where they are not compressed. - Rust on internal transmission iron/steel components. If water in the ATF has been found and the source of the water entry has not been identified, or if a leaking in-radiator transmission oil cooler is suspected (with no evidence of cross-contamination in the coolant recovery reservoir), a simple and quick test kit is available that detects the presence of ethylene glycol in ATF. The "Gly-Tek" test kit, available from the Nelco Company, should be obtained and the ATF tested to make an accurate decision on the need for radiator replacement. This can help to prevent customer comebacks if the in-radiator transmission oil cooler is leaking and reduce repair expenses by avoiding radiator replacement if the cooler is not leaking. These test kits can be obtained from: Nelco Company Test kits can be ordered by phone or through the website listed above. Orders are shipped standard delivery time but can be shipped on a next day delivery basis for an extra charge. One test kit will complete 10 individual fluid sample tests. For vehicles repaired under warranty, the cost of the complete test kit plus shipping charges should be divided by 10 and submitted on the warranty claim as a net item. The transmission should be repaired or replaced based on the normal cost comparison procedure. Important If water or coolant is found in the transmission, the following components MUST be replaced. - Replace all of the rubber-type seals. - Replace all of the composition-faced clutch plates and/or bands. - Replace all of the nylon parts. - Replace the torque converter. - Thoroughly clean and rebuild the transmission, using new gaskets and oil filter. Important The following steps must be completed when repairing or replacing. Flush and flow check the transmission oil cooler using J 45096. Refer to Corporate Bulletin Number 02-07-30-052F- Automatic Transmission Oil Cooler Flush and Flow Test Essential Tool J 45096 TransFlow. - Thoroughly inspect the engine cooling system and hoses and clean/repair as necessary. Page 4900 1. Lubricate a NEW O-ring seal with transmission fluid. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the VSS and bolt. ^ Tighten the bolt to 10 Nm (89 inch lbs.). 3. If equipped with the 8.1L engine, connect the VSS electrical connector (5). 4. If equipped with the 6.6L engine, connect the VSS electrical connector (4). 5. Lower the vehicle. 6. Check the transmission fluid level. Add if necessary. Page 13563 Body Control Module (BCM) - C3 Part 1 Page 9721 C153 4-Wheel Drive Harness To Engine Harness Page 15547 Ambient Light Sensor (With RPO Code CJ3) Page 12826 Automatic Transmission - 4L60-E/4L65-E Page 7511 Control Module: Diagrams Page 5382 10. Disconnect the fuel and EVAP quick connect fittings. 11. Cap the fuel and EVAP lines at the fuel tank in order to avoid possible system contamination. 12. Remove the EVAP line from the clips (2) on the fuel tank. 13. Disconnect the quick connect fittings from the EVAP canister. 14. If vehicle is a regular cab, remove the fuel and EVAP bundle nuts. Page 9146 4. Install the ground, then the washer and then the bolt to the frame. Important: It is important to use the bolts, washers and nuts specified in this bulletin. These parts have been identified due to their conductive finish. 5. Install a washer and nut to the back side of the frame. Tighten Tighten the nut to 9 Nm (79 lb in). 6. Cover the front and back side of the repair area using Rubberized Undercoating. An additional check can be made to ensure a good connection for the battery cable to frame ground. It is possible for this ground to cause similar symptoms with the ABS as described above. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Parts Information Warranty Information Disclaimer Page 12200 Page 9798 Relay Box: Diagrams Junction Block - Rear Lamps - C1 Page 4091 Oxygen Sensor: Service and Repair Heated Oxygen Sensor (HO2S) Replacement Bank 2 Sensor 1 HEATED OXYGEN SENSOR (HO2S) REPLACEMENT BANK 2 SENSOR 1 REMOVAL PROCEDURE 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. Disconnect the connector position assurance (CPA) retainer. 3. Remove the heated oxygen sensor (HO2S) from the clips NOTE: Refer to Heated Oxygen and Oxygen Sensor Notice in Service Precautions. 4. If equipped with a 4.8L or 5.3L engine, disconnect the HO2S electrical connector. Page 9009 Fuse Block - Underhood C1 Part 3 Page 16083 7. Insert the J 38125-13A (GM P/N 12031876-1) tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the Terminal Repair Kit to ensure that the correct release tool is used. 8. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. REPAIR PROCEDURE Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. Page 10099 7. Install the power steering pressure hose (2) to the power steering pump. ^ Tighten the fitting to 28 Nm (20 ft. lbs.). 8. Install the oil pan skid plate, if equipped. 9. Install the oil pan skid plate bolts. ^ Tighten the retaining bolts to 20 Nm (15 ft. lbs.). 10. Lower the vehicle. 11. Install the intermediate shaft. Refer to Intermediate Steering Shaft Replacement - Lower. 12. Install the power steering pulley. Refer to Power Steering Pulley Replacement. 13. Fill and bleed the power steering system. Refer to Bleeding the Power Steering System. Page 11351 Ambient Temperature Sensor / Switch HVAC: Service and Repair AMBIENT AIR TEMPERATURE SENSOR REPLACEMENT REMOVAL PROCEDURE 1. Remove the Park/Turn Signal. 2. Disconnect the electrical connector from the ambient air temperature sensor (3). 3. Remove the ambient air temperature sensor (3). INSTALLATION PROCEDURE 1. Install the ambient air temperature sensor (3). 2. Connect the electrical connector to the ambient air temperature sensor (3). 3. Install the Park/Turn Signal. Page 2156 Inspect the fan clutch for smooth operation. Inspect for a bent fan shaft or bent mounting flange. 9. Inspect the water pump drive shaft for being bent. Also inspect the water pump bearings for smooth operation and excessive play. Compare the water pump with a known, good water pump. 10. Accessory drive component brackets that are bent, cracked, or loose may put an extra strain on that accessory drive component causing it to vibrate. Drive Belt Whine Drive Belt Whine Diagnosis Diagnostic Aids The drive belt(s) will not cause the whine. If the whine is intermittent, verify that it is not the accessory drive component(s) by varying their loads, making sure they are operating to their maximum capacity. An overcharged air conditioning (A/C) system, a power steering system restriction or the incorrect fluid, or a failing generator are suggested items to inspect. Test Description Steps 1 - 5 The number(s) below refer to the step(s) in the diagnostic table. 3. This test is to verify that the whine is being caused by the accessory drive component(s). Remove the drive belt(s) and operate the engine for a few seconds, this will verify if the whining noise is related to the accessory drive component. With the drive belt(s) removed the water pump will not operate and the engine may overheat. Also diagnostic trouble codes (DTCs) may set when the engine is operated with the drive belt(s) removed. 4. This inspection should include checking the drive belt tensioner and the drive belt idler pulley bearings. The drive belt(s) may have to be installed and the accessory drive components operated separately by varying their loads. Refer to the suspected accessory drive component for the proper removal and installation procedure. Page 5383 15. If vehicle is a extended cab, remove the fuel and EVAP bundle nuts. 16. Remove the fuel and EVAP bundle. INSTALLATION PROCEDURE 1. Install the fuel and EVAP bundle. NOTE: Refer to Fastener Notice in Service Precautions. 2. If vehicle is a extended cab, install the fuel and EVAP bundle nuts. Tighten Tighten the nuts to 12 N.m (106 lb in). 3. If vehicle is a regular cab, install the fuel and EVAP bundle nuts. Tighten Tighten the nuts to 12 N.m (106 lb in). Locations Instrument Panel Switches-LH Page 15309 Parts Information Parts are currently available from GMSPO. Warranty Information Page 10192 Do not apply force to the steering wheel position sensor and the adapter and bearing assembly in a sideways direction. Seat the adapter and bearing assembly into the steering column jacket. 5. Connect the steering wheel position sensor connector. 6. Notice: Refer to Fastener Notice in Service Precautions. Align the marks on the upper intermediate shaft and the steering column shafts, where they connect, that you made during the removal procedure. 7. Install the intermediate shaft to the steering column pinch bolt. ^ Tighten the nut to 62 Nm (46 ft. lbs.). 8. Connect the negative battery cable. 9. Enable the SIR system. Page 10451 9. Install the adjustment bolt (3) and the adjuster nut (4), for vehicles with MN8, MT1 AND MW3. 10. Remove the J 36202 releasing the tension on the torsion bar until the load is taken up by the adjustment bolt. 11. Remove the safety stands. 12. Lower the vehicle. 13. Measure the Z height. Refer to Trim Height Inspection Procedure in Suspension General Diagnosis. 14. Turn the adjustment bolt (2) clockwise to increase the Z height and counterclockwise to decrease the Z height. Page 973 Page 3782 Electrical Symbols Part 10 Page 8538 Electrical - Trailer Brakes Apply With Headlamps ON Trailer Adapter Kit: All Technical Service Bulletins Electrical - Trailer Brakes Apply With Headlamps ON Bulletin No.: 02-05-22-004C Date: April 05, 2005 TECHNICAL Subject: Trailer Brakes Applied When Headlights/Park Lamps Are On, Brake Controller Illumination (Modify Brake Controller Wiring Harness) Models: 2002-2005 Cadillac Escalade, Escalade EXT 1999-2005 Chevrolet Silverado 2000-2005 Chevrolet Suburban, Tahoe 2002-2005 Chevrolet Avalanche 1999-2005 GMC Sierra 2000-2005 GMC Yukon, Yukon XL 2003-2005 HUMMER H2 Supercede: This bulletin is being revised to add additional model years. Please discard Corporate Bulletin Number 02-05-22-004B (Section 05 - Brakes). Condition Some customers may comment that when the headlamps or park lamps are on, the brakes on the trailer are always applied, or that the back lighting for the trailer brake controller only illuminates when the brakes are applied. Cause The cause of this condition may be due to wiring changes within the vehicle electrical system for the 2003 model year. Correction Inspect the brake controller wiring harness jumper that is plugged into the vehicle relay block-body. The relay block-body is located under the left side of the instrument panel near the left kick panel, behind a plastic cover. Page 600 Memory Seat Module - C4 Part 1 Page 7027 9. Install the nut (2) and washer (3) retaining the wheel drive shaft assembly to the wheel hub and bearing. ^ Tighten the nut to 240 Nm (177 ft. lbs.). 10. Install the wheel speed sensor and brake hose mounting bracket bolt to the steering knuckle. ^ Tighten the brake hose clip bolt to 12 Nm (106 inch lbs.). 11. Install the rotor. Refer to Brake Rotor Replacement - Front in Disc Brakes. 12. Install the tire and wheel. 13. Lower the vehicle. Page 1531 Accelerator Pedal Position Sensor: Diagrams Accelerator Pedal Position (APP) Sensor Part 1 Page 1115 Installation Procedure 1. Install the door module into the switch panel bezel until it snaps into place. 2. Install the switch panel bezel and module to the door panel. Notice: Refer to Fastener Notice in Service Precautions. 3. Install the screw that retains the switch panel bezel (1) to the front door panel. Tighten the screw to 2 N.m (18 lb in). 4. Connect the electrical connectors. 5. Install the front door trim panel. 6. If equipped with camper mirrors program the door module. Refer to Service Programming System (SPS) in Programming. See: Testing and Inspection/Programming and Relearning Switch Replacement - Door Lock and Side Window - Passenger Page 9215 C221 I/P Harness To Body Harness (With Dual Stage Air Bag) Page 9587 Junction Block - Rear Lamps - C2 Page 12720 6. See wiring diagram shown above for details. 5. Replace the OnStar(R) Vehicle Communication Interface Module (VCIM) in the vehicle with the provided Digitally-Capable VCIM. Refer to the Communication Interface Module Replacement procedure in the Cellular Communication section of SI. This kit may include a new VCIM bracket. If it does, use this new bracket on the vehicle and discard the original bracket. The kit may also include a small wiring jumper cable. If it does, plug the wiring jumper cable into the connector on the VCIM and the other end to the corresponding vehicle wiring harness connector. ^ For 2001, 2002 and 2003 Chevrolet Impala and Monte Carlo, do not reinstall the black plastic OnStar(R) module cover onto the vehicle after the VCIM and module bracket have been installed. This black plastic cover will no longer fit on the vehicle. ^ The upgrade kit for 2002 Sevilles and DeVilles, and some 2003 Sevilles and DeVilles, will contain a large bracket. To install the new VCIM into this bracket you'll need to carefully line up the notch in the VCIM with the tab in the bracket. Page 11692 Air Bag Deactivation Switch: Service and Repair INFLATABLE RESTRAINT INSTRUMENT PANEL (I/P) MODULE DISABLE SWITCH REPLACEMENT REMOVAL PROCEDURE CAUTION: Refer to SIR Caution in Service Precautions. 1. Remove the instrument panel trim bezel. 2. Remove the I/P module switch from the lower right opening of the switch plate panel. 3. Disconnect the I/P module switch electrical connector. INSTALLATION PROCEDURE 1. Connect the I/P module switch electrical connector. 2. Install the I/P module switch into the lower right opening of the switch plate panel. 3. Install the instrument panel trim bezel. Page 13568 Body Control Module (BCM) - C6 Part 1 Diagram Information and Instructions Auxiliary Blower Motor: Diagram Information and Instructions Truck Zoning TRUCK ZONING Truck Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that corresponds to where they are located in the vehicle. The table explains the numbering system. Page 14072 Electrical Symbols Part 12 Page 7676 2. Connect the selector switch electrical connectors (2, 3). 3. Slide the selector switch into the housing until the switch snaps into place. Important: Make sure that the selector switch is seated properly in the housing before installing the I/P cluster bezel. 4. Install the I/P cluster bezel. Page 10880 Electrical Symbols Part 2 Page 10254 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Page 7215 Electrical Symbols Part 6 Locations Left Rear Underhood - Front Of Dash Page 322 Check - Vehicle. The Diagnostic System Check will provide the following information: ^ The identification of the control modules which command the system ^ The ability of the control modules to communicate through the serial data circuit ^ The identification of any stored diagnostic trouble codes (DTCs) and their status The use of the Diagnostic System Check will identify the correct procedure for diagnosing the system and where the procedure is located. Visual/Physical Inspection Perform the following visual inspections; ^ Inspect for aftermarket devices which could affect the operation of the Radio/Audio System. Refer to Checking Aftermarket Accessories in SI. ^ Inspect the easily accessible and visible system components for obvious damage or conditions which could cause the symptom. Intermittent Conditions Faulty electrical connections or wiring may be the cause of intermittent conditions. Refer to Testing for Intermittent Conditions and Poor Connections in SI. Symptom List Page 10779 Do not reuse the nut. A new nut must be used when installing the wheel drive shaft. Remove the wheel driveshaft assembly retaining nut (2) and washer (3) from the wheel driveshaft. 7. Disengage the wheel drive shaft from the wheel hub and bearing using J 45859 or equivalent. 8. Remove the wheel hub and the 15-series bearing mounting bolts (4). 9. Remove the wheel hub and bearing (4) mounting bolts, 25/35 series. 10. Remove the wheel hub and bearing and splash shield from the vehicle. 11. Remove the O-ring seal from the steering knuckle bore, 25/35 series. 12. Remove the wheel speed sensor mounting bolt (5). 13. Clean and inspect the O-ring seal, 25/35 series. 14. Replace the seal if the following conditions exist: ^ Nicks ^ Cuts Page 6909 9. Assemble the tripot housing and the tripot seal using the following procedure: 1. Pinch the swage ring (2) slightly by hand in order to distort it into an oval shape. 2. Slide the distorted swage ring (2) over the large diameter of the seal. 3. Place the tripot housing over the spider assembly. 4. Install the seal onto the tripot housing. 5. Align the tripot seal (1), with the swage ring (2) in place, over the flat area on the tripot housing (3). Page 10098 1. Notice: Refer to Fastener Notice in Service Precautions. Install the bracket (3) to the rear of the pump (1). ^ Tighten the rear bracket retaining nuts to 50 Nm (37 ft. lbs.). 2. Install the power steering pump. 3. Install the bolt retaining the rear bracket to the engine. ^ Tighten the rear power steering bracket bolt to engine bracket to 50 Nm (37 ft. lbs.). 4. Install the bolts to the front of the pump. ^ Tighten the bolts to 50 Nm (37 ft. lbs.). 5. Install the power steering pump return hoses (2,4) to the power steering pump and install the retaining clamps. 6. Raise the vehicle. Refer to Vehicle Lifting. Page 897 circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links CIRCUIT PROTECTION - FUSIBLE LINKS Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Flat Wire Repairs FLAT WIRE REPAIRS NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Heated Oxygen Sensor (HO2S) Wiring Repairs HEATED OXYGEN SENSOR (HO2S) WIRING REPAIRS TOOLS REQUIRED J 38125-D Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: - Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-D. Repairing Damaged Wire Insulation REPAIRING DAMAGED WIRE INSULATION Page 5655 5. Compress the reverse boost valve sleeve into the bore of the oil pump to expose the retaining ring slot. 6. Install the reverse boost valve retaining ring, then slowly release tension on the reverse boost valve sleeve. 7. Install the transmission filter. Page 9462 Auxiliary Power Outlet: Description and Operation POWER OUTLETS - DESCRIPTION AND OPERATION The 120-volt auxiliary power outlets (APO) are located in the cab and within the pickup bed. The APOs provide 120 volts A/C at 60 hertz with a total a total circuit current of 20 amps. All of the APOs are protected by a ground fault detector located in the starter generator control module (SGCM). The ground fault detector will turn OFF all the outlets if a short to ground is detected or a current overload of greater than 20 amps occurs. After correcting the APOs circuit fault, the APO momentary push button switch on the instrument panel (I/P) may be pressed to reset the ground fault detector. The 120-volt APOs are activated with a momentary push button that located on the I/P. There are 3 states displayed by the 120-volt APO switch indicator lamp. If the lamp is illuminated, then the APOs circuit is activated and the vehicle is in the normal mode. A flashing indicator lamp signals that the system is in the continuous mode. If the indicator is OFF, the 120-volt A/C APOs are OFF. For more information on the hybrid system, review the following Description and Operations. - Energy Storage Box (ESB) Description and Operation in Starting and Charging - Hybrid Control Module (HCM) Description and Operation in Starting and Charging - Starter/Generator Description and Operation in Starting and Charging - Starter/Generator Control Module (SGCM) Description and Operation in Starting and Charging Page 9437 SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-D. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: - The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair Tools Required J 38125-D Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-D. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Page 8106 4. Install the pushrod (3) and the stop lamp switch (2) to the brake pedal pin (1). 5. Install the pushrod retaining clip (4). Weatherstrip Replacement - Auxiliary Rear Door Weatherstrip: Service and Repair Weatherstrip Replacement - Auxiliary Weatherstrip Replacement - Auxiliary Removal Procedure 1. Open the door. 2. Pull the weather-strip from the pinchweld flange. Installation Procedure 1. Push the weather-strip over the pinch-weld flange. 2. Close the door. Page 5125 EVAPORATIVE EMISSION (EVAP) HOSES/PIPES REPLACEMENT - CANISTER/FUEL TANK (PICKUP AND CAB/CHASSIS) REMOVAL PROCEDURE IMPORTANT: Clean all the evaporative emission (EVAP) line connections and surrounding areas prior to disconnecting the fittings in order to avoid possible fuel/EVAP system contamination. 1. Remove the EVAP canister. 2. Remove the EVAP canister line (1). 3. Remove the EVAP canister purge line (2). 4. Cap the fuel and EVAP lines in order to prevent possible fuel/EVAP system contamination. INSTALLATION PROCEDURE 1. Remove the caps from the fuel and EVAP lines. 2. Install the EVAP canister purge line (2). 3. Install the EVAP canister line (1). 4. Install the EVAP canister. Page 4377 Crankshaft Position Sensor: Description and Operation CRANKSHAFT POSITION (CKP) SENSOR The crankshaft position (CKP) sensor is a three wire sensor based on the magneto resistive principle. A magneto resistive sensor uses two magnetic pickups between a permanent magnet. As an element such as a reluctor wheel passes the magnets the resulting change in the magnetic field is used by the sensor electronics to produce a digital output pulse. The PCM supplies a 12-volt, low reference, and signal circuit to the CKP sensor. The sensor returns a digital ON/OFF pulse 24 times per crankshaft revolution. Page 10907 6. Use fingers to squeeze the 2 locking legs of the cover. 7. Apply pressure and gently rock the cover until one locking leg is unseated. 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. Page 7581 Page 4866 5. If equipped with a 6.0L engine, disconnect the HO2S electrical connector. 6. Remove the HO2S. INSTALLATION PROCEDURE IMPORTANT: A special anti-seize compound is used on the HO2S threads. The compound consists of liquid graphite and glass beads. The graphite tends to burn away, but the glass beads remain, making the sensor easier to remove. New, or service replacement sensors already have the compound applied to the threads. If the sensor is removed from an exhaust component and if for any reason the sensor is to be reinstalled, the threads must have anti-seize compound applied before the reinstallation. 1. If reinstalling the old sensor, coat the threads with anti-seize compound GM P/N 12377953, or equivalent. NOTE: Refer to Component Fastener Tightening Notice in Service Precautions. 2. Install the HO2S. Tighten Tighten the sensor to 42 N.m (31 lb ft). Page 15319 The values in the table are approximate values based on information obtained from properly operating vehicles. Actual results may vary slightly. Page 8762 Tighten the bolt to 17 N.m (13 lb ft). 24. Snap the positive battery cable cap closed. 25. Connect the negative battery cable. Diagrams Power Door Lock Switch: Diagrams Door Lock Switch - Driver (Base Only) Recall 04V045000: Possible Hydro-Boost Defect Power Steering Pump: All Technical Service Bulletins Recall 04V045000: Possible Hydro-Boost Defect DEFECT: Certain sport utility vehicles, pickup trucks, and passenger vans fail to comply with the requirements of Federal Motor Vehicle Safety Standard No. 135, "Passenger Car Brake Systems." Some of these vehicles were produced with an out-of-specification brake hydro-boost housing relief valve bore. Consequently, the valve O-ring seal may fracture. Steering efforts may be slightly increased while braking or parking. Under certain driving conditions, a fractured seal may also require an increase in the applied brake pedal effort to achieve the same vehicle deceleration. REMEDY: Dealers are to replace the hydro-boost relief valve. The manufacturer has reported that owner notification is expected to begin during the second quarter of 2004. Owners may contact Cadillac at 1-866-982-2339; Chevrolet at 1-800-630-2438; GMC at 1-866-996-9463; or Hummer at 1-866-486-6376. Instruments - Oil Life Monitoring System Oil Change Reminder Lamp: All Technical Service Bulletins Instruments - Oil Life Monitoring System Bulletin No.: 04-06-04-045 Date: June 22, 2004 INFORMATION Subject: Oil Life Monitoring System - PCM Reset Models: 2004 All GM Passenger Cars and Trucks Important: The Oil Life Monitoring System can be found on many General Motor's vehicles prior to 2004. Refer to SI and/or the Owner's Manual for detailed information. The purpose of this bulletin is to help technicians identify which vehicles are equipped with the oil life monitoring system. Although many General Motors vehicles prior to 2004 have been equipped with the oil life monitoring system, the 2004 model year vehicles were used as a starting point to validate the system/scan tool functionality. Customers have come to depend on the Oil Life Monitoring System found on most General Motor's vehicles to inform them when it's time for an oil change. If for any reason the PCM is replaced, it is important to access the "Percent of Oil Life Remaining" from the vehicle's current PCM PRIOR to removing the PCM. This value must be programmed into the new PCM (after it is installed in the vehicle) by using the scan tool. Note: Failure to reprogram the value to the new PCM will result in missed maintenance, which may cause damage to the engine. Important: If the replacement module is not programmed with the remaining engine oil life, the engine oil will need to changed at 5,000 km (3,000 mi) from the last engine oil change. Disclaimer Page 5360 8. Remove the fuel line clips from the brackets on the transmission. 9. If equipped with 4-wheel drive (4WD), remove the fuel line clip from the bracket on the transfer case. 10. Disconnect the fuel and EVAP quick connect fittings. 11. Cap the fuel and EVAP lines at the fuel tank in order to avoid possible system contamination. 12. Remove the EVAP line from the clips (2) on the fuel tank. 13. Disconnect the quick connect fittings from the EVAP canister. Page 5954 Electronic Components Page 4976 Right Side of the Engine Page 11825 ^ Reinstall the fuse and fuse panel cover. ^ Press the "Enter" button to perform the "Refresh" function. ^ "Test in Progress" will be displayed and the right front passenger door lock will cycle once. ^ The screen will display "Procedure Completed". ^ Press the "Exit" button as necessary to return to the main menu screen. 3. Using the switches in the right front passenger door, verify that the power window and power door lock located in that door function properly. Important: The calibrations required for performing SPS reprogram in the next step are based on the type of exterior rearview mirror the vehicle has. To determine the correct calibration, check the Service Parts Identification Label on the vehicle for the RPO code for exterior mirrors. 4. Follow normal Service Programming System (SPS) to reprogram the passenger door module with the current calibration available in TIS 2000. 5. After reprogramming is complete, using the switches in the right front passenger door, verify that the power window and power door lock located in that door function properly. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 339 Circuit/System Testing Component Testing Page 9355 Important The following information MUST be documented on the repair order. Failure to do so may result in a chargeback. - Customer vehicle condition. - Was a Service Lamp or Service Message illuminated? If yes, specify which Service Lamp or Service Message. - Was a DTC(s) set? If yes, specify which DTC(s) were set. - After following the procedure contained within this bulletin, could the condition be duplicated? ‹› If the condition was not duplicated, then document the affected module/component connector name and number on the repair order. - If the condition was duplicated after the procedure contained within this bulletin was followed, and additional diagnosis led to the replacement of a module or component, the SI Document ID Number MUST be written on the repair order. Parts Information Alternate Distributor For All of North America Note NyoGel(R) 760G Lubricant* is equivalent to GMSPO P/N 12377900, and P/N 10953529 (Canada), specified for use to correct the condition in this bulletin. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to: Warranty Information (Saab Models) Page 1291 Install the oil level sensor to the oil pan. ^ Tighten the sensor to 13 Nm (115 inch lbs.). 2. Connect the oil level sensor electrical connector (3). 3. Fill the engine oil. Page 8085 The information shown is for the 1999-2002 wiring harnesses and for the 2003-05 wiring harness. To modify a 12171982, 15366255 or 15086884 harness for use in a 2003-05 vehicle, switch the wires in cavities "A" and "D". To modify a 15085418 harness for use in a 1999-2002 vehicle (see model list at the front of this bulletin for applicable models), switch the wires in cavities "A" and "D". Warranty Information When the correct wiring harness P/N is matched to the specific model year of the vehicle, everything works properly. Therefore, conversion of an incorrect wiring jumper to match the vehicle would not be considered a warrantable repair. Disclaimer Page 336 DTC B2483: Global Positioning System (GPS) Antenna Malfunction Short to Ground DTC B2484: Global Positioning System (GPS) Antenna Malfunction Open Circuit Conditions for Running the DTCs The ignition is in RUN or ACC position System voltage is between 9.5 - 15.5 volts. The above conditions are met for more than 1 second. Conditions for Setting the DTCs B2462 02: The CIM detects a short to ground on the navigation antenna signal circuit. B2462 04: The CIM detects an open/high resistance on the navigation antenna signal circuit. B2483: The CIM detects a short to ground on the navigation antenna signal circuit. B2484: The CIM detects an open/high resistance on the navigation antenna signal circuit. Action Taken When the DTCs Set The OnStar(R) status LED turns red. The OnStar(R) Call Center cannot locate the vehicle. Conditions for Clearing the DTCs The condition responsible for setting the DTC no longer exists. A history DTC will clear once 50 consecutive malfunction-free ignition cycles have occurred. Circuit/System Testing Turn OFF the ignition. 1. Disconnect the navigation antenna coax cable from the VCIM. 2. Ignition ON, test for 4.5-5.5 volts between the VCIM coax cable center conductor terminal at the VCIM and ground. ^ If not within the specified range, replace the VCIM. Refer to the appropriate vehicle in SI. 3. Reconnect the coax cable to the VCIM. 4. Disconnect the coax cable from the navigation antenna. 5. Test for 4.55.5 volts between the coax cable center conductor and the outer shield. ^ If not within the specified range, replace the coax cable. 6. If all circuits test normal, replace the navigation antenna. Refer to the appropriate vehicle in SI. DTC B2470 DTC Descriptor DTC B2470 04: Cellular Phone Antenna Circuit Malfunction Open Circuit Circuit/System Description The cellular antenna is connected to the vehicle communication interface module (VCIM) with an RG-58 coax cable. The VCIM collects the data from the cellular antenna once every second. Fuel Injector Coil Test Fuel Injector: Testing and Inspection Fuel Injector Coil Test FUEL INJECTOR COIL TEST CIRCUIT DESCRIPTION The control module enables the appropriate fuel injector pulse for each cylinder. Ignition voltage is supplied directly to the fuel injectors. The control module controls each fuel injector by grounding the control circuit via a solid state device called a driver. A fuel injector coil winding resistance that is too high or too low will affect engine driveability. A fuel injector control circuit DTC may not set, but a misfire may be apparent. The fuel injector coil windings are affected by temperature. The resistance of the fuel injector coil windings will increase as the temperature of the fuel injector increases. DIAGNOSTIC AIDS - The use of Dielectric compound GM P/N 12377900 (Canadian P/N 10953529) in the fuel injector electrical connector may eliminate a corrosion condition. - Monitoring the misfire current counters, or misfire graph, may help isolate the fuel injector that is causing the condition. - Operating the vehicle over a wide temperature range may help isolate the fuel injector that is causing the condition. - Perform the fuel injector coil test within the conditions of the customers concern. A fuel injector condition may only be apparent at a certain temperature, or under certain conditions. - If the fuel injector coil test does not isolate the condition perform the fuel injector balance test. Refer to Fuel Injector Balance Test with Special Tool or Fuel Injector Balance Test with Tech 2. See: Computers and Control Systems/Testing and Inspection/Component Tests and General Diagnostics See: Computers and Control Systems/Testing and Inspection/Component Tests and General Diagnostics TEST Steps 1 - 3 Page 11469 11. Install the steering column trim covers. 12. Enable the SIR system. Refer to SIR Disabling and Enabling Zone 3. Page 7578 21. With the trunnion seated in the bearing cup, press the bearing cup into the yoke until the bearing cup is flush with the yoke ear. 22. Install the opposite bearing cup part way into the yoke ear. 23. Ensure that the trunnions start straight and true into both bearing cups. 24. Press the opposite bearing cup into the yoke ear while working the cross all the time in order to inspect for free unbinding movement of the trunnions in the bearing cups. Important: If there seems to be a hang up or binding, stop pressing. Inspect the needle bearings for misalignment in the bearing cup. 25. Press the bearing cup into the yoke until the bearing cup retainer groove is visible over the top of the bearing cup. 26. Assemble the bearing retainer in the retainer groove. 27. Continue pressing until both retainers can be snapped into place. 28. If the retainer is difficult to seat, the yoke can be sprung slightly with a firm blow from a soft-faced dead blow hammer. 29. It may be necessary to lubricate the snap ring with a slight amount of chassis grease so that the snap ring seats in the bearing cup groove. 30. Install the slip yoke onto the output shaft in the transfer case. 31. Align the reference marks on the pinion flange and the propeller shaft. 32. Install the yoke retainers and bolts. Tighten Tighten the yoke retainer bolts to 25 N.m (19 lb ft). 33. Lower the vehicle. Page 13698 5. Drill a 3 mm (1/8 in) pilot hole at each center punch location. Important: Drill bit must be exact size. 6. Drill an 11.5 mm (29/64 in) hole at the pilot locations for the studs. 7. Clean and prepare all of the bare metal surfaces. Important: Prior to refinishing, refer to the publication GM 4901M-D-2000 GM Approved Refinish Materials for recommended products. Do not combine paint systems. Refer to paint manufacturer's recommendations. 8. Apply approved anti-corrosion primer. 9. Apply a full-bodied caulk to the entire hinge mounting surface in order to ensure a proper seal. Notice: Refer to Fastener Notice in Service Precautions. 10. Align the hinge (1) and the backing plate (4) with the holes in the door (2) and install the bolts (3). Tighten the hinge to the pillar nuts to 25 N.m (18 lb ft). 11. Clean and prepare all of the surfaces as necessary for refinishing. 12. Apply the sealers. Refinish the surfaces as necessary. 13. Install and align all of the related panels and the components. Emissions - MIL ON/DTC P0446 Stored In ECM Evaporative Check Valve: All Technical Service Bulletins Emissions - MIL ON/DTC P0446 Stored In ECM TECHNICAL Bulletin No.: 02-06-04-037I Date: September 16, 2010 Subject: Check Engine Light On, Fuel Tank Hard to Fill, DTCs P0442, P0446, P0455 or P0449 Set (Replace Evaporative Emission (EVAP) Vent Valve Solenoid Assembly and Add/Relocate Filter Box Using Service Kit) Models: 1999-2007 Chevrolet Silverado (Classic) Models 1999-2007 GMC Sierra (Classic) Models 2007-2010 Chevrolet Silverado Models (Including Hybrid) 2007-2010 GMC Sierra Models (Including Hybrid) Supercede: This bulletin is being revised to add the 2010 model year and to include the Hybrid models. Please discard Corporate Bulletin Number 02-06-04-037H (Section 06 - Engine/Propulsion System). Condition Some customers may comment about the check engine light being illuminated. They may also comment that their vehicle is difficult to fill with fuel or when filling, the pump continuously shuts off before the tank is full. When checking the vehicle for DTCs, the ECM may report one or more of the following DTCs set as current or in history: P0442, P0446, P0449 or P0455. Cause The EVAP canister vent solenoid (CVS) valve draws fresh air into the system through a vent. Under certain operating conditions, dirt and dust intrusion into the EVAP CVS fresh air intake/venting system, may result in restricted air flow. Under certain operating conditions, water, if ingested into the EVAP CVS fresh air intake/venting system, may reach the CVS valve causing corrosion in the CVS valve, and may cause restrictions in the fresh air intake path, when the valve is in the closed position. Correction (1999-2007 Classic/Old Style Models) After following the published SI diagnostics and determining that the EVAP canister vent valve is the cause of the MIL light, replace the existing EVAP canister vent valve assembly with a new assembly. This new assembly is a sealed unit that is designed to be vented through a remote filter box. To ensure correct installation, follow the procedures below. Important DO NOT replace the EVAP canister assembly for this concern unless it fails the leak test. 1999-2003 Model Year (Use Service Kit P/N 19207762) 1. Raise the vehicle. Suitably support the vehicle. 2. Disconnect the EVAP canister vent valve electrical connector, if equipped. 3. Disengage the two vent valve pipe clips securing the pipe to the underbody. Remove the clips from the underbody and discard. 4. Disconnect the vent valve pipe at the EVAP canister. 5. Remove and retain the EVAP canister vent valve bracket mounting bolt. 6. Remove the complete EVAP canister vent valve assembly with bracket attached and discard. Page 3923 Accelerator Pedal Position (APP) Sensor Part 2 Front Suspension Wheel Fastener: Service and Repair Front Suspension Wheel Stud Replacement ^ Tools Required J 43631 Ball Joint Remover Removal Procedure 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Remove the tire and wheel. 3. Remove the brake rotor. Refer to Brake Rotor Replacement - Front in Disc Brakes. 4. Remove the wheel stud from the hub flange using the J 43631. 5. Remove the wheel stud from the hub flange. Installation Procedure 1. Install the new stud into the hub flange hole using firm hand pressure. 2. Install 4 washers to the new wheel stud. 3. Thread a wheel nut onto the new stud with the flat side facing the front hub flange. 4. Tighten the lug nut until the stud contacts the back of the hub flange. 5. Remove the wheel nut. 6. Remove the washers. 7. Install the brake rotor. Refer to Brake Rotor Replacement Front in Disc Brakes. 8. Install the tire and wheel. 9. Remove the safety stands. 10. Lower the vehicle. Page 13891 Windshield Moulding / Trim: Service and Repair Windshield Side Reveal Molding Replacement Windshield Side Reveal Molding Replacement Removal Procedure 1. Pull back the front door sealing weatherstrip (1) to expose the windshield reveal molding screws. 2. Remove the screws from the windshield reveal molding. 3. Remove the windshield reveal molding from the windshield pillar. Installation Procedure 1. Install the windshield reveal molding to the windshield pillar. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the screws to the windshield reveal molding. Tighten the screws to the windshield reveal molding to 2 N.m (18 lb in). 3. Install the front door sealing weatherstrip (1) to the pinch-weld. 4. Close the door. Page 4127 3. Connect the VSS electrical connector (3). Lower the vehicle. Page 1169 Seat Bolster/Lumbar Switch - Driver (With RPO Code AN3) Page 3429 Disclaimer Engine Controls - Aftermarket Accessory Usage Engine Control Module: All Technical Service Bulletins Engine Controls - Aftermarket Accessory Usage INFORMATION Bulletin No.: 04-06-04-054B Date: November 18, 2010 Subject: Info - Non-GM Parts and Accessories (Aftermarket) Models: 2011 and Prior GM Passenger Cars and Trucks Supercede: This bulletin is being revised to add model years and update to the new U.S. Fixed Operation Manager (FOM) and Canada Warranty Manager (WM) names. Please discard Corporate Bulletin Number 04-06-04-054A (Section 06 - Engine/Propulsion System). The recent rise and expansion of companies selling non-GM parts and accessories has made it necessary to issue this reminder to dealers regarding GM's policy on the use and installation of these aftermarket components. When a dealer is performing a repair under the New Vehicle Limited Warranty, they are required to use only genuine GM or GM-approved parts and accessories. This applies to all warranty repairs, special policy repairs or any repairs paid for by GM. Parts and accessories advertised as being "the same" as parts manufactured by GM, but not sold through GM, do not qualify for use in warranty repairs, special policy repairs or any repairs paid for by GM. During a warranty repair, if a GM original equipment part is not available through GM Customer Care and Aftersales (GM CC&A;), ACDelco(R) distributors, other GM dealers or approved sources, the dealer is to obtain comparable, non-GM parts and clearly indicate, in detail, on the repair order the circumstances surrounding why non-GM parts were used. The dealer must give customers written notice, prior to the sale or service, that such parts or accessories are not marketed or warranted by General Motors. It should also be noted that dealers modifying new vehicles and installing equipment, parts and accessories obtained from sources not authorized by GM are responsible for complying with the National Traffic and Motor Vehicle Safety Act. Certain non-approved parts or assemblies, installed by the dealer or its agent not authorized by GM, may result in a change to the vehicle's design characteristics and may affect the vehicle's ability to conform to federal law. Dealers must fully understand that non-GM approved parts may not have been validated, tested or certified for use. This puts the dealer at risk for potential liability in the event of a part or vehicle failure. If a GM part failure occurs as the result of the installation or use of a non-GM approved part, the warranty will not be honored. A good example of non-authorized modification of vehicles is the result of an ever increasing supply of aftermarket devices available to the customer, which claim to increase the horsepower and torque of the Duramax(TM) Diesel Engines. These include the addition of, but are not limited to one or more of the following modifications: - Propane injection - Nitrous oxide injection - Additional modules (black boxes) that connect to the vehicle wiring systems - Revised engine calibrations downloaded for the engine control module - Calibration modules which connect to the vehicle diagnostic connector - Modification to the engine turbocharger waste gate Although the installation of these devices, or modification of vehicle components, can increase engine horsepower and torque, they may also negatively affect the engine emissions, reliability and/or durability. In addition, other powertrain components, such as transmissions, universal joints, drive shafts, and front/rear axle components, can be stressed beyond design safety limits by the installation of these devices. General Motors does not support or endorse the use of devices or modifications that, when installed, increase the engine horsepower and torque. It is because of these unknown stresses, and the potential to alter reliability, durability and emissions performance, that GM has adopted a policy that prevents any UNAUTHORIZED dealer warranty claim submissions to any remaining warranty coverage, to the powertrain and driveline components whenever the presence of a non-GM (aftermarket) calibration is confirmed - even if the non-GM control module calibration is subsequently removed. Refer to the latest version of Bulletin 09-06-04-026 (V8 Gas Engines) or 06-06-01-007 (Duramax(TM) Diesel Engines) for more information on dealer requirements for calibration verification. These same policies apply as they relate to the use of non-GM accessories. Damage or failure from the use or installation of a non-GM accessory will not be covered under warranty. Failure resulting from the alteration or modification of the vehicle, including the cutting, welding or disconnecting of the vehicle's original equipment parts and components will void the warranty. Additionally, dealers will NOT be reimbursed or compensated by GM in the event of any legal inquiry at either the local, state or federal level that Brakes - ABS Lamp ON/DTC's C0265/C0201/U1041 Set Grounding Point: All Technical Service Bulletins Brakes - ABS Lamp ON/DTC's C0265/C0201/U1041 Set TECHNICAL Bulletin No.: 04-05-25-002E Date: March 11, 2009 Subject: ABS Light On, DTCs C0265, C0201, U1041 Set and/or Loss of Communication with Brake Module (Reground EBCM Ground) Models Supercede: This bulletin is being revised to add step 2 to the procedure and update the Parts and Warranty Information. Please discard Corporate Bulletin Number 04-05-25-002D (Section 05 - Brakes). Condition Some customers may comment that the ABS light is on. Upon further inspection, DTCs C0265 and C0201 may be set in the brake module. It is also possible for DTC U1041 to set in other modules. There may also be a loss of communication with the brake module. Cause A poor connection at the EBCM ground is causing unnecessary replacement of brake modules. Important: The EBCM ground is different for each application. Refer to the list below for the proper ground reference: ^ Midsize Utilities = Ground 304 ^ SSR = Ground 400 ^ Fullsize Trucks and Utilities = Ground 110 Correction Important: Do not replace the brake module to correct this condition. Perform the following repair before further diagnosis of the EBCM. Perform the following steps to improve the connection of the EBCM Ground: 1. Remove the EBCM Ground. The EBCM Ground is located on the frame beneath the driver's side door. If multiple grounds are found in this location, the EBCM ground can be identified as the heavy (12-gauge) wire. 2. If the original fastener has a welded on nut, remove the nut from the frame, and if required, enlarge the bolt hole to accommodate the new bolt and nut. 3. Clean the area, front and back, using a tool such as a *3M(TM) Scotch-Brite Roloc disc or equivalent. Page 7082 10. Place the J 9522-3 on the open horizontal bearing cups. Press the lower bearing cup out of the yoke ear. 11. If you do not completely remove the bearing cup, lift the cross and insert the J 9522-5 between the seal and the bearing cup you are removing. Continue pressing the bearing cup out of the yoke. 12. Rotate the propeller shaft. Press the opposite bearing cup out of the drive shaft yoke. 13. Remove the old slip yoke and universal joint. 14. Inspect the retaining ring grooves for dirt, corrosion, or pieces of the old ring. 15. Inspect the bearing cup bores for burrs or imperfections. 16. Clean the retaining ring grooves. Corrosion, dirt, rust, or pieces of the old retaining ring may prevent the bearing cups from pressing into place or prevent the bearing retainers from properly seating. 17. Install the new nickel-plated slip yoke and universal joint. See parts table below for parts information. 18. Remove the bearing cups from the universal joint. 19. Assemble one bearing cup part way into one side of the yoke. Turn the yoke ear toward the bottom. 20. Assemble the cross into the yoke so that the trunnion seats freely into the bearing cup. Page 1191 4. Press the button a second time, 2 light bars will glow indicating the MEDIUM temperature setting for the entire seat. 5. Press the button a third time, 1 light bar will glow indicating the LOW temperature setting for the entire seat. 6. Press the button a fourth time to turn the entire heated seat OFF. 7. To heat ONLY the seat back, press the vertical (LH) button one time. ^ An ON/OFF indicator light over the heated seat back symbol will glow to designate that ONLY the seat back is being heated. ^ All 3 light bars over the horizontal (RH) button will glow indicating the HIGH temperature setting for ONLY the seat back. 8. Press the button a second time, 2 light bars will glow indicating the MEDIUM temperature setting for ONLY the seat back. 9. Press the button a third time, 1 light bar will glow indicating the LOW temperature setting for ONLY the seat back. 10. Press the button a fourth time to turn the heated seat back OFF. Switch Diagnostics Important: In order to eliminate unnecessary part replacement and comeback repairs, it is essential that the appropriate diagnostic tables and aids found in the applicable manuals are followed. 1. Verify the condition prior to making any repairs. Refer to Seats and Seat Controls in the applicable Owners Manual or this bulletin for proper heated seat switch operation information. 2. If an improperly operating front heated seat condition exists, refer to the Diagnostic Information and Procedures in the Seats sub-section of the applicable Service Manual in order to diagnose the system accurately. 3. When measuring the resistance of the seat heater elements, ensure the values are within the updated range of 1.5-5.5 ohms. Refer to DTC B2425 or B2430-Clearing the DTC in the Diagnostic Information and Procedures in the Seats sub-section of the applicable Service Manual. Customer Information Some heated seat components from the above listed vehicles have been returned to the Warranty Parts Center (WPC) for heat function not operating properly. Analyses of these parts show 'no out of specification condition' or No Trouble Found (NTF). 1. Provide customers with the knowledge that if bumped, either one of the heated seat switches can be activated/deactivated accidentally. 2. Ensure customers have a thorough understanding of how the heated seat switches function. Disclaimer Page 3362 Oil Pan: Service and Repair Oil Pan Cover Replacement Oil Pan Cover Replacement Removal Procedure 1. Drain the engine oil. 2. Remove the oil pan cover bolts (1), cover (2), and gasket (3). 3. Discard the gasket. Installation Procedure 1. Notice: Refer to Fastener Notice in Service Precautions. Install a new oil pan cover gasket (3), the cover (2) and bolts (1). ^ Tighten the bolts to 12 Nm (106 inch lbs.). 2. Refill the engine oil. Refer to Capacities - Approximate Fluid and/or Fluid and Lubricant Recommendations. Page 7268 Steps 1-4 Steps 5-6 The number(s) below refer to the step number(s) on the diagnostic table. 2. Lack of communication may be due to a partial or total malfunction of the class 2 serial data circuit. The specified procedure will determine the particular condition. 3. The presence of DTCs indicates that the PCM or TAC has detected a fault. 4. The presence of DTCs which begin with "U" indicate some other module is not communicating. The specified procedure will compile all the available information before tests are performed. 5. This step insures that the PTO options in the scan tool are set according to the upfitters recommendations. Body - Pick Up Box Damaged by Aftermarket Accessories Technical Service Bulletin # 01-08-66-014B Date: 050208 Body - Pick Up Box Damaged by Aftermarket Accessories Pickup Box Sheet Metal Fracture/Damage with Aftermarket Accessories Installed (Repair Pickup Box Damage and Install Pickup Box Reinforcements) # 01-08-66-014B - (Feb 8, 2005) Models: 1999-2003 Chevrolet Silverado (New Body Style) 1999-2003 GMC Sierra New Body Style) with Steel Fleetside Pickup Box (RPO E63) 2004-2005 Chevrolet Silverado 1500 Series Crew Cab with 5'8" Pickup Box 2004-2005 GMC Sierra 1500 Series Crew Cab with 5'8" Pickup Box Except Dual Rear Wheel (RPO R05), Stepside (RPO E62) and Inner Composite (RPO E37) Pickup Boxes This bulletin is being revised to add the 2004-2005 1500 Series Crew Cab with 5'8" pickup box and change equipment weight capacity information. Please discard Corporate Bulletin Number 01-08-66-014A (Section 08--Body and Accessories). Built Prior to the VIN Breakpoints shown. Important: Implementation of this Service Bulletin by "GM of Canada" dealers requires prior District Service Manager approval. Condition Some customers may comment about pickup box sheet metal fractures/damage when using aftermarket accessories such as tool boxes, window barrier and ladder racks. Page 2654 Fuse Block - Underhood C4 Part 1 Page 9014 Fuse Block - Underhood C2 Part 3 Page 10418 For vehicles repaired under warranty, use the table. Disclaimer Heater Hose Replacement - Inlet Heater Hose: Service and Repair Heater Hose Replacement - Inlet HEATER HOSE REPLACEMENT - INLET TOOLS REQUIRED J 43181 Quick Connect Connector Removal Tool REMOVAL PROCEDURE 1. Drain the cooling system. Refer to Draining and Filling Cooling System (with HP2)Draining and Filling Cooling System (without HP2) in Cooling System. 2. Remove the air intake tube. 3. Remove the heater and surge tank hose from the mounting clip. 4. Using the J 43181 disconnect the heater hose from the heater core inlet. 4.1. Install the J 43181 to the heater core pipe. 4.2. Close the tool around the heater core pipe. 4.3. Firmly pull the tool into the quick connect end of the heater hose. 4.4. Firmly grasp the heater hose. Pull the heater hose forward in order to disengage the hose from the heater core. 5. Remove the inlet heater hose from the engine. Page 871 Electrical Symbols Part 8 Page 8399 5. Install the park brake cable taking care to correctly route the cable though the guides and the body mounts. 6. Pull down on the park brake cable in front of the equalizer and install the left park brake cable to the equalizer bar. 7. Remove the safety stands. 8. Lower the vehicle. (W/O NYS) Park Brake Cable Replacement - Right Rear (w/o NYS) Removal Procedure 1. Release the park brake. 2. Raise and support the vehicle. Refer Vehicle Lifting Page 5322 Fuel Pump (FP) Relay-Secondary (w/Dual Tanks) Service and Repair Gear Sensor/Switch: Service and Repair Encoder Motor Sensor Replacement Removal Procedure Important: For ease of reassembly, shift the transfer case to 2HI prior to removing any components. 1. Remove the encoder motor. 2. Place the encoder motor on a clean work bench, 3. Remove the 2 screws (2) from the motor cover. 4. Remove the 2 screws (1) from the casting. 5. Remove the cover. 6. Remove and save the shim on the output gear. 7. Remove and discard the orange rubber seal from the cover. 8. Remove the output gear (1). Page 1162 Power Seat Switch: Locations Driver Seat (1 Of 2) Page 11557 Inflatable Restraint Sensing And Diagnostic Module: Service and Repair INFLATABLE RESTRAINT SENSING AND DIAGNOSTIC MODULE REPLACEMENT REMOVAL PROCEDURE CAUTION: Do not strike or jolt the inflatable restraint sensing and diagnostic module (SDM). Before applying power to the SDM, make sure that it is securely fastened with the arrow facing toward the front of the vehicle. Failure to observe the correct installation procedure could cause SIR deployment, personal injury, or unnecessary SIR system repairs. - Refer to SIR Caution in Service Precautions. 1. Disable the SIR system. Refer to SIR Disabling and Enabling Zone 7. 2. Remove the drivers seat. 3. Remove the driver side door sill plate. 4. Fold back the carpet to access the inflatable restraint sensing and diagnostic module (SDM). 5. Remove the connector position assurance (CPA) (1) from the inflatable restraint sensing and diagnostic module (SDM) wiring harness connector (2). 6. Push down the flex lock button (3) and slide the connector locking cover (4) to the open position. Page 896 Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses CIRCUIT PROTECTION - FUSES The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the Page 6782 31. Install the ring gear onto the differential case. 32. Install the ring gear bolts. Hand start each bolt to ensure that the ring gear is properly seated to the differential case. 33. Tighten the ring gear bolts. Tighten the ring gear bolts alternately and in stages, gradually pulling the ring gear onto the differential case. Tighten Tighten the ring gear bolts in sequence to 120 N.m (88 lb ft). 34. Install the differential side bearings by performing the following steps: 34.1. In order to protect the differential case, install the J 8107-2 in the case on the side opposite the bearing installation. 34.2. Install the J 22761(2) and the J 8092 (1) onto the differential case bearing as shown. 34.3. Drive the differential case bearing onto the case using the J 22761 and the J 8092. 35. Install the new differential case assembly into the carrier. 36. Clean the sealing surface of each half of the differential carrier case and the inner axle housing to differential carrier assembly. The surfaces must be clean of all grease and oil. 37. Apply a bead of sealer, P/N 1052942 (Canadian P/N 10953466), or equivalent, to one differential carrier case half sealing surface. 38. Install the right differential carrier case half. 39. Install the differential carrier case bolts Tighten Tighten the differential carrier case bolts to 47 N.m (35 lb ft). 40. Install the front drive axle clutch shaft to the differential carrier. 41. Install the left side inner axle shaft by doing the following steps: 41.1. Install the left side inner shaft into the differential carrier assembly until the inner shaft is seated against the differential side gear. 41.2. While holding the inner shaft against the differential side gear, turn the inner shaft in order to align the splines of the inner shaft with the splines on the differential side gear. 41.3. Drive the inner into the differential case side gear using a soft-faced mallet until the retaining ring on the inner shaft is fully seated within the groove in the differential case side gear. Pull back on the inner shaft to ensure that the inner shaft is properly retained in the differential case side gear. 42. Apply sealant, P/N 1052942 (Canadian P/N 10953466), or equivalent, to the inner axle housing to differential carrier sealing surface. Page 11448 Inflatable Restraint Sensing And Diagnostic Module: Diagrams Inflatable Restraint Sensing and Diagnostic Module (SDM) - Part 1 Page 11330 HVAC Control Module - C1 Part 2 Page 12927 Amplifier: Service and Repair AMPLIFIER REPLACEMENT REMOVAL PROCEDURE 1. If equipped with a Bose. amplifier, remove the radio amp fuse located under the hood electrical center. 2. Remove the floor console bezel. 3. Remove the cupholder. 4. Remove the bolts (1) retaining the console to the instrument panel (I/P). 5. Remove the console storage bin. 6. Remove the center console end panel. 7. Disconnect the audio amplifier electrical connectors. 8. Remove the 4 screws retaining the upper console bracket to the lower console bracket. The front 2 screws (1) are shown in the graphic. Page 5109 6. Remove the fuel pipe bracket nut. 7. Remove the fuel pipe bracket from the bellhousing stud. 8. Remove the fuel line clips from the brackets on the transmission. 9. If equipped with 4-wheel drive (4WD), remove the fuel line clip from the bracket on the transfer case. 10. Disconnect the fuel and EVAP quick connect fittings. 11. Cap the fuel and EVAP lines at the fuel tank in order to avoid possible system contamination. Page 7888 Remote Programming Feature 1. Connect the scan tool to the vehicle. 2. Power-up the scan tool and select the Service Programming feature. 3. Select the appropriate vehicle. 4. Press the Request Info button on the scan tool. 5. Connect the scan tool to the computer station. 6. Follow the menu select items for reprogramming and provide information about the type of device you are programming and whether you are reprogramming or replacing the electronic control unit (ECU). 7. Select "vehicle" from the selection menu. 8. Select the module you wish to program. 9. Select "Normal" for Programming Type. 10. Select the applicable software calibrations. 11. Transfer data file to the scan tool. 12. Connect the scan tool to the vehicle. 13. Turn ON the ignition, with the engine OFF. 14. Select the Service Programming feature on the scan tool. 15. Press the Program button on the scan tool. Programming Using Scan Tool Pass-Through Connection 1. Connect the scan tool to vehicle and power it up. 2. Connect the computer station to the scan tool. 3. Select "PC Using Scan Tool Connection" from the programming menu on the computer station. 4. Follow the menu select items for reprogramming and provide information about the type of device you are programming and whether you are reprogramming or replacing the electronic control unit (ECU). 5. Select "vehicle" from the selection menu. 6. Select the module you wish to program. 7. Select "Normal" for Programming Type. 8. Select the applicable software calibrations. 9. Transfer data file to the scan tool. Page 10653 ACCESSORY WHEEL AND TIRE INFORMATION FORM You have just modified your vehicle by installing an "Accessory Package" which includes Wheels and Tires. This form contains important information about your accessory installation. In an effort to provide superior service to you, our customer, we ask that you please present this form to your Servicing Dealer when removing or installing wheels and tires on your vehicle. This form contains important information necessary to service your vehicle. Disclaimer Page 12133 networks, and will not require an upgrade in connection with the cellular industry's transition to the digital network. In order to verify the type of OnStar(R) Hardware in a vehicle, type the VIN into the VIN look-up tool, which is available at the OnStar(R) Online Enrollment website within GM GlobalConnect (for U.S. dealers) or InfoNet (for Canadian dealers). Disclaimer Page 11618 Disclaimer Page 7439 Transfer Case Actuator: Service and Repair Transfer Case Encoder Motor Replacement Removal Procedure 1. Remove the transfer case shield, if equipped. 2. Remove the front propeller shaft. 3. Disconnect the encoder motor electrical connector. 4. Remove the encoder motor bolts. 5. Remove the encoder motor. 6. Remove the actuator insulator gasket. 7. If replacing the encoder motor, remove the locating pins from the old motor. Installation Procedure Important: ^ If the encoder motor is being replaced because it is defective, ensure that the transfer case is in the neutral position. Manually shift the unit at the shift shaft. Use a crescent wrench, if necessary. ^ If the encoder motor is being replaced, a new gasket will come with the encoder motor. DO NOT reuse the old gasket. ^ A NEW encoder motor does NOT come with locating pins. Page 9387 For vehicles repaired under warranty, use the table. Disclaimer Body - TPO Fascia Cleaning Prior to Painting Paint: All Technical Service Bulletins Body - TPO Fascia Cleaning Prior to Painting INFORMATION Bulletin No.: 08-08-51-002 Date: March 12, 2008 Subject: New Primer For TPO Fascias and Affected Cleaning Process of Painting Operation Models: 2009 and Prior Passenger Cars and Trucks 2009 and Prior HUMMER H2, H3 The purpose of this bulletin is to inform the technician that General Motors has made a change in the primer it uses for TPO plastic for service parts. This new primer comes in several different colors from five different suppliers. This change affects the cleaning process of the painting operation. The new process is as follows. 1. Wash with soap and water. 2. Clean with a 50% mix of isopropyl alcohol and water (or a waterborne cleaner). Check with your paint supplier for product recommendations. 3. Scuff sand per your paint suppliers recommendations. Note: The use of a solvent-type cleaner will soften, or begin to dissolve the primer. Base coats do not have any affect on this primer. 4. Reclean with a 50% mix of isopropyl alcohol and water (or a waterborne cleaner). All fascias, with the exception of the Corvette, Camaro, and Cadillac XLR, are made of TPO. You may find other TPO parts with this primer. If the technician has a question as to the type of plastic they are painting, inspect the back of the part for the plastic symbol (TPO). Disclaimer Page 15163 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Weather Pack Connectors WEATHER PACK CONNECTORS The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. Page 1424 Outside Temperature Display Sensor: Service and Repair AMBIENT AIR TEMPERATURE SENSOR REPLACEMENT REMOVAL PROCEDURE 1. Remove the radiator grille from the vehicle. 2. Remove the push pin retainer from the sensor mounted on the radiator support brace. 3. Disconnect the electrical connector from the sensor. INSTALLATION PROCEDURE 1. Connect the electrical connector to the sensor. 2. Install the sensor to the radiator support brace and install the push pin retainer. 3. Install the radiator grille to the vehicle. Service and Repair Parking Brake Warning Switch: Service and Repair Park Brake Warning Lamp Switch Replacement Removal Procedure 1. Caution: Refer to Battery Disconnect Caution in Service Precautions. Disconnect the negative battery cable. 2. Remove the MID-bussed electrical center from the bracket. 3. Disconnect the park brake warning lamp switch electrical connector. 4. Remove the park brake warning lamp switch mounting bolt. 5. Remove the park brake warning lamp switch. Installation Procedure Page 8290 Brake Caliper: Service and Repair Brake Caliper Replacement - Front Brake Caliper Replacement - Front Caution: Refer to Brake Dust Caution in Service Precautions. Caution: Refer to Brake Fluid Irritant Caution in Service Precautions. Removal Procedure 1. Inspect the fluid level in the brake master cylinder reservoir. 2. If the brake fluid level is midway between the maximum-full point and the minimum allowable level, no brake fluid needs to be removed from the reservoir before proceeding. 3. If the brake fluid level is higher than midway between the maximum-full point and the minimum allowable level, remove brake fluid to the midway point before proceeding. 4. Raise and support the vehicle. Refer Vehicle Lifting 5. Remove the tire and wheel assembly. 6. Compress the brake caliper pistons. ^ Install a large C-clamp over the top of the caliper housing and against the back of the outboard pad. ^ Slowly tighten the C-clamp until the pistons are pushed completely into the caliper bores. ^ Remove the C-clamp from the caliper. 7. Clean all dirt and foreign material from the brake hose end. 8. Important: Install a rubber cap or plug to the exposed brake pipe fitting end to prevent brake fluid loss and contamination. Remove the brake hose to caliper bolt from the brake caliper. 9. Remove and discard the 2 copper brake hose gaskets. These gaskets may be stuck to the brake caliper housing or the brake hose end. 10. Remove the brake hose from the caliper. Page 9628 Fuse Block: Application and ID Junction Block - I/P Location View Location View Page 6328 5. Compress the reverse boost valve sleeve into the bore of the oil pump to expose the retaining ring slot. 6. Install the reverse boost valve retaining ring, then slowly release tension on the reverse boost valve sleeve. 7. Install the transmission filter. Page 2341 3. Install the booster outlet hose to the power steering pump nipple (5) and retaining clamp. 4. Install the booster inlet hose (1) to the booster. 5. Install the gear inlet hose to the booster. ^ Tighten both power steering inlet hose fittings to 32 Nm (24 ft. lbs.). Notice: Refer to Fastener Notice in Service Precautions. 6. Install the booster outlet hose (3) to the booster and install the retaining clamp (2). 7. Remove the drain pan from under the vehicle. 8. Bleed the power steering system. Refer to Bleeding the Power Steering System. 9. Connect the energy storage box after servicing the vehicle. (Rack and Pinion) Power Steering Hose Assembly Replacement (Rack and Pinion) Page 8503 3. Remove the master cylinder nuts. Do not remove the pipes from the master cylinder. Position the master cylinder away from the booster head. Secure the master cylinder in an upright position. 4. Disconnect the power brake booster inlet hose, the steering gear inlet hose, and the power brake booster outlet hose from the booster assembly. 5. Remove the booster pump rod retainer from the lever. 6. Remove the stop lamp switch from the lever. 7. Remove the booster pump rod from the lever. 8. Remove the nuts at the booster. 9. Remove the booster assembly. Installation 1. Install the booster assembly to the vehicle. 2. Install the nuts at the booster. Page 6423 Shift Interlock Solenoid: Service and Repair Automatic Transmission Shift Lock Actuator Replacement Removal Procedure 1. Caution: Refer to SIR Caution in Service Precautions. Disable the SIR system. 2. Remove the body control module (BCM). 3. Put the shift lever clevis into the neutral position. 4. Disconnect the electrical connector. 5. Using a small screwdriver, pry the automatic transmission shift lock control actuator away from the steering column jacket and the cable shift cam. 6. Remove the shift lock control actuator. Installation Procedure 1. Firmly install the shift lock control actuator onto the steering column jacket and the cable shift cam. 2. Connect the electrical connector. 3. Adjust the shift lock control actuator (with the shift lever clevis in the neutral position) in the following way: 1. Pull out the tab (1) on the adjuster block side (2) of the shift lock control actuator. 2. Press on the adjuster block (2) to compress the internal adjuster spring which disengages the adjuster teeth. Slide the adjuster block (2) as far away from the actuator as possible. 3. Lock the adjuster block (2) in place by pushing in on the tab (1). 4. Inspect the shift lock control actuator for the following items: Page 14201 1. Install the door module into the switch panel bezel until it snaps into place. 2. Install the switch panel bezel and module to the door panel. Notice: Refer to Fastener Notice in Service Precautions. 3. Install the screw that retains the switch panel bezel (1) to the front door panel. Tighten the screw to 2 N.m (18 lb in). 4. Connect the electrical connectors. 5. Install the front door trim panel. 6. If equipped with camper mirrors program the door module. Refer to Service Programming System (SPS). See: Testing and Inspection/Programming and Relearning Page 8056 Traction Control Switch: Service and Repair Traction Control Switch Replacement Removal Procedure 1. Remove instrument panel (IP) bezel. 2. Gently lift the switch retaining tabs (1) and remove the traction control switch (2) from the instrument panel (IP) assembly (3). 3. Disconnect the harness connector from the traction control switch. Installation Procedure 1. Connect the harness connector to the traction control switch. 2. Install the traction control switch (2) into the instrument panel (IP) assembly (3), making sure that all of the switch retaining tabs (1) are engaged. 3. Install instrument panel (IP) bezel. Page 355 Page 9026 Fuse Block - Underhood C9 Fuse Block- I/P C1 Interior - Erratic Memory Seat Operation Memory Positioning Module: Customer Interest Interior - Erratic Memory Seat Operation Bulletin No.: 04-08-50-016C Date: August 12, 2005 TECHNICAL Subject: Memory Seat May Not Return to Requested Position (Reprogram Driver Seat Module) Models: 2003-2005 Cadillac Escalade, Escalade ESV, Escalade EXT 2003-2005 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2003-2005 GMC Sierra, Yukon, Yukon XL, Yukon Denali All with Seat FRT, Individual (Non BKT) (RPO AN3) 2003-2005 HUMMER H2 with Seat, Front Bucket Deluxe (RPO AR9) Supercede: This bulletin is being revised to update the correction information. Please discard Corporate Bulletin Number 04-08-50-016B (Section 08 - Body and Accessories). Condition Some customers may comment that with repeated cycling of the memory seat between the "exit" and one of the "presets", the position of the seat may "creep" forward or rearward out of expected adjustment. Cause There is a coding deficiency in the software for the memory seat module. Correction Technicians are to reprogram the driver seat module with an updated software calibration. The previous bulletin stated to use a service calibration that was released with TIS satellite data update version 4.5. Feedback has proved that calibration to be ineffective in eliminating the memory seat creep condition. An updated service calibration was released with TIS satellite data update version 6.5 available June 13, 2005. This new calibration has additional memory seat creep protection. As always, make sure your Tech 2(R) is updated with the latest software version. Important: After programming is complete, move the seat all the way rearward and down, then bump the seat slightly forward and up. This position will be just off the end of travel hard stops. Reset both memory seat exit positions at this position. Having the seat set at just off the hard stops will aid in reducing the creep condition. Warranty Information Page 11791 Disclaimer Page 4507 6. Use fingers to squeeze the 2 locking legs of the cover. 7. Apply pressure and gently rock the cover until one locking leg is unseated. 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. Page 558 Disclaimer Page 4027 - HVAC Actuator - Inflatable Restraint Sensing and Diagnostic Module (SDM) - Any AIR BAG module - Seatbelt Lap Anchor Pretensioner - Seatbelt Retractor Pretensioner - An SIR system connection or connector condition resulting in the following DTCs being set: B0015, B0016, B0019, B0020, B0022, or B0023 - Powertrain Control Module (PCM) - Remote Control Door Lock Receiver (RCDLR) - Transmission Control Module (TCM) Correction Important DO NOT replace the control module, wiring or component for the following conditions: - The condition is intermittent and cannot be duplicated. - The condition is present and by disconnecting and reconnecting the connector the condition can no longer be duplicated. Use the following procedure to correct the conditions listed above. 1. Install a scan tool and perform the Diagnostic System Check - Vehicle. Retrieve and record any existing history or current DTCs from all of the control modules (refer to SI). ‹› If any DTC(s) are set, refer to Diagnostic Trouble Code (DTC) List - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). ‹› If DTCs are not set, refer to Symptoms - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). 2. When identified, use the appropriate DTC Diagnostics, Symptoms, Schematics, Component Connector End Views and Component Locator documents to locate and disconnect the affected harness connector(s) which are causing the condition. Note Fretting corrosion looks like little dark smudges on electrical terminals and appear where the actual electrical contact is being made. In less severe cases it may be unable to be seen or identified without the use of a magnifying glass. Important DO NOT apply an excessive amount of dielectric lubricant to the connectors as shown, as hydrolock may result when attempting to mate the connectors. Use ONLY a clean nylon brush that is dedicated to the repair of the conditions in this bulletin. 3. With a one-inch nylon bristle brush, apply dielectric lubricant to both the module/component side and the harness side of the affected connector(s). 4. Reconnect the affected connector(s) and wipe away any excess lubricant that may be present. 5. Attempt to duplicate the condition by using the following information: - DTC Diagnostic Procedure - Circuit/System Description - Conditions for Running the DTC - Conditions for Setting the DTC - Diagnostic Aids - Circuit/System Verification ‹› If the condition cannot be duplicated, the repair is complete. ‹› If the condition can be duplicated, then follow the appropriate DTC, Symptom or Circuit/System Testing procedure (refer to SI). Repair Order Documentation Page 13517 Electrical Symbols Part 8 Page 9057 Relay Block - I/P C3 Part 1 Page 12176 Diagnostic Trouble Codes DTC U1000 and U1255 Circuit/System Description Modules connected to the Class 2 serial data circuit monitor for serial data communications during normal vehicle operation. Operating information and commands are exchanged among the modules. When a module receives a message for a critical operating parameter, the module records the identification number of the module which sent the message for State of Health monitoring. A critical operating parameter is one which, when not received, requires that the module use a default value for that parameter. When a module does not associate an identification number with at least one critical parameter within 5 seconds of beginning serial data communication, DTC U1000 or U1255 DTC is set. When more than one critical parameter does not have an identification number associated with it, the DTC will only be reported once. The Class 2 serial data communications circuit on this vehicle are in a hybrid ring and star configuration. Each module on the ring has 2 serial data circuits connected to it, except the following modules which have only 1 serial data circuit connected them: Door Latch Assembly (Door Jamb Switch) - Driver C2 Door Switch: Diagrams Door Latch Assembly (Door Jamb Switch) - Driver C2 Door Latch Assembly (Door Jamb Switch) - Driver C2 Front Suspension Suspension Travel Bumper: Service and Repair Front Suspension Spring Bumper Replacement Removal Procedure 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Unsnap the spring bumper from the mounting cup. For 4WD 15-Series and 2WD 25/35-Series. 3. Remove the nut from the spring bumper stud. For 4WD 15-Series and 2WD 25/35-Series. 4. Remove the spring bumper. Installation Procedure 1. Snap the spring bumper to the mounting cup. For 4WD 15-Series and 2WD 25/35-Series. Page 1525 Turn Signal Multifunction Switch - C4 (With RPO Code K34) Service and Repair Rear Door Window Motor: Service and Repair Window Regulator Motor Replacement - Rear Door Removal Procedure 1. Raise the window. If the window motor is inoperable, remove the window to gain access to the window motor retaining screws. Refer to Window Replacement - Rear Door. 2. Remove the door trim panel. 3. Remove the water deflector. 4. Remove the door speaker. 5. Support the window. 6. Disconnect the wiring harness from the window regulator motor. 7. Remove the 3 bolts from the window motor located on the front side of the motor. Important: Do not allow the cable gear come out of the housing. A failure will result with the cable coming off the spool. 8. Separate the motor from the cable housing by wiggling the window motor. Observe the orientation of the window motor. 9. Remove the motor from the window regulator assembly. Installation Procedure 1. Install the motor to the cable housing by wiggling motor into place. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the 3 bolts to the window motor. Tighten the bolts to 5 N.m (44 lb in). 3. Install the window, if removed. 4. Connect the wiring harness to the window regulator motor. 5. Remove the window support. 6. Connect the wire connector to the switch to inspect the operation of the window. 7. Install the speaker. 8. Install the water deflector. 9. Install the door trim panel. Page 15128 Cruise Control Module (CCM) Part 2 Page 11606 5. Remove the bolt (1) from the seat belt anchor. INSTALLATION PROCEDURE NOTE: Refer to Fastener Notice in Service Precautions. 1. Install the bolt (1) to the seat belt anchor. Tighten Tighten the bolt to 52 N.m (38 lb ft). Page 4081 Heated Oxygen Sensor (HO2S) Bank 1 Sensor 2 Drivetrain - Transfer Case Control Module Replacement Control Module: All Technical Service Bulletins Drivetrain - Transfer Case Control Module Replacement Bulletin No.: 05-04-21-002 Date: March 10, 2005 INFORMATION Subject: Guidelines for Replacement of Transfer Case Control Module (TCCM) Models: 2005 and Prior Light Duty Trucks with New Venture Gear (NVG) Transfer Case (RPOs NP1, NP4, NP8) Dealers are replacing the TCCM unnecessarily. Dealers are replacing the TCCM with codes stored in HISTORY only. The TCCM does not have a current fault condition when tested. Parts reviewed at the Warranty Parts Center (WPC) have a 75% No Trouble Found (NTF) rate. The only two legitimate reasons to replace the TCCM are: ^ Diagnostic Trouble Code (DTC) C0550 ^ NO Communication with a scan tool. DTC C0550 This DTC indicates that the module has an internal fault and should be replaced. No Communication ^ The no communication conditions referenced here are also caused by a module internal fault to a point where the module physically will not talk. A technician cannot pull DTCs from the module because it will not communicate. The module is electrically dead. ^ No communication is not to be confused with a U1026 code. This code tells the technician that the module may still be functioning but is temporarily off line. This code may be set by the Instrument Panel (IP) or the Powertrain Control Module (PCM) against the TCCM. The technician needs to figure out why the module went off line. These are typically caused by connection concerns. There is no need to replace a TCCM for a U1026 DTC. Diagnostic Aids ^ When diagnosing a transfer case electrical control system, ALWAYS check power and ground wiring first. ^ Test the connections for intermittent or poor connections, complete plug insertion, bent pins, pushed out terminals and water contamination. Page 9086 Fuse Block - Underhood - Secondary Wire Entry (With RPO Code HP2) Part 3 Page 12032 ^ Pay the dealer the regular retail price (no discounts are available) for one of the following 1-year, non-refundable OnStar(R) Analog-to-Digital Transition (ADT) Service Subscription Plans: ^ 1-year Safe & Sound Subscription: $199 ($289 in Canada) ^ 1-year Directions & Connections Subscription: $399 ($579 in Canada) ^ Pay the dealer the applicable state and local sales taxes on the subscription: ^ U.S. Dealers: Taxes only apply in these states: CT, DC, FL, HI, ND, NJ, NM, NY, SC, SD, TX, and WV ^ Canadian Dealers: All applicable taxes ^ Pay the dealer a one-time charge of $15 for the upgrade: ^ U.S. Dealers: Do not collect taxes on the $15 ^ Canadian Dealers: Collect all applicable taxes on the $15 Note: Dealers should NOT remit OnStar(R) ADT-related taxes to their taxing authority as OnStar(R) is responsible for tax remittance. Please Be Sure To Read these Important Points: ^ The 1-year OnStar(R) subscription is not refundable or transferable to another person. Upgraders can apply unused subscription months to a new or Certified Pre-Owned digital OnStar-equipped GM vehicle purchase or lease. As noted above, the digital upgrade program requires the subscriber to purchase a one-year prepaid OnStar(R) subscription. Assuming the subscriber intends to keep their vehicle, but subsequently purchases or leases a 2006 model year or newer OnStar(R)-equipped new or certified used GM vehicle, in the interest of subscriber satisfaction, they may apply remaining unused whole months of the subscription to the new vehicle. The subscription may not be applied to another person's vehicle. Important: This is a customer satisfaction measure that would usually occur several months after an upgrade. It is not intended to be leveraged as part of a new/used vehicle purchase or lease transaction. ^ The $15 charge is not refundable. ^ Dealer ADT kit orders are VIN specific. Dealer kit orders require a VIN and must be exchanged with the OnStar(R) unit in the vehicle with that VIN. Proper activation and enrollment depends on this step. ^ You must put the actual miles on the Repair Order. Do not estimate. ^ Customers will receive a Hands-Free Calling number once the digital hardware is installed and configured. ^ Any nametags that were stored in the old system will need to be re-set by the subscriber once the new hardware is installed. ^ Customers are responsible for the charges described above regardless of whether their vehicle is in or out of the New Vehicle Warranty period. In addition, customers should not be charged labor costs. Dealers can charge GM the labor for the upgrade as specified at the end of this bulletin using the listed labor operation. ^ Vehicles eligible for an OnStar(R) hardware upgrade are listed in this bulletin. Vehicle upgradeability can also be determined by typing the VIN into the field entitled "Determine VIN Hardware Functionality" on the OnStar(R) Online Enrollment website, located in the sales or service workbench tab of GM GlobalConnect. Canadian Dealers can use a similar tool that is available within InfoNET. ^ Access to the sales and/or service workbench in the GM GlobalConnect website can be granted by the dealership's Partner Security Coordinator (PSC). If you are unsure who the PSC is, check with the Sales Manager. Ordering the Upgrade Kit/Upgrade kit Installation Ordering the Upgrade Kit 1. To order a kit, you will need to access the OnStar(R) Online Enrollment webpage, located under the sales or service workbench of GM GlobalConnect (infoNET for Canadian upgrade orders). These kits cannot be ordered from GMSPO. Page 1925 Four Wheel Drive Selector Switch: Service and Repair Transfer Case - NVG 263-NP1 Transfer Case Shift Control Switch Replacement Removal Procedure 1. Remove the instrument panel (IP) cluster bezel. 2. Pull the tabs on the side of the transfer case driver control switch out. 3. Pull the transfer case driver control switch straight out from the panel. Installation Procedure 1. Important: Make sure that the transfer case control switch is seated properly in the instrument panel before installing the instrument panel trim bezel. Install the transfer case driver control switch into the instrument panel. 2. Install the IP cluster bezel. TPMS System - Service And Re-Learning Sensor IDs Tire Pressure Module: Technical Service Bulletins TPMS System - Service And Re-Learning Sensor IDs INFORMATION Bulletin No.: 10-03-16-001 Date: July 19, 2010 Subject: TPMS System Service and Re-Learning Sensor IDs Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks 2010 and Prior HUMMER H2 2009 and Prior HUMMER H3 2010 and Prior Saturn Models 2009 and Prior Saab 9-7X with Wheel-Mounted Tire Pressure Sensors In the event that the spare tire, which is normally not equipped with a tire pressure monitor (TPM) sensor, is installed in place of one of the road tires and the vehicle is driven above 40 km/h (25 mph) for 20 minutes or more, the TPM indicator icon on the instrument panel cluster (IPC) will flash for approximately one minute and then remain on steady each time the ignition is turned ON, indicating a diagnostic trouble code (DTC) has been set. The driver information center (DIC), if equipped, will also display a SERVICE TIRE MONITOR type message. When the road tire is repaired and reinstalled in the original location, the TPM indicator icon illumination and DIC message may remain displayed until the DTC is cleared. To ensure that the TPM indicator and the DIC message are cleared after service, it is necessary to clear any TPM DTCs using a scan tool. If a scan tool is unavailable, performing the TPM relearn procedure using a TPM diagnostic tool will provide the same results. It is advised to perform the relearn procedure away from other vehicles to prevent picking up a stray sensor signal. If one or more of the TPM sensors are missing or damaged and have been replaced, then the relearn procedure must be performed. Disclaimer Page 9325 1. Install the engine electrical center bracket assembly to the front fender. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the 4 retaining bolts (1). Tighten Tighten the 4 retaining bolts (1) to 9 N.m (80 lb in). 3. Align the electrical center block (1) stubs in the slots so that the tabs (2) retains it in place. Page 9811 Location View Location View Page 1761 Air Bag Deactivation Switch: Description and Operation Inflatable Restraint I/P Module Disable Switch INFLATABLE RESTRAINT I/P MODULE DISABLE SWITCH The instrument panel (I/P) module disable switch is a manual 2-position key switch. The I/P module disable switch allows the vehicle operator the ability to enable or disable the I/P module (passenger frontal air bag). The I/P module disable switch interfaces with the passenger presence system (PPS) module to request the enabling or disabling of the I/P module. The occupants are notified of the enabling or disabling of the I/P module via the I/P module disable switch ON/OFF indicator and the PASSENGER AIR BAG ON/OFF indicators located on the rear view mirror. Page 6831 9. Place an alignment mark between the pinion and the pinion yoke. 10. Install the J 8614-01 as shown. 11. Remove the pinion nut while holding the J 8614-01. 12. Remove the washer. 13. Install the J 8614-2 (2) and the J 8614-3 (3) into the J 8614-01 (1) as shown. 14. Remove the pinion yoke by turning the J 8614-3 (3) clockwise while holding the J 8614-01 (1). Use a container in order to retrieve the lubricant. 15. Remove the pinion oil seal. Use a suitable seal removal tool. Do not damage the housing. Installation Procedure 1. Install a new pinion oil seal using the J 22388 (8.6 inch, 9.5 inch axles) or the J 44414 (10.5 inch, 11.5 inch axle). 2. Apply sealant GM P/N 12346004 (Canadian P/N 10953480) or equivalent to the splines of the pinion yoke. Page 519 Driver Door Module (DDM) - C5 (With RPO Code AN3) Part 1 Page 4531 Data Link Connector (DLC) Diagram 3 Page 9035 Fuse Block- I/P C3 Part 2 Page 10860 Air Duct: Service and Repair Air Outlet Duct Replacement - Floor, LH AIR OUTLET DUCT REPLACEMENT - FLOOR, LH REMOVAL PROCEDURE 1. Remove the push pin (5) from the left floor air outlet duct (4). 2. Remove the left floor duct (1) from the HVAC module (2). INSTALLATION PROCEDURE 1. Install the left floor air outlet duct (1) to the HVAC module (2). 2. Install the push pin (2) to the left floor air outlet duct. Page 12014 4.1. Unplug the SRS control module's connector (A). 4.2. Cut off the cable tie (B), detach the connector's rear end face (C), and pull out the connecting rail (D). 4.3. Extract pin 15, cut off the cable terminal and insulate the end with tape (E). Fold back the cable and secure it with tape (F). 4.4. Fit the connecting rail and end face. 4.5. Plug in the connector (A) and secure the cables with cable ties (B). 5. Remove the parcel shelf trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6. M03: Replace the optic cable on the right-hand side Wheels/Tires - Tire Radial Force Variation (RFV) Wheels: All Technical Service Bulletins Wheels/Tires - Tire Radial Force Variation (RFV) INFORMATION Bulletin No.: 00-03-10-006F Date: May 04, 2010 Subject: Information on Tire Radial Force Variation (RFV) Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X 2000-2005 Saturn L Series 2003-2007 Saturn ION Supercede: This bulletin is being revised to considerably expand the available information on Radial Force Variation (RFV) and should be reviewed in whole. Please discard Corporate Bulletin Number 00-03-10-006E (Section 03 - Suspension). Important - Before measuring tires on equipment such as the Hunter GSP9700, the vehicle MUST be driven a minimum of 16 km (10 mi) to ensure removal of any flat-spotting. Refer to Corporate Bulletin Number 03-03-10-007E - Tire/Wheel Characteristics of GM Original Equipment Tires. - Equipment such as the Hunter GSP9700 MUST be calibrated prior to measuring tire/wheel assemblies for each vehicle. The purpose of this bulletin is to provide guidance to GM dealers when using tire force variation measurement equipment, such as the Hunter GSP9700. This type of equipment can be a valuable tool in diagnosing vehicle ride concerns. The most common ride concern involving tire radial force variation is highway speed shake on smooth roads. Tire related smooth road highway speed shake can be caused by three conditions: imbalance, out of round and tire force variation. These three conditions are not necessarily related. All three conditions must be addressed. Imbalance is normally addressed first, because it is the simpler of the three to correct. Off-vehicle, two plane dynamic wheel balancers are readily available and can accurately correct any imbalance. Balancer calibration and maintenance, proper attachment of the wheel to the balancer, and proper balance weights, are all factors required for a quality balance. However, a perfectly balanced tire/wheel assembly can still be "oval shaped" and cause a vibration. Before balancing, perform the following procedures. Tire and Wheel Diagnosis 1. Set the tire pressure to the placard values. 2. With the vehicle raised, ensure the wheels are centered on the hub by loosening all wheel nuts and hand-tightening all nuts first by hand while shaking the wheel, then torque to specifications using a torque wrench, NOT a torque stick. 3. Visually inspect the tires and the wheels. Inspect for evidence of the following conditions and correct as necessary: - Missing balance weights - Bent rim flange - Irregular tire wear - Incomplete bead seating - Tire irregularities (including pressure settings) - Mud/ice build-up in wheel - Stones in the tire tread - Remove any aftermarket wheels and/or tires and restore vehicle to original condition prior to diagnosing a smooth road shake condition. 4. Road test the vehicle using the Electronic Vibration Analyzer (EVA) essential tool. Drive for a sufficient distance on a known, smooth road surface to duplicate the condition. Determine if the vehicle is sensitive to brake apply. If the brakes are applied lightly and the pulsation felt in the steering wheel increases, refer to the Brakes section of the service manual that deals with brake-induced pulsation. If you can start to hear the vibration as a low boom noise (in addition to feeling it), but cannot see it, the vehicle likely has a first order (one pulse per propshaft revolution) driveline vibration. Driveline first order vibrations are high enough in frequency that most humans can start to hear them at highway speeds, but are too high to be able to be easily seen. These issues can be caused by driveline imbalance or misalignment. If the vehicle exhibits this low boom and the booming pulses in-and-out on a regular basis (like a throbbing), chances are good that the vehicle could have driveline vibration. This type Trim Height Inspection Procedure Alignment: Service and Repair Trim Height Inspection Procedure Trim Height Inspection Procedure Trim Height Measurements Trim height is a predetermined measurement relating to vehicle ride height. Incorrect trim heights can cause bottoming out over bumps, damage to the suspension components and symptoms similar to wheel alignment problems. Check the trim heights when diagnosing suspension concerns and before checking the wheel alignment. Perform the following before measuring the trim heights: 1. Make sure the vehicle is on a level surface, such as a alignment rack. 2. Remove the alignment rack floating pins. 3. Set the tire pressures to the pressure shown on the certification label. 4. Check the fuel level. Add additional weight if necessary to simulate a full tank. 5. Make sure the rear compartment is empty except for the spare tire. 6. Close the doors and hood. Z Height Measurement Important: K models only the Z height must be adjusted before the alignment. The Z height dimension measurement determines the proper ride height for the front end of the vehicle. Vehicles equipped with torsion bars use a adjusting arm in order to adjust the Z height dimension. Vehicles without torsion bars have no adjustment and could require replacement of suspension components. 1. Important: All dimensions are measured vertical to the ground. Cross vehicle Z heights should be within 12 mm (0.47 inch) to be considered correct. Place hand on the front bumper and jounce the front of the vehicle. Make sure that there is at least 38 mm (1.5 inch) of movement while jouncing. 2. Allow the vehicle to settle into position. 3. Measure from the pivot bolt center line (2) down to the lower corner (5) of the steering knuckle (1) in order to obtain the Z height measurement (4). 4. Repeat the jouncing operation 2 more times for a total of 3 times. 5. Use the highest and the lowest measurements to calculate the average height. 6. The true Z height dimension number is the average of the highest and the lowest measurements. Refer to Trim Height Specifications. Z Height Adjustment Page 15781 Door Switch: Diagrams Door Latch Assembly (Door Jamb Switch) - RR C2 (Crew Cab Only) Door Latch Assembly (Door Jamb Switch) - RR C2 (Crew Cab Only) Page 1314 Cabin Temperature Sensor / Switch: Description and Operation AIR TEMPERATURE SENSORS The air temperature sensors are a 2-wire negative temperature co-efficient thermistor. The vehicle uses the following air temperature sensors: Ambient Air Temperature Sensor - Inside Air Temperature Sensor Assembly - Upper Left Air Temperature Sensor - Upper Right Air Temperature Sensor - Lower Left Air Temperature Sensor - Lower Right Air Temperature Sensor A signal and a low-reference circuit enables the sensor to operate. As the air temperature surrounding the sensor increases, the sensor resistance decreases. The sensor signal voltage decreases as the resistance decreases. The sensor operates within a temperature range between -40°C (-40°F) to 101°C (215°F). The sensor signal varies between 0.5 volts. The input of the duct air temperature sensors are different from the ambient and inside sensors. The HVAC control module converts the signal to a range between 0-255 counts. As the air temperature increases the count value will decrease. If the HVAC control module detects a malfunctioning sensor, then the control module software will use a defaulted air temperature value. The default value for the ambient and inside air temperature sensors will be displayed on the scan tool. The default value for the duct air temperature sensors will not be displayed on the scan tool. The scan tool parameter for the duct air temperature sensors are the actual state of the signal circuit. The default action ensures that the HVAC system can adjust the inside air temperature near the desired temperature until the condition is corrected. The ambient air temperature sensor mounts underhood and can be affected by city traffic, by idling, and by restarting a hot engine. Therefore, the HVAC control module filters the value of the ambient air temperature sensor for temperature display. The ambient air temperature value is updated under the above conditions. The scan tool has the ability to update the displayed ambient air temperature. To update the ambient air temperature display on the HVAC control module, perform the following procedure: Simultaneously press the MODE, FRONT DEFROST and REAR DEFROST switches. 1. Turn ON the ignition. 2. Simultaneously press the MODE, FRONT DEFROST and REAR DEFROST switches. Page 6300 Disclaimer Page 6301 Fluid Pump: Technical Service Bulletins A/T - 4L60-E Oil Pump Identification Bulletin No.: 03-07-30-056 Date: November 05, 2003 INFORMATION Subject: 4L60-E Automatic Transmission Oil Pump First And Second Design Identification Models: 1997-2002 Chevrolet Camaro 1997-2002 Pontiac Firebird 2002-2004 Cadillac Escalade, Escalade EXT 1997-1999 Chevrolet C/K Full Size Pickup 1997-2004 Chevrolet Astro, Blazer, Corvette, Express, S-10, Suburban 1999-2004 Chevrolet Silverado 2000-2004 Chevrolet Tahoe 2002-2004 Chevrolet Avalanche, TrailBlazer 2004 Chevrolet Colorado, SSR 1997-1999 GMC Suburban 1997-2001 GMC Jimmy 1997-2004 GMC Envoy, Safari, Savana, Sierra, Sonoma 1999-2004 GMC Denali 2000-2004 GMC Yukon, Yukon XL 2004 GMC Canyon 1997-2004 Oldsmobile Bravada 2003-2004 HUMMER H2 with 4L60-E Automatic Transmission (RPOs M30, M32, M33) Page 1862 Park Neutral Position (PNP) Switch C175 Page 1126 Seat Lumbar Motor/Position Sensor - Driver (With RPO Code AN3) Page 13396 Electrical Symbols Part 9 Page 15451 Door Switch: Diagrams Door Latch Assembly (Door Jamb Switch) - LR C2 (Crew Cab Only) Door Latch Assembly (Door Jamb Switch) - LR C2 (Crew Cab Only) Page 13040 2. Disconnect the C2 32-way blue connector from the VIU and tape the connector to a secure location. Refer to Cellular Communications Connector End Views and related schematics in SI, if required. Important: DO NOT perform the OnStar(R) reconfiguration and/or programming procedure. 3. Secure the VIU in its original brackets and/or mounting locations and reinstall the VIU and interior components that were removed to gain access to the VIU. Refer to OnStar Vehicle Interface Unit Replacement in SI. 2002 Through 2006 Model Year Vehicles (Except Saab Vehicles) 2002 through 2006 Model Year Vehicles (Except Saab Vehicles) Important: The Tech 2 diagnostic tool must be updated with version 28.002 or later in order to successfully perform the VCIM setup procedure and disable the analog system. 1. Connect the Tech 2 to the data link connector (DLC), which is located under the instrument panel of the vehicle. 2. Turn the Tech 2 ON by pressing the power button. Important: Tech 2 screen navigation to get to the setup procedure depends on the year and make of the vehicle. The actual name of the setup procedure (Setup New OnStar or VCIM Setup) depends on model year and vehicle make as well. Example Tech 2 navigation to the setup procedure Tech 2 screen is provided below. ^ Diagnostics >> (2) 2002 >> Passenger Car >> Body >> C >> OnStar >> Special Functions >> Setup New OnStar >> ^ Diagnostics >> (5) 2005 >> Passenger Car >> (4) Buick >> C >> Body >> Vehicle Comm. Interface Module >> Module Setup >> VCIM Setup >> 3. Setup VCIM using the Tech 2. Follow on-screen instructions when you have reached the setup Tech 2 screen. 2000-2002 Saab 9-3 (9400) 4D/5D; 2000-2003 Saab 9-3 (9400) CV 2000-2002 Saab 9-3 (9400) 4D/5D; 2000-2003 Saab 9-3 (9400) CV 1. Remove the ground cable from the battery's negative terminal. 2. Apply the handbrake brake. 3. Detach the floor console. 4. Remove the switch and the floor console: 3.1. Twist loose the immobilizer unit (A), bayonet fitting. Unplug the unit's connector. 3.2. Remove the ignition switch cover (B) by first undoing the rear edge of the cover and then unhooking the front edge. Unplug the ignition Page 9606 Relay Block - I/P C10 Part 2 Page 15154 Refer to the table as a guide in selecting the correct test adapter for frontprobing connectors: Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure SCAN TOOL SNAPSHOT PROCEDURE Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: - Snapshot - taken from the Snapshot menu choice - Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information Locations Air Temperature Sensor - Outside Page 15241 Control Module References Part 7 Page 9386 Note The rivet stud and surrounding panel area MUST BE properly refinished PRIOR to the installation of the electrical ground wire terminal and conductive nut to maintain a secure, stable and corrosion-free electrical ground. 11. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 12. Allow the refinished repair area to cure sufficiently before removing the protective material applied to the rivet stud threads. 13. Remove the painters tape or equivalent from the rivet stud threads. 14. Using GM approved residue-free solvent or equivalent, thoroughly clean the rivet stud threads to remove any adhesive and allow to dry. 15. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive rivet stud. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 16. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 17. Install the electrical ground wire terminal to the M6 conductive rivet stud. 18. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 19. Install the M6 conductive nut to the rivet stud and: Tighten Tighten to 8 Nm (71 lb in) 20. Verify proper system operation. Parts Information Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use: Warranty Information (Saab Models) Page 9015 Fuse Block - Underhood C2 Part 4 Page 7810 Page 9249 C388 Seat Motor Jumper Harness To Passenger Seat Harness (With RPO Code AG2) Page 3632 For vehicles repaired under warranty, use the table. Disclaimer Page 11754 Accessory Delay Module: Scan Tool Testing and Procedures Scan Tool Data Definitions SCAN TOOL DATA DEFINITIONS Courtesy Lamp Switch: Input showing state of the courtesy lamp as commanded by the BCM. Cargo Door Ajar Switch: Input from the liftgate and liftglass indicating their status. Driver Door Ajar Switch (w/o DDM): Input from the driver door indicating door status. Left Rear/Rear Cargo Door Ajar Switch: Input from the left rear door indicating its status. Passenger Door Ajar Switch (w/o PDM): Input from the front passenger door indicating door status. RAP Relay: Output indicates the RAP Relay state that the control module has commanded. Right Rear Door Ajar Sw.: Input from the right rear door indicating door status. BCM Data List DDM Data List PDM Data List SRS - Air Bag Lamp ON/DTC B0092 Set Seat Occupant Sensor: Customer Interest SRS - Air Bag Lamp ON/DTC B0092 Set Bulletin No.: 02-09-41-002A Date: March 24, 2004 TECHNICAL Subject: Air Bag Lamp On, Passenger Air Bag Indicator Always Reads OFF, DTC B0092 Set (Repair Passenger Presence System (PPS) Sensor Harness) Models: 2003-2004 Cadillac Escalade, Escalade EXT 2003-2004 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2003-2004 GMC Sierra, Yukon, Yukon XL with Sensor Indicator Inflatable Restraint Front Passenger/Child Presence Detector (RPO ALO) Supercede: This bulletin is being revised to add the 2004 model year. Please discard Corporate Bulletin Number 02-09-41-002 (Section 09 - Restraints). Condition Some customers may comment that the Air Bag Lamp is on and the Passenger Air Bag indicator always reads OFF. Upon investigation, the technician may find DTC B0092 set. Cause The cause of this condition may be a shorted Passenger Presence System (PPS) sensor wire. The PPS sensor harness is located under the front passenger seat. This harness may be pinched between the seat frame and the track/riser. Correction Locate the PPS sensor (1) and inspect the harness for proper routing. If the harness is pinched between the seat frame and the track/riser, use the procedure listed below to repair wire(s). 1. Move the front passenger seat to the full rearward and full tilt up position. 2. Loosen the seat frame to track/riser nut and remove the harness. 3. Tighten the seat frame to track/riser nut. 4. Repair any damaged wires. Refer to Wiring Repairs in the Wiring Systems sub-section of the Service Manual. Warranty Information Page 7591 ^ Knock or Clunk Noise ^ Rear Drive Axle Noises (SI Document ID #700580) ^ Launch Shudder/Vibration on Acceleration (Replace Propeller Shaft and Install a New Pinion Flange/Seal), Bulletin # 02-04-17-001 ^ Information on 2-3 Upshift or 3-2 Downshift Clunk Noise, Bulletin # 01-07-30-042 ^ Driveline Clunk When Stopping (Reprogram Powertrain Control Module (PCM), Bulletin # 03-07-30-028 Correction Replace the rear drive shaft slip yoke with a new nickel-plated slip yoke. See the parts table below. Follow the service procedure below. 1. Raise the vehicle on a hoist. 2. Reference mark the propeller shaft to the pinion flange connection. Important: Do not pound on the propeller shaft yoke ears. Never pry or place any tool between a yoke and a universal joint. 3. Remove the bolts and the yoke retainers from the pinion flange. 4. Slide the propeller shaft forward and out of the rear pinion flange. 5. Lower the rear of the propeller shaft and pull the driveshaft out of the transfer case. Note: Never clamp propeller shaft tubing in a vise. Clamping could dent or deform the tube causing an imbalance or unsafe condition. Always clamp on one of the yokes and support the shaft horizontally. Avoid damaging the slip yoke sealing surface. Nicks may damage the bushing or cut the lip seal. 6. Support the propeller shaft in a line horizontal with the table of a press. Important: Remove the front slip yoke and the universal joint together. The new nickel-plated slip yoke comes with a new universal joint. 7. Disassemble the snap rings by pinching the ends together with a pair of pliers. 8. If the ring does not readily snap out of the groove in the yoke, tap the end of the cup lightly in order to relieve the pressure from the ring. 9. Place the universal joint so that the lower ear of the yoke is supported on a 30 mm (1-1/8 in) hex head socket or a 27 mm (1-1/16 in) socket. Page 3056 8. Remove the adjusting nut. 9. Remove the hub from the axle housing. 10. Remove the rotor, if necessary. 11. Remove the oil seal from the wheel hub using a suitable seal removal tool. 12. Remove the inner hub bearing. 13. Remove the inner hub bearing cup using a brass drift and a hammer. Page 16114 5. Install the front door trim panel. 6. If equipped with camper mirrors program the door module. Refer to Service Programming System (SPS) in Programming. Page 9806 Junction Block - I/P Wire Entry Part 3 Page 11968 2007 Model Year Vehicles and Newer all have Digital OnStar(R) Modules. Part 1 OnStar(R) Description and Operation This OnStar(R) digital system consists of the following components: ^ Vehicle Communication Interface Module (VCIM) ^ OnStar(R) button assembly ^ Microphone ^ Cellular antenna ^ Navigation antenna Note This system also interfaces with the factory installed vehicle audio system. Vehicle Communication Interface Module (VCIM) The vehicle communication interface module (VCIM) is a cellular device that allows the user to communicate data and voice signals over the national cellular network. Power is provided by a dedicated, fused B+ circuit. Ground is provided through the vehicle wiring harness attached to the module. The ignition state is determined by the VCIM through serial data messaging. Dedicated circuits are used to connect the VCIM to a microphone, the button assembly, and to command the status LED. The VCIM communicates with the rest of the vehicle modules using the serial data bus. The module houses 2 technology systems, one to process GPS data, and another for cellular information. The cellular system connects the OnStar(R) system to the cellular carrier's communication system by interacting with the national cellular infrastructure. The module sends and receives all cellular communications over the cellular antenna and cellular antenna coax. GPS satellites orbiting earth are constantly transmitting signals of their current location. The OnStar(R) system uses the GPS signals to provide location on demand. The module also has the capability of activating the horn, initiating door lock/unlock, or activating the exterior lamps using the serial data circuits. These functions can be commanded by the OnStar(R) Call Center per: a customer request. OnStar(R) Button Assembly The OnStar(R) button assembly may be part of the rearview mirror, or a separate, stand alone unit. The button assembly is comprised of 3 buttons and a status LED. The buttons are defined as follows: ^ The answer/end call button, which is black with a white phone icon, allows the user to answer and end calls or initiate speech recognition. ^ The blue OnStar(R) call center button, which displays the OnStar(R) logo, allows the user to connect to the OnStar(R) call center. ^ The emergency button, which displays a white cross with a red background, sends a high priority emergency call to the OnStar(R) call center when pressed. The VCIM supplies 10 volts to the OnStar(R) button assembly on the keypad supply voltage circuit. When pressed, each button completes a circuit across a resistor allowing a specific voltage to be returned to the VCIM on the keypad signal circuit. Depending upon the voltage range returned the VCIM is able to identify which button has been pressed. The OnStar(R) status LED is located with the button assembly. The LED is green when the system is ON and operating normally. When the status LED is green and flashing, it is an indication that a call is in progress. When the LED is red, this indicates a system malfunction is present. In the event there is a system malfunction and the OnStar(R) system is still able to make a call, the LED will flash red during the call. If the LED does not illuminate, this may indicate that the customers OnStar(R) subscription is not active or has expired. Push the blue OnStar button to connect to an advisor who can then verify the account status. Each LED is controlled by the VCIM over dedicated LED signal circuits. Ground for the LED is provided by the wiring harness attached to the button assembly. Page 1192 Seat Heater Switch: Locations Driver Door Page 13292 10. Disconnect and remove the OnStar(R) jumper harness. Note: You will need to remove the short GPS cable from this jumper harness. 11. Untape the cell antenna coax from the body harness in the trunk. This will be necessary to provide adequate length to connect to the new VCIM. 12. Fasten three retainer clips (1) from the kit to the new bracket that is included in the kit, and position the VCIM to the bracket (2). 13. Install the three bolts from the kit. Tighten the bolts to 10 Nm (89 lb in). 14. Connect the new OnStar(R) jumper harness supplied in the kit to the VCIM (two white connectors on module). 15. Connect small GPS coax cable jumper harness supplied in the kit (end with blue plastic housing) to VCIM GPS connector. 16. Position the VCIM / bracket assembly to the studs. 17. Install the bracket nuts saved from the Removal Procedure above to the VCIM / bracket assembly mounting studs. Tighten the nuts to 4 Nm (35 lb in). 18. Connect the new OnStar(R) jumper harness to the body wiring harness (C410 connector). 19. Connect small coax cable jumper from VCIM to the OnStar(R) Global Positioning Satellite (GPS) antenna coaxial cable at the connector previously left in the vehicle (short jumper removed from old harness in step 5.10). 20. Connect the cellular coaxial cable previously left in vehicle to the OnStar(R) VCIM. 21. Verify that all harnesses are properly secured in vehicle. 6. After replacing the VCIM, it is essential to configure the new OnStar(R) system. Failure to configure the system will result in an additional customer visit for repair. DO NOT press and hold the white dot or phone button on the keypad as it will not reset this version of the OnStar(R) system and may result in a DTC being set. Use of the TIS2WEB and SPS applications, along with the Tech2(R), are required in order to perform the VCIM configuration and setup procedure for this vehicle. The configuration and set-up procedure is now a two-step process which enables an automated activation by the OnStar(R) Center, without a button press by the technician to the OnStar(R) Call Center. 1. Connect the Tech2(R) to the vehicle. Description and Operation Compass: Description and Operation COMPASS The mirror uses 2 magnetic field sensors for compass direction. One sensor is for north and south, the other is for east and west. The mirror supplies a signal and low reference to each sensor. As the vehicle travels with or against the earth's magnetic pull, there will be a change in voltage on one or both sensors. As a result of the change in voltage, the mirror changes the heading on the compass display. Page 1346 A/C Low Pressure Switch Page 2125 Compression Check: Testing and Inspection Engine Compression Test 1. Charge the battery if the battery is not fully charged. 2. Disable the ignition system. 3. Disable the fuel injection system. 4. Remove all the spark plugs. 5. Turn the ignition to the ON position. 6. Depress the accelerator pedal to position the throttle plate wide open. 7. Start with the compression gage at zero and crank the engine through four compression strokes, four puffs. 8. Check the compression for each cylinder. Record the readings. 9. If a cylinder has low compression, inject approximately 15 ml (1 tablespoon) of engine oil into the combustion chamber through the spark plug hole. Check the compression again and record the reading. 10. The minimum compression in any one cylinder should not be less than 70 percent of the highest cylinder. No cylinder should read less than 690 kPa (100 psi). For example, if the highest pressure in any one cylinder is 1 035 kPa (150 psi), the lowest allowable pressure for any other cylinder would be 725 kPa (105 psi). (1 035 x 70% = 725) (150 x 70% = 105). ^ Normal - Compression builds up quickly and evenly to the specified compression for each cylinder. ^ Piston Rings Leaking - Compression is low on the first stroke. Compression builds up with the following strokes, but does not reach normal. Compression improves considerably when you add oil. ^ Valves Leaking - Compression is low on the first stroke. Compression usually does not build up on the following strokes. Compression does not improve much when you add oil. ^ If two adjacent cylinders have lower than normal compression, and injecting oil into the cylinders does not increase the compression, the cause may be a head gasket leaking between the cylinders. Page 8976 Location View Page 11970 these systems will then completely power OFF. OnStar(R) Module Expected Current Draw The expected current draw of the OnStar(R) module in various ignition modes are as follows: ^ Ignition ON ‐ 240 to 400 mA ^ Ignition OFF ‐ 3 to 20 mA for 48 hours ^ Ignition OFF ‐ 0.2 to 0.8 mA after 48 hours (120 hours on specified vehicle communication platforms (VCPs)). Note During extended voltage testing for battery parasitic draw, it is possible to observe a voltage spike caused by the following: ^ A cellular registration call that was triggered by the local cellular system. ^ The OnStar(R) system has set a monthly trigger for a vehicle data upload call for the OnStar(R) Vehicle Diagnostic E‐mail upload. OnStar(R) System States of Readiness The OnStar(R) system will use the following 4 states of readiness, depending upon the type of cellular market the vehicle is in when the ignition is turned OFF. ^ High power ^ Low power ^ Sleep ^ Digital standby The high power state is in effect whenever the ignition is in the ON or RUN position, retained accessory power (RAP) is enabled, and/or the OnStar(R) system is sending or receiving calls or when the system is performing a remote function. The low power state is in effect when the OnStar(R) system is idle with the ignition in the ON or RUN position, or with RAP enabled. The sleep state is entered after the vehicle has been shut OFF and the RAP has timed out. At a predetermined time recorded within the VCIM, the system re-enters the low power state to listen for a call from the OnStar(R) Call Center for 1 minute. After this interval, the system will again return to the sleep state for 9 minutes. If a call is sent during the 1 minute interval, the OnStar(R) system will receive the call and immediately go into the high power mode to perform any requested functions. If a call is not received during the 1 minute interval, the system will go back into the sleep mode for another 9 minutes. This process will continue for up to 48 hours, after which the OnStar(R) system will turn OFF until the ignition is turned to the ON or RUN position. The digital standby power state is entered after the vehicle has been shut off and the RAP has timed out while in a digital cellular area. When in digital standby mode, the OnStar(R) module is able to perform all remote functions as commanded by an OnStar(R) advisor at any time, for a continuous 48 hours. After 48 hours, the OnStar(R) module will go into sleep mode until a wake up signal from the vehicle is seen by the CIM. If the OnStar module loses the digital cellular signal it will revert to analog mode and follow the standard sleep state (9 minutes OFF, 1 minute standby) based on the time of the GPS signals, this will continue until a digital cellular signal is again received. If the OnStar(R) system loses battery power while the system is in a standby or sleep mode, the system will remain OFF until battery power is restored and the ignition is turned to the ON or RUN position. Deactivated OnStar(R) Accounts In the event that a customer has not upgraded their vehicle to a digital system, the account has been deactivated. The customers have been previously notified of the steps required to upgrade their vehicles. After the OnStar(R) account has been deactivated, customers will experience the following: ^ The OnStar(R) status LED will not illuminate ^ The OnStar(R) system will NOT attempt to connect to the OnStar(R) Call Center in the event of a collision or if the vehicle's front air bags deploy for any other reason. ^ An emergency button press will result in a demo message being played, indicating the service has been deactivated and needs to be upgraded. Page 7195 1. Install the control lever insulator, if removed. 2. Install the control lever boot to the control lever, if removed. 3. Install the control lever. 4. If alignment of the control lever is necessary, or if the shift lever assembly was replaced perform the following: 1. The nut must be seated at the bottom of the thread runout on the shift lever. 2. Seat the control lever against the shift lever assembly adjustment nut. 3. Back the control lever off the nut in order to align the index mark on the control lever perpendicular to the edge of the control lever boot retainer. 5. Ensure that the index mark is located on the passenger side and that the shift pattern is aligned parallel to the vehicle centerline or rotated no more than 6 degrees clockwise. Notice: Refer to Fastener Notice in Service Precautions. 6. Hold the control lever and tighten the shift lever assembly nut against the control lever. ^ Tighten the nut to 37 Nm (27 ft. lbs.). 7. Seat the control lever boot to the floor. 8. Install the control lever boot screws, if removed. ^ Tighten the screws to 1.6 Nm (14 inch lbs.). 9. Install the control lever boot retainer, if removed. Page 11742 Inflatable Restraint Seat Position Switch - Right ((With RPO Code AL0) Procedures Power Seat Switch: Procedures Lumbar Switch Replacement LUMBAR SWITCH REPLACEMENT REMOVAL PROCEDURE 1. Remove the power seat switch bezel containing the lumbar switch (1) from the seat. 2. Remove the lumbar switch screws from the power seat switch bezel. 3. Remove the lumbar switch. INSTALLATION PROCEDURE 1. Install the lumbar switch to the power seat switch bezel. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the lumbar switch screws. Tighten Tighten the screws to 2 N.m (18 lb in). 3. Install the power seat switch bezel (1) to the seat. Seat Switch Bezel Replacement SEAT SWITCH BEZEL REPLACEMENT REMOVAL PROCEDURE Page 9330 8. Install the left side end panel. Page 12096 Diagnostic Trouble Codes DTC U1000 and U1255 Circuit/System Description Modules connected to the Class 2 serial data circuit monitor for serial data communications during normal vehicle operation. Operating information and commands are exchanged among the modules. When a module receives a message for a critical operating parameter, the module records the identification number of the module which sent the message for State of Health monitoring. A critical operating parameter is one which, when not received, requires that the module use a default value for that parameter. When a module does not associate an identification number with at least one critical parameter within 5 seconds of beginning serial data communication, DTC U1000 or U1255 DTC is set. When more than one critical parameter does not have an identification number associated with it, the DTC will only be reported once. The Class 2 serial data communications circuit on this vehicle are in a hybrid ring and star configuration. Each module on the ring has 2 serial data circuits connected to it, except the following modules which have only 1 serial data circuit connected them: Page 5078 Extended Cab Short Box Shown Below, Other Configurations Similar 6. Install the new canister vent valve solenoid to the fuel tank clip or mounting bracket as shown above. The valve port closest to the electrical connector must point towards the canister. 7. Cut bulk 5/8" heater hose to a length of approximately 76 mm (3 in). Install the hose between the solenoid and the canister pipe and secure using clamps. 8. Attach bulk 5/8" heater hose to the vent port and secure using a clamp. Run a length as needed along the frame rail routing to the area above the transmission. 9. Cut the hose to determined length and install the supplied filter box. Secure using a clamp. 10. Remove the transmission support and lower the transmission assembly as necessary to allow for access to the new filter box location. 11. Secure the filter box to the transmission vent hose just forward of the hose tee-section using a tie strap. DO NOT pinch or restrict the transmission vent hose. The filter box opening should be pointing downward. 12. Raise the transmission and reinstall the transmission support. 13. Connect the EVAP canister vent valve electrical connector. 14. Tie strap the hose as needed along the frame rail in order to keep the hose away from pinch-points and heat sources. 15. Lower the vehicle. Correction (2007-2010 New Style Models) After following the published SI diagnostics and determining that the EVAP canister vent valve is the cause of the MIL light, replace the EVAP canister vent valve assembly and relocate the remote filter box. To ensure correct installation, follow the procedures below. Important DO NOT replace the EVAP canister assembly for this concern unless it fails the leak test. Use Service Kit P/N 19207763 1. Raise the vehicle. Suitably support the vehicle. 2. Disconnect the EVAP canister vent valve electrical connector. Page 1474 Door Switch: Diagrams Door Latch Assembly (Door Jamb Switch) - LR C2 (Crew Cab Only) Door Latch Assembly (Door Jamb Switch) - LR C2 (Crew Cab Only) Campaign - HVAC Blower Not Functional Runs Continuously Control Module HVAC: All Technical Service Bulletins Campaign - HVAC Blower Not Functional Runs Continuously SPECIAL COVERAGE Bulletin No.: 11046 Date: April 07, 2011 Subject: 11046 - Special Coverage Adjustment - Heating, Ventilation, and Air Conditioning Blower Not Fully Functional on All Blower Speeds, Inoperative, or Runs Continuously with the Ignition Off Models: 2003-2006 Chevrolet Avalanche, Suburban, Tahoe 2003-2007 Chevrolet Silverado 2003-2006 GMC Yukon, Yukon XL 2003-2007 GMC Sierra Equipped with Manual HVAC (CJ3) or Heavy Duty Heater (C42) Due to part availability, owner letters will be released in phases starting with older model year first. Owners for model year vehicles not included in first phase owner mailing will receive an owner advisory letter. The letter will inform the customer that parts are not yet available and that another letter will be sent to them when parts become available. A copy of this letter will be attached to the dealer message announcing this bulletin. In the meantime, if a customer brings their vehicle to the dealership with the condition described in this bulletin, repair the vehicle using the parts called out in this bulletin. Condition On some 2003-2006 model year Chevrolet Avalanche, Suburban, Tahoe; GMC Yukon, Yukon XL; and 2003-2007 model year Chevrolet Silverado and GMC Sierra vehicles equipped with a manual heating, ventilation, and air conditioning (HVAC) system (CJ3) or heavy duty heater (C42), the interface between the electrical terminals of the relay resistor module and the wiring connector that powers the module may be incapable of conducting higher current levels for sustained periods of blower motor operation. In addition, moisture and other contaminants may enter the fresh air intake plenum and contact the internal circuit of the module or corrode the terminals. Either of the above may cause the relay resistor module or wiring connector to overheat, resulting in one or more of the following symptoms: - The HVAC blower may not function on certain or all blower speed settings - A burning plastic smell or smoke may be present in the vehicle - The HVAC blower may run continually with the ignition in the OFF position In very rare events, if the above symptoms are ignored, a fire could occur. Special Coverage Adjustment This special coverage covers the condition described above for a period of 10 years or 240,000 km, whichever occurs first, from the date the vehicle was originally placed in service, regardless of ownership. Dealers are to install a new blower motor resistor and resistor module connector. The repairs will be made at no charge to the customer. For vehicles covered by Vehicle Service Contracts, all eligible claims with repair orders on or after April 8, 2011 are covered by this special coverage and must be submitted using the labor operation codes provided with this bulletin. Claims with repair orders prior to April 8, 2011 must be submitted to the Service Contract provider. Vehicles Involved Involved are certain 2003-2006 model year Chevrolet Avalanche, Suburban, Tahoe; GMC Yukon, Yukon XL; and 2003-2007 model year Chevrolet Silverado and GMC Sierra vehicles equipped with a manual HVAC (CJ3) or heavy duty heater (C42). Important Dealers are to confirm vehicle eligibility prior to beginning repairs by using the Applicable Warranties section in the Global Warranty Management system. Parts Information Page 7858 For vehicles repaired under warranty, use the table. Disclaimer OnStar(R) - Cellular Antenna Replacement Parts Antenna, Phone: Technical Service Bulletins OnStar(R) - Cellular Antenna Replacement Parts Bulletin No.: 00-08-46-002A Date: April 12, 2005 INFORMATION Subject: OnStar(R) System Cellular Antenna Replacement Parts Availability Models: 1996-2005 Passenger Cars and Light Duty Trucks 2003-2005 HUMMER H2 with OnStar(R) and Glass Mounted Antennas Supercede: This bulletin is being revised to update the model years, models and parts information. Please discard Corporate Bulletin Number 00-08-46-002 (Section 08 - Body & Accessories). Replacement parts for the OnStar(R) system cellular antenna are available as follows: ^ Cellular Antenna Kit - If the antenna mast or exterior base is damaged or missing or if the antenna base has separated from the exterior glass surface. ^ Cellular Antenna Inner Coupling - If the antenna coupling on the inside of the glass requires replacement. Important: If glass replacement is required, both the Cellular Antenna Kit and the Cellular Antenna Inner Coupling are required. The kits listed contain all the necessary parts and instructions needed to properly install a new cellular antenna exterior base or interior coupling to the glass surface. To obtain maximum adhesion during installation, the instructions included in the kits must be followed carefully and exactly as written. Important: Do not attempt to reinstall the original cellular antenna exterior base or interior coupling using any type of glue, adhesive tapes, etc. Doing so may eliminate the cellular signal transfer through the glass and reduce the maximum performance of the system that includes air bag deployment notification. Important: To obtain maximum adhesion between the new cellular exterior base or interior coupling and the glass surface, the base, coupling and glass must be kept dry and above 15°C (60°F) during the installation and for the 24 hours immediately following the installation. Not keeping the vehicle dry and above the temperature listed for 24 hours may result in the new cellular antenna exterior base or interior coupling coming off. Parts Information Parts are currently available from GMSPO. Page 6848 Remove the ring gear from the differential case. Drive the gear off with a brass drift if necessary. Installation Procedure 1. Determine the pinion position shim thickness and the pinion preload shim thickness for the drive pinion gear. 2. Important: The mating surface of the ring gear and the differential case must be clean and free of burrs before installing the ring gear. Install the ring gear to the differential case. Align the holes in the differential case to the bolts holes in the ring gear. 3. Important: The ring gear bolts have right-hand threads. Install the new ring gear bolts. Hand start each bolt to ensure that the ring gear is properly installed to the differential case. 4. Notice: Refer to Fastener Notice in Service Precautions. ^ Tighten the new ring gear bolts. Tighten the ring gear bolts alternately and in stages, gradually pulling the ring gear onto the differential case. ^ Tighten the new ring gear bolts to 178 Nm (131 ft. lbs.). 5. Install the differential assembly. 6. Fill the axle with lubricant. Use the proper fluid. 7. Lower the vehicle. 10.5 Inch Axle Drive Pinion and Ring Gear Replacement (10.5 Inch Axle) Removal Procedure 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Remove the differential assembly. 3. Remove the pinion gear bearing retainer. 4. Remove the pinion and the pinion bearings. Page 6092 11. Bottom retaining clip (3) 12. Cover gasket (4) 13. Cover (5) 14. Cover bolts (6) Notice: Refer to Fastener Notice in Service Precautions. 2. Tighten the cover bolts (61). ^ Tighten the bolts to 24 Nm (18 ft. lbs.). 3. Install the transmission filter. Forward Servo Replacement Forward Servo Replacement Removal Procedure 1. Remove the transmission filter. 2. Remove the forward servo cover bolts, cover, and gasket. 3. Remove the following parts: 1. Forward servo piston pin (5) 2. O-ring seal (4) 3. Servo piston (3) 4. Retainer (2) 5. Piston spring (1) Installation Procedure 1. Install the following parts: ^ Piston spring (1) ^ Retainer (2) ^ Servo piston (3) ^ O-ring seal (4) ^ Forward servo piston pin (5) Notice: Refer to Fastener Notice in Service Precautions. 2. Install the forward servo gasket, cover, and bolts. ^ Tighten the bolts to 24 Nm (18 ft. lbs.). Specifications Brake Bleeding: Specifications HYDRAULIC BRAKE SYSTEM Delco Supreme II Brake Fluid or equivalent DOT-3 brake fluid. Emissions - MIL ON/DTC P0446 Stored In ECM Evaporative Canister Filter: Customer Interest Emissions - MIL ON/DTC P0446 Stored In ECM TECHNICAL Bulletin No.: 02-06-04-037I Date: September 16, 2010 Subject: Check Engine Light On, Fuel Tank Hard to Fill, DTCs P0442, P0446, P0455 or P0449 Set (Replace Evaporative Emission (EVAP) Vent Valve Solenoid Assembly and Add/Relocate Filter Box Using Service Kit) Models: 1999-2007 Chevrolet Silverado (Classic) Models 1999-2007 GMC Sierra (Classic) Models 2007-2010 Chevrolet Silverado Models (Including Hybrid) 2007-2010 GMC Sierra Models (Including Hybrid) Supercede: This bulletin is being revised to add the 2010 model year and to include the Hybrid models. Please discard Corporate Bulletin Number 02-06-04-037H (Section 06 - Engine/Propulsion System). Condition Some customers may comment about the check engine light being illuminated. They may also comment that their vehicle is difficult to fill with fuel or when filling, the pump continuously shuts off before the tank is full. When checking the vehicle for DTCs, the ECM may report one or more of the following DTCs set as current or in history: P0442, P0446, P0449 or P0455. Cause The EVAP canister vent solenoid (CVS) valve draws fresh air into the system through a vent. Under certain operating conditions, dirt and dust intrusion into the EVAP CVS fresh air intake/venting system, may result in restricted air flow. Under certain operating conditions, water, if ingested into the EVAP CVS fresh air intake/venting system, may reach the CVS valve causing corrosion in the CVS valve, and may cause restrictions in the fresh air intake path, when the valve is in the closed position. Correction (1999-2007 Classic/Old Style Models) After following the published SI diagnostics and determining that the EVAP canister vent valve is the cause of the MIL light, replace the existing EVAP canister vent valve assembly with a new assembly. This new assembly is a sealed unit that is designed to be vented through a remote filter box. To ensure correct installation, follow the procedures below. Important DO NOT replace the EVAP canister assembly for this concern unless it fails the leak test. 1999-2003 Model Year (Use Service Kit P/N 19207762) 1. Raise the vehicle. Suitably support the vehicle. 2. Disconnect the EVAP canister vent valve electrical connector, if equipped. 3. Disengage the two vent valve pipe clips securing the pipe to the underbody. Remove the clips from the underbody and discard. 4. Disconnect the vent valve pipe at the EVAP canister. 5. Remove and retain the EVAP canister vent valve bracket mounting bolt. 6. Remove the complete EVAP canister vent valve assembly with bracket attached and discard. Page 1996 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly, Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Pull to Seat Connectors PULL TO SEAT CONNECTORS TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Engine Controls - 4L60E/4L65E A/T 2nd Gear Start PROM - Programmable Read Only Memory: All Technical Service Bulletins Engine Controls 4L60E/4L65E A/T 2nd Gear Start Bulletin No.: 05-07-30-013 Date: May 09, 2005 TECHNICAL Subject: 4L60-E/4L65-E Automatic Transmission Second Gear Start, Lack/Loss of Power When Accelerating From a Stop (Reprogram Powertrain Control Module (PCM) Models: 2004-2005 Cadillac Escalade 2004-2005 Chevrolet Avalanche, Express, Silverado, Suburban, Tahoe 2004-2005 GMC Savana, Sierra, Yukon 2004-2005 HUMMER H2 with 4L60-E (RPO M30) or 4L65-E (RPO M32) Automatic Transmission Condition Some customers may comment on a slip on launch, low power on a launch or a second gear start when accelerating from a stop. This condition is usually very intermittent, occurring only once in a few thousand miles of driving. A Tech 2 or VDR snapshot of the event may show 2nd gear being commanded for approximately two seconds, then 1st gear commanded as would be expected. Cause This condition may be caused by an intermittent VSS signal, which causes the PCM to command second gear. Important: There are other conditions that can cause the transmission to start in a gear higher than first. The following are a few of these conditions. ^ Some DTCs can cause the transmission to start in a higher gear. Check for the presence of DTCs and repair as appropriate before proceeding. ^ Debris on top of the spacer plate or in the valve body or a leaking shift solenoid can cause a 4L60-E or 4L65-E transmission to start in a gear higher than first. A start in a higher gear caused by any of these conditions typically occurs with much greater frequency. Refer to Service Bulletin 01-07-30-036D or newer for diagnostic information of these conditions. ^ Placing the shift lever in the D2 position will cause a 4L60-E or 4L65-E transmission to start in second gear. Correction Important: ^ This bulletin ONLY applies to 2004-2005 models year vehicles listed above. ^ Some DTCs can cause the transmission to start in a higher gear. Check for the presence of DTCs and repair as appropriate before proceeding. 1. Using a scan tool, check for the presence of DTCs. If DTCs are present, refer to the appropriate SI Document before proceeding with this calibration. Important: These calibrations also contain the 2-3 shift clunk calibration as detailed in bulletin 05-07-30-012. 2. Technicians are to reprogram the PCM with an updated software calibration. This new service calibration was released with TIS satellite data update version 5 or later available May 1, 2005. Refer to Service Programming System (SPS) in Vehicle Control Systems in the appropriate SI Document. Warranty Information Page 6154 For vehicles repaired under warranty, use the table. Disclaimer Automatic Transmission - 4L60-E/4L65-E Pressure Regulating Solenoid: Service and Repair Automatic Transmission - 4L60-E/4L65-E Pressure Regulator Replacement Removal Procedure 1. Remove the transmission filter. 2. Compress the reverse boost valve sleeve into the bore of the oil pump to release tension on the reverse boost valve retaining ring. 3. Remove the reverse boost valve retaining ring, then slowly release tension on the reverse boost valve sleeve. 4. Remove the reverse boost valve sleeve (5) and the reverse boost valve (4). 5. Remove the pressure regulator isolator spring (3) and the pressure regulator valve spring (2). 6. Remove the pressure regulator valve (1). Installation Procedure 1. Install the pressure regulator valve (1). 2. Install the pressure regulator isolator spring (3) and the pressure regulator valve spring (2). 3. Install the reverse boost valve (4) in the reverse boost valve sleeve (5). 4. Install the reverse boost valve (4) and sleeve (5) in the oil pump cover. Page 7012 The torque specification for the wheel drive shaft nut has been revised as shown in the table. Disclaimer Page 11597 In summary, whenever a vehicle subject to this recall enters your vehicle inventory, or is in your dealership for service in the future, please take the steps necessary to be sure the recall correction has been made before selling or releasing the vehicle. Disclaimer Page 14986 Ashtray Replacement (Console) Ash Tray: Service and Repair Ashtray Replacement (Console) Ashtray Replacement (Console) Ashtray in the luxury console is replaced as an assembly with the cupholder. Refer to Cupholder Replacement (Luxury) Cupholder Replacement (Non-Luxury) Cupholder Replacement (Rear) Cupholder Replacement (Pro). Page 5582 Steps 10 - 14 Page 1159 1. Set the front wheels in the straight ahead position. Notice: On the 2002 and later model year vehicles the steering column LOCK was removed from the steering column. It is critical that the J 42640 - Steering column Anti-Rotation Pin is used when servicing steering columns on 2002 and later model year vehicles. Failure to use the J 42640 may result in damage to the SIR coil. 2. Set the steering wheel in the LOCK position on 2001 and prior model year vehicles. 3. For 2002 and later vehicles install the J 42640 in the steering column lower access hole. 4. From under the hood remove the lower bolt that connects the upper intermediate shaft to the steering gear coupling shaft. 5. Slide the shaft towards the dash in order to disengage the shaft from the steering gear coupling shaft. 6. For vehicles equipped with adjustable foot pedals perform the following steps: 1. Reposition the carpet away from the accelerator pedal position (APP) sensor. 2. Remove the two nuts retaining the accelerator pedal to the bulkhead. 3. Reposition the accelerator pedal out of the way so the intermediate shaft can be removed. Page 15394 Disclaimer Page 10002 Tire Pressure Sensor: Technical Service Bulletins Tire Monitor System - TPM Sensor Information INFORMATION Bulletin No.: 08-03-16-003 Date: May 12, 2008 Subject: Warranty Reduction - Transfer of Tire Pressure Monitoring (TPM) Sensors to Replacement Wheels and Allowable TPM Sensor Replacements Models: 2000-2009 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2009 HUMMER H2 2006-2009 HUMMER H3 2005-2009 Saab 9-7x with On-Wheel TPM Sensors TPM Sensor / Wheel Warranty Reviews During the last warranty review period it was noted that wheels being returned under the GM New Vehicle Warranty were being shipped back to General Motors with the TPM sensor still attached to the wheel. Return rates ran as high as 60% with the TPM sensors still attached. Operational TPM sensors should not be returned to GM and are to be transferred to replacement wheels if they become necessary. Important: Operational TPM Sensors that are returned under warranty to General Motors will be charged back to the dealer.Sensors have a 10 year /150,000 mile (240,000 km) battery life, and should be transferred if one or more wheels are replaced. TPM Valve Stem / Grommet (0-ring) Replacement When the TPM sensors are transferred to new wheels you should replace the component used to seal the TPM sensor stem to the wheel. On sensors with an aluminum stem and visible nut on the outside of the wheel a replacement grommet (0-ring) should be used to assure a proper seal. The sensor retaining nut (except Aveo) should be tightened to 7 N.m (62 lb in) for all vehicles except Pontiac Vibe (4.0 N.m (35.4 lb in)). Important: ^ DO NOT overtorque the retaining nut. Notice: ^ Factory installed TPM Sensors come with plastic aluminum or nickel-plated brass stem caps. These caps should not be changed. Chrome plated steel caps may cause corrosion of aluminum valve stems due to incompatibility of the metals. On current style sensors the entire rubber stem is replaceable. The service interval on the revised TPM sensor with replaceable stem is the same as for any other traditional valve stem. Replace the stem at the time of tire replacement sensor transfer or whenever air seepage is suspected at the valve stem. When replacing the valve stem tighten the screw to 1.3 N.m (11.5 lb in). For either style of TPM sensor see the service parts guide for the correct GM part numbers to order and use. Disclaimer TPMS System - Service And Re-Learning Sensor IDs Tire Pressure Sensor: Technical Service Bulletins TPMS System - Service And Re-Learning Sensor IDs INFORMATION Bulletin No.: 10-03-16-001 Date: July 19, 2010 Subject: TPMS System Service and Re-Learning Sensor IDs Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks 2010 and Prior HUMMER H2 2009 and Prior HUMMER H3 2010 and Prior Saturn Models 2009 and Prior Saab 9-7X with Wheel-Mounted Tire Pressure Sensors In the event that the spare tire, which is normally not equipped with a tire pressure monitor (TPM) sensor, is installed in place of one of the road tires and the vehicle is driven above 40 km/h (25 mph) for 20 minutes or more, the TPM indicator icon on the instrument panel cluster (IPC) will flash for approximately one minute and then remain on steady each time the ignition is turned ON, indicating a diagnostic trouble code (DTC) has been set. The driver information center (DIC), if equipped, will also display a SERVICE TIRE MONITOR type message. When the road tire is repaired and reinstalled in the original location, the TPM indicator icon illumination and DIC message may remain displayed until the DTC is cleared. To ensure that the TPM indicator and the DIC message are cleared after service, it is necessary to clear any TPM DTCs using a scan tool. If a scan tool is unavailable, performing the TPM relearn procedure using a TPM diagnostic tool will provide the same results. It is advised to perform the relearn procedure away from other vehicles to prevent picking up a stray sensor signal. If one or more of the TPM sensors are missing or damaged and have been replaced, then the relearn procedure must be performed. Disclaimer Page 5547 Crankshaft Position Sensor: Description and Operation CRANKSHAFT POSITION (CKP) SENSOR The crankshaft position (CKP) sensor is a three wire sensor based on the magneto resistive principle. A magneto resistive sensor uses two magnetic pickups between a permanent magnet. As an element such as a reluctor wheel passes the magnets the resulting change in the magnetic field is used by the sensor electronics to produce a digital output pulse. The PCM supplies a 12-volt, low reference, and signal circuit to the CKP sensor. The sensor returns a digital ON/OFF pulse 24 times per crankshaft revolution. Page 12300 IMPORTANT: Ensure the harness is routed to the right side of the large plastic pin as shown (2). 3. Install the harness retainer to the panel. 4. Swing the rear part of the assembly to the headliner so that the retainer is seated. NOTE: Refer to Fastener Notice in Service Precautions. 5. Install the two rear retaining bolts. Tighten Tighten the 2 rear retaining bolts to 9 N.m (80 lb in). 6. Move the screen to the open position. 7. Install the 2 front retaining bolts (2). Tighten Tighten the 2 front retaining bolts to 9 N.m (80 lb in). 8. Install the rear screw cover. Page 15435 Outside Temperature Display Sensor: Service and Repair AMBIENT AIR TEMPERATURE SENSOR REPLACEMENT REMOVAL PROCEDURE 1. Remove the radiator grille from the vehicle. 2. Remove the push pin retainer from the sensor mounted on the radiator support brace. 3. Disconnect the electrical connector from the sensor. INSTALLATION PROCEDURE 1. Connect the electrical connector to the sensor. 2. Install the sensor to the radiator support brace and install the push pin retainer. 3. Install the radiator grille to the vehicle. Page 7107 1. Install the spacer (if applicable) onto the rear of the crankshaft. 2. Install the manual transmission engine flywheel to the crankshaft, if applicable. 3. Install the automatic transmission engine flywheel to the crankshaft, if applicable. Important: Longer flywheel bolts must be used on applications using a flywheel spacer. 4. Apply threadlock GM P/N 12345382 (Canadian P/N 10953489), or equivalent to the threads of the flywheel bolts. Air Conditioning - Diagnose A/C Low Pressure Switch Low Pressure Sensor / Switch: Technical Service Bulletins Air Conditioning - Diagnose A/C Low Pressure Switch INFORMATION Bulletin No.: 04-01-38-010A Date: January 21, 2010 Subject: Diagnostic Information to Accurately Diagnose A/C Low Pressure Switch Using Kent Moore Special Tool GE-47742 Models: 2002-2006 Cadillac Escalade, Escalade EXT 2003-2006 Cadillac Escalade ESV 1999-2007 Chevrolet Silverado 2000-2006 Chevrolet Suburban, Tahoe 2002-2007 Chevrolet Avalanche 1999-2007 GMC Sierra 2000-2006 GMC Yukon, Yukon XL 2001-2006 GMC Yukon Denali XL 2001-2007 GMC Sierra Denali, Yukon Denali XL 2003-2008 HUMMER H2 with Air Conditioning Supercede: This bulletin is being revised to update the model years. Please discard Corporate Bulletin Number 04-01-38-010 (Section 01 - HVAC). Currently, technicians cannot accurately determine the air conditioning (A/C) low pressure switch open/close pressure point by measuring pressure at the low side service port. This is because the evaporator is between the low side service port and the A/C low pressure switch. Correlating pressures measured at the low side service port to actual pressures at the A/C low pressure switch port is difficult because of the multiple variables that impact pressure drop across the evaporator. Providing a pressure range that would take into account all these variables would result in a pressure range that would be too broad to be useful for diagnostic purposes. Kent Moore special tool GE-47742 will allow technicians to monitor the actual pressures at which the A/C low pressure switch opens and closes under actual operating conditions. Technicians are to use the following steps to install and use Kent Moore special tool GE-47742 to measure A/C low pressure switch opening and closing pressures: 1. Disconnect the wire harness from the A/C low pressure switch. 2. Remove the A/C low pressure switch from the accumulator. 3. Install the A/C low pressure switch, using the threaded port with an O-ring, onto special tool GE-47742. 4. Install special tool GE-47742, with the A/C low pressure switch attached, onto the accumulator. Important Removing the seal from the A/C low pressure switch wire harness connector is required. Failure to remove the seal before plugging it into the switch will lead to misdiagnosis. The "plunger effect" of plugging the connector with a seal into the A/C low pressure switch induces a pressure on the back side of the switch. This pressure will skew the opening/closing characteristics of the switch 34-69 kPa (5-10 psi) until the pressure bleeds off. The time required for the connection induced pressure to bleed off can be 20 minutes or longer. 5. Remove the seal from the A/C low pressure switch wire harness connector. 6. Connect the wire harness, without the seal, to the A/C low pressure switch. 7. Connect the low side service hose from the ACR2000(R) or GE-48800 to the service port on special tool GE-47742. 8. Connect a Tech2(R) to the vehicle. 9. Start the vehicle and maintain an engine speed of 1500 RPM. Set the HVAC controls as follows: - Set the A/C control switch to ON. - Set the mode control switch to A/C and engage recirculation mode. - Set the blower motor speed to LOW. - Set the temperature control to full cold. - Set the auxiliary blower motor speed to LOW. If equipped. - Set the auxiliary temperature control to full cold. If equipped. - The vehicle must be operating with no sun load (in the shade). 10. Use the Tech2(R) to determine the A/C low pressure switch status and the ACR2000(R) or GE-48800 to determine the A/C low side pressure. Simultaneously monitor the switch status and the pressure at which the A/C low pressure switch opens and closes. The Tech2(R) will display switch status as "Normal" for Closed and "Low Pressure" for Open. A properly operating switch should open between 138-172 kPa (20-25 psi) Page 9072 Location View Engine Controls - MIL ON/Misfire/Misfire DTC's Set Ground Strap: All Technical Service Bulletins Engine Controls - MIL ON/Misfire/Misfire DTC's Set Bulletin No.: 06-06-04-046 Date: September 12, 2006 INFORMATION Subject: Information on Engine Misfire MIL/SES Light Illuminated or Flashing DTC P0300, P0301, P0302, P0303, P0304, P0305, P0306, P0307, P0308, P0420 or P0430 Models: 1999-2007 Cadillac, Chevrolet, GMC Full-Size Pickup and/or Utility Trucks with 4.8L, 5.3L, 5.7L, 6.0L or 6.2L VORTEC GEN III, GEN IV, V-8 Engine (VINs V, C, T, Z, B, 3, M, 0, J, R, U, N, Y, K, 8 - RPOs LR4, LY2, LM7, L59, L33, LC9, LH6, LMG, LY5, L31, LQ4, LQ9, L76, LY6, L92) with Active Fuel Management(TM) and E85 Flex Fuel If you encounter vehicles that exhibit the above conditions, refer to SI for the appropriate DTC(s) set. If no trouble is found, the cause may be due to an ECM ground terminal that has corroded with rust over time. Inspect the main engine wiring harness ground terminal (G103) for this condition. The wire terminal (G103) attaches either to the front or to the rear of the right side cylinder head, depending on the model year of the Full Size Pickup and/or Utility Trucks. If the ECM ground terminal has been found to be corroded, then follow the service procedure outlined in this bulletin to correct the corrosion issue. Remove either the nut or bolt securing the main engine wiring harness ground terminal (G103) to the right cylinder head. Refer to the above illustration to determine where the ground is located on the vehicle (1). Diagrams Cruise Control Module: Diagrams Cruise Control Module (CCM) Part 1 Page 3647 7. Reposition the inlet heater hose clamp (4) from the auxiliary water pump (1). 8. Remove the inlet heater hose (6) from the auxiliary water pump (1). INSTALLATION PROCEDURE 1. Install the inlet heater hose (6) to the auxiliary water pump (1). 2. Position the inlet heater hose clamp (4) to the auxiliary water pump (1). 3. Install the inlet heater hose to the engine. 4. Position the inlet heater hose clamp to the engine. IMPORTANT: Align the arrow at the throttle body end of the duct with the throttle body attaching stud. Page 14897 1. Remove the screws retaining the power seat switch bezel. 2. Disconnect the electrical connectors. 3. Remove the lumbar support switch. 4. Remove the power seat adjuster switch assembly. INSTALLATION PROCEDURE 1. Install the power seat adjuster switch assembly to the seat switch bezel. 2. Install the lumbar support switch to the seat switch bezel. 3. Connect the electrical connectors. NOTE: Refer to Fastener Notice in Service Precautions. 4. Install the screws retaining the power seat switch bezel. Tighten Tighten the screws to 2 N.m (18 lb in). Seat Switch Replacement - Power SEAT SWITCH REPLACEMENT - POWER REMOVAL PROCEDURE Page 3247 Steps 14 - 15 The number(s) below refer to the step(s) in the diagnostic table. 2. The chirping noise may not be engine related. This step is to verify that the engine is making the noise. If the engine is not making the noise do not proceed any further in this table. 3. The noise may be an internal engine noise. Remove the drive belt(s) and operate the engine for a few seconds, this will verify if the chirping noise is related to the drive belt(s) or not. With the drive belt(s) removed the water pump will not operate and the engine may overheat. Also diagnostic trouble codes (DTCs) may set when the engine is operated with the drive belt(s) removed. 4. Inspect the drive belt(s) for signs of pilling. Pilling is the small balls, pills, or strings in the drive belt grooves caused by the accumulation of rubber dust. 6. Misalignment of the accessory drive pulley(s) may be caused from improper mounting or incorrect installation of an accessory drive component, or the pulley may be bent inward or outward from a previous repair. Test for a misaligned accessory drive pulley using a straight edge in the pulley grooves across two or three pulleys. If a misaligned pulley is found, refer to that accessory drive component for the proper removal and installation procedure for that pulley. 10. Inspection of the fasteners can eliminate the possibility that a incorrect bolt, nut, spacer, or washer was installed. 12. Inspection of the accessory drive pulley(s) should include inspecting for bends, dents, or other damage to the pulley(s) that would prevent the drive belt(s) from seating properly in the pulley grooves or on the smooth surface of the pulley when the back side of the drive belt is used to drive the pulley. 14. Replacing the drive belt(s) when it is not damaged or there is not excessive pilling will only be a temporary repair. Drive Belt Excessive Wear Drive Belt Excessive Wear Diagnosis Diagnostic Aids Excessive wear on a drive belt(s) is usually caused by incorrect installation or the incorrect drive belt(s) for the application. Minor misalignment of the accessory drive pulley(s) will not cause excessive wear, but will probably cause the drive belt(s) to make a noise or fall off. Excessive misalignment of the accessory drive pulley(s) will cause excessive wear and may also make the drive belt(s) fall off. Test Description Page 2064 Alignment: Service and Repair Front Wheel Alignment Front Caster and Camber Adjustment Front Caster and Camber Adjustment 1. Important: Caster measurements or valves must be compensated for the measured frame angle. Caster is relative to frame, the caster values must be compensated for the measured frame angle by using a digital protractor or equivalent on a flat portion of the frame in front of the rear tire. 2. Frame angle is positive when higher in the rear. Measure both sides of the frame and take an average from those measurements. Then add the average frame angle to the caster reading when making adjustments. 3. Frame angle is negative when lower in the rear. Measure both sides of the frame and take an average from the measurements. Then subtract the Page 11794 1. Install the cable retainers to the roof and pillar. 2. Connect the cables (3) to the module. 3. Connect the cables to the antenna base. IMPORTANT: Ensure the cables are routed properly and there is no sharp bends in the cables. 4. Install the headliner. 5. Install the I/P trim panel. Junction Block - I/P Relay Box: Locations Junction Block - I/P Location View Location View Page 3214 19. Remove the positive crankcase ventilation (PCV) hose. 20. Loosen the valve rocker arm cover bolts. 21. Remove the valve rocker arm cover. Page 8065 Parts Information Place unused material on dealer shelf for future use. Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Brakes/Wheels - Excessive Debris Build Up Wheels: All Technical Service Bulletins Brakes/Wheels - Excessive Debris Build Up Bulletin No.: 04-05-23-005 Date: June 22, 2004 INFORMATION Subject: Availability of Rear Wheel Mud Flaps to Reduce Debris Build-up on Rear Brake Calipers and/or Rear Wheels Models: 1999-2004 Chevrolet Silverado Pickup Models 1999-2004 GMC Sierra Pickup Models This bulletin is to inform dealers of the release of rear wheel mud flaps. The above models that are exposed to extensive off-paved roads may benefit from the mud flaps. The mud flaps have been developed to minimize the amount of stones and/or mud that can impact and collect on the rear caliper and/or wheel rim. Please advise customers that the installation of these mud flaps and following the recommended off-road driving information provided in their Owner's Manual should greatly reduce the possibility of accelerated rear brake component wear and/or rim damage. Install the mud flap forward of each rear wheel using the following procedure. Important: Always work from outboard to inboard, drilling one hole at a time and securing with a fastener. Follow the sequence of the procedure. This will prevent distortion of the mud flap. 1. Raise the vehicle. Support the vehicle. 2. Locate the pickup box side panel rear brace. 3. Remove the existing outboard upper fastener on the brace. 4. Install the mud flap through the "V" of the brace. Install the previously removed fastener in the hole (2) of the mud flap to the brace. Do not tighten the fastener at this time. 5. Using the mud flap as a template, locate and mark the location of the hole (1) in the pickup box wheel house. Page 5368 1. Install the fuel and EVAP bundle. NOTE: Refer to Fastener Notice in Service Precautions. 2. If vehicle is a crew cab or extended cab, install the fuel and EVAP bundle clip nuts. Tighten Tighten the nuts to 12 N.m (106 lb in). 3. If vehicle is a regular cab, install the fuel and EVAP bundle clip nuts. Tighten Tighten the nuts to 12 N.m (106 lb in). 4. Remove the caps from the fuel and EVAP lines at the fuel tank. 5. Connect the fuel and EVAP quick connect fittings. 6. If equipped with 4WD, install the torsion bar bracket. Page 16237 Rear Door Window Glass Weatherstrip: Service and Repair Door Window Sealing Strip Sealing Strip Replacement - Rear Door Window Belt Outer Removal Procedure Important: The outer belt sealing strip seals between the inner and outer door panels and the window at the belt line. The outer sealing strip is replaceable. Do not remove the inner sealing strip, because the strip is attached to the glass run channel. 1. Lower the window. 2. Remove the outer sealing strip from the door. Installation Procedure 1. Align the sealing strip in place. Lower and press the strip into place. 2. Raise the window. Page 15943 High Temperature Conditions Tools Required J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency MEASURING FREQUENCY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage MEASURING VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop MEASURING VOLTAGE DROP NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Page 4525 Control Module References Part 6 Page 9913 Note The rivet stud and surrounding panel area MUST BE properly refinished PRIOR to the installation of the electrical ground wire terminal and conductive nut to maintain a secure, stable and corrosion-free electrical ground. 11. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 12. Allow the refinished repair area to cure sufficiently before removing the protective material applied to the rivet stud threads. 13. Remove the painters tape or equivalent from the rivet stud threads. 14. Using GM approved residue-free solvent or equivalent, thoroughly clean the rivet stud threads to remove any adhesive and allow to dry. 15. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive rivet stud. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 16. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 17. Install the electrical ground wire terminal to the M6 conductive rivet stud. 18. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 19. Install the M6 conductive nut to the rivet stud and: Tighten Tighten to 8 Nm (71 lb in) 20. Verify proper system operation. Parts Information Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use: Warranty Information (Saab Models) Page 2421 Air Conditioning - Diagnose A/C Low Pressure Switch Low Pressure Sensor / Switch: Technical Service Bulletins Air Conditioning - Diagnose A/C Low Pressure Switch INFORMATION Bulletin No.: 04-01-38-010A Date: January 21, 2010 Subject: Diagnostic Information to Accurately Diagnose A/C Low Pressure Switch Using Kent Moore Special Tool GE-47742 Models: 2002-2006 Cadillac Escalade, Escalade EXT 2003-2006 Cadillac Escalade ESV 1999-2007 Chevrolet Silverado 2000-2006 Chevrolet Suburban, Tahoe 2002-2007 Chevrolet Avalanche 1999-2007 GMC Sierra 2000-2006 GMC Yukon, Yukon XL 2001-2006 GMC Yukon Denali XL 2001-2007 GMC Sierra Denali, Yukon Denali XL 2003-2008 HUMMER H2 with Air Conditioning Supercede: This bulletin is being revised to update the model years. Please discard Corporate Bulletin Number 04-01-38-010 (Section 01 - HVAC). Currently, technicians cannot accurately determine the air conditioning (A/C) low pressure switch open/close pressure point by measuring pressure at the low side service port. This is because the evaporator is between the low side service port and the A/C low pressure switch. Correlating pressures measured at the low side service port to actual pressures at the A/C low pressure switch port is difficult because of the multiple variables that impact pressure drop across the evaporator. Providing a pressure range that would take into account all these variables would result in a pressure range that would be too broad to be useful for diagnostic purposes. Kent Moore special tool GE-47742 will allow technicians to monitor the actual pressures at which the A/C low pressure switch opens and closes under actual operating conditions. Technicians are to use the following steps to install and use Kent Moore special tool GE-47742 to measure A/C low pressure switch opening and closing pressures: 1. Disconnect the wire harness from the A/C low pressure switch. 2. Remove the A/C low pressure switch from the accumulator. 3. Install the A/C low pressure switch, using the threaded port with an O-ring, onto special tool GE-47742. 4. Install special tool GE-47742, with the A/C low pressure switch attached, onto the accumulator. Important Removing the seal from the A/C low pressure switch wire harness connector is required. Failure to remove the seal before plugging it into the switch will lead to misdiagnosis. The "plunger effect" of plugging the connector with a seal into the A/C low pressure switch induces a pressure on the back side of the switch. This pressure will skew the opening/closing characteristics of the switch 34-69 kPa (5-10 psi) until the pressure bleeds off. The time required for the connection induced pressure to bleed off can be 20 minutes or longer. 5. Remove the seal from the A/C low pressure switch wire harness connector. 6. Connect the wire harness, without the seal, to the A/C low pressure switch. 7. Connect the low side service hose from the ACR2000(R) or GE-48800 to the service port on special tool GE-47742. 8. Connect a Tech2(R) to the vehicle. 9. Start the vehicle and maintain an engine speed of 1500 RPM. Set the HVAC controls as follows: - Set the A/C control switch to ON. - Set the mode control switch to A/C and engage recirculation mode. - Set the blower motor speed to LOW. - Set the temperature control to full cold. - Set the auxiliary blower motor speed to LOW. If equipped. - Set the auxiliary temperature control to full cold. If equipped. - The vehicle must be operating with no sun load (in the shade). 10. Use the Tech2(R) to determine the A/C low pressure switch status and the ACR2000(R) or GE-48800 to determine the A/C low side pressure. Simultaneously monitor the switch status and the pressure at which the A/C low pressure switch opens and closes. The Tech2(R) will display switch status as "Normal" for Closed and "Low Pressure" for Open. A properly operating switch should open between 138-172 kPa (20-25 psi) Page 369 8.2. Remove the console (A) together with the OnStar(R) control modules. 8.3. Remove the connectors (B). Important: The optic cable must not be bent with a radius less than 25 mm (1 in). Important: Secure the wiring harness so that there is no risk of chafing and rattling. 8.4. Fold back the wiring harness and tape over the connectors (C). Fold back the wiring harness once more and secure with cable ties (D). Page 3360 19. If equipped, install the oil pan skid plate. 20. Install the oil pan skid plate bolts. ^ Tighten the bolts to 20 Nm (15 ft. lbs.). 21. Install the transmission cover bolts ^ Tighten the bolt to 12 Nm (106 inch lbs.). 22. Raise the front drive axle into position. 23. If equipped with 4WD, install the differential carrier upper mounting bolt and nut until snug. Do not tighten at this time. 24. If equipped with 4WD, install the differential carrier lower mounting bolt and nut. ^ Tighten the bolts to 100 Nm (75 ft. lbs.). Page 9207 C210 Brake/Clutch Harness To Beacon Harness (With RPO Codes 5G4/TRW) Page 12217 4.1. Unplug the SRS control module's connector (A). 4.2. Cut off the cable tie (B), detach the connector's rear end face (C), and pull out the connecting rail (D). 4.3. Extract pin 15, cut off the cable terminal and insulate the end with tape (E). Fold back the cable and secure it with tape (F). 4.4. Fit the connecting rail and end face. 4.5. Plug in the connector (A) and secure the cables with cable ties (B). 5. Remove the parcel shelf trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6. M03: Replace the optic cable on the right-hand side Service Precautions Jump Starting: Service Precautions CAUTION: Batteries produce explosive gases. Batteries contain corrosive acid. Batteries supply levels of electrical current high enough to cause burns. Therefore, in order to reduce the risk of personal injury while working near a battery, observe the following guidelines: - Always shield your eyes. - Avoid leaning over the battery whenever possible. - Do not expose the battery to open flames or sparks. - Do not allow battery acid to contact the eyes or the skin. - Flush any contacted areas with water immediately and thoroughly. - Get medical help. Page 2037 Washer Fluid Level Switch Page 12314 Electrical Symbols Part 4 Tire/Wheel - Spare Tire Is Non-Matching To Other Tires Spare Tire: All Technical Service Bulletins Tire/Wheel - Spare Tire Is Non-Matching To Other Tires INFORMATION Bulletin No.: 02-03-10-001E Date: November 01, 2010 Subject: Spare Tire is a Different Size than Other Tires Models: 2002-2011 Cadillac Escalade Models 1999-2007 Chevrolet Silverado (Classic) 2000-2011 Chevrolet Suburban, Tahoe 2002-2011 Chevrolet Avalanche 1999-2007 GMC Sierra (Classic) 2001 GMC Sierra C3 2001-2011 GMC Yukon Models 2002-2011 GMC Sierra Denali Supercede: This bulletin is being revised to update the model years. Please discard Corporate Bulletin Number 02-03-10-001D (Section 03 - Suspension). This bulletin is being issued to supply additional information concerning the spare tire on the above vehicles. You or your customers may have noticed that the spare tire has a 16-inch diameter steel wheel or 17-inch diameter aluminum wheel while the road tires have a 17-inch, 18-inch, 20-inch or 22-inch diameter aluminum wheel. Although the spare tire has a different wheel diameter and may be a different brand, the rolling circumference is nearly identical to the road tires. The size difference will not cause a concern because the spare and the other tires will travel the same distance in one revolution. This combination of non-matching tires is used most often on full-size trucks. These vehicles use a road tire and wheel combination that may be too large to conveniently fit the storage compartment space of the vehicle. The customer may not be able to easily remove the spare tire/wheel from the storage area because of its size and/or weight. A steel spare wheel, rather than an aluminum one, may be used since the spare is stowed under the vehicle where it is exposed to road and weather elements. A steel wheel is less likely to incur cosmetic damage while in the stowed position for long periods of time. Please provide this information to your customers. Also, remind your customers of the importance of following the tire maintenance schedule as listed in their Owner Manual. Additional tire care information can be found by visiting www.gmtiresafety.com or contacting GM toll-free. Disclaimer Interior - Erratic Memory Seat Operation Memory Positioning Module: Customer Interest Interior - Erratic Memory Seat Operation Bulletin No.: 04-08-50-016C Date: August 12, 2005 TECHNICAL Subject: Memory Seat May Not Return to Requested Position (Reprogram Driver Seat Module) Models: 2003-2005 Cadillac Escalade, Escalade ESV, Escalade EXT 2003-2005 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2003-2005 GMC Sierra, Yukon, Yukon XL, Yukon Denali All with Seat FRT, Individual (Non BKT) (RPO AN3) 2003-2005 HUMMER H2 with Seat, Front Bucket Deluxe (RPO AR9) Supercede: This bulletin is being revised to update the correction information. Please discard Corporate Bulletin Number 04-08-50-016B (Section 08 - Body and Accessories). Condition Some customers may comment that with repeated cycling of the memory seat between the "exit" and one of the "presets", the position of the seat may "creep" forward or rearward out of expected adjustment. Cause There is a coding deficiency in the software for the memory seat module. Correction Technicians are to reprogram the driver seat module with an updated software calibration. The previous bulletin stated to use a service calibration that was released with TIS satellite data update version 4.5. Feedback has proved that calibration to be ineffective in eliminating the memory seat creep condition. An updated service calibration was released with TIS satellite data update version 6.5 available June 13, 2005. This new calibration has additional memory seat creep protection. As always, make sure your Tech 2(R) is updated with the latest software version. Important: After programming is complete, move the seat all the way rearward and down, then bump the seat slightly forward and up. This position will be just off the end of travel hard stops. Reset both memory seat exit positions at this position. Having the seat set at just off the hard stops will aid in reducing the creep condition. Warranty Information Page 470 Electrical Symbols Part 8 Page 4257 Air Induction Components Page 10263 Control Module References Part 6 Page 3820 Control Module References Part 6 Page 9760 C306 Infotainment Jumper Harness To Console Harness (With RPO Code Y91) Part 2 Fuel Pressure Gage Installation and Removal Fuel Pressure: Testing and Inspection Fuel Pressure Gage Installation and Removal FUEL PRESSURE GAGE INSTALLATION AND REMOVAL INSTALLATION PROCEDURE TOOLS REQUIRED J 34730-1A Fuel Pressure Gage CAUTION: - Refer to Gasoline/Gasoline Vapors Caution in Service Precautions. - Refer to Fuel Gage Leak Caution in Service Precautions. 1. Remove the engine sight shield. 2. Remove the fuel rail pressure fitting cap. 3. Connect the J 34730-1A to the fuel pressure valve. Wrap a shop towel around the fitting while connecting the gage in order to avoid spillage. 4. Install the bleed hose on J 34730-1A into an approved container. REMOVAL PROCEDURE 1. Remove the bleed hose on the J 34730-1A from the approved container. 2. Remove the shop towel from around the fitting and discard into an approved container. 3. Disconnect the J 34730-1A from the fuel pressure valve. 4. Install the fuel rail pressure fitting cap. 5. Install the engine sight shield. Locations Engine Oil Pressure (EOP) Sensor And CMP Sensor Page 7762 3. Remove the right rear speed sensor. Installation Procedure 1. Notice: Refer to Fastener Notice in Service Precautions. Install the right rear speed sensor. ^ Tighten the speed sensor to 15 Nm (11 ft. lbs.). 2. Connect the right rear speed sensor electrical connector (3). 3. Lower the vehicle. Page 7516 1. Disconnect the shift control module electrical connectors. 2. Unsnap and remove the shift control module from the bracket. Installation Procedure Page 2683 Relay Block - I/P C1 Part 1 Page 9592 Relay Block - I/P C1 Part 3 Page 6102 6. Install the J 29714-A. 7. Compress the servo cover with J 29714-A. Important: Flat-faced servo cover retaining rings that have been removed when servicing a transmission for any reason should not be re-used. 8. Remove the servo cover retaining ring. 9. Install the new round wire servo cover ring, P/N 24232065. 10. Remove J 29714-A. 11. Clean the servo cover area with Brake Clean and shop air. 12. Lower the vehicle. 13. Fill the transmission to the proper level with DEXRON(R)III transmission fluid. Refer to the appropriate SI Document. Parts Information Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use the table. Page 9007 Fuse Block - Underhood C1 Part 1 Page 3967 Fuel Level Sensor: Description and Operation Fuel System Description (Cab Chassis) FUEL LEVEL SENSOR The fuel level sensor is a part of the fuel sender assembly. The position of the float arm indicates the fuel level. The fuel level sensor contains a variable resistor which changes resistance in correspondence with the amount of fuel in the fuel tank. On models that are equipped with a single fuel tank, the fuel level sensor is wired directly to the instrument panel (IP) cluster. On models equipped with dual fuel tanks, both fuel level sensors are wired to the PCM. The PCM calculates the total fuel level in both tanks. The instrument panel (IP) fuel gage displays the total fuel level in both fuel tanks. Page 9521 Fuse Block - Underhood - Secondary Wire Entry (With RPO Code HP2) Part 4 Capacity Specifications Fluid - Differential: Capacity Specifications Differential Fluid Capacity Differential Oil Capacity Front Drive Axle (8.25") ....................................................................................................................... ............................................ 1.43 liters (1.51 quarts) Front Drive Axle (9.25") .................................... ............................................................................................................................... 1.73 liters (1.83 quarts) Rear Drive Axle (8.6") ............................................................................................................. ......................................................... 2.03 liters (2.15 quarts) Rear Drive Axle (9.5") .......................... ............................................................................................................................................ 2.60 liters (2.75 quarts) Rear Drive Axle (9.75") .................................................................................................. .................................................................. 2.84 liters (3.00 quarts) Rear Drive Axle (10.5") ............... ..................................................................................................................................................... 2.60 liters (2.75 quarts) Rear Drive Axle (11.5") .......................................................................................... .......................................................................... 3.00 liters (3.17 quarts) Lubricant Level - 8.6 Inch Axle Differential Oil Capacity Capacity .................................................................................................................................................... 15-40 mm from bottom edge of the fill plug hole Lubricant Level - 9.5, 10.5 Inch Axles Differential Oil Capacity Capacity ............................................................................................................................................... ........................ 0-10 mm below the fill plug opening Lubricant Level - 9.75 Inch Axel Differential Oil Capacity Capacity ............................................................................................................................................... .......................... 0-4 mm below the fill plug opening Lubricant Level - 11.5 Inch Axle Differential Oil Capacity Capacity ............................................................................................................................................... ...................... 17-21 mm below the fill plug opening Page 9829 Junction Block - I/P Wire Entry Part 3 Page 3867 Remove all rust from the ground terminal, the cylinder head and the retaining nut or bolt. Position the main engine wiring harness ground terminal and install the nut or bolt. Tighten: Tighten the retaining nut or bolt to 16 N.m (12 lb ft). Apply some type of electrical moisture sealant to protect the harness terminal from further corrosion. Disclaimer Page 14164 2.2. Press together the top and the bottom covers. 2.3. Inspect the operation of the transmitter. 3. Synchronize the transmitter. Refer to Transmitter Synchronization. Page 5745 Page 6846 1. Important: The mating surface of the ring gear and the differential case must be clean and free of burrs before installing the ring gear. Install the ring gear to the differential case. 2. Important: The ring gear bolts on the 8.6 inch and the 9.5 inch axles have left-hand threads. The ring gear bolts on the 11.5 inch axle have right-hand threads. Install the new ring gear bolts.Hand start each bolt to ensure that the ring gear is properly installed to the differential case. 3. Notice: Refer to Fastener Notice in Service Precautions. ^ Tighten the ring gear bolts, Tighten the ring gear bolts alternately and in stages, gradually pulling the ring gear onto the differential case. ^ For the 8.6 inch axle, tighten the ring gear bolts in sequence to 120 Nm (89 ft. lbs.). ^ For the 9.5 inch axle, tighten the ring gear bolts in sequence to 140 Nm (103 ft. lbs.). ^ For the 11.5 inch axle, tighten the ring gear bolts in sequence to 237 Nm (175 ft. lbs.). 4. Install the pinion bearing cups. 5. Determine the selective shim thickness for the pinion gear. 6. Install the selective shim onto the pinion. 7. Install the inner pinion bearing to the pinion. 8. Install a new collapsible spacer. 9. Lubricate the pinion bearings with axle lubricant. 10. Install the outer pinion bearing into the axle housing. 11. Install the new pinion oil seal. 12. Install the pinion into the axle housing. 13. Install the pinion yoke. 14. Install the differential assembly. 15. Fill the axle with lubricant. Use the proper fluid. 16. Lower the vehicle. 9.75 Inch Axle Drive Pinion and Ring Gear Replacement (9.75 Inch Axle) ^ Tools Required J 22536 Pinion Driver Removal Procedure 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Remove the differential assembly. 3. Remove the drive pinion yoke and the pinion oil seal. Page 1460 Steering Wheel And Column Sub-System Components Page 6026 6. Remove the 1-2 shift solenoid retainer (395) and the 1-2 shift solenoid (267A). 7. Remove the 2-3 shift solenoid retainer (395) and the 2-3 shift solenoid (367A). 8. Remove the 3-2 control solenoid retainer (395) and the 3-2 control solenoid (394). Installation Procedure 1. Install the 3-2 control solenoid (394) and the 3-2 control solenoid retainer (395). Page 7104 Flex Plate: Specifications Flywheel to Converter Automatic Transmission - 4L80-E/4L85-E Flywheel to Converter .......................................................................................................................... .................................................... 43 Nm (32 ft. lbs.) Automatic Transmission - 4L60-E/4L65-E Flywheel to Torque Converter Bolts ........................................................................................................................................................ 63 Nm (46 ft. lbs.). Page 5573 Tighten Tighten the bolts to 8 N.m (71 lb in). 3. If equipped with RPO HP2, position the cable (w/bracket) and install the 3-phase cable bracket to the studs. 4. Install the 3-phase cable bracket nuts. Tighten Tighten the nuts to 15 N.m (11 lb ft). 5. If equipped with RPO HP2, install the 3-phase cable to the SGCM. 6. Install the 3-phase cable nuts to the SGCM. Tighten Tighten the nuts to 9 N.m (80 lb in). 7. Install the SGCM cover and bolts. Tighten Tighten the bolts to 9 N.m (80 lb in). Page 8522 13. Using a clean shop towel, clean up any fluid that may have leaked out of the hydraulic brake booster when removing the original valve. 14. Position the master cylinder (and brake combination valve mounting bracket on full size pickups and utilities) on the mounting bolts on the hydraulic brake booster. 15. With the master cylinder mounted flush to the booster, install the nuts. Tighten Tighten the nuts to 33 N.m (24 lb ft). 16. On van models, install the diagonal brace with the water deflector attached to it between the left fender and the radiator. Install the two bolts. Tighten Tighten bolts to 25 N.m (18 lb ft). 17. Start the engine and verify the hydraulic brake booster operation. 18. Turn the engine OFF and check the power steering fluid reservoir. Add fluid if necessary. 19. Close the hood. Page 11624 Disclaimer Page 9775 C330 Body Harness To Passenger Seat Harness (With RPO Code AL0) Page 16296 Wiper Blade: Service and Repair Wiper Blade Element Replacement WIPER BLADE ELEMENT REPLACEMENT REMOVAL PROCEDURE IMPORTANT: Replace the wiper blade element if it is removed from the wiper blade. 1. Remove the wiper blade from the wiper arm. 2. Remove the bottom claws (2) of the wiper blade (1) from the notches in the wiper blade element (3). 3. Pull the wiper blade element (3) out through the wiper blade claws (2). INSTALLATION PROCEDURE IMPORTANT: Keep the wiper blade claws in the rubber claw channel of the wiper blade element. Do not allow the claws of the wiper blade to contact the metal spline of the wiper blade element. 1. Insert the open end of the wiper blade element (3) into the bottom claws of the wiper blade (2). 2. Guide the wiper blade element (3) through the wiper blade (1) claw sets. 3. Engage the bottom claw (2) of the wiper blade (1) into the notches in wiper blade element (3). 4. Install the wiper blade onto the wiper arm. TPMS System - Service And Re-Learning Sensor IDs Tire Pressure Sensor: Technical Service Bulletins TPMS System - Service And Re-Learning Sensor IDs INFORMATION Bulletin No.: 10-03-16-001 Date: July 19, 2010 Subject: TPMS System Service and Re-Learning Sensor IDs Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks 2010 and Prior HUMMER H2 2009 and Prior HUMMER H3 2010 and Prior Saturn Models 2009 and Prior Saab 9-7X with Wheel-Mounted Tire Pressure Sensors In the event that the spare tire, which is normally not equipped with a tire pressure monitor (TPM) sensor, is installed in place of one of the road tires and the vehicle is driven above 40 km/h (25 mph) for 20 minutes or more, the TPM indicator icon on the instrument panel cluster (IPC) will flash for approximately one minute and then remain on steady each time the ignition is turned ON, indicating a diagnostic trouble code (DTC) has been set. The driver information center (DIC), if equipped, will also display a SERVICE TIRE MONITOR type message. When the road tire is repaired and reinstalled in the original location, the TPM indicator icon illumination and DIC message may remain displayed until the DTC is cleared. To ensure that the TPM indicator and the DIC message are cleared after service, it is necessary to clear any TPM DTCs using a scan tool. If a scan tool is unavailable, performing the TPM relearn procedure using a TPM diagnostic tool will provide the same results. It is advised to perform the relearn procedure away from other vehicles to prevent picking up a stray sensor signal. If one or more of the TPM sensors are missing or damaged and have been replaced, then the relearn procedure must be performed. Disclaimer Restraints - Seat Belt Warning Lamp On/Buckling Issues Seat Belt Buckle: All Technical Service Bulletins Restraints - Seat Belt Warning Lamp On/Buckling Issues INFORMATION Bulletin No.: 09-09-40-001A Date: February 02, 2011 Subject: Seat Belt Buckle Latching Issues and/or Seat Belt Warning Lights Illuminated Models: 2011 and Prior GM Passenger Cars and Trucks (Including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7 X Supercede: This bulletin is being revised to add the 2011 model year. Please discard Corporate Bulletin Number 09-09-40-001 (Section 09 - Restraints). This bulletin is being published to advise dealers about seat belt buckles not operating and/or seat belt warning light illumination, as well as difficulty latching and unlatching the buckle or the buckle release button sticking. Analysis of warranty data has determined that this condition may be caused by sticky beverages being spilled onto or into the seat belt buckle assembly. Foreign debris from food, candy wrappers, paper and coins can also contribute to this condition. Important If foreign material (debris) or sticky liquids are the cause of the concern, show the customer the condition of the component (buckle assembly) and explain how it is affecting the function of the restraint system. Strongly recommend that the component be replaced. Point out the fact that this is not a manufacturing defect and is not covered by the new vehicle warranty. If the customer declines to have parts replaced, the service department management must make a notation on the service record that the lack of functionality of seating position with an inoperative buckle was fully explained to the customer. The service department management must advise the customer that having a non-functioning buckle in a seating position voids ability to use that seating position (no one should ride in the seat). Also make the customer aware that it may be against the law to ride in a vehicle without wearing a restraint system. Important Never insert anything other than the seat belt latch plate into the buckle assembly. Do not attempt to dig anything out of a buckle with a tool. Never try to wash out a buckle to remove a spilled liquid as this may damage the buckle. Use the following steps to determine the cause of the concern. 1. Inspect the buckle assembly with a light shining on the latch plate insertion area. Look for any debris or foreign objects in the buckle. 2. If any debris or foreign objects are observed, try to vacuum out the item. After the foreign material is removed, latch and unlatch the seat belt. If the system functions properly, do not replace the seat belt buckle assembly. 3. If the condition has not been corrected, inspect the buckle assembly for any sticky residue. If sticky residue is found, inform the customer that a substance was spilled on the seat belt buckle assembly causing the malfunction. The buckle assembly will need to be replaced at the customer's expense. 4. Refer to SI for seat belt component replacement. Important If foreign material (debris) or sticky liquids are the cause of the concern, show the customer the condition of the component (buckle assembly) and explain how it is affecting the function of the restraint system. Strongly recommend that the component be replaced at the customer's expense. Point out the fact that this is not a manufacturing defect and is not covered by the new vehicle warranty. If the customer declines to have parts replaced, the service department management must make a notation on the service record that the lack of functionality of seating position with an inoperative buckle was fully explained to the customer. The service department management must advise customer that having a non-functioning buckle in a seating position voids ability to use that seating position (no one should ride in the seat). Also make the customer aware that it may be against the law to ride in a vehicle without wearing a restraint system. 5. If further restraint diagnosis is required, refer to Seat Belt System Operational and Functional Checks in SI. Page 13397 Electrical Symbols Part 10 Page 2007 circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links CIRCUIT PROTECTION - FUSIBLE LINKS Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Flat Wire Repairs FLAT WIRE REPAIRS NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Heated Oxygen Sensor (HO2S) Wiring Repairs HEATED OXYGEN SENSOR (HO2S) WIRING REPAIRS TOOLS REQUIRED J 38125-D Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: - Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-D. Repairing Damaged Wire Insulation REPAIRING DAMAGED WIRE INSULATION Locations Ambient Light Sensor Page 5501 Accelerator Pedal Position Sensor: Description and Operation ACCELERATOR PEDAL POSITION (APP) SENSOR The accelerator pedal assembly contains 2 individual APP sensors within the assembly. The APP sensors 1 and 2 are potentiometer type sensors, each with the following circuits: - A 5-volt reference circuit - A low reference circuit - A signal circuit The APP sensors are used to determine the pedal angle. The control module provides each APP sensor a 5-volt reference circuit and a low reference circuit. The APP sensors then provide the control module with signal voltage proportional to pedal movement. Both APP sensor signal voltages are low at rest position and increase as the pedal is applied. Page 14287 WA5456/43 - WA7156/46 Page 9225 C275 Steering Column Harness To Steering Wheel Module Coil (With RPO Code AL0) Page 5461 Fuel Tank Unit: Service and Repair FUEL SENDER ASSEMBLY REPLACEMENT TOOLS REQUIRED J 45722 Fuel Sender Lock Ring Wrench REMOVAL PROCEDURE 1. Remove the fuel tank. 2. Disconnect the fuel line from the sending unit. 3. Disconnect the evaporative emission (EVAP) line from the sending unit. 4. Using J 45722 remove the sending unit lock ring. CAUTION: Drain the fuel from the fuel sender assembly into an approved container in order to reduce the risk of fire and personal injury. Never store the fuel in an open container. 5. Remove the sending unit and seal. Discard the seal. 6. Clean the sending unit sealing surfaces. INSTALLATION PROCEDURE CAUTION: In order to reduce the risk of fire and personal injury that may result from a fuel leak, always replace the fuel sender gasket when reinstalling the fuel sender assembly. IMPORTANT: The fuel strainer must be in a horizontal position when installing the sending unit is installed in the tank. When installing the sending unit, assure that the fuel strainer does not block full travel of the float arm. 1. Install a NEW sending unit seal. 2. Install the sending unit. Page 10666 hot particles embed themselves in the chrome layer and create a small pit. If the material is allowed to sit on the wheel while it is exposed to moisture or salt, it will corrode the wheel beneath the chrome leaving a pit or small blister in the chrome. Heavy brake dust build-up should be removed from wheels by using GM Chrome Cleaner and Polish, P/N 1050173 (in Canada use 10953013). For moderate cleaning, light brake dust build-up or water spots use GM Swirl Remover Polish, P/N 12377965 (in Canada, use Meguiars Plast-X(TM) Clear Plastic Cleaner and Polish #G12310C**). After cleaning, the wheel should be waxed using GM Cleaner Wax, P/N 12377966 (in Canada, use Meguiars Cleaner Wax #M0616C**), which will help protect the wheel from brake dust and reduce adhesion of any brake dust that gets on the wheel surface. For general maintenance cleaning, PEEK Metal Polish† may be used. It will clean and shine the chrome and leave behind a wax coating that may help protect the finish. Warranty of Stardust Corroded Chrome Wheels Wheels returned with pitting or spotting as a result of neglect and brake dust build-up may be replaced one time. Important Notify the customer that this is a one time replacement. Please stress to the customer the vital importance of keeping the wheels clean and free of prolonged exposure to brake dust build-up. "GM of Canada" dealers require prior approval by the District Manager - Customer Care and Service Process (DM-CCSP). Customer Assistance and Instructions GM has looked for ways customers may improve the appearance of wheels damaged by acidic cleaners. The following product and procedure has been found to dramatically improve the appearance of stained wheels. For wheels that have milky stains caused by acidic cleaners try the following: Notice THE 3M CHROME AND METAL POLISH REQUIRED FOR THIS PROCEDURE IS AN EXTREMELY AGGRESSIVE POLISH/CLEANER. THE WHEELS MUST BE CLEANED BEFORE APPLICATION TO AVOID SCRATCHING THE WHEEL SURFACE. THIS PRODUCT WILL REDUCE THE THICKNESS OF THE CHROME PLATING ON THE WHEEL AND IF USED INCORRECTLY OR EXCESSIVELY MAY REMOVE THE CHROME PLATING ALL TOGETHER, EXPOSING A LESS BRIGHT AND BRASSY COLORED SUB-LAYER. FOLLOW INSTRUCTIONS EXACTLY. 1. Wash the wheels with vigorously with soap and water. This step will clean and may reduce wheel staining. Flood all areas of the wheel with water to rinse. 2. Dry the wheels completely. Notice Begin with a small section of the wheel and with light pressure buff off polish and examine results. ONLY apply and rub with sufficient force and time to remove enough staining that you are satisfied with the results. Some wheels may be stained to the extent that you may only achieve a 50% improvement while others may be able to be restored to the original lustre. IN ALL CASES, only apply until the results are satisfactory. 3. Apply 3M Chrome and Metal Polish #39527* with a clean terry cloth towel. As you apply the polish, the staining will be diminished. 4. When dry, buff off the polish with a clean portion of the towel. 5. Repeat application of the 3M Chrome and Metal Polish until satisfied with the results. If continued applications fail to improve the appearance further discontinue use. This procedure will improve the appearance of the wheels and may, with repeated applications, restore the finish dramatically. For wheels that exhibit spotting from road chemicals the above procedure may marginally improve the condition but will not restore the finish or remove the pitting. In this type of staining the wheel finish has actually been removed in spots and no manner of cleaning will restore the finish. †*We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Parts Information Page 9431 6. Use fingers to squeeze the 2 locking legs of the cover. 7. Apply pressure and gently rock the cover until one locking leg is unseated. 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. Page 8229 6. Remove the park brake cable from the park brake actuator lever. 7. Remove the wheel bearing. 8. Remove the park brake shoe. 9. Remove the park brake actuator lever housing from the backing plate. 10. Remove the backing plate. Installation Procedure 1. Install the park brake actuator lever housing to the backing plate. 2. Install the park brake shoe. 3. Install the wheel bearing and adjust the park brake shoe. 4. Install the park brake cable to the park brake actuator lever. 5. Notice: Refer to Fastener Notice in Service Precautions. Install the rear park brake bracket bolt. ^ Tighten the bolt to 61 Nm (45 ft. lbs.). Interior - Erratic Memory Seat Operation Memory Positioning Module: All Technical Service Bulletins Interior - Erratic Memory Seat Operation Bulletin No.: 04-08-50-016C Date: August 12, 2005 TECHNICAL Subject: Memory Seat May Not Return to Requested Position (Reprogram Driver Seat Module) Models: 2003-2005 Cadillac Escalade, Escalade ESV, Escalade EXT 2003-2005 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2003-2005 GMC Sierra, Yukon, Yukon XL, Yukon Denali All with Seat FRT, Individual (Non BKT) (RPO AN3) 2003-2005 HUMMER H2 with Seat, Front Bucket Deluxe (RPO AR9) Supercede: This bulletin is being revised to update the correction information. Please discard Corporate Bulletin Number 04-08-50-016B (Section 08 - Body and Accessories). Condition Some customers may comment that with repeated cycling of the memory seat between the "exit" and one of the "presets", the position of the seat may "creep" forward or rearward out of expected adjustment. Cause There is a coding deficiency in the software for the memory seat module. Correction Technicians are to reprogram the driver seat module with an updated software calibration. The previous bulletin stated to use a service calibration that was released with TIS satellite data update version 4.5. Feedback has proved that calibration to be ineffective in eliminating the memory seat creep condition. An updated service calibration was released with TIS satellite data update version 6.5 available June 13, 2005. This new calibration has additional memory seat creep protection. As always, make sure your Tech 2(R) is updated with the latest software version. Important: After programming is complete, move the seat all the way rearward and down, then bump the seat slightly forward and up. This position will be just off the end of travel hard stops. Reset both memory seat exit positions at this position. Having the seat set at just off the hard stops will aid in reducing the creep condition. Warranty Information HVAC System - Manual Control Module HVAC: Diagrams HVAC System - Manual HVAC Control Module - C1 Part 1 Page 3366 Rear of the Engine Page 1716 Intake Air Temperature (IAT)/Mass Air Flow (MAF) Sensor Page 5193 INSTALLATION PROCEDURE NOTE: Refer to Fastener Notice in Service Precautions. 1. If required, install the fuel composition sensor to the bracket and install the bolts. Tighten Tighten bolts to 10 N.m (89 lb in). 2. Install the fuel composition sensor. 3. Install the fuel composition sensor nuts. Tighten Tighten nuts to 17 N.m (13 lb ft). 4. Connect the fuel pipes to the fuel composition sensor. 5. Install the fuel line retainers (1). Page 3752 6. If equipped with a 4.3L, 4.8L, or 5.3L engine, install the left exhaust manifold pipe nuts. Tighten the nuts to 50 Nm (39 ft. lbs.). 7. If equipped with a 6.0L or 8.1L engine, perform the following: 1. Connect the oxygen sensor electrical connector (1). 2. Connect the CPA retainer. 8. Remove the adjustable jackstands from catalytic converter or exhaust manifold pipe. 9. If equipped with a 4.3L, 4.8L, or 5.3L engine, perform the following: 1. Connect the oxygen sensor electrical connector (1). 2. Connect the CPA retainer. 3. Clip the oxygen sensor electrical connector to the hose clip. 10. If equipped with a 4.3L, 4.8L, or 5.3L engine, perform the following: 1. Connect the forward oxygen sensor electrical connector. Page 15077 9. Install the LH and RH rear taillamp assemblies. 10. Place the LH and RH center reinforcement into position on the pickup box. ^ On the 2.4 m (8 ft) long pickup box models, this center reinforcement fits over the existing center stake hole. ^ On the 1.7 m (5 ft., 8 in) and 2 m (6.5 ft) short box models, these center reinforcements are recommended to be installed. The reinforcements should be centered between the front and rear reinforcements on the pickup box. 12. Mark the holes necessary for drilling and remove the brackets. 13. Drill 7.5 mm (0.30 in) holes into the weld flange of the side outer panel. 14. Touch-up the drilled holes as necessary. Refer to step 6 under the Front Reinforcement Installation procedure. 15. Place the center reinforcements back onto the pickup box. 16. Install the M6 bolts through the reinforcement and side panel with the nuts. Tighten Tighten the bolts to 9 Nm (79 lb-in). 17. Remove any metal shavings from the pickup box after installation. *Maximum Equipment Weight Capacities (Equipment and Cargo) ^ Ladder Rack and Cargo - 340 kg (750 lb) ^ Cross Toolbox and Cargo - 181 kg (400 lb) ^ Side Tool Boxes and Cargo - 113 kg (250 lb) (per side) *The combined weight for all rail-mounted equipment should not exceed 454 kg (1,000 lb). Excluded is the 1500 Series Crew Cab models with 5'8" pick-up box length. A reinforcement kit for rail-mounted add-on equipment is recommended as described in this bulletin. Ladder racks are not recommended for 1500 Series Crew Cab models with 5'8"pick-up box. Maximum recommended cross-mounted tool box and cargo weight is 136 kg (300 lb) for the 1500 Series Crew Cab with 5'8"pick-up box. Connector Views Brake Lamp: Connector Views Tail/Stop Lamp - Left Page 13549 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves SPLICING COPPER WIRE USING SPLICE SLEEVES TOOLS REQUIRED J 38125-D Terminal Repair Kit IMPORTANT: Use only GM splice sleeves, other splice sleeves may not protect the splice from moisture or a provide good electrical connection. Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. Page 14864 Seat Horizontal Position Sensor - Driver (With RPO Code AN3) Page 9248 C330 Body Harness To Passenger Seat Harness (With RPO Code AL0) Page 714 Parts required to complete this special coverage are to be obtained from General Motors Customer Care and Aftersales (GMCC&A;). Service Procedure Note The resistor module connector and blower motor resistor will need to be replaced if one or more of the symptoms below is present. - The HVAC blower may not function on certain or all blower speed settings - A burning plastic smell or smoke may be present in the vehicle - The HVAC blower may run continually with the ignition in the OFF position Determine if one or more of the above symptoms is present. If required refer to HVAC diagnostic information in SI. Refer to Resistor Module Connector and Blower Motor Resistor Replacement in this bulletin if one or more of the symptoms is present. Other HVAC repairs are NOT covered in this product safety special coverage bulletin. Resistor Module Connector and Blower Motor Resistor Replacement 1. Remove the blower fuses (Htr A/C & HVAC 1 fuses). 2. Lower the close-out panel enough to gain access to the resistor module connector. 3. Disconnect the connector from the resistor module. Note Connector replacement is required even if the connector was replaced on a previous service repair. 4. Remove the tape from the wiring harness to expose the wiring. 5. Cut the wires back far enough from the connector to eliminate any melted insulation on the wire. Note Use the old connector as a map for splicing the wires for the new connector. Be sure to use the correct crimping tool from the terminal repair kit J 38125. Use only Duraseal splice sleeves. Other splice sleeves may not protect the splice from moisture or provide a good electrical connection. 6. Install the new connector. Use the yellow splice sleeves provided with the connector. 7. Install the new blower motor resistor. 8. Reinstall the fuses. Test the blower motor to make sure all speeds are functional. 9. Reinstall the hush panel/close-out panel. Customer Reimbursement Customer requests for reimbursement of previously paid repairs to correct the condition described in this bulletin are to be submitted to the dealer prior to or by December 31, 2012. Repairs must have occurred within the 10 years of the date the vehicle was originally placed in service, or 240,000 kilometres, whichever occurs first. When a customer requests reimbursement, they must provide the following: Instruments - IPC Odometer Programming Reference Guide Odometer: All Technical Service Bulletins Instruments - IPC Odometer Programming Reference Guide INFORMATION Bulletin No.: 07-08-49-020D Date: December 06, 2010 Subject: IPC Odometer Programming Method Quick Reference Guide Models: 2003-2011 GM Passenger Cars and Trucks (Including Saturn) 2003-2010 HUMMER H2, H3 2005-2009 Saab 9-7X Attention: This bulletin applies to vehicles sold in the U.S. and Canada Only. Supercede: This bulletin is being revised to add information for the 2011 model year and add new 2011 vehicles. Please discard Corporate Bulletin Number 07-08-49-020C (Section 08 - Body and Accessories). The purpose of this bulletin is to provide a reference guide to help identify which season odometer programming method to use after replacing the instrument panel cluster (IPC). The three season odometer programming methods in use today are listed below. In addition, this reference guide lists the component where the season odometer value is stored. The season odometer value may be stored in the IPC, the driver information center (DIC) or the integrated body control module (IBCM), also commonly called a body control module (BCM). Season Odometer Programming Methods in Use Today 1. IPC reprogramming and setup using the service programming system (SPS). 2. Odometer setup at the electronic service center (ESC) when using an exchange IPC/DIC. 3. Tech 2(R) - The Tech 2 is used to set up a replacement BCM, which includes loading the odometer value that is displayed and stored in the IPC. A replacement IPC will display the previously stored vehicle odometer value, communicated from the BCM, after cycling the ignition or driving the vehicle. *The odometer programming is integrated as part of the BCM programming procedure. It is not a stand-alone event. Page 14082 TOOLS REQUIRED J 34142-B 12 V Unpowered Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. When testing for voltage: 1. Attach 1 lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach 1 lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Using Connector Test Adapters USING CONNECTOR TEST ADAPTERS NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-B Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires USING FUSED JUMPER WIRES TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Connector Position Assurance Locks CONNECTOR POSITION ASSURANCE LOCKS The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Terminal Position Assurance Locks TERMINAL POSITION ASSURANCE LOCKS The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Push to Seat Connectors PUSH TO SEAT CONNECTORS TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Page 16063 Electrical Symbols Part 5 Service and Repair Gear Sensor/Switch: Service and Repair Encoder Motor Sensor Replacement Removal Procedure Important: For ease of reassembly, shift the transfer case to 2HI prior to removing any components. 1. Remove the encoder motor. 2. Place the encoder motor on a clean work bench, 3. Remove the 2 screws (2) from the motor cover. 4. Remove the 2 screws (1) from the casting. 5. Remove the cover. 6. Remove and save the shim on the output gear. 7. Remove and discard the orange rubber seal from the cover. 8. Remove the output gear (1). Page 12850 7.3. If equipped, connect the rear seat heater's connector and install the switch. 8. Install the floor console: 8.1. Install the floor console's retaining bolts (C) and retaining nuts (F). 8.2. Align the rear cover; make sure that the air duct connects firmly to the air nozzle. Screw in the cover (E). 8.3. Install the ashtray/cover (D). 8.4. Install the ignition switch cover (B). 8.5. Plug in the immobilizer unit (A) connector. Install the unit, bayonet fitting. 9. Remove the OnStar(R) control modules and secure the wiring: 9.1. Remove the right-hand rear luggage compartment trim in accordance with WIS - 8. Body - Interior equipment - Adjustment/Replacement. 9.2. Unplug the connectors (A) from the OnStar(R) control modules. 9.3. Remove the console (B) together with the OnStar(R) control modules. Page 9251 C396 Body Harness To Right Rear Door Harness (Crew Cab) Part 2 Automatic Transmission - 4L60-E/4L65-E Transmission Position Switch/Sensor: Service and Repair Automatic Transmission 4L60-E/4L65-E Park/Neutral Position Switch Replacement ^ Tools Required J 41364-A Park Neutral Switch Aligner Removal Procedure 1. Apply the park brake. 2. Shift the transmission into neutral. 3. If equipped with 4-wheel drive (4WD), remove the front propeller shaft. 4. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 5. Disconnect the park/neutral position (PNP) switch electrical connector (2). 6. Remove the manual shaft lever nut. Page 6016 Electronic Components Page 12782 Page 15850 The 1999 though early 2003 wiring harness jumper that plugs into the relay block will have a reddish/brown 6-way connector and a tag with the last four digits of the wiring harness part number. Second design 2003-05 may have a white plastic connector with part number 5418 as well. ^ The 1999 jumper is/was P/N 12171982 with a pink/purple tag identifier of 1982. This number has been superseded to 15366255, with a pink/purple tag identifier of 6255. ^ The 2000 jumper harness is P/N 15366255. The pink/purple tag identifier is 6255. ^ The 2001-2002 jumper is P/N 15086884. The orange tag identifier is 6884. ^ The 2003-05 jumper is P/N 15085418. The orange tag identifier is 5418. When transferring the brake controller with the wiring jumper attached from a 2001-2002 vehicle to a 2003-05 vehicle, a change to the jumper harness connector must be performed. Page 15690 License Lamp - Right Page 12573 Page 14181 1. Raise the window. 2. Remove the door trim panel. 3. Remove the water deflector. 4. Disconnect the inside door lock rod from the handle retainer clip. 5. Disconnect the manual door lock rod from the door retainer clips. 6. Remove the rubber plug in order to disengage the outside handle rod retainer. 4L60/4L60-E/4L65-E Transmission Tow/Haul Switch: Testing and Inspection 4L60/4L60-E/4L65-E Transmission Tow/Haul Switch/Indicator Always On or Inoperative Circuit Description Tow/haul mode enables the operator to achieve enhanced shift performance when towing or hauling a load. When tow/haul mode is selected, the tow/haul switch input signal to the body control module (BCM) is momentarily toggled to zero volts. This signals the powertrain control module (PCM) to extend the length of time between upshifts and increase transmission line pressure. Cycling the tow/haul switch again disables tow/haul mode and returns the transmission to a normal shift pattern. Diagnostic Aids If the electrical circuit tests are OK and the tow/haul shift pattern is not occurring, there may be a mechanical/hydraulic condition that prevents tow/haul operation. Refer to Symptoms - Automatic Transmission. Page 257 Conditions for Running the DTC Ignition is in RUN or ACC position System voltage is between 9.5 - 15.5 volts. The above conditions are met for more than 1 second. Conditions for Setting the DTC The VCIM does not detect the presence of a cellular antenna for more than 1 second. Action Taken When the DTC Sets The vehicle is unable to connect to the OnStar(R) Call Center. The OnStar(R) status LED turns red. Conditions for Clearing the DTC The VCIM detects the presence of a cellular antenna. A history DTC clears after 50 malfunction-free ignition cycles. Circuit/System Testing Perform a visual inspection as shown above in order to verify that the cellular antenna and the cellular antenna coupling assembly are not damaged. If any components are damaged replace the assembly. DTC B2476 or B2482 DTC Descriptors Wheels - Chrome Wheel Brake Dust Accumulation/Pitting Wheels: All Technical Service Bulletins Wheels - Chrome Wheel Brake Dust Accumulation/Pitting Bulletin No.: 04-03-10-012B Date: February 01, 2008 INFORMATION Subject: Pitting and Brake Dust on Chrome wheels Models: 2008 and Prior GM Passenger Cars and Trucks (including Saturn) 2008 and Prior HUMMER H2, H3 2005-2008 Saab 9-7X Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 04-03-10-012A (Section 03 - Suspension). Analysis of Returned Wheels Chrome wheels returned under the New Vehicle Limited Warranty for pitting concerns have recently been evaluated. This condition is usually most severe in the vent (or window) area of the front wheels. This "pitting" may actually be brake dust that has been allowed to accumulate on the wheel. The longer this accumulation builds up, the more difficult it is to remove. Cleaning the Wheels In all cases, the returned wheels could be cleaned to their original condition using GM Vehicle Care Cleaner Wax, P/N 12377966 (in Canada, P/N 10952905). When using this product, you should confine your treatment to the areas of the wheel that show evidence of the brake dust build-up. This product is only for use on chromed steel or chromed aluminum wheels. Parts Information Warranty Information Wheel replacement for this condition is NOT applicable under the terms of the New Vehicle Limited Warranty. Disclaimer Page 3997 Manifold Absolute Pressure (MAP) Sensor Service and Repair Oil Pressure Sensor: Service and Repair Engine Oil Pressure Sensor and/or Switch Replacement ^ Tools Required J 41712 Oil Pressure Switch Socket Removal Procedure 1. If necessary, remove the engine sight shield. 2. Disconnect the oil pressure sensor electrical connector (1). 3. Using J 41712 or equivalent, remove the oil pressure sensor. Installation Procedure Page 932 Body Control Module: Removal and Replacement BODY CONTROL MODULE REPLACEMENT REMOVAL PROCEDURE CAUTION: Refer to Battery Disconnect Caution in Service Precautions. 1. Disconnect the negative battery cable(s). 2. Remove the knee bolster. 3. Disconnect the brown connector. 4. Disconnect all other connectors (1). 5. Remove the BCM from the sliding bracket. INSTALLATION PROCEDURE Left Front Seat Belt Retractor: Service and Repair Left Front SEAT BELT RETRACTOR REPLACEMENT - LEFT FRONT CAUTION: To avoid personal injury to the occupants of the vehicle, observe the following precautions: - More than one supplier's seat belts are used, therefore, install ONLY the seat belt components specified in the GM parts catalog. - To verify that the correct seat belt components were installed, insert the seat belt latch in the seat belt buckle. The latch must be fully seated and be retained in the buckle until purposely released. REMOVAL PROCEDURE 1. Move the front seat to the full forward position. IMPORTANT: Do not remove the seat back cover from the head restraint retainers. 2. Remove the seat back cover and pad. 3. Separate the seat foam from the cardboard to gain access to the retainer on the seat belt side. 4. Remove the seat belt side cardboard retainers. 5. Move the cardboard outwards to gain access to the lower seat belt retractor bolt. 6. Remove the retractor bolt. 7. Remove the retractor tower retaining screw. 8. Remove the retractor tower cover. Page 5978 12. Inspect the TCC solenoid and wiring harness for the following defects: ^ Damage ^ Cracked connectors ^ Exposed wires ^ Loose pins Installation Procedure 1. Install the wiring harness and TCC solenoid with a new O-ring seal to the transmission. 2. Install the pass-through electrical connector to the transmission case. 3. Notice: Refer to Fastener Notice in Service Precautions. Install the valve body bolts which retain the internal wiring harness and install the TCC solenoid bolts. ^ Tighten the control valve body bolts to 11 Nm (97 inch lbs.). ^ Tighten the TCC solenoid bolts to 11 Nm (97 inch lbs.). Page 1896 Page 7654 2. Important: Ensure the drain hole on the boot of the rear output shaft seal is facing down toward the ground. Using the J 37668-A, install the rear output shaft to the transfer case. 3. Install the rear propeller shaft. 4. Check the fluid level, Add fluid if necessary. 5. Install the transfer case shield, if equipped. Transfer Case Input Shaft Seal Replacement Transfer Case Input Shaft Seal Replacement ^ Tools Required J 42738 Seal Installer Removal Procedure 1. Remove the transfer case. 2. Using a flat-tipped screwdriver, remove the input shaft seal. Installation Procedure Important: When installing the input shaft seal, make sure that the part numbers on the seal are facing outward (away from the body of the transfer case). A/C - Hiss Noise From Instrument Panel Hose/Line HVAC: Customer Interest A/C - Hiss Noise From Instrument Panel Bulletin No.: 06-01-38-002 Date: March 17, 2006 TECHNICAL Subject: A/C System Refrigerant Hiss Noise (Replace Liquid Line) Models: 2003-2006 Cadillac Escalade Models 2003-2006 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2003-2006 GMC Sierra, Yukon Models with 4.3L, 4.8L, 5.3L, 6.0L or 8.1L Engine (VINs X, V, T, Z, B, U, N, G - RPOs LU3, LR4, LM7, L59, L33, LQ4, LQ9, L18) and Air Conditioning (RPOs CJ2, CJ3 and C69) Condition Some customers may comment on a hiss noise coming from the instrument panel. The noise has also been described as sounding like a gurgle or water spattering. The noise occurs when the Air Conditioning (A/C) compressor engages and may continue for 5 to 10 seconds after the compressor disengages or the A/C system is turned off. The noise is most noticeable when the vehicle is at idle or is being driven at low speeds. The noise is undetectable after about one minute when the A/C system has been turned off or the vehicle has been turned off. Cause This condition may be caused by the expanding refrigerant as it passes through the orifice tube. Correction Technicians are to verify that the customer concern is only as described in the condition statement above. If the customer concern is a refrigerant hiss noise, then technicians are to perform the normal diagnostic procedures for an A/C system concern. The ACR2000 should be used to check the A/C system performance, charge level and discharge temperatures. This will eliminate the possibility that another condition is contributing to this customer concern. If the A/C system is performing properly, and all other possible sources of this noise are eliminated, then technicians are to replace the A/C liquid line. Use the proper part number as described in the parts information box below. Verify that the noise has been eliminated and that the A/C system operates normally. Parts Information Important: The trucks affected by this bulletin that have rear air conditioning were built with two different length condensers. The short condenser is 762 mm (30.0 in) long. The long condenser is 914 mm (36.0 in) long. Be sure to measure the length of the condenser before ordering one of the tubes listed below for vehicles with rear air conditioning. Page 10106 Power Steering Pump: Service and Repair Power Steering Pump Wiring Harness Replacement Power Steering Pump Wiring Harness Replacement Removal Procedure 1. Disconnect the energy storage box before servicing the vehicle. 2. Remove the coolant surge tank to gain access to the electrical connectors. 3. Disconnect the electrical connectors (2) from the harness. 4. Remove the bolt retaining the wiring harness bracket (3) from the engine block. 5. Remove the electrical wiring harness clip (4) from the bracket. Electrical - MIL ON/DTC's Set By Various Control Modules Wiring Harness: Customer Interest Electrical - MIL ON/DTC's Set By Various Control Modules TECHNICAL Bulletin No.: 09-06-03-004D Date: December 08, 2010 Subject: Intermittent No Crank/No Start, No Module Communication, MIL, Warning Lights, Vehicle Messages or DTCs Set by Various Control Modules - Diagnosing and Repairing Fretting Corrosion (Disconnect Affected Connector and Apply Dielectric Lubricant) Models: 2011 and Prior GM Passenger Cars and Trucks Attention: This repair can be applied to ANY electrical connection including, but not limited to: lighting, body electrical, in-line connections, powertrain control sensors, etc. DO NOT over apply lubricant to the point where it prevents the full engagement of sealed connectors. A light coating on the terminal surfaces is sufficient to correct the condition. Supercede: This bulletin is being revised to update the Attention statement and add the 2011 model year. Please discard Corporate Bulletin Number 09-06-03-004C (Section 06 Engine/Propulsion System). Condition Some customers may comment on any of the following conditions: - An intermittent no crank/no start - Intermittent malfunction indicator lamp (MIL) illumination - Intermittent service lamp illumination - Intermittent service message(s) being displayed The technician may determine that he is unable to duplicate the intermittent condition. Cause This condition may be caused by a buildup of nonconductive insulating oxidized debris known as fretting corrosion, occurring between two electrical contact surfaces of the connection or connector. This may be caused by any of the following conditions: - Vibration - Thermal cycling - Poor connection/terminal retention - Micro motion - A connector, component or wiring harness not properly secured resulting in movement On low current signal circuits this condition may cause high resistance, resulting in intermittent connections. On high current power circuits this condition may cause permanent increases in the resistance and may cause a device to become inoperative. Representative List of Control Modules and Components The following is only a representative list of control modules and components that may be affected by this connection or connector condition and DOES NOT include every possible module or component for every vehicle. - Blower Control Module - Body Control Module (BCM) - Communication Interface Module (CIM) - Cooling Fan Control Module - Electronic Brake Control Module (EBCM) - Electronic Brake and Traction Control Module (EBTCM) - Electronic Suspension Control (ESC) Module - Engine Control Module (ECM) - Heating, Ventilation and Air Conditioning (HVAC) Control Module Wheels - Chrome Wheel Staining/Pitting/Corrosion Wheels: All Technical Service Bulletins Wheels - Chrome Wheel Staining/Pitting/Corrosion INFORMATION Bulletin No.: 00-03-10-002F Date: April 21, 2011 Subject: Chemical Staining, Pitting, Corrosion and/or Spotted Appearance of Chromed Aluminum Wheels Models: 2012 and Prior GM Cars and Trucks Supercede: This bulletin is being revised to update model years, suggest additional restorative products and add additional corrosion information. Please discard Corporate Bulletin Number 00-03-10-002E (Section 03 - Suspension). Important You may give a copy of this bulletin to the customer. What is Chemical Staining of Chrome Wheels? Figure 1 Chemical staining in most cases results from acid based cleaners (refer to Figure 1 for an example). These stains are frequently milky, black, or greenish in appearance. They result from using cleaning solutions that contain acids on chrome wheels. Soap and water is usually sufficient to clean wheels. If the customer insists on using a wheel cleaner they should only use one that specifically states that it is safe for chromed wheels and does not contain anything in the following list. (Dealers should also survey any products they use during prep or normal cleaning of stock units for these chemicals.) - Ammonium Bifluoride (fluoride source for dissolution of chrome) - Hydrofluoric Acid (directly dissolves chrome) - Hydrochloric Acid (directly dissolves chrome) - Sodium Dodecylbenzenesulfonic Acid - Sulfamic Acid - Phosphoric Acid - Hydroxyacetic Acid Notice Many wheel cleaner instructions advise to take care to avoid contact with painted surfaces. Most customers think of painted surfaces as the fenders, quarter panels and other exterior sheet metal. Many vehicles have painted brake calipers. Acidic wheel cleaners may craze, crack, or discolor the paint on the brake calipers. Damage from wheel cleaners is not covered under the vehicle new car warranty. Soap and water applied with a soft brush is usually all that is required to clean the calipers. Whenever any wheel cleaner is used, it must be THOROUGHLY rinsed off of the wheel with clean, clear water. Special care must be taken to rinse under the hub cap, balance weights, wheel nuts, lug nut caps, between the wheel cladding and off the back side of the wheel. Wheels returned to the Warranty Parts Center (WPC) that exhibit damage from wheel cleaners most often have the damage around and under the wheel weight where the cleaner was incompletely flushed away. Notice Page 4260 1. Locate the air flow direction arrow (2) on the MAF/IAT sensor. 2. Install the MAF/IAT sensor to the air cleaner assembly. NOTE: Refer to Fastener Notice in Service Precautions. 3. Tighten the MAF/IAT clamp. Tighten Tighten the clamp to 7 N.m (62 lb in). 4. Connect the MAF/IAT sensor electrical connector (4). 5. Push in the gray CPA retainer. 6. Install the air cleaner outlet duct. Page 7218 Electrical Symbols Part 10 Page 6820 9. Remove the outer pinion bearing cup using a hammer and a brass drift in the slots provided.Move the drift back and forth between one side of the cup and the other in order to work the cups out of the retainer evenly. 10. Remove the inner pinion bearing cup using a hammer and a brass drift in the slots provided.Move the drift back and forth between one side of the cup and the other in order to work the cups out of the retainer evenly. 11. Remove the pinion gear pilot bearing using a brass drift and a hammer. Installation Procedure 1. Install the pinion gear pilot bearing using the J 22761. 2. Install the inner pinion bearing cup into the pinion gear bearing retainer using the J 37624 (2) and the J 8092 (1). Page 6049 This diagnostic table should be used when addressing a harsh 1-2 shift concern. Disclaimer Page 9614 Application Table Part 1 Diagram Information and Instructions Steering Mounted Controls Transmitter: Diagram Information and Instructions Truck Zoning TRUCK ZONING Truck Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that corresponds to where they are located in the vehicle. The table explains the numbering system. Page 9179 C104 I/P Harness To Forward Lamp Harness (With RPO Code YE9) Page 14378 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Page 10064 2. Connect the power steering inlet hose to the power steering pump (5).Install the retaining clamp. 3. Connect the power steering outlet hose (4) to the power steering gear (3).Install the retaining clamp. 4. Bleed the power steering system. Refer to Bleeding the Power Steering System. 5. Inspect all the hose connections for leaks. 6. Install the front grille. Refer to Grille Replacement (GMC) Grille Replacement (Chevrolet) in Exterior Trim. (With Hydroboost) Power Steering Cooler Pipe/Hose Replacement (With Hydroboost) Removal Procedure 1. Remove the front grille. Refer to Grille Replacement (GMC) Grille Replacement (Chevrolet) in Exterior Trim. 2. Notice: Refer to Power Steering Hose Disconnected Notice in Service Precautions. Place a drain pan under the vehicle. 3. Siphon the fluid from the reservoir to prevent excess spillage. 4. Remove the clamp retaining the power steering cooler inlet hose (3) to the power steering gear (2). 5. Remove the clamp retaining power steering cooler outlet hose (5) to the power steering pump (1). 6. Remove the bolts (2) retaining the power steering cooler from the radiator support. 7. Remove the power steering cooler from the vehicle. Installation Procedure Page 316 Page 10851 3. Connect the electrical connector to the recirculation actuator (1). 4. Install the air distribution duct. Recirculation Actuator (Visteon) RECIRCULATION ACTUATOR REPLACEMENT (VISTEON) REMOVAL PROCEDURE 1. Remove the HVAC module assembly. 2. Remove the screws from the evaporator core cover (1). 3. Remove the evaporator core cover (1) from the HVAC module assembly (2). 4. Remove the screws from the recirculation actuator (1). 5. Remove the recirculation actuator (1) from the HVAC module assembly (2). With Special Tool Fuel: Testing and Inspection With Special Tool ALCOHOL/CONTAMINANTS-IN-FUEL DIAGNOSIS (WITH SPECIAL TOOL) DESCRIPTION Water contamination in the fuel system may cause driveability conditions such as hesitation, stalling, no start, or misfires in one or more cylinders. Water may collect near a single fuel injector at the lowest point in the fuel injection system, and cause a misfire in that cylinder. If the fuel system is contaminated with water, inspect the fuel system components for rust or deterioration. Ethanol concentrations of greater than 10 percent can cause driveability conditions and fuel system deterioration. Fuel with more than 10 percent ethanol could result in driveability conditions such as hesitation, lack of power, stalling, or no start. Excessive concentrations of ethanol used in vehicles not designed for it may cause fuel system corrosion, deterioration of rubber components, and fuel filter restriction. TEST PROCEDURE 1. Test the fuel composition using J 44175 Fuel Composition Tester and J 44175-3 Instruction Manual. 2. If water appears in the fuel sample, perform the following steps: 2.1. Clean the fuel system. Refer to Fuel System Cleaning. 2.2. Replace the fuel filter if the vehicle is equipped with a serviceable fuel filter. 3. Subtract 50 from the reading on the DMM in order to obtain the percentage of alcohol in the fuel sample. Refer to the examples in the Fuel Composition Test Examples table. 4. If the fuel sample contains more than 15 percent ethanol, add fresh, regular gasoline to the vehicle's fuel tank. 5. Test the fuel composition. 6. If testing shows the ethanol percentage is still more than 15 percent, replace the fuel in the vehicle. Page 2076 Steps 7 - 9 Page 8914 Auxiliary Power Outlet Switch (With RPO Code HP2) Page 8624 1. Install the gasket. 2. Install the booster assembly. 3. Install the 4 booster to bulkhead nuts. Tighten Tighten the nuts to 36 N.m (26 lb-ft). 4. Snap the stop lamp switch onto the pushrod to the power brake booster. 5. Install the stop lamp switch with the pushrod on the brake pedal pin. 6. Install the brake switch retainer. 7. Connect the electrical connector to the stop lamp switch. 8. Install the master cylinder to the booster. 9. Install the master cylinder mounting nuts. Tighten Tighten the nuts to 36 N.m (27 lb-ft). 10. Connect the power brake booster outlet hose, the steering gear inlet hose, and the power brake booster inlet hose. Tighten ^ Tighten the power brake booster inlet hose to 28 N.m (20 lb-ft). ^ Tighten the steering gear inlet hose to 28 N.m (20 lb-ft). Important: Maintain the fluid level throughout the bleed procedure. 11. Remove the pump reservoir cap. Important: Page 1695 Vehicle Speed Sensor: Service and Repair Automatic Transmission - 4L60-E/4L65-E Vehicle Speed Sensor (VSS) Replacement Removal Procedure 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. Disconnect the vehicle speed sensor (VSS) electrical connector (2). 3. Remove the VSS bolt (2). 4. Remove the VSS (1). 5. Remove the O-ring seal (3). Installation Procedure 1. Install the O-ring seal (3) onto the VSS (1). 2. Coat the O-ring seal (3) with a thin film of transmission fluid. 3. Install the VSS (1). 4. Notice: Refer to Fastener Notice in Service Precautions. Install the VSS bolt (2). ^ Tighten the bolt to 11 Nm (97 inch lbs.). Page 12709 Page 11907 Claim Information - GM, Saturn Canada and Saab Canada Only Claim Information - Saturn US Only Customer Reimbursement Claims - Special Attention Required Customer reimbursement claims must have entered into the "technician comments" field the CSO # (if repair was completed at a Saturn Retail Facility) date, mileage, customer name, and any deductibles and taxes paid by the customer. Claim Information - Saab US Only Passlock Function Engine Control Module: Description and Operation Passlock Function VEHICLE/POWERTRAIN CONTROL MODULE The VCM/PCM communicates with the BCM over the Class 2 serial data line. When the BCM determines a no start condition, it sends a Class 2 serial data password to the VCM/PCM in order to disable the fuel injection system. If the BCM receives the expected voltage from the Passlock(TM) sensor, the BCM sends a class 2 serial data password to the VCM/PCM in order to enable the fuel injection system. The VCM/PCM then allows the vehicle to start correctly. If the Class 2 serial data password from the BCM to the VCM/PCM is not within the Vehicle Security Status Message, the fuel injectors will shut OFF during a start attempt. The SECURITY telltale will be illuminated for 10 minutes. If the VCM/PCM does not receive the same password from the BCM as the last learned one, the vehicle will start and then stalls due to the Fuel Lockout. Transfer Case - NVG 149-NP3 Seals and Gaskets: Service and Repair Transfer Case - NVG 149-NP3 Transfer Case Output Shaft Seal Replacement - Front Transfer Case Output Shaft Seal Replacement - Front ^ Tools Required J 8092 Driver Handle - J 43484 Output Shaft Seal Installer Removal Procedure 1. Remove the transfer case shield, if equipped. 2. Remove the front propeller shaft. 3. Insert a flat-tipped screw driver into the inner race. 4. Pry the inner race back. 5. Insert a small pry bar into the inner race. Important: When performing the following service procedure, the outer part of the seal will slightly move out of the transfer case with the inner part seal. 6. Pry the inner part of the seal from the outer seal body. 7. Remove the inner part of the seal. Page 5200 Disclaimer Page 5359 Fuel Supply Line: Service and Repair Fuel Hose/Pipes Replacement - Chassis (Cab/Chassis-Front) FUEL HOSE/PIPES REPLACEMENT - CHASSIS (CAB/CHASSIS - FRONT) REMOVAL PROCEDURE IMPORTANT: Clean the fuel and evaporative emission (EVAP) connections and surrounding areas prior to disconnecting the lines in order to avoid possible system contamination. 1. Relieve the fuel system pressure. Refer to Fuel Pressure Relief Procedure. 2. Disconnect the fuel feed line (1) at the engine. 3. Disconnect the EVAP canister purge tube line (2). 4. Cap the fuel rail in order to avoid possible system contamination. 5. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 6. Remove the fuel pipe bracket nut. 7. Remove the fuel pipe bracket from the bellhousing stud. Page 8660 4. Install the ground, then the washer and then the bolt to the frame. Important: It is important to use the bolts, washers and nuts specified in this bulletin. These parts have been identified due to their conductive finish. 5. Install a washer and nut to the back side of the frame. Tighten Tighten the nut to 9 Nm (79 lb in). 6. Cover the front and back side of the repair area using Rubberized Undercoating. An additional check can be made to ensure a good connection for the battery cable to frame ground. It is possible for this ground to cause similar symptoms with the ABS as described above. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Parts Information Warranty Information Disclaimer Page 12570 Page 7069 Page 14100 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves SPLICING COPPER WIRE USING SPLICE SLEEVES TOOLS REQUIRED J 38125-D Terminal Repair Kit IMPORTANT: Use only GM splice sleeves, other splice sleeves may not protect the splice from moisture or a provide good electrical connection. Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. Page 9193 C152 Chassis Harness To Engine Harness Part 2 Fuel Pressure Gage Installation and Removal Fuel Pressure: Testing and Inspection Fuel Pressure Gage Installation and Removal FUEL PRESSURE GAGE INSTALLATION AND REMOVAL INSTALLATION PROCEDURE TOOLS REQUIRED J 34730-1A Fuel Pressure Gage CAUTION: - Refer to Gasoline/Gasoline Vapors Caution in Service Precautions. - Refer to Fuel Gage Leak Caution in Service Precautions. 1. Remove the engine sight shield. 2. Remove the fuel rail pressure fitting cap. 3. Connect the J 34730-1A to the fuel pressure valve. Wrap a shop towel around the fitting while connecting the gage in order to avoid spillage. 4. Install the bleed hose on J 34730-1A into an approved container. REMOVAL PROCEDURE 1. Remove the bleed hose on the J 34730-1A from the approved container. 2. Remove the shop towel from around the fitting and discard into an approved container. 3. Disconnect the J 34730-1A from the fuel pressure valve. 4. Install the fuel rail pressure fitting cap. 5. Install the engine sight shield. Page 5771 Steps 1-9 Test Description The numbers below refer to the step numbers on the diagnostic table. 2. This step tests for a faulty tow/haul switch. 3. This step tests for voltage input from the BCM to the tow/haul switch. 6. This step tests for ground integrity. Page 9512 Body Harness Passlock Function Engine Control Module: Description and Operation Passlock Function VEHICLE/POWERTRAIN CONTROL MODULE The VCM/PCM communicates with the BCM over the Class 2 serial data line. When the BCM determines a no start condition, it sends a Class 2 serial data password to the VCM/PCM in order to disable the fuel injection system. If the BCM receives the expected voltage from the Passlock(TM) sensor, the BCM sends a class 2 serial data password to the VCM/PCM in order to enable the fuel injection system. The VCM/PCM then allows the vehicle to start correctly. If the Class 2 serial data password from the BCM to the VCM/PCM is not within the Vehicle Security Status Message, the fuel injectors will shut OFF during a start attempt. The SECURITY telltale will be illuminated for 10 minutes. If the VCM/PCM does not receive the same password from the BCM as the last learned one, the vehicle will start and then stalls due to the Fuel Lockout. Page 10844 2. Disconnect the electrical connector (4) from the right air temperature actuator (3). 3. Remove the screws from the right air temperature actuator (3). 4. Remove the right air temperature actuator (3) from the HVAC module assembly (2). INSTALLATION PROCEDURE 1. Install the right air temperature actuator (3) from the HVAC module assembly (2). NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the screws to the right air temperature actuator (3). Tighten Tighten the screws to 2 N.m (18 lb in). 3. Connect the electrical connector to the right air temperature actuator. 4. Install the I/P carrier. 5. Reprogram the air temperature actuator. Refer to Re-Calibrating Actuators. See: Testing and Inspection/Component Tests and General Diagnostics Mode Actuator (With RPO Code D07) MODE ACTUATOR REPLACEMENT (W/ D07) REMOVAL PROCEDURE Page 12354 Control Module References Part 3 Transfer Case - NVG 246-NP8 Four Wheel Drive Selector Switch: Service and Repair Transfer Case - NVG 246-NP8 Transfer Case Shift Control Switch Replacement Removal Procedure 1. Remove the instrument panel (I/P) cluster bezel. 2. Using a flat-tipped screwdriver, gently pry the retaining clips open on the housing. 3. Slide out the selector switch until the electrical connector are accessible. 4. Disconnect the selector switch electrical connectors (2, 3). 5. Remove the selector switch from the housing. Installation Procedure 1. Position the selector switch close to the housing so the electrical connectors can be connected. OnStar(R) - Loss of GPS Signal/Hands Free Issues Emergency Contact Module: Customer Interest OnStar(R) - Loss of GPS Signal/Hands Free Issues Bulletin No.: 02-08-46-007C Date: November 19, 2007 INFORMATION Subject: Information on OnStar(R) System - Possible Loss of GPS Signal, Hands-Free Calling Minutes Expire Prematurely and/or Inability to Add Hands-Free Calling Minutes Models: 2001-2008 GM Passenger Cars and Light Duty Trucks (Including Saturn) 2003-2008 HUMMER H2 2006-2008 HUMMER H3 2005-2008 Saab 9-7X with OnStar(R) System (RPO UE1) Supercede: This bulletin is being revised to add the 2008 model year, warranty information and to provide GPS signal recovery steps (under Dealer Action heading) to do PRIOR to determining if the VIU/VCIM needs replacement. Please discard Corporate Bulletin Number 02-08-46-007B (Section 08 - Body & Accessories). If the vehicle currently has analog-upgradable OnStar(R) hardware, then the customer should be made aware of the digital upgrade program per the latest version of Service Bulletin # 05-08-46-006. Any analog OnStar system that is not upgraded prior to the end of 2007 will be deactivated due to the upcoming phase-out of the analog cellular network in the U.S. and Canada. If the vehicle has recently been upgraded or has had a service replacement unit installed, this bulletin may not be applicable. Certain 2001-2008 model year vehicles equipped with OnStar(R) may exhibit a condition with the Global Positioning System (GPS) that causes inaccuracies in the GPS clock. The GPS system is internal to the OnStar(R) Vehicle Interface Unit (VIU) or the Vehicle Communication Interface Module (VCIM). This inaccuracy can result in a symptom where the OnStar(R) Call Center is unable to obtain an accurate GPS signal, hands-Free Calling minutes expire prematurely and/or the inability to add Hands-Free calling minutes. Customer Notification OnStar(R) will notify the customer by mail with instructions to contact their dealership service department. Dealer Action Not all vehicles will require VIU/VCIM replacement. The GPS signal in some vehicles may be recoverable. To determine if the signal is recoverable, simply connect the Tech2(R) and using the GPS information data display option, observe the GPS date and time. If the date/time stamps are equal to a date approximately 19 years in the future, the GPS clock has exceeded its capacity and the VIU/VCIM will need to be replaced. If the date/time stamp is in the past or near future, the GPS clock has simply generated an inaccurate value and may be recoverable by performing the following power-up reset. To initiate a power-up reset, battery voltage (batt. +) must be removed from the VIU/VCIM. The preferred methods, in order, of initiating the reset are outlined below. Remove the fuse that supplies Battery positive (Batt. +) voltage to the module (refer to the applicable Service Information schematics for the appropriate fuse). The next preferred method is to remove the connector to the OnStar(R) unit that Batt + is contained. The least preferable method is to remove the negative terminal of the vehicle battery. This will not only initiate the power-up reset, but it may also result in the loss of radio presets and other stored personalization information/settings in other modules as well. After initiating the power-up reset, the GPS data will be set to the defaulted date and time and will require an acquisition of the GPS signal in order to gain the proper date and time. Acquiring the GPS signal requires running the vehicle in an open/unobstructed view of the sky. First, contact OnStar(R) Technical Support by pressing the blue button. Allow the OnStar(R) Technical Advisor to activate the GPS recovery process. This should take approximately 10 minutes. Continue to Fuel System - Cranks But No Start/Inaccurate Fuel Gauge Fuel Gauge Sender: Customer Interest Fuel System - Cranks But No Start/Inaccurate Fuel Gauge Bulletin No.: 04-08-49-018E Date: January 05, 2005 TECHNICAL Subject: Cranks But No Start, Stall, Inaccurate/Incorrect Fuel Gauge Reading, No Fuel, Vehicle is Out of Fuel and Fuel Gauge Reads Above Empty (Replace Fuel Level Sensor) Models: 2001-2004 Cadillac Trucks 1999-2004 Chevrolet and GMC Trucks with Gasoline Engine (VINs Z, X, V, T, U, N, G, 6, 8 - RPOs LU3, LR4, LM7, LQ4, LQ9, L59, L18,LK5 L52) Attention: Parts are currently available for vehicles with Variable Fuel (VIN Z - RPO L59) vehicles. Please refer to Corporate Bulletin Number 04-06-04-01 2B or newer for Variable Fuel (VIN Z - RPO L59) vehicles. Supercede: This bulletin is being revised to include information on the Chevrolet Colorado and the GMC Canyon. Please discard Corporate Bulletin Number 04-08-49-018D (Section 08 - Body and Accessories). Condition Some customers may comment on the vehicle stalling and will not restart, vehicle ran out of fuel, vehicle appears to be out of fuel but the fuel gauge reads above empty. The fuel gauge may read 1/4 tank. Cause Contamination on the fuel sending card may cause inaccurate/incorrect fuel gauge readings. Correction Follow the service procedure below for diagnosis and repair of this concern. 1. Confirm that the vehicle is actually out of fuel. ^ If the vehicle is not out of fuel but Engine Cranks but Does Not Run, refer to the appropriate Service Information. ^ If the vehicle is out of fuel and the gauge does not read empty, test the fuel gauge. Refer to the following information: - Fuel Gage Inaccurate or Inoperative Single Tank - Fuel Gage Inaccurate or Inoperative Dual Tanks - Fuel Gage Inaccurate or Inoperative Colorado and Canyon 2. If testing reveals that the fuel gauge is operating correctly, replace the fuel sensor assembly and auxiliary tank fuel level sensor if equipped. 3. Replace the fuel level sensor. Refer to the following appropriate service information: ^ Fuel Level Sensor Replacement 4.8L and 5.3L Engines ^ Fuel Level Sensor Replacement 6.0L Engine - Front Tank ^ Fuel Level Sensor Replacement 6.0L Engine - Rear Tank ^ Fuel Level Sensor Replacement 8.1L vehicles with Front Tank ^ Fuel Level Sensor Replacement 8.1 L vehicles with Rear Tank Specifications Compression Check: Specifications The minimum compression in any one cylinder should not be less than 70 percent of the highest cylinder. No cylinder should read less than 690 kPa (100 psi). For example, if the highest pressure in any one cylinder is 1035 kPa (150 psi), the lowest allowable pressure for any other cylinder would be 725 kPa (105 psi). Multiply the highest cylinder pressure by 70 percent, 1035 kPa x 70 percent = 725 kPa (150 psi x 70 percent = 105 psi), in order to determine the lowest allowable pressure in any other cylinder. Page 7557 Four Wheel Drive Selector Switch: Service and Repair Transfer Case - NVG 263-NP1 Transfer Case Shift Control Switch Replacement Removal Procedure 1. Remove the instrument panel (IP) cluster bezel. 2. Pull the tabs on the side of the transfer case driver control switch out. 3. Pull the transfer case driver control switch straight out from the panel. Installation Procedure 1. Important: Make sure that the transfer case control switch is seated properly in the instrument panel before installing the instrument panel trim bezel. Install the transfer case driver control switch into the instrument panel. 2. Install the IP cluster bezel. Page 9489 For vehicles repaired under warranty, use the table. Disclaimer Page 3587 Processes shown in the Table 3 are capable of recycling waste engine coolants (DEX-COOL(R) or conventional) to a conventional (green) coolant. Recycling conventional coolant can be accomplished at your facility by a technician using approved EQUIPMENT (listed by model number in Table 3), or by an approved coolant recycling SERVICE which may recycle the coolant at your facility or at an offsite operation. Refer to the table for GM approved coolant recyclers in either of these two categories. Should you decide to recycle the coolant yourself, strict adherence to the operating procedures is imperative. Use ONLY the inhibitor chemicals supplied by the respective (GM approved) recycling equipment manufacturer. Sealing Tablets Cooling System Sealing Tablets (Seal Tabs) should not be used as a regular maintenance item after servicing an engine cooling system. Discoloration of coolant can occur if too many seal tabs have been inserted into the cooling system. This can occur if seal tabs are repeatedly used over the service life of a vehicle. Where appropriate, seal tabs may be used if diagnostics fail to repair a small leak in the cooling system. When a condition appears in which seal tabs may be recommended, a specific bulletin will be released describing their proper usage. Water Quality The integrity of the coolant is dependent upon the quality of DEX-COOL(R) and water. DEX-COOL(R) is a product that has enhanced protection capability as well as an extended service interval. These enhanced properties may be jeopardized by combining DEX-COOL(R) with poor quality water. If you suspect the water in your area of being poor quality, it is recommended you use distilled or de-ionized water with DEX-COOL(R). "Pink" DEX-COOL(R) DEX-COOL(R) is orange in color to distinguish it from other coolants. Due to inconsistencies in the mixing of the dyes used with DEX-COOL(R), some batches may appear pink after time. The color shift from orange to pink does not affect the integrity of the coolant, and still maintains the 5 yr/150,000 mile (240,000 km) service interval. Back Service Only use DEX-COOL(R) if the vehicle was originally equipped with DEX-COOL(R). Page 5672 Electronic Components Steering - Underhood Clunk Heard/Felt in Steering Wheel Steering Column Bearing: All Technical Service Bulletins Steering - Underhood Clunk Heard/Felt in Steering Wheel TECHNICAL Bulletin No.: 00-02-35-003N Date: March 26 2008 Subject: Clunking Noise Under Hood and Can Be Felt in Steering Wheel and/or Steering Column (Replace Upper Intermediate Steering Shaft [I-Shaft] Assembly) Models: 2002-2006 Cadillac Escalade Models 1999-2007 Chevrolet Silverado Models (Classic) 2000-2006 Chevrolet Suburban, Tahoe Models 2002-2006 Chevrolet Avalanche 1999-2007 GMC Sierra Models (Classic) 2000-2006 GMC Yukon, Yukon XL Models 2003-2006 HUMMER H2 Attention: This Service Bulletin DOES NOT include Mid-Size Utilities such as Buick Rainier, Chevrolet TrailBlazer Models, GMC Envoy Models or Oldsmobile Bravada. Refer to Service Bulletin 02-02-35-006A or newer for Mid-Size Utilities. Supercede: This bulletin is being revised to add diagnostic information (refer to Diagnostic Tips) to check the lower steering column bearing as a potential source of the noise. Please discard Corporate Bulletin Number 00-02-35-003M (Section 02-Steering). Condition Some customers may comment on a clunk-type noise coming from under the hood that also can be felt in the steering wheel. These conditions may be more noticeable when turning at low speeds on rough road surfaces. Diagnostic Tips Use the information below to help diagnose the source of the noise. ^ The lower steering column bearing may create the same noise as the intermediate shaft. Before replacing the I-shaft, verify the noise isn't being caused by movement from the lower steering column bearing. Check the bearing for movement by pushing up and down on the I-shaft where it attaches to the steering column. ^ Frame Snap and/or Popping Type Noise - A frame snap or popping type noise can be duplicated on rough or smooth road surfaces with steering wheel input to the left or the right. This type of noise can be HEARD and is typically louder with the windows rolled down. For additional information refer to Corporate Bulletin Number 03-08-61-002F or newer - Snap/Popping Type Noise Coming from Front of Vehicle (Remove Front Crossmember Change Fastener Orientation). ^ Intermediate Shaft Clunk - Intermediate shaft clunk is heard and FELT in the steering wheel and/or steering column area typically while driving on rough road surfaces with steering wheel input. Correction Important: ^ I-shaft P/N 19153614 has been designed to replace previous designed dampened and non-dampened I-shafts. The physical difference in the yoke size will accommodate all vehicles listed in this bulletin. ^ Due to the design of the new I-shaft, it is not possible to lubricate/grease the I-shaft. Replace the steering column upper intermediate shaft with an improved design shaft that will eliminate the clunk noise using the procedure listed below. Page 6916 9. Place a brass drift against the CV joint cage (1). 10. Tap gently on the brass drift with a hammer in order to tilt the cage (1). 11. Remove the first chrome alloy ball (2) when the CV joint cage (1) tilts. 12. Tilt the CV joint cage (1) in the opposite direction to remove the opposing chrome alloy ball (2). 13. Repeat this process to remove all six of the balls. 14. Pivot the CV joint cage (4) and the inner race 90 degrees to the center line of the outer race (1). At the same time, align the cage windows (3) with the lands of the outer race (2). 15. Lift out the cage (4) and the inner race. Component Locations Torque Converter Clutch Solenoid: Component Locations Automatic Transmission - 4L60-E/4L65-E Automatic Transmission Electronic Component Views (M30/M32) Electronic Components Page 6861 13. Install the J 8614-2 (2) and the J 8614-3 (3) into the J 8614-01 (1) as shown. 14. Remove the pinion yoke by turning the J 8614-3 (3) clockwise while holding the J 8614-01 (1). 15. Remove the oil seal using a suitable seal removal tool. Important: Carefully remove the oil seal from the bore. Do not distort or scratch the aluminum case. Installation Procedure 1. Install the oil seal by doing the following: 1. Position the oil seal over the seal bore. 2. Install the J 36366 over the oil seal. 3. Strike the J 36366 with a hammer until the seal flange seats on the axle housing surface. 2. Apply sealant GM P/N 12346004 (Canadian P/N 10953480) or equivalent to the splines of the drive pinion yoke. 3. Install the pinion yoke. Align the reference marks made during removal. 4. Seat the pinion yoke onto the pinion shaft by tapping it with a soft-faced hammer until a few pinion shaft threads show through the yoke. Notice: Refer to Pinion Flange/Yoke Installation Notice in Service Precautions. 5. Install the washer and a new pinion nut. 6. Install the J 8614-01 onto the pinion yoke as shown. 7. Tighten the pinion nut while holding the J 8614-01. Door Latch Assembly (Door Jamb Switch) - Driver C2 Door Switch: Diagrams Door Latch Assembly (Door Jamb Switch) - Driver C2 Door Latch Assembly (Door Jamb Switch) - Driver C2 Page 4503 7. Insert the J 38125-13A (GM P/N 12031876-1) tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the Terminal Repair Kit to ensure that the correct release tool is used. 8. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. REPAIR PROCEDURE Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. Electrical - No Module Communication/DTCs/Warning Lamps Wiring Harness: Customer Interest Electrical - No Module Communication/DTCs/Warning Lamps Bulletin No.: 03-08-50-014A Date: January 20, 2006 TECHNICAL Subject: No Communication with Any Modules, Memory Seat May Not Recall, Multiple U-DTCs Set or Instrument Panel Cluster (IPC) Warning Indicators, Crank No Start (Inspect/Repair Affected Wiring Harness) Models: 2003-2006 Cadillac Escalade, Escalade ESV, Escalade EXT 2003-2006 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2003-2006 GMC Sierra, Yukon, Yukon XL with Front, Individual (Non-Bkt) Seat (RPO AN3) and/or Active Brake Control (Stabilitrak(R)) (RPO JL4) Supercede: This bulletin is being revised to update the various conditions and add the 2004-2006 model years, additional diagnostic and warranty information. Please discard Corporate Bulletin Number 03-08-50-014 (Section 08 - Body & Accessories). Condition Some customers may comment on any of the following conditions: ^ Various IPC Warning indicators are coming on. ^ Driver Information Center (DIC) displays "Unknown Driver". ^ Memory seat may not recall. ^ RKE fobs may be inoperative. ^ Radio or HVAC may shut off. ^ Engine cranks but will not start. Upon investigation, the Technician may find multiple U-DTCs set. Cause On RPO AN3 equipped vehicles, a chafed or pinched seat wiring harness under the driver seat may be a cause of this condition. Because of the routing, a portion of the seat wiring harness may rest on the inboard edge of the seat track or frame. Over time, the harness may be pinched or chafed because of the seat movement. Refer to the above illustration. The illustration shows the inverted position of the seat bottom. The arrow shows the primary location Page 4946 8. Connect the oxygen sensor electrical connectors (1, 2). 9. Connect the CPA retainers. 10. Clip the oxygen sensors electrical connectors to the following: ^ Hose clip ^ Transmission crossmember 11. Connect the oxygen sensor electrical connectors. 12. Connect the CPA retainers. 13. Install the clip around the engine harness and the oxygen sensor pigtail. 14. Connect the oxygen sensor electrical connector. 15. If equipped, clip the oxygen sensor connection to the floor reinforcement. 16. Lower the vehicle. Page 15740 Ambient Light Sensor: Service and Repair AMBIENT LIGHT SENSOR REPLACEMENT REMOVAL PROCEDURE 1. Remove the instrument panel top cover. 2. Disconnect the electrical connector (1) to the ambient light sensor on the underside of the IP top cover. 3. Turn the ambient light sensor 1/4 turn and remove it from the IP top cover. INSTALLATION PROCEDURE 1. Install the ambient light sensor to the underside of the IP top cover, turning it 1/4 turn to secure it in place. 2. Connect the electrical connector (1) to the ambient light sensor on the underside of the IP top cover. 3. Install the instrument panel top cover. Page 12886 networks, and will not require an upgrade in connection with the cellular industry's transition to the digital network. In order to verify the type of OnStar(R) Hardware in a vehicle, type the VIN into the VIN look-up tool, which is available at the OnStar(R) Online Enrollment website within GM GlobalConnect (for U.S. dealers) or InfoNet (for Canadian dealers). Disclaimer Page 3591 Coolant: Fluid Type Specifications ENGINE COOLANT The cooling system in your vehicle is filled with DEX-COOL engine coolant. This coolant is designed to remain in your vehicle for 5 years or 150,000 miles (240 000 km), whichever occurs first, if you add only DEX-COOL extended life coolant. A 50/50 mixture of clean, drinkable water and DEX-COOL coolant will: ^ Give freezing protection down to -34°F (-37°C). ^ Give boiling protection up to 265°F (129°C). ^ Protect against rust and corrosion. ^ Help keep the proper engine temperature. ^ Let the warning lights and gages work as they should. NOTICE: Using coolant other than DEX-COOL may cause premature engine, heater core or radiator corrosion. In addition, the engine coolant may require changing sooner, at 30,000 miles (50 000 km) or 24 months, whichever occurs first. Any repairs would not be covered by your warranty. Always use DEX-COOL (silicate-free) coolant in your vehicle. WHAT TO USE Use a mixture of one-half clean, drinkable water and one-half DEX-COOL coolant which won't damage aluminum parts. If you use this coolant mixture, you don't need to add anything else. CAUTION: Adding only plain water to your cooling system can be dangerous. Plain water, or some other liquid such as alcohol, can boil before the proper coolant mixture will. Your vehicle's coolant warning system is set for the proper coolant mixture. With plain water or the wrong mixture, your engine could get too hot but you would not get the overheat warning. Your engine could catch fire and you or others could be burned. Use a 50/50 mixture of clean, drinkable water and DEX-COOL coolant. NOTICE: If you use an improper coolant mixture, your engine could overheat and be badly damaged. The repair cost would not be covered by your warranty. Too much water in the mixture can freeze and crack the engine, radiator, heater core and other parts. If you have to add coolant more than four times a year, check your cooling system. NOTICE: If you use the proper coolant, you do not have to add extra inhibitors or additives which claim to improve the system. These can be harmful. Engine Controls - Aftermarket Accessory Usage Engine Control Module: All Technical Service Bulletins Engine Controls - Aftermarket Accessory Usage INFORMATION Bulletin No.: 04-06-04-054B Date: November 18, 2010 Subject: Info - Non-GM Parts and Accessories (Aftermarket) Models: 2011 and Prior GM Passenger Cars and Trucks Supercede: This bulletin is being revised to add model years and update to the new U.S. Fixed Operation Manager (FOM) and Canada Warranty Manager (WM) names. Please discard Corporate Bulletin Number 04-06-04-054A (Section 06 - Engine/Propulsion System). The recent rise and expansion of companies selling non-GM parts and accessories has made it necessary to issue this reminder to dealers regarding GM's policy on the use and installation of these aftermarket components. When a dealer is performing a repair under the New Vehicle Limited Warranty, they are required to use only genuine GM or GM-approved parts and accessories. This applies to all warranty repairs, special policy repairs or any repairs paid for by GM. Parts and accessories advertised as being "the same" as parts manufactured by GM, but not sold through GM, do not qualify for use in warranty repairs, special policy repairs or any repairs paid for by GM. During a warranty repair, if a GM original equipment part is not available through GM Customer Care and Aftersales (GM CC&A;), ACDelco(R) distributors, other GM dealers or approved sources, the dealer is to obtain comparable, non-GM parts and clearly indicate, in detail, on the repair order the circumstances surrounding why non-GM parts were used. The dealer must give customers written notice, prior to the sale or service, that such parts or accessories are not marketed or warranted by General Motors. It should also be noted that dealers modifying new vehicles and installing equipment, parts and accessories obtained from sources not authorized by GM are responsible for complying with the National Traffic and Motor Vehicle Safety Act. Certain non-approved parts or assemblies, installed by the dealer or its agent not authorized by GM, may result in a change to the vehicle's design characteristics and may affect the vehicle's ability to conform to federal law. Dealers must fully understand that non-GM approved parts may not have been validated, tested or certified for use. This puts the dealer at risk for potential liability in the event of a part or vehicle failure. If a GM part failure occurs as the result of the installation or use of a non-GM approved part, the warranty will not be honored. A good example of non-authorized modification of vehicles is the result of an ever increasing supply of aftermarket devices available to the customer, which claim to increase the horsepower and torque of the Duramax(TM) Diesel Engines. These include the addition of, but are not limited to one or more of the following modifications: - Propane injection - Nitrous oxide injection - Additional modules (black boxes) that connect to the vehicle wiring systems - Revised engine calibrations downloaded for the engine control module - Calibration modules which connect to the vehicle diagnostic connector - Modification to the engine turbocharger waste gate Although the installation of these devices, or modification of vehicle components, can increase engine horsepower and torque, they may also negatively affect the engine emissions, reliability and/or durability. In addition, other powertrain components, such as transmissions, universal joints, drive shafts, and front/rear axle components, can be stressed beyond design safety limits by the installation of these devices. General Motors does not support or endorse the use of devices or modifications that, when installed, increase the engine horsepower and torque. It is because of these unknown stresses, and the potential to alter reliability, durability and emissions performance, that GM has adopted a policy that prevents any UNAUTHORIZED dealer warranty claim submissions to any remaining warranty coverage, to the powertrain and driveline components whenever the presence of a non-GM (aftermarket) calibration is confirmed - even if the non-GM control module calibration is subsequently removed. Refer to the latest version of Bulletin 09-06-04-026 (V8 Gas Engines) or 06-06-01-007 (Duramax(TM) Diesel Engines) for more information on dealer requirements for calibration verification. These same policies apply as they relate to the use of non-GM accessories. Damage or failure from the use or installation of a non-GM accessory will not be covered under warranty. Failure resulting from the alteration or modification of the vehicle, including the cutting, welding or disconnecting of the vehicle's original equipment parts and components will void the warranty. Additionally, dealers will NOT be reimbursed or compensated by GM in the event of any legal inquiry at either the local, state or federal level that Page 3233 Drive Belt: Technical Service Bulletins Engine - Serpentine Drive Belt Wear Information Bulletin No.: 04-06-01-013 Date: April 29, 2004 INFORMATION Subject: Information on Serpentine Belt Wear Models: 2004 and Prior Passenger Cars and Trucks 2003-2004 and Prior HUMMER H2 All current GM vehicles designed and manufactured in North America were assembled with serpentine belts that are made with an EPDM material and should last the life of the vehicle. It is extremely rare to observe any cracks in EPDM belts and it is not expected that they will require maintenance before 10 years or 240,000 km (150,000 mi) of use. Older style belts, which were manufactured with a chloroprene compound, may exhibit cracks depending on age. However, the onset of cracking typically signals that the belt is only about halfway through its usable life. A good rule of thumb for chloroprene-based belts is that if cracks are observed 3 mm (1/8 in) apart, ALL AROUND THE BELT, the belt may be reaching the end of its serviceable life and should be considered a candidate for changing. Small cracks spaced at greater intervals should not be considered as indicative that the belt needs changing. Any belt that exhibits chunking should be replaced. Disclaimer Automatic Transmission Input Shaft Speed (AT ISS) Sensor Connector Page 14545 Disclaimer Page 12522 Check - Vehicle. The Diagnostic System Check will provide the following information: ^ The identification of the control modules which command the system ^ The ability of the control modules to communicate through the serial data circuit ^ The identification of any stored diagnostic trouble codes (DTCs) and their status The use of the Diagnostic System Check will identify the correct procedure for diagnosing the system and where the procedure is located. Visual/Physical Inspection Perform the following visual inspections; ^ Inspect for aftermarket devices which could affect the operation of the Radio/Audio System. Refer to Checking Aftermarket Accessories in SI. ^ Inspect the easily accessible and visible system components for obvious damage or conditions which could cause the symptom. Intermittent Conditions Faulty electrical connections or wiring may be the cause of intermittent conditions. Refer to Testing for Intermittent Conditions and Poor Connections in SI. Symptom List Page 8480 Page 12915 Audio Amplifier C1 - With RPO Code UQ7, Without RPO Code Y91 - Part 2 Page 9263 Junction Block - I/P Wire Entry Part 1 Page 4628 Body Control Module (BCM) Diagram Information and Instructions Power Take-Off: Diagram Information and Instructions Truck Zoning TRUCK ZONING Truck Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that corresponds to where they are located in the vehicle. The table explains the numbering system. Wheels - Chrome Wheel Brake Dust Accumulation/Pitting Wheels: All Technical Service Bulletins Wheels - Chrome Wheel Brake Dust Accumulation/Pitting Bulletin No.: 04-03-10-012B Date: February 01, 2008 INFORMATION Subject: Pitting and Brake Dust on Chrome wheels Models: 2008 and Prior GM Passenger Cars and Trucks (including Saturn) 2008 and Prior HUMMER H2, H3 2005-2008 Saab 9-7X Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 04-03-10-012A (Section 03 - Suspension). Analysis of Returned Wheels Chrome wheels returned under the New Vehicle Limited Warranty for pitting concerns have recently been evaluated. This condition is usually most severe in the vent (or window) area of the front wheels. This "pitting" may actually be brake dust that has been allowed to accumulate on the wheel. The longer this accumulation builds up, the more difficult it is to remove. Cleaning the Wheels In all cases, the returned wheels could be cleaned to their original condition using GM Vehicle Care Cleaner Wax, P/N 12377966 (in Canada, P/N 10952905). When using this product, you should confine your treatment to the areas of the wheel that show evidence of the brake dust build-up. This product is only for use on chromed steel or chromed aluminum wheels. Parts Information Warranty Information Wheel replacement for this condition is NOT applicable under the terms of the New Vehicle Limited Warranty. Disclaimer Page 15828 Turn Signal Multifunction Switch - C2 Page 14919 Driver Door Module (DDM) - C5 (Memory/Heated Seat Switch) Part 2 Page 10786 5. Disconnect the electrical connector from the A/C low pressure switch. 6. Remove the compressor hose nut from the accumulator. 7. Remove the compressor hose from the accumulator. 8. Remove the nut (2) from the evaporator fitting. 9. Remove the accumulator bracket nut (4) from the retaining stud. 10. Remove the accumulator (3). 11. Remove the retaining bracket bolt (5). 12. Remove the retaining bracket (6) from the accumulator. 13. Remove and discard the O-ring seals. INSTALLATION PROCEDURE 1. Install new O-ring seals. 2. Install the retaining bracket (6) to the accumulator. NOTE: Refer to Fastener Notice in Service Precautions. 3. Install the retaining bracket bolt (5). Tighten Tighten the bolt to 10 N.m (89 lb in). 4. Install the accumulator (3). 5. Install the accumulator bracket nut (4). Tighten Tighten the nut to 9 N.m (80 lb in). 6. Install the nut (2) to the evaporator fitting. Page 5351 3. If vehicle is a regular cab, install the fuel feed, EVAP, and return pipe assembly nuts. Tighten Tighten the nuts to 12 N.m (106 lb in). 4. Remove the caps from the fuel pipes at the fuel tank. 5. Connect the fuel feed and return pipes at the fuel tank. 6. If equipped with 4WD, install the torsion bar bracket. 7. Install the EHCU (1). 8. Install the bolts (4) attaching the EHCU bracket to the frame (5). Tighten Tighten the bolts to 25 N.m (18 lb ft). OnStar(R) - Loss of GPS Signal/Hands Free Issues Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Loss of GPS Signal/Hands Free Issues Bulletin No.: 02-08-46-007C Date: November 19, 2007 INFORMATION Subject: Information on OnStar(R) System - Possible Loss of GPS Signal, Hands-Free Calling Minutes Expire Prematurely and/or Inability to Add Hands-Free Calling Minutes Models: 2001-2008 GM Passenger Cars and Light Duty Trucks (Including Saturn) 2003-2008 HUMMER H2 2006-2008 HUMMER H3 2005-2008 Saab 9-7X with OnStar(R) System (RPO UE1) Supercede: This bulletin is being revised to add the 2008 model year, warranty information and to provide GPS signal recovery steps (under Dealer Action heading) to do PRIOR to determining if the VIU/VCIM needs replacement. Please discard Corporate Bulletin Number 02-08-46-007B (Section 08 - Body & Accessories). If the vehicle currently has analog-upgradable OnStar(R) hardware, then the customer should be made aware of the digital upgrade program per the latest version of Service Bulletin # 05-08-46-006. Any analog OnStar system that is not upgraded prior to the end of 2007 will be deactivated due to the upcoming phase-out of the analog cellular network in the U.S. and Canada. If the vehicle has recently been upgraded or has had a service replacement unit installed, this bulletin may not be applicable. Certain 2001-2008 model year vehicles equipped with OnStar(R) may exhibit a condition with the Global Positioning System (GPS) that causes inaccuracies in the GPS clock. The GPS system is internal to the OnStar(R) Vehicle Interface Unit (VIU) or the Vehicle Communication Interface Module (VCIM). This inaccuracy can result in a symptom where the OnStar(R) Call Center is unable to obtain an accurate GPS signal, hands-Free Calling minutes expire prematurely and/or the inability to add Hands-Free calling minutes. Customer Notification OnStar(R) will notify the customer by mail with instructions to contact their dealership service department. Dealer Action Not all vehicles will require VIU/VCIM replacement. The GPS signal in some vehicles may be recoverable. To determine if the signal is recoverable, simply connect the Tech2(R) and using the GPS information data display option, observe the GPS date and time. If the date/time stamps are equal to a date approximately 19 years in the future, the GPS clock has exceeded its capacity and the VIU/VCIM will need to be replaced. If the date/time stamp is in the past or near future, the GPS clock has simply generated an inaccurate value and may be recoverable by performing the following power-up reset. To initiate a power-up reset, battery voltage (batt. +) must be removed from the VIU/VCIM. The preferred methods, in order, of initiating the reset are outlined below. Remove the fuse that supplies Battery positive (Batt. +) voltage to the module (refer to the applicable Service Information schematics for the appropriate fuse). The next preferred method is to remove the connector to the OnStar(R) unit that Batt + is contained. The least preferable method is to remove the negative terminal of the vehicle battery. This will not only initiate the power-up reset, but it may also result in the loss of radio presets and other stored personalization information/settings in other modules as well. After initiating the power-up reset, the GPS data will be set to the defaulted date and time and will require an acquisition of the GPS signal in order to gain the proper date and time. Acquiring the GPS signal requires running the vehicle in an open/unobstructed view of the sky. First, contact OnStar(R) Technical Support by pressing the blue button. Allow the OnStar(R) Technical Advisor to activate the GPS recovery process. This should take approximately 10 minutes. Continue to Capacity Specifications Fluid - Transfer Case: Capacity Specifications Information not supplied by the manufacturer. Capacity Specifications Fluid - A/T: Capacity Specifications Transmission Fluid 4L-60-E Pan Removal .......................................................................................... ........................................................................................................... 4.7L (5.0 Qt) Overhaul ............. .............................................................................................................................................................. ............................. 10.6L (11.0 Qt) 4L80-E Pan Removal ................................................................... .................................................................................................................................. 7.3L (7.7 Qt) Overhaul .............................................................................................................................................. .......................................................... 12.8L (13.5 Qt) Allison Pan Removal ....................................... .............................................................................................................................................................. 7.0L (7.4 Qt) Overhaul ......................................................................................................................... ............................................................................... 12.0L (12.7 Qt) Page 10732 Axle Nut: Specifications Axle Shaft Nut ...................................................................................................................................... ................................................ 240 Nm (177 ft. lbs.) Page 7543 Fluid - Transfer Case: Service and Repair Transfer Case - NVG 246-NP8 Transfer Case Fluid Replacement Removal Procedure Important: When performing the following procedures, use only hand tools to remove and install the drain and fill plugs. 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. Remove the transfer case shield, if equipped. 3. Remove the fill plug. 4. Remove the drain plug. Installation Procedure 1. Notice: Refer to Fastener Notice in Service Precautions. Important: Use only drain and fill plugs that are made from aluminum. Steel or brass plugs are not compatible with the magnesium case. Install the drain plug. ^ Tighten the plug to 20 Nm (15 ft. lbs.). 2. Fill the transfer case to the bottom of the fill plug hole with Auto-Trak II, transfer case fluid, GM P/N 12378508 (Canadian P/N 10953626). Page 3713 1. Install the heat shield (2), and bolts (1) to the exhaust manifold (1), if necessary. Tighten the bolts to 9 Nm (80 inch lbs.). 2. Important: ^ Tighten the exhaust manifold bolts as specified in the service procedure. Improperly installed and/or leaking exhaust manifold gaskets may affect vehicle emissions and/or On-Board Diagnostics (OBD) II system performance. ^ The cylinder head exhaust manifold bolt hole threads must be clean and free of debris or threadlocking material. Important: Do not apply sealant to the first three threads of the bolt. Apply a 5 mm (0.2 inch) wide band of threadlock GM P/N 12345493 (Canadian P/N 10953488), or equivalent to the threads of the exhaust manifold bolts. 3. Install the exhaust manifold, NEW gasket and bolts. 1. Tighten the bolts a first pass to 15 Nm (11 ft. lbs.). Tighten the bolts beginning with the center 2 bolts. Alternate from side-to-side, and work toward the outside bolts. 2. Tighten the bolts a final pass to 25 Nm (18 ft. lbs.). Tighten the bolts beginning with the center 2 bolts. Alternate from side-to-side, and work toward the outside bolts. 4. Using a flat punch, bend over the exposed edge of the exhaust manifold gasket at the front of the right cylinder head. 5. Install the spark plugs. 6. Raise the vehicle. 7. Install the exhaust manifold pipe nuts. Tighten the nuts to 50 Nm (37 ft. lbs.). 8. Lower the vehicle. Page 6115 Disclaimer Page 3692 Water Pump: Service and Repair Water Pump Replacement (4.8L, 5.3L, and 6.0L Engines) Removal Procedure 1. Drain the cooling system. 2. Loosen the air cleaner outlet duct clamps at the following locations: ^ Throttle body ^ Mass Airflow/Intake Air Temperature (MAF/IAT) sensor 3. Remove the radiator inlet hose clip from the outlet duct. 4. Remove the air cleaner outlet duct. 5. If necessary, remove the engine sight shield. 6. Remove the radiator vent inlet hose from the radiator hose clips. 7. Reposition the inlet hose clamp at the water pump. 8. Remove the inlet hose from the water pump. 9. Remove the fan blade. 10. Remove the accessory drive belt. Replacement - Accessory (4.8L, 5.3L, and 6.0L Engines) Drive Belt Replacement - Accessory (5.3L Engine w/RPO HP2) in Engine Mechanical - 4.8L, 5.3L, and 6.0L. Page 10815 ^ Reinstall the fuse and fuse panel cover. ^ Press the "Enter" button to perform the "Refresh" function. ^ "Test in Progress" will be displayed and the right front passenger door lock will cycle once. ^ The screen will display "Procedure Completed". ^ Press the "Exit" button as necessary to return to the main menu screen. 3. Using the switches in the right front passenger door, verify that the power window and power door lock located in that door function properly. Important: The calibrations required for performing SPS reprogram in the next step are based on the type of exterior rearview mirror the vehicle has. To determine the correct calibration, check the Service Parts Identification Label on the vehicle for the RPO code for exterior mirrors. 4. Follow normal Service Programming System (SPS) to reprogram the passenger door module with the current calibration available in TIS 2000. 5. After reprogramming is complete, using the switches in the right front passenger door, verify that the power window and power door lock located in that door function properly. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 2073 Fuel Pressure: Testing and Inspection Fuel System Diagnosis FUEL SYSTEM DIAGNOSIS SYSTEM DESCRIPTION The control module enables the fuel pump relay when the ignition switch is turned ON. The control module will disable the fuel pump relay within two seconds unless the control module detects ignition reference pulses. The control module continues to enable the fuel pump relay as long as ignition reference pulses are detected. The control module disables the fuel pump relay within two seconds if ignition reference pulses cease to be detected and the ignition remains ON. The Fuel System is a returnless on-demand design. The fuel pressure regulator is a part of the fuel sender assembly, eliminating the need for a return pipe from the engine. A returnless fuel system reduces the internal temperature of the fuel tank by not returning hot fuel from the engine to the fuel tank. Reducing the internal temperature of the fuel tank results in lower evaporative emissions. The fuel tank stores the fuel supply. An electric turbine style fuel pump attaches to the fuel sender assembly inside the fuel tank. The fuel pump supplies high pressure fuel through the fuel filter and the fuel feed pipe to the fuel injection system. The fuel pump provides fuel at a higher rate of flow than is needed by the fuel injection system. The fuel pump also supplies fuel to a venturi pump located on the bottom of the fuel sender assembly. The function of the venturi pump is to fill the fuel sender assembly reservoir. The fuel pressure regulator, a part of the fuel sender assembly, maintains the correct fuel pressure to the fuel injection system. The fuel pump and sender assembly contains a reverse flow check valve. The check valve and the fuel pressure regulator maintain fuel pressure in the fuel feed pipe and the fuel rail in order to prevent long cranking times. TEST Steps 1 - 2 Page 8588 Page 468 Electrical Symbols Part 5 Page 15177 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-8 (12085115) crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-8 (12085115) until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes SPLICING INLINE HARNESS DIODES Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate Service Data wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. 9. Tape the diode to the harness or connector using electrical tape. Instruments - Unable to Reset Oil Life Monitor Oil Change Reminder Lamp: All Technical Service Bulletins Instruments - Unable to Reset Oil Life Monitor Bulletin No.: 04-06-04-043 Date: June 17, 2004 TECHNICAL Subject: Unable to Reset Engine Oil Life Monitor (Reprogram PCM) Models: 2004 Buick Rainier 2004 Cadillac Escalade, Escalade ESV, Escalade EXT 2004 Chevrolet Avalanche, Express, SSR, Silverado, Suburban, Tahoe, Trailblazer 2004 GMC Envoy, Savana, Sierra, Yukon, Yukon XL with V8 Engine (VINs G, N, P, T, U, V, Z - RPOs L18, LQ9, LM4, LM7, LQ4, LR4, L59) and Electronic Throttle Control Condition Some owners may comment that they are unable to reset the Engine Oil Life Monitor. Correction Reprogram the PCM with calibration operating system P/N 12587603 or later. The new calibration was released beginning with TIS satellite data update version 8.0 for 2003, available August 2003. As always, make sure your TECH2(R) is updated with the latest software version. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 1566 Crankshaft Position Sensor: Description and Operation CRANKSHAFT POSITION (CKP) SENSOR The crankshaft position (CKP) sensor is a three wire sensor based on the magneto resistive principle. A magneto resistive sensor uses two magnetic pickups between a permanent magnet. As an element such as a reluctor wheel passes the magnets the resulting change in the magnetic field is used by the sensor electronics to produce a digital output pulse. The PCM supplies a 12-volt, low reference, and signal circuit to the CKP sensor. The sensor returns a digital ON/OFF pulse 24 times per crankshaft revolution. Engine Controls - MIL ON/Misfire/Misfire DTC's Set Engine Control Module: All Technical Service Bulletins Engine Controls - MIL ON/Misfire/Misfire DTC's Set Bulletin No.: 06-06-04-046 Date: September 12, 2006 INFORMATION Subject: Information on Engine Misfire MIL/SES Light Illuminated or Flashing DTC P0300, P0301, P0302, P0303, P0304, P0305, P0306, P0307, P0308, P0420 or P0430 Models: 1999-2007 Cadillac, Chevrolet, GMC Full-Size Pickup and/or Utility Trucks with 4.8L, 5.3L, 5.7L, 6.0L or 6.2L VORTEC GEN III, GEN IV, V-8 Engine (VINs V, C, T, Z, B, 3, M, 0, J, R, U, N, Y, K, 8 - RPOs LR4, LY2, LM7, L59, L33, LC9, LH6, LMG, LY5, L31, LQ4, LQ9, L76, LY6, L92) with Active Fuel Management(TM) and E85 Flex Fuel If you encounter vehicles that exhibit the above conditions, refer to SI for the appropriate DTC(s) set. If no trouble is found, the cause may be due to an ECM ground terminal that has corroded with rust over time. Inspect the main engine wiring harness ground terminal (G103) for this condition. The wire terminal (G103) attaches either to the front or to the rear of the right side cylinder head, depending on the model year of the Full Size Pickup and/or Utility Trucks. If the ECM ground terminal has been found to be corroded, then follow the service procedure outlined in this bulletin to correct the corrosion issue. Remove either the nut or bolt securing the main engine wiring harness ground terminal (G103) to the right cylinder head. Refer to the above illustration to determine where the ground is located on the vehicle (1). Page 5475 Important: The intake plenum should also be checked for excessive warpage that may cause an uneven clamping pressure of the seal. If the plenum is found to be warped it will need to be replaced. Service Information states, "An intake manifold with warpage in excess of 3 mm (0.118 in) over a 200 mm (7.87 in) area should be replaced." Intake warpage is measured at the gasket sealing surfaces and should be measured within a 200 mm (7.87 in) area. This measurement is across only two of the intake runner port openings. Measurements taken across the entire distance of all four intake runner ports will lead to unnecessary manifold replacements. Important: Measurements taken across the entire distance of all four intake runner ports will lead to unnecessary intake manifold replacements. 1. Locate a straight edge across the intake manifold cylinder head deck surface. Position the straight edge across two runner port openings. 2. Insert a feeler gauge between the intake manifold and the straight edge. An intake manifold with warpage in excess of 3 mm (0.118 in) over a 200 mm (7.87 in) area is warped and should be replaced. Do not replace intake manifolds with warpage that measures less than 3 mm (0.118 in) over a 200 mm (7.87 in). Parts Information Warranty Information For vehicles repaired under warranty, use the table. Page 4863 5. If equipped with a 6.0L engine, disconnect the HO2S electrical connector. 6. Remove the HO2S. INSTALLATION PROCEDURE IMPORTANT: A special anti-seize compound is used on the HO2S threads. The compound consists of liquid graphite and glass beads. The graphite tends to burn away, but the glass beads remain, making the sensor easier to remove. New, or service replacement sensors already have the compound applied to the threads. If the sensor is removed from an exhaust component and if for any reason the sensor is to be reinstalled, the threads must have anti-seize compound applied before the reinstallation. 1. If reinstalling the old sensor, coat the threads with anti-seize compound GM P/N 12377953, or equivalent. NOTE: Refer to Component Fastener Tightening Notice in Service Precautions. Page 1711 Mass Air Flow (MAF) Sensor: Service and Repair MASS AIR FLOW (MAF)/INTAKE AIR TEMPERATURE (IAT) SENSOR REPLACEMENT REMOVAL PROCEDURE IMPORTANT: Use care when handling the mass air flow/intake air temperature (MAF/IAT) sensor. Do not dent, puncture, or otherwise damage the honeycell located at the air inlet end of the MAF/IAT. Do not touch the sensing elements or allow anything including cleaning solvents and lubricants to come in contact with them. Use a small amount of a non-silicone based lubricant, on the air duct only, to aid in installation. 1. Remove the air cleaner outlet duct. 2. Pull out the gray connector position assurance (CPA) retainer. 3. Push down on the black clip in order to disconnect the MAF/IAT sensor electrical connector (4). 4. Loosen the MAF/IAT clamp. 5. Remove the MAF/IAT sensor from the air cleaner assembly. INSTALLATION PROCEDURE IMPORTANT: The embossed arrow on the MAF/IAT sensor indicates the proper air flow direction. The arrow must point toward the engine. Page 923 Body Control Module (BCM) - C6 Part 2 Page 3252 3. The squeal may be an internal engine noise. Remove the drive belt(s) and operate the engine for a few seconds, this will verify if the squealing noise is related to the drive belt(s) or an accessory drive component. With the drive belt(s) removed the water pump will not operate and the engine may overheat. Also diagnostic trouble codes (DTCs) may set when the engine is operated with the drive belt(s) removed. 4. This test is to verify that an accessory drive component(s) does not have a seized bearing. With the belt(s) removed, test the bearings in the accessory drive component(s) for smooth operation. Also test the accessory drive component(s) with the engine operating by varying the load on the accessory drive component(s) to verify that the component(s) is operating properly. 5. This test is to verify that the drive belt(s) tensioner(s) are not operating properly. If the drive belt tensioner(s) are not operating properly, proper belt tension may not be achieved to keep the drive belt(s) from slipping which could cause a squealing noise. 6. This test is to verify that the drive belt(s) is not too long, which would prevent the drive belt tensioner(s) from operating properly. Also if the incorrect length drive belt(s) was installed, it may not be routed correctly and may be turning an accessory drive component in the incorrect direction. 7. Misalignment of the accessory drive pulley(s) may be caused from improper mounting or incorrect installation of a accessory drive component, or the pulley may be bent inward or outward from a previous repair. Test for a misaligned pulley using a straight edge in the pulley grooves across two or three pulleys. If a misaligned pulley is found, refer to that accessory drive component for the proper removal and installation procedure for that pulley. 8. Inspect the accessory drive pulley(s) to verify that they are the correct diameter or width. Using a known good vehicle, compare the accessory drive pulleys. Drive Belt Vibration Drive Belt Vibration Diagnosis Diagnostic Aids The accessory drive components may have an affect on engine vibration. An overcharged air conditioning (A/C) system, a power steering system restriction, or the incorrect fluid, or an extra load placed on the generator are suggested items to inspect. To help identify an intermittent or an improper condition, vary the loads on the accessory drive components. Test Description Page 9205 C206 I/P Harness To Body Harness (With RPO Codes Y91/HP2) Part 1 Page 2943 Do not use cleaning solutions that contain hydrofluoric, oxalic and most other acids on chrome wheels (or any wheels). If the customer is unsure of the chemical make-up of a particular wheel cleaner, it should be avoided. For wheels showing signs of milky staining from acidic cleaners, refer to Customer Assistance and Instructions below. Warranty of Stained Chrome Wheels Stained wheels are not warrantable. Most acid based cleaners will permanently stain chrome wheels. Follow-up with dealers has confirmed that such cleaners were used on wheels that were returned to the Warranty Parts Center (WPC). Any stained wheels received by the WPC will be charged back to the dealership. To assist the customer, refer to Customer Assistance and Instructions below. Pitting or Spotted Appearance of Chrome Wheels Figure 2 A second type or staining or finish disturbance may result from road chemicals, such as calcium chloride used for dust control of unpaved roads. The staining will look like small pitting (refer to Figure 2). This staining will usually be on the leading edges of each wheel spoke, but may be uniformly distributed. If a vehicle must be operated under such conditions, the chrome wheels should be washed with mild soap and water and thoroughly rinsed as soon as conveniently possible. Important Road chemicals, such as calcium chloride used for dust control of unpaved roads, can also stain chrome wheels. The staining will look like small pitting. This staining will usually be on the leading edges of each wheel spoke. This is explained by the vehicle traveling in the forward direction while being splashed by the road chemical. If a vehicle must be operated under such conditions, the chrome wheels should be washed with mild soap and water and thoroughly rinsed as soon as conveniently possible. Warranty of Pitted or Spotted Chrome Wheels Wheels returned with pitting or spotting as a result of road chemicals may be replaced one time. Damage resulting from contact with these applied road chemicals is corrosive to the wheels finish and may cause damage if the wheels are not kept clean. Important Notify the customer that this is a one time replacement. Please stress to the customer the vital importance of keeping the wheels clean if they are operating the vehicle in an area that applies calcium chloride or other dust controlling chemicals! "GM of Canada" dealers require prior approval by the District Manager - Customer Care and Service Process (DM-CCSP). "Stardust" Corrosion of Chrome Wheels Figure 3 A third type of finish disturbance results from prolonged exposure to brake dust and resultant penetration of brake dust through the chrome. As brakes are applied hot particles of brake material are thrown off and tend to be forced through the leading edge of the wheel spoke windows by airflow. These Page 5813 Page 2542 Disclaimer Page 15063 - On the 2.4 m (8 ft) long pickup box models, this center reinforcement fits over the existing center stake hole. - On the 1.7 m (5 ft. 8 in.) and 2 m (6.5 ft) short box models, these center reinforcements are recommended to be installed. The reinforcements should be centered between the front and rear reinforcements on the pickup box. 12. Mark the holes necessary for drilling and remove the brackets. 13. Drill 7.5 mm (0.30 in) holes into the weld flange of the side outer panel. 14. Touch-up the drilled holes as necessary. Refer to step 6 under the Front Reinforcement Installation procedure. 15. Place the center reinforcements back onto the pickup box. 16. Install the M6 bolts through the reinforcement and side panel with the nuts. Tighten Tighten the bolts to 9 Nm (79 lb-in). 17. Remove any metal shavings from the pickup box after installation. *Maximum Equipment Weight Capacities (Equipment and Cargo) ^ Ladder Rack and Cargo - 340 kg (750 lb) ^ Cross Toolbox and Cargo - 181 kg (400 lb) ^ Side Tool boxes and Cargo - 113 kg (250 lb) (per side) *The combined weight for all rail-mounted equipment should not exceed 454 kg (1,000 lb). Excluded is the 1500 Series Crew Cab models with 5'8" pickup box length. A reinforcement kit for rail-mounted add-on equipment is recommended as described in this bulletin. Ladder racks are not recommended for 1500 Series Crew Cab models with 5'8"pickup box. Maximum recommended cross-mounted tool box and cargo weight is 136 kg (300 lb) for the 1500 Series Crew Cab with 5'8" pickup box. Page 13647 10. Align the hinge and backing plate with the holes in the door. Install bolts. Tighten bolts to 25 N.m (20 ft. lb.) (Fig.1.20). 11. Apply sealers and refinish as necessary. Do not combine paint systems. Refer to paint manufacturer's recommendations. 12. Install and align all related panels and components. Page 6257 Fluid Filter - A/T: Service and Repair 4L80-E/4L85-E Automatic Transmission Fluid/Filter Replacement Removal Procedure 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. Place a drain pan under the transmission oil pan. 3. Remove the oil pan drain plug, if equipped. 4. Allow the transmission fluid to drain completely. 5. Apply a small amount of sealant GM P/N 12346004 (Canadian P/N 10953480), or equivalent to the treads of the drain plug, if equipped. Notice: Refer to Fastener Notice in Service Precautions. 6. Install the oil pan drain plug. ^ Tighten the oil pan drain plug to 18 Nm (13 ft. lbs.). 7. Remove the drain pan from under the transmission oil pan. 8. Support the transmission with a transmission jack. 9. Remove the transmission mount nuts. 10. Remove the transmission support bolts and nuts. 11. Remove the transmission support side bracket bolts and bracket. 12. Remove the transmission support. 13. Disconnect the range selector cable end (2) from the transmission range selector lever ball stud (1). Page 10229 Electrical Symbols Part 14 Page 13588 3. Install assist step bracket nuts (2). Torque the bolts to 50 N.m (37 lb ft) 4. Install the lower body-mount cushion assemblies (2) to the vehicle. 5. With an assistant, raise the assist step to the vehicle. 6. With an assistant, install the following: 1. The washers 2. The body mount bolts (1) Torque bolts to 90 N.m (66 lb ft) Page 1017 7. Disconnect the SDM wiring harness connector (1) from the SDM (3). 8. Remove the SDM mounting fasteners. 9. Remove the SDM from the vehicle. IMPORTANT: The following repair procedures should only be used in the event that the inflatable restraint sensing and diagnostic module (SDM) mounting studs and/or fasteners are damaged to the extent that the SDM may no longer be properly mounted. 10. Repair the fasteners using the following procedure: 10.1. Remove the stripped nut and discard the nut. 10.2. Drill out the weld spots to the weld stud from the floor pan side, then remove and discard the stud. 10.3. Condition the floor panel attaching surface where the new stud is to be installed. 10.4. Install new weld stud GM P/N 115115602 and clamp the weld stud. 10.5. Migweld the stud at the drilled holes from above or below the floor pan, as required. 10.6. Apply body sealer GM P/N 9984248 around any exposed openings. 10.7. Install a new fastener GM P/N 11515933. INSTALLATION PROCEDURE 1. Remove any dirt, grease, or other contaminants from the mounting surface. 2. Install the SDM (3) horizontally to the vehicle. 3. Point the arrow on the SDM toward the front of the vehicle. NOTE: Refer to Fastener Notice in Service Precautions. 4. Install the SDM mounting fasteners. Tighten Tighten fasteners to 10 N.m (89 lb in). 5. Connect the SDM wiring harness connector (1) to the SDM. Page 11458 Inflatable Restraint I/P Module Disable Switch (With RPO Code C99) Page 2945 *This product is currently available from 3M. To obtain information for your local retail location please call 3M at 1-888-364-3577. **This product is currently available from Meguiars (Canada). To obtain information for your local retail location please call Meguiars at 1-800-347-5700 or at www.meguiarscanada.com. ^ This product is currently available from Tri-Peek International. To obtain information for your local retail location please call Tri-Peek at 1-877-615-4272 or at www.tripeek.com. Disclaimer Page 7162 Fluid - M/T: Service and Repair ZF S6-650 Transmission Fluid Replacement Removal Procedure 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. Remove the oil fill plug. 3. Place a suitable drain pan under the transmission in order to catch the drained transmission fluid. 4. Remove the oil drain plug. 5. Remove any old sealant from the transmission housing and plugs. Installation Procedure 1. Apply sealant GM P/N 12346004 (Canadian P/N 10953480), or equivalent to the treads of the oil drain and fill plugs. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the oil drain plug. ^ Tighten the plug to 35 Nm (26 ft. lbs.). 3. Fill the transmission to just below the bottom of the fill plug hole. Refer to Lubrication Specifications. 4. Install the oil fill plug. ^ Tighten the plug to 35 Nm (26 ft. lbs.). 5. Lower the vehicle. Page 4674 Control Module References Part 3 Page 12667 Page 4297 Body Control Module: Diagnostic Aids Basic Knowledge Required BASIC KNOWLEDGE REQUIRED Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the Service Data. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories CHECKING AFTERMARKET ACCESSORIES Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: - Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions INDUCING INTERMITTENT FAULT CONDITIONS In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: - Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. Page 11155 For vehicles repaired under warranty, use the table. Disclaimer Wheels/Tires - 20 Inch Wheels Available From GM Wheels: All Technical Service Bulletins Wheels/Tires - 20 Inch Wheels Available From GM Bulletin No.: 03-03-10-006F Date: September 27, 2006 INFORMATION Subject: 20" Wheels Available Through GM Accessories Models: 1999-2007 Chevrolet Silverado 1500 Series Only (Classic) 1999-2007 GMC Sierra 1500 Series Only (Classic) Excludes 1999-2000 Vehicles with 4.3L Engine (VIN W - RPO L35) Excludes Vehicles with Quadrasteer (RPO NYS) Excludes Parallel Hybrid Truck (RPO HP2) Excludes 2001-2004 Vehicles with Traction Control (RPO NW7) combined with 3.42 Axle Ratio (RPO GU6) Page 868 Electrical Symbols Part 4 Page 4854 Heated Oxygen Sensor (HO2S) Bank 2 Sensor 2 Drivetrain - Wheel Drive Shaft Nut Torque Revision Axle Nut: Technical Service Bulletins Drivetrain - Wheel Drive Shaft Nut Torque Revision Bulletin No.: 04-04-95-001 Date: March 02, 2004 SERVICE MANUAL UPDATE Subject: Revised Wheel Drive Shaft Nut Torque Specification Models: 2002-2004 Cadillac Escalade, Escalade EXT 2003-2004 Cadillac Escalade ESV 1999-2004 Chevrolet Silverado 2000-2004 Chevrolet Suburban 2002-2004 Chevrolet Avalanche 2003-2004 Chevrolet Astro, Express 1999-2004 GMC Sierra 2000-2004 GMC Yukon, Yukon XL 2003-2004 GMC Safari, Savana 2003-2004 HUMMER H2 This bulletin is being issued to revise the torque specification for the wheel drive shaft nut in the Wheel Drive Shafts sub-section of the Service Manual. Please replace the current information in the Service Manual with the following information. The following information has been updated within SI. If you are using a paper version of this Service Manual, please make a reference to this bulletin on the affected page. Page 8622 visible in the clear adapter tube). If fluid is seen coming out of the inlet port adapter up to 65 Nm (48 lb-ft) maximum torque, the hydro-boost booster assembly is "OK", Proceed to Step 19. A. If NO fluid is seen exiting from the inlet port adapter, complete Steps 19-27 and then repeat Steps 1-18. B. If no fluid is visible from the second evaluation, replace the hydro-boost unit. Proceed to the appropriate procedure found in this bulletin. 19. Loosen the clamp bolt, remove the clamp containment bolt, and remove the accumulator pressure clamp. Remove the inlet port adapter from the supply port of the booster. Wipe the excess power steering fluid off of the adapter with a clean, lint-free shop cloth. Store the adapter in a clean location, such as a plastic bag. 20. Reinstall the supply hose/tube to the booster. Tighten Tighten to 28 N.m (21 lb-ft). 21. Clean any spilled fluid from the outside of the booster. 22. For Express/Savana only: ^ Connect the reservoir outlet hose to the booster unit. Keeping the hose end higher than reservoir, reposition the reservoir onto the mounting studs. A. Install the remote power steering reservoir mounting nuts. Tighten Tighten to 7 Nm (58 lb in). 23. Start the engine and run at idle. Depress the brake pedal 5 times. Turn the steering wheel to the "steering lock" position. Hold for 1-2 seconds. Check to see if there is any leakage from the ports/fittings. 24. Turn the engine off. 25. If leaks were observed, re-check that the fittings are at the recommended torque values. Repeat Steps 17 and 18. 26. Check the power steering reservoir fluid level, add fluid if necessary. 27. Close the hood. Hydro-Boost(R) Replacement - Avalanche, Express, Savana, Silverado, Sierra, Suburban, Yukon XL Tools Required ^ J 35555 Metal Mityvac ^ J 43485 Power Steering Bleeder Adapter Removal 1. Apply the park brake and block the wheels. Page 9561 Fuse Block - Underhood C4 Part 1 Description and Operation Accessory Delay Module: Description and Operation RETAINED ACCESSORY POWER (RAP) DESCRIPTION AND OPERATION SERIAL DATA CONTROL OF RETAINED ACCESSORY POWER (RAP) The class 2 modules receive the power mode message from the body control module (BCM) over the serial data circuits, indicating when the RAP power mode is current. The BCM monitors the ignition switch position, battery condition and passenger compartment doors status to determine whether RAP should be initiated. The modules then support the operation of the systems under their control as required by their RAP power mode operation. RAP will end when one of the following conditions is met: The BCM receives an input indicating the opening of any compartment door. - The BCM internal timer for the RAP expires after approximately 10 minutes. - The BCM detects a decrease in battery capacity below a prescribed limit. The BCM then sends a serial data power mode message Off-Awake ending the RAP function. The class 2 RAP functions are: The power windows - The radio Page 12680 The control module ID number list above provides a method for determining which module is not communicating. A module with a class 2 serial data circuit malfunction or which loses power during the current ignition cycle will have a Loss of Communication DTC set by other modules that depend on information from that failed module. The modules that can communicate will set a DTC indicating the module that cannot communicate. Diagnostic Order When more than one Loss of Communication DTC is set in either one module or in several modules, diagnose the DTCs in the following order: 1. Current DTCs before history DTCs unless told otherwise in the diagnostic table. 2. The DTC which is reported the most times. 3. From the lowest number DTC to the highest number DTC. Conditions for Running the DTC The following DTCs do not have a current status: ^ B1327 ^ B1328 ^ U1300 ^ U1301 ^ U1305 AND ^ The vehicle power mode requires serial data communication to occur. Conditions for Setting the DTC A node alive message has not been received from a module with a learned identification number within the last 5 seconds. Action Taken When the DTC Sets Page 9534 Junction Block - I/P Wire Entry Part 1 Exhaust Manifold Replacement - Left Exhaust Manifold: Service and Repair Exhaust Manifold Replacement - Left Exhaust Manifold Replacement - Left (4.8L, 5.3L, and 6.0L Engine) Removal Procedure 1. Raise and suitably support the vehicle. 2. Remove the exhaust manifold pipe nuts. 3. Lower the vehicle. 4. Remove the spark plugs. 5. Remove the exhaust manifold bolts, manifold, and gasket. 6. Discard the gasket. 7. Remove the heat shield bolts (3), and shield (2) from the exhaust manifold (1), if necessary. 8. Clean and inspect the exhaust manifold. Installation Procedure Page 12697 Page 330 The module uses a default value for the missing parameter. Conditions for Clearing the DTC A current DTC clears when the malfunction is no longer present. A history DTC clears when the module ignition cycle counter reaches the reset threshold, without a repeat of the malfunction. Diagnostic Aids When multiple Loss of Communication DTCs are set concurrently, the cause is likely to be 2 opens in the ring portion of the class 2 serial data circuit. Use the Control Modules and Devices ‐ Description and Identification Number table in order to determine which modules are not communicating. Use the class 2 serial data circuit schematic in order to determine the location of the opens. Test Description Page 10177 1. Set the front wheels in the straight ahead position. Notice: On the 2002 and later model year vehicles the steering column LOCK was removed from the steering column. It is critical that the J 42640 - Steering column Anti-Rotation Pin is used when servicing steering columns on 2002 and later model year vehicles. Failure to use the J 42640 may result in damage to the SIR coil. 2. Set the steering wheel in the LOCK position on 2001 and prior model year vehicles. 3. For 2002 and later vehicles install the J 42640 in the steering column lower access hole. 4. From under the hood remove the lower bolt that connects the upper intermediate shaft to the steering gear coupling shaft. 5. Slide the shaft towards the dash in order to disengage the shaft from the steering gear coupling shaft. 6. For vehicles equipped with adjustable foot pedals perform the following steps: 1. Reposition the carpet away from the accelerator pedal position (APP) sensor. 2. Remove the two nuts retaining the accelerator pedal to the bulkhead. 3. Reposition the accelerator pedal out of the way so the intermediate shaft can be removed. Page 12169 Page 6915 3. Slide the boot (5) down the halfshaft bar (4) and away from the CV joint outer race (1). 4. Wipe all grease away from the face of the CV joint. 5. Find the halfshaft bar retaining snap ring (3), which is located in the inner race (2). 6. Spread the snap ring ears apart using J 8059 (or equivalent). 7. Pull the CV joint (1) and the CV joint boot (5) from the halfshaft bar (4). 8. Discard the old CV joint boot (5). Page 5518 INSTALLATION PROCEDURE NOTE: Refer to Fastener Notice in Service Precautions. 1. If required, install the fuel composition sensor to the bracket and install the bolts. Tighten Tighten bolts to 10 N.m (89 lb in). 2. Install the fuel composition sensor. 3. Install the fuel composition sensor nuts. Tighten Tighten nuts to 17 N.m (13 lb ft). 4. Connect the fuel pipes to the fuel composition sensor. 5. Install the fuel line retainers (1). Page 8400 3. For all 15 series vehicles, relieve the tension from the park brake cable by pulling down on the park brake cable in front of the equalizer and removing the right park brake cable from the equalizer bar. 4. For 25/35 series vehicles, disable the park brake cable automatic adjuster. Refer to Disabling the Park Brake Cable Automatic Adjuster. 5. For 25/35 series vehicles, disconnect the cable at the equalizer. Page 5438 2. Install the fuel level sensor retaining clip. 3. Connect the fuel level sensor electrical connector. 4. Install the fuel level sensor electrical connector retaining clip. Page 3781 Electrical Symbols Part 9 Page 4981 4. Connect the EVAP canister purge solenoid electrical connector (1). 5. Install the EVAP line to the canister purge solenoid (1). 6. Install the engine sight shield. Page 9184 C117 Battery Negative Harness To Accessory Jumper Harness (With RPO Code 9L4) Page 11677 Tighten the bolt to 53 N.m (39 lb ft). 3. Install the rear seat belt to body bolts. Tighten Tighten the bolts to 53 N.m (39 lb ft). 4. Install the rear quarter trim panel. 5. Install the rear seat, if removed. Page 1931 12. Install the cover. Notice: Refer to Fastener Notice in Service Precautions. 13. Install 2 NEW screws (1) to the casting. ^ Tighten the screws to 2 Nm (18 inch lbs.). 14. Install 2 NEW longer screws (2) to the motor cover. ^ Tighten the screws to 3 Nm (26 inch lbs.). 15. Install the encoder motor. Page 9643 Fuse Block: Service and Repair Body Wiring Harness Junction Block Replacement BODY WIRING HARNESS JUNCTION BLOCK REPLACEMENT REMOVAL PROCEDURE 1. Remove the cover retaining nut. 2. Remove the cover by pushing in the tabs. 3. Remove the harness from the front of the junction block. 4. Remove the junction block from the bracket by pressing to release the tabs. 5. Remove the junction block in order to gain access to the rear of the block to remove the retaining bolts. 6. Remove the retaining bolts. 7. Separate the wire harness block from the junction block by inserting a screw driver in between. 8. Remove the junction block from the vehicle. INSTALLATION PROCEDURE 1. Install the wire harness block to the junction block. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the retaining bolts. Tighten Tighten the bolts to 6 N.m (53 lb in). 3. Install the junction block to the bracket. Page 2235 Fuel Pressure Release: Service and Repair Fuel Pressure Relief Procedure FUEL PRESSURE RELIEF PROCEDURE TOOLS REQUIRED J 34730-1A Fuel Pressure Gage CAUTION: Relieve the fuel system pressure before servicing fuel system components in order to reduce the risk of fire and personal injury. After relieving the system pressure, a small amount of fuel may be released when servicing the fuel lines or connections. In order to reduce the chance of personal injury, cover the regulator and the fuel line fittings with a shop towel before disconnecting. This will catch any fuel that may leak out. Place the towel in an approved container when the disconnection is complete. 1. Disconnect the negative battery cable. 2. Install the J 34730-1A. 3. Loosen the fuel fill cap in order to relieve fuel tank vapor pressure. 4. Open the valve on J 34730-1A in order to bleed the system pressure. The fuel connections are now safe for servicing. 5. Drain any fuel remaining in the gage into an approved container. 6. Once the system pressure is completely relieved, remove the J 34730-1A. Page 3550 Spark Plug: Specifications Spark Plug Torque ............................................................................................................................... ........................................................ 15 Nm (11 lb ft) Spark Plug Gap ................................................ ........................................................................................................................................ 1.01 mm (0.040 in) Automatic Transmission - 4L60-E/4L65-E Fluid Line/Hose: Service and Repair Automatic Transmission - 4L60-E/4L65-E Transmission Fluid Cooler Hose/Pipe Replacement Removal Procedure 1. Remove the front grill assembly. 2. Remove the transmission fluid cooler hose from the Auxiliary oil cooler. 3. Remove the transmission fluid cooler hose from the radiator. 4. Raise the vehicle. Refer to Vehicle Lifting. 5. Remove the engine protection shield. 6. Remove the cooling lines from the transmission. 7. Remove the oil cooling lines from the vehicle. Installation Procedure 1. Install the transmission oil cooler lines to the vehicle. 2. Install the cooling lines to the transmission. Specifications Compression Check: Specifications The minimum compression in any one cylinder should not be less than 70 percent of the highest cylinder. No cylinder should read less than 690 kPa (100 psi). For example, if the highest pressure in any one cylinder is 1035 kPa (150 psi), the lowest allowable pressure for any other cylinder would be 725 kPa (105 psi). Multiply the highest cylinder pressure by 70 percent, 1035 kPa x 70 percent = 725 kPa (150 psi x 70 percent = 105 psi), in order to determine the lowest allowable pressure in any other cylinder. Page 15198 Electrical Symbols Part 5 Page 10266 Steering Wheel Driver Information Center (DIC) Controls - Right (With RPO Code YE9) AWD/4WD - AWD/4WD Lamps/System Inop./DTC C0550 Control Module: All Technical Service Bulletins AWD/4WD - AWD/4WD Lamps/System Inop./DTC C0550 Bulletin No.: 02-04-21-006E Date: July 20, 2006 TECHNICAL Subject: Inoperative 4WD/AWD Lamps, Inoperative 4WD/AWD System, DTC C0550 Set, No Communication with TCCM (Reprogram Transfer Case Control Module) Models: 2004 Buick Rainier 2002-2004 Chevrolet TrailBlazer, TrailBlazer EXT 2003-2004 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2002-2004 GMC Envoy, Envoy XL 2003-2004 GMC Sierra, Yukon, Yukon XL 2004 GMC Envoy XUV 2002-2004 Oldsmobile Bravada with Electronic Shift or Active Transfer Case (RPOs NP1, NP4 or NP8) Supercede: This bulletin is being revised to add Subject information and change the labor operation. This bulletin cancels and supersedes Bulletin Number 03-04-21-006. Please discard Corporate Bulletin Numbers 02-04-21-006D and 03-04-21-006 (Section 04 - Driveline/Axle). Condition Some customers may comment that the 4WD/AWD indicator lights on the selector switch do not work, or the 4WD/AWD system may be inoperative and/or the service 4WD light is illuminated. The condition is typically intermittent and always occurs at key-up. Upon investigation, the technician may find DTC C0550 set. Cause The Transfer Case Control Module (TCCM) has not received the wake-up call during key-up and has remained in the "sleep mode". When the TCCM is in the "sleep mode", it will not communicate with the class II bus or the Tech 2(R). Correction 1. Try to communicate with the TCCM. If no communication, go to step 2. If communication is possible, go to step 5. 2. Remove the underhood (ATCM or TREC) TCCM fuse. 3. Wait 30 seconds. 4. Reinstall the fuse. The module should wake up and communicate with the Tech 2(R). 5. Check for codes in the TCCM. If a C0550 is found current or in history with or without other codes, replace the module and go to step 6. 6. Reprogram the TCCM with the latest TIS software using normal SPS procedures. 7. Verify operation and that no codes are present. Important: For the 2002 model year, the TCCM must be replaced and reprogrammed. Warranty Information Page 4853 Heated Oxygen Sensor (HO2S) Bank 2 Sensor 1 Page 7251 Control Module References Part 1 Recall - Brake Booster Pressure Accumulator Cracking Technical Service Bulletin # 05006 Date: 050323 Recall - Brake Booster Pressure Accumulator Cracking Product Safety - Hydro-Boost Accumulator Over-Pressurization # 05006 - (Mar 23, 2005) Models: 2004 Chevrolet Kodiak 2004-2005 Chevrolet Avalanche, Express, Silverado, Suburban 2004 GMC TopKick 2004-2005 GMC Savana, Sierra, Yukon XL Condition General Motors has decided that a defect, which relates to motor vehicle safety, exists in certain 2004 Chevrolet Kodiak and GMC TopKick; 2004-2005 Chevrolet Avalanche, Express, Silverado, Suburban; GMC Savana, Sierra, Yukon XL vehicles. On some of these vehicles, the hydraulic brake booster's pressure accumulator may crack and/or separate from the Hydro-Boost(R) assembly during normal vehicle operating conditions. If a separation were to occur and the hood of the vehicle were open, fragments from the accumulator could cause injury to people in the immediate area. In addition, the presence of this crack or fractured surface could allow the hydraulic fluid to leak from the accumulator circuit of the booster assembly. The loss of fluid would cause increased steering and braking effort. Correction Dealers are to inspect the hydraulic brake booster, and replace it if necessary. Vehicles Involved Involved are certain 2004 Chevrolet Kodiak and GMC TopKick; 2004-2005 Chevrolet Avalanche, Express, Silverado, Suburban; GMC Savana, Sierra, Wheels - Chrome Wheel Staining/Pitting/Corrosion Wheels: All Technical Service Bulletins Wheels - Chrome Wheel Staining/Pitting/Corrosion INFORMATION Bulletin No.: 00-03-10-002F Date: April 21, 2011 Subject: Chemical Staining, Pitting, Corrosion and/or Spotted Appearance of Chromed Aluminum Wheels Models: 2012 and Prior GM Cars and Trucks Supercede: This bulletin is being revised to update model years, suggest additional restorative products and add additional corrosion information. Please discard Corporate Bulletin Number 00-03-10-002E (Section 03 - Suspension). Important You may give a copy of this bulletin to the customer. What is Chemical Staining of Chrome Wheels? Figure 1 Chemical staining in most cases results from acid based cleaners (refer to Figure 1 for an example). These stains are frequently milky, black, or greenish in appearance. They result from using cleaning solutions that contain acids on chrome wheels. Soap and water is usually sufficient to clean wheels. If the customer insists on using a wheel cleaner they should only use one that specifically states that it is safe for chromed wheels and does not contain anything in the following list. (Dealers should also survey any products they use during prep or normal cleaning of stock units for these chemicals.) - Ammonium Bifluoride (fluoride source for dissolution of chrome) - Hydrofluoric Acid (directly dissolves chrome) - Hydrochloric Acid (directly dissolves chrome) - Sodium Dodecylbenzenesulfonic Acid - Sulfamic Acid - Phosphoric Acid - Hydroxyacetic Acid Notice Many wheel cleaner instructions advise to take care to avoid contact with painted surfaces. Most customers think of painted surfaces as the fenders, quarter panels and other exterior sheet metal. Many vehicles have painted brake calipers. Acidic wheel cleaners may craze, crack, or discolor the paint on the brake calipers. Damage from wheel cleaners is not covered under the vehicle new car warranty. Soap and water applied with a soft brush is usually all that is required to clean the calipers. Whenever any wheel cleaner is used, it must be THOROUGHLY rinsed off of the wheel with clean, clear water. Special care must be taken to rinse under the hub cap, balance weights, wheel nuts, lug nut caps, between the wheel cladding and off the back side of the wheel. Wheels returned to the Warranty Parts Center (WPC) that exhibit damage from wheel cleaners most often have the damage around and under the wheel weight where the cleaner was incompletely flushed away. Notice Page 10787 Tighten Tighten the nut to 16 N.m (12 lb ft). 7. Install the compressor hose to the accumulator. 8. Install the compressor hose nut to the accumulator. Tighten Tighten the nut to 16 N.m (12 lb ft). 9. Connect the electrical connector to the A/C low pressure switch. 10. Install the nut to the evaporator tube (3). Tighten Tighten the nut to 25 N.m (18 lb ft). 11. Install the evaporator tube to the evaporator. 12. Install the evaporator tube nut to the evaporator. Tighten Tighten the nut to 16 N.m (12 lb ft). 13. Evacuate and recharge the system. Refer to Refrigerant Recovery and Recharging. 14. Leak test the fittings of the component using the J 39400-A. Page 1993 IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections TESTING FOR INTERMITTENT AND POOR CONNECTIONS TOOLS REQUIRED - J 35616-C GM-Approved Terminal Test Kit - J 38125-D Terminal Repair Kit - J 42675 Flat-Wire Probe Adapter Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector. - Poor terminal to wire connection - Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. - Wire insulation which is rubbed through - This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. - Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. Testing For Proper Terminal Contact It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-D or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-D, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. Fuel System - Cranks But No Start/Inaccurate Fuel Gauge Fuel Gauge Sender: All Technical Service Bulletins Fuel System - Cranks But No Start/Inaccurate Fuel Gauge Bulletin No.: 04-08-49-018E Date: January 05, 2005 TECHNICAL Subject: Cranks But No Start, Stall, Inaccurate/Incorrect Fuel Gauge Reading, No Fuel, Vehicle is Out of Fuel and Fuel Gauge Reads Above Empty (Replace Fuel Level Sensor) Models: 2001-2004 Cadillac Trucks 1999-2004 Chevrolet and GMC Trucks with Gasoline Engine (VINs Z, X, V, T, U, N, G, 6, 8 - RPOs LU3, LR4, LM7, LQ4, LQ9, L59, L18,LK5 L52) Attention: Parts are currently available for vehicles with Variable Fuel (VIN Z - RPO L59) vehicles. Please refer to Corporate Bulletin Number 04-06-04-01 2B or newer for Variable Fuel (VIN Z - RPO L59) vehicles. Supercede: This bulletin is being revised to include information on the Chevrolet Colorado and the GMC Canyon. Please discard Corporate Bulletin Number 04-08-49-018D (Section 08 - Body and Accessories). Condition Some customers may comment on the vehicle stalling and will not restart, vehicle ran out of fuel, vehicle appears to be out of fuel but the fuel gauge reads above empty. The fuel gauge may read 1/4 tank. Cause Contamination on the fuel sending card may cause inaccurate/incorrect fuel gauge readings. Correction Follow the service procedure below for diagnosis and repair of this concern. 1. Confirm that the vehicle is actually out of fuel. ^ If the vehicle is not out of fuel but Engine Cranks but Does Not Run, refer to the appropriate Service Information. ^ If the vehicle is out of fuel and the gauge does not read empty, test the fuel gauge. Refer to the following information: - Fuel Gage Inaccurate or Inoperative Single Tank - Fuel Gage Inaccurate or Inoperative Dual Tanks - Fuel Gage Inaccurate or Inoperative Colorado and Canyon 2. If testing reveals that the fuel gauge is operating correctly, replace the fuel sensor assembly and auxiliary tank fuel level sensor if equipped. 3. Replace the fuel level sensor. Refer to the following appropriate service information: ^ Fuel Level Sensor Replacement 4.8L and 5.3L Engines ^ Fuel Level Sensor Replacement 6.0L Engine - Front Tank ^ Fuel Level Sensor Replacement 6.0L Engine - Rear Tank ^ Fuel Level Sensor Replacement 8.1L vehicles with Front Tank ^ Fuel Level Sensor Replacement 8.1 L vehicles with Rear Tank Page 270 2. Connect the Techline Information System (TIS) terminal to the Tech2(R). 3. Scroll to the bottom of the Controller List, and select the "ONSA TIS2WEB Pass-Thru OnStar(R) Activation (Replaced/Upgraded Units Only)" option using the Service Programming System (SPS). Important: Do not use the clear DTC function. This will only temporarily turn the LED to green. 4. Upon completion of the OnStar(R) TIS2WEB step, disconnect the TIS terminal from the Tech2(R) and perform the VCIM/OnStar(R) Set-up Procedure using the Tech2(R). The set up procedure is located under the special function menu option. Important: Failure to perform the above steps will result in a red LED, DTC being set and limited or incomplete OnStar(R) services, and will require a customer return visit to the dealership. 5. The default language for the new VCIM will be English. To change to French or Spanish, access the special functions menu on the Tech 2(R), and follow the instructions accordingly. 7. Skip to the next step if the vehicle to be upgraded is not listed below: ^ 2002-2004 Cadillac DeVille ^ 2002-2004 Cadillac Seville ^ 2005 Cadillac STS Set up the Dash Integration Module (DIM) using the following procedure: 1. On the Tech2(R) select the correct Year, Make and Model. 2. Enter Dash Integration Module (DIM) > Special Functions > Set Options > Misc. Options 1 > and turn off phone (if the vehicle does not have the UV8 option). 3. Enter Nav Radio Present and set to "No Nav" (if the vehicle does not have a navigation radio). 4. Turn the ignition off and open the door to turn off the RAP. 5. Turn the ignition on and enter the Vehicle Comm. Interface Module > Special Functions > Set Up OnStar /VCIM. 6. When prompted select "No Phone" (if the vehicle does not have the UV8 phone) and "No Nav" (if the vehicle does not have a navigation radio). 7. Turn the ignition off and open the door to turn off the RAP. Important: OnStar(R) Emergency Services are immediately available after these steps, however, full configuration, including activation of Hands-Free Calling, may take up to 24 hours to complete. Processing the Module Exchange Processing the Module Exchange For this program, submitting a credit request for the removed OnStar(R) VCIM (the core) will be performed through a website. When this process is followed, the removed Analog / Digital-Ready VCIM, in most cases, will not be mailed back to the distributor, but can be scrapped by the dealership. U.S. Dealers 1. Return the removed Analog / Digital-Ready OnStar(R) VCIM to the Parts Manager. 2. The Parts Manager will log onto www.autocraft.com. 3. Select Account Maintenance. 4. Select Outstanding Cores. Page 4291 Electrical Symbols Part 9 Page 9023 Fuse Block - Underhood C4 Part 3 Fuse Block - Underhood C5 Brakes - Low Speed ABS Activation/No DTC's Set Wheel Speed Sensor: Customer Interest Brakes - Low Speed ABS Activation/No DTC's Set TECHNICAL Bulletin No.: 03-05-25-007D Date: May 01, 2009 Subject: Antilock Brake (ABS) Activation At Low Speeds (Clean Wheel Speed Sensor Mounting Surface) Models: 2002-2006 Cadillac Escalade, Escalade EXT 2003-2006 Cadillac Escalade ESV 1999-2006 Chevrolet Silverado 2001-2006 Chevrolet Suburban, Tahoe 2002-2006 Chevrolet Avalanche 2003-2006 Chevrolet Express 2007 Chevrolet Silverado Classic 1999-2006 GMC Sierra 2001-2006 GMC Yukon, Yukon Denali, Yukon XL, Yukon Denali XL 2003-2006 GMC Savana 2007 GMC Sierra Classic 2003-2006 HUMMER H2 .............................................................................................................................................................. .................................................................................. Supercede: This bulletin is being revised to add the 2007 Silverado/Sierra Classic models. Please discard Corporate Bulletin Number 03-05-25-007C (Section 05 - Brakes). .............................................................................................................................................................. .................................................................................. Condition Some customers may comment on ABS activation at low speeds, usually below 8 km/h (5 mph). Upon investigation, the technician will find no DTCs set. Cause The cause of this condition may be an increased air gap between the wheel speed sensor and the hub reluctor ring due to rust and debris built up on the sensor mounting surface. Correction Measure AC voltage and clean the wheel speed sensor mounting surfaces. 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in the General Information sub-section of the Service Manual. 2. Disconnect both the front wheel speed sensor connectors at the frame and harness. 3. Place a Digital Volt Meter (DVM) across the terminals of each wheel speed sensor connector. 4. Rotate the wheel clockwise approximately one revolution per second. The minimum reading should be at least 350 ACmV's. If the reading is less than 350 ACmV's, remove the wheel speed sensor. Refer to the applicable Wheel Speed Sensor Replacement procedure in the ABS sub-section of the Service Manual. 5. Plug the wheel speed sensor bore in order to prevent debris from falling into the hub during service. 6. Clean the wheel speed sensor mounting surface using a wire brush, sand paper, emery cloth, scotch brite, or other suitable material. Be sure to thoroughly clean the wheel speed sensor surface. There should be no rust or corrosion. 7. Check the sensor head to determine if it has been warped/distorted due to the corrosion build up or other causes. Check the mounting surface on the sensor head for flatness by placing it on the edge of a metal machinists scale or other suitable straight edge to measure the flatness. Check the sensor for flatness in multiple (minimum 3) positions/directions. If the sensor head is distorted, replace the sensor. 8. Apply (spray) two thin coats of the specified rust penetrating lubricant (corrosion inhibitor) to the complete sensor mounting surface on the bearing hub. Allow to dry for 3-5 minutes between coats. Use ONLY Rust Penetrating Lubricant, P/N 89022217 (in Canada, P/N 89022218). 9. When the corrosion inhibitor is dry to the touch (about 10 minutes), apply a thin layer of bearing grease to the hub surface and sensor O-ring prior to sensor installation. Use ONLY Wheel Bearing Lubricant, P/N 01051344 (in Canada, P/N 993037). 10. Install either the original sensor or a new one in the hub. Ensure that the sensor is seated flush against the hub. Refer to the applicable Wheel Speed Sensor Replacement procedure in the ABS sub-section of the Service Manual. 11. Place the DVM across the sensor terminals and recheck the voltage while rotating the wheel. The voltage should now read at least 350 ACmV's. Page 879 High Temperature Conditions Tools Required J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency MEASURING FREQUENCY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage MEASURING VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop MEASURING VOLTAGE DROP NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Page 9613 Fuse Block: Application and ID Fuse Block - Underhood Location View Page 15684 Horn Switch: Service and Repair Horn Switch Replacement Removal Procedure 1. Caution: Refer to Servicing the SIR System Caution in Cautions and Notices. Disable the SIR system. 2. Remove the inflatable restraint steering wheel module. 3. Remove the horn plunger from the steering column by pressing inward to the stop and rotating the horn plunger 90 degrees. 4. Disconnect the captured screws (1,4) to the horn contact plate (2) from the steering wheel (3). 5. Remove the horn switch (2) from the steering wheel (3). Installation Procedure 1. Install the horn switch (2) to the steering wheel (3). 2. Notice: Refer to Fastener Notice in Service Precautions. Connect the captured screws (1,4) from the horn contact plate (2) to the steering wheel (3). ^ Tighten the screws to 5.5 Nm (50 inch lbs.). Page 11902 Page 3276 6. Remove the engine mount heat shield, if equipped. 7. Important: DO NOT raise and/or support the engine by the crankshaft balancer, or oil pan. Raise and support the engine using an adjustable (screw type) jack stand. 8. Remove the engine mount-to-engine mount bracket bolts. 9. Remove the engine mount bolts. 10. Remove the right engine mount. Installation Procedure Page 5994 Vehicle Speed Sensor (VSS) Tow/Haul Switch Location Page 13109 Test Description DTC U1001 and U1254 Circuit/System Description Modules connected to the Class 2 serial data circuit monitor for serial data communications during normal vehicle operation. Operating information and commands are exchanged among the modules. When a module receives a message for a critical operating parameter, the module records the identification number of the module which sent the message for State of Health monitoring. A critical operating parameter is one which, when not received, requires that the module use a default value for that parameter. Once an identification number is learned by a module, it will monitor for that module's Node Alive message. Each module on the class 2 serial data circuit which is powered and performing functions that require detection of a communications malfunction is required to send a Node Alive message every 2 seconds. When no message is detected from a learned identification number for 5 seconds, a DTC U1XXX where XXX is equal to the 3-digit identification number is set. Page 12433 * Dealers using WINs: Add 0.2 hours to the labor time for administrative allowance for the module exchange. Dealers using GWM: Submit 0.2 hours administrative allowance under "Administration Time" for the module exchange. ** The $25 represents the additional net amount allowed for the module exchange. *** Dealers are to claim only administrative allowance of 0.2 hours when the module is replaced by Masscomp's Mobile Unit. Dealers using WINS should submit the 0.2 hours administrative allowance in labor time. Dealer using GWM should submit the 0.2 hours administrative allowance under Administrative Time. Customer Notification OnStar will notify customers of this program on their vehicle. Dealer Program Responsibility All unsold new vehicles in dealers'/retailers' possession and subject to this program must be held and inspected/repaired per the service procedure of this program bulletin before customers take possession of these vehicles. Dealers/retailers are to service all vehicles subject to this program at no charge to customers, regardless of mileage, age of vehicle, or ownership, through April 30, 2011. Customers who have recently purchased vehicles sold from your vehicle inventory, and for which there is no customer information indicated on the dealer/retailer listing, are to be contacted by the dealer/retailer. Arrangements are to be made to make the required correction according to the instructions contained in this bulletin. A copy of the customer letter is provided in this bulletin for your use in contacting customers. Program follow-up cards should not be used for this purpose, since the customer may not as yet have received the notification letter. Page 15962 If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Sir/SRS Wiring Repairs SIR/SRS WIRING REPAIRS TOOLS REQUIRED J 38125-D Terminal Repair Kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-D contains the following items: - Special sealed splices - in order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping tool - A heat torch - An instruction manual The sealed splices have the following 2 critical features: - A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-D also serves as a generic terminal repair kit. The kit contains the following items: - A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors Engine - Intake Manifold Inspection/Replacement Intake Manifold: Technical Service Bulletins Engine - Intake Manifold Inspection/Replacement INFORMATION Bulletin No.: 00-06-01-026C Date: February 03, 2010 Subject: Intake Manifold Inspection/Replacement After Severe Internal Engine Damage Models: 2010 and Prior Passenger Cars and Trucks (Including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X Supercede: This bulletin is being revised to include additional model years. Please discard Corporate Bulletin Number 00-06-01-026B (Section 06 - Engine). When replacing an engine due to internal damage, extreme care should be taken when transferring the intake manifold to the new Goodwrench service engine long block. Internal damage may result in the potential discharge of internal engine component debris in the intake manifold via broken pistons and/or bent, broken, or missing intake valves. After removing the intake manifold from the engine, the technician should carefully inspect all of the cylinder head intake ports to see if the valve heads are still present and not bent. Usually when the valve heads are missing or sufficiently bent, internal engine component debris will be present to varying degrees in the intake port of the cylinder head. If this debris is present in any of the cylinder head intake ports, the intake manifold should be replaced. This replacement is required due to the complex inlet runner and plenum configuration of most of the intake manifolds, making thorough and complete component cleaning difficult and nearly impossible to verify complete removal of debris. Re-installation of an intake manifold removed from an engine with deposits of internal engine component debris may result in the ingestion of any remaining debris into the new Goodwrench service engine. This may cause damage or potential failure of the new service engine. Disclaimer Page 2605 Body Harness Page 4083 Heated Oxygen Sensor (HO2S) Bank 2 Sensor 2 Drivetrain - Excessive Effort When Shift 2HI to 4HI Differential Fluid - M/T: Customer Interest Drivetrain - Excessive Effort When Shift 2HI to 4HI TECHNICAL Bulletin No.: 09-04-19-002A Date: February 17, 2011 Subject: 4WD System Shift Performance in Cold Ambient Temperatures (Use Synthetic Fluid in Light Duty Front Axles with 8.5" Ring Gears) Models: 1999-2011 Chevrolet Silverado 1500 Series Models 1999-2011 GMC Sierra 1500 Series Models Equipped with 4WD and 8.25" Front Axle Ring Gears (Transfer Case RPOs NP2, NQG) Attention: It is important to determine the RPO for the transfer case in GWM/IVH prior to applying this bulletin. This bulletin applies ONLY to vehicles equipped with 8.25" front axle ring gears, used in conjunction with a manual transfer case (RPOs NP2, NQG). Supercede: This bulletin is being revised to add the 2011 model year. Please discard Corporate Bulletin Number 09-04-19-002 (Section 04 - Driveline/Axle). Condition Some customers may comment about the effort required to shift from 2HI to 4HI in cold ambient temperatures at -6°C (20°F) or below. Cause This condition may be caused by the standard front axle being equipped with conventional mineral oil axle fluid. In cold ambient temperatures, prior to complete warm up, the fluid viscosity is thick. This may affect transfer case shift performance prior to full warm up. Correction Drain the front axle fluid and refill with GM SAE 75W-90 Synthetic Axle Fluid, P/N 89021677 (in Canada, 89021678). Refer to Front Axle Lubricant Replacement in SI. It is important to use synthetic fluid in this 8.25" axle to improve the performance of the 4WD system in cold ambient temperatures. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 12377 Disclaimer Page 5056 Important The new canister vent valve will be installed in a new location, outside of the frame. 7. Position and secure the new valve assembly to the frame bracket on the outside of the frame using the existing hole and mounting bolt. Tighten Tighten the bracket mounting bolt to 12 Nm (106 lb in). 8. Connect the vent valve pipe to the EVAP canister. 9. Install the two vent valve pipe clips into the existing underbody holes. 10. Connect the EVAP canister vent valve electrical connector, if equipped. 11. Attach bulk 5/8" heater hose to the vent valve port and secure using a clamp. Run a length as needed along the frame rail routing to the area above the transmission. 12. Cut the hose to determined length and install the supplied filter box. Secure using a clamp. 13. Remove the transmission support and lower the transmission assembly as necessary to allow for access to the new filter box location. 14. Secure the filter box to the transmission vent hose just forward of the hose tee-section using a tie strap. DO NOT pinch or restrict the transmission vent hose. The filter box opening should be pointing downward. 15. Raise the transmission and reinstall the transmission support. 16. Tie strap the hose as needed along the frame rail in order to keep the hose away from pinch-points and heat sources. 17. Lower the vehicle. 2004-2007 Model Year (Use Service Kit P/N 19152349) 1. Raise the vehicle. Suitably support the vehicle. 2. Disconnect the EVAP canister vent valve electrical connector. 3. Disconnect the canister pipe from the vent valve. 4. Push in the retainer and remove the existing canister vent valve from the fuel tank clip or mounting bracket. Discard the old valve. 5. Cut back the existing canister pipe approximately 51 mm (2 in) to remove the quick connect end. Crew Cab Short Box Shown Below, Other Configurations Similar Page 13033 Page 5894 are secure and the TIS terminal operating software is up to date. 1. Verify the battery charge of 12 to 16 volts. The battery must be able to maintain the charge during programming. Use an additional jump battery if necessary. 2. Use the normal "request method" through "Service Programming System" to request information from the vehicle. 3. At the Techline Terminal, enter TIS SPS programming system. 4. Select Tech 2(R) from the "Select Diagnostic Tool" window. 5. Select Reprogram ECU from the Select Programming Process window. 6. Select Vehicle from the "Select ECU Location" window. 7. Select Next to go to the "Preparing for Communication" instruction screen. 8. Select Next to view the Validate Vehicle ID Number screen. If the vehicle ID number does not appear on the screen, manually insert the VIN into the VIN window of the Validate Vehicle ID Number screen. 9. Select Next to view the "Supported Controllers" screen. 10. Select PCM/VCM Powertrain/Vehicle Control Module from "Supported Controllers" window. 11. Select Next to view the "Select Programming Type" window. 12. Select Normal from the Select Programming Type window. 13. Select Next to view the "Service Programming System Calibration Selection" screen. 14. Select Next to view Summary screen. 15. Verify that current and selected calibration information is displayed on the Summary screen. 16. Select Next to download the calibration to the Tech 2(R). 17. Back at the vehicle, enter "Service Programming Systems". 18. Select Program ECU and follow the on-screen instructions. 19. When programming is complete, do the following: 19.1. Turn the Tech 2(R) OFF. 19.2. Turn the ignition switch OFF. 20. Wait 30 seconds. 21. Turn the ignition switch to ON with the engine OFF. 22. Go into Diagnostics and check for DTC codes. 23. Clear all codes. Claim Information Page 15998 Heated Glass Element: Scan Tool Testing and Procedures Scan Tool Data Definitions SCAN TOOL DATA DEFINITIONS BODY CONTROL MODULE (BCM) Rear Defog Relay: When the BCM energizes the RR DEFOG relay, the scan tool will display On. When the BCM de-energizes the RR DEFOG relay, the scan tool will display Off. Rear Defrost Switch: When rear defrost switch is pressed the scan tool displays On. Body Control Module (BCM) HVAC Control Module Body Control Module (BCM) Page 1208 Memory/Heated Seat Switch - Driver (DDM C5) Part 1 Locations Instrument Panel Switches-LH Campaign - Deactivation Of Analog OnStar(R) Technical Service Bulletin # 08089C Date: 081118 Campaign - Deactivation Of Analog OnStar(R) # 08089C: Special Coverage Adjustment - Analog OnStar Deactivation (Nov 18, 2008) Subject: 08089C -- SPECIAL COVERAGE ADJUSTMENT - ANALOG ONSTAR(R) DEACTIVATION Page 2400 ^ Knock or Clunk Noise ^ Rear Drive Axle Noises (SI Document ID #700580) ^ Launch Shudder/Vibration on Acceleration (Replace Propeller Shaft and Install a New Pinion Flange/Seal), Bulletin # 02-04-17-001 ^ Information on 2-3 Upshift or 3-2 Downshift Clunk Noise, Bulletin # 01-07-30-042 ^ Driveline Clunk When Stopping (Reprogram Powertrain Control Module (PCM), Bulletin # 03-07-30-028 Correction Replace the rear drive shaft slip yoke with a new nickel-plated slip yoke. See the parts table below. Follow the service procedure below. 1. Raise the vehicle on a hoist. 2. Reference mark the propeller shaft to the pinion flange connection. Important: Do not pound on the propeller shaft yoke ears. Never pry or place any tool between a yoke and a universal joint. 3. Remove the bolts and the yoke retainers from the pinion flange. 4. Slide the propeller shaft forward and out of the rear pinion flange. 5. Lower the rear of the propeller shaft and pull the driveshaft out of the transfer case. Note: Never clamp propeller shaft tubing in a vise. Clamping could dent or deform the tube causing an imbalance or unsafe condition. Always clamp on one of the yokes and support the shaft horizontally. Avoid damaging the slip yoke sealing surface. Nicks may damage the bushing or cut the lip seal. 6. Support the propeller shaft in a line horizontal with the table of a press. Important: Remove the front slip yoke and the universal joint together. The new nickel-plated slip yoke comes with a new universal joint. 7. Disassemble the snap rings by pinching the ends together with a pair of pliers. 8. If the ring does not readily snap out of the groove in the yoke, tap the end of the cup lightly in order to relieve the pressure from the ring. 9. Place the universal joint so that the lower ear of the yoke is supported on a 30 mm (1-1/8 in) hex head socket or a 27 mm (1-1/16 in) socket. Page 3393 11. Loosen the intake manifold bolts. 12. Remove the intake manifold. 13. Remove the intake manifold gaskets (1) from the intake manifold. 14. Discard the old intake manifold gaskets. 15. If required, clean and inspect the intake manifold. Installation Procedure 1. Install NEW intake manifold gaskets (1) to the intake manifold. Page 1660 5. If equipped with a 6.0L engine, disconnect the HO2S electrical connector. 6. Remove the HO2S. INSTALLATION PROCEDURE IMPORTANT: A special anti-seize compound is used on the HO2S threads. The compound consists of liquid graphite and glass beads. The graphite tends to burn away, but the glass beads remain, making the sensor easier to remove. New, or service replacement sensors already have the compound applied to the threads. If the sensor is removed from an exhaust component and if for any reason the sensor is to be reinstalled, the threads must have anti-seize compound applied before the reinstallation. 1. If reinstalling the old sensor, coat the threads with anti-seize compound GM P/N 12377953, or equivalent. NOTE: Refer to Component Fastener Tightening Notice in Service Precautions. 2. Install the HO2S. Tighten Tighten the sensor to 42 N.m (31 lb ft). Page 843 8. Install the left side end panel. Page 11108 Air Temperature Sensors - Lower Left Page 4441 The malfunction indicator lamp (MIL) is located in the instrument panel cluster. The MIL will display as either SERVICE ENGINE SOON or one of the following symbols when commanded ON: The MIL indicates that an emissions related fault has occurred and vehicle service is required. The following is a list of the modes of operation for the MIL: - The MIL illuminates when the ignition is turned ON, with the engine OFF. This is a bulb test to ensure the MIL is able to illuminate. - The MIL turns OFF after the engine is started if a diagnostic fault is not present. - The MIL remains illuminated after the engine is started if the control module detects a fault. A diagnostic trouble code (DTC) is stored any time the control module illuminates the MIL due to an emissions related fault. The MIL turns OFF after three consecutive ignition cycles in which a Test Passed has been reported for the diagnostic test that originally caused the MIL to illuminate. - The MIL flashes if the control module detects a misfire condition which could damage the catalytic converter. - When the MIL is illuminated and the engine stalls, the MIL will remain illuminated as long as the ignition is ON. - When the MIL is not illuminated and the engine stalls, the MIL will not illuminate until the ignition is cycled OFF and then ON. TRIP A trip is an interval of time during which the diagnostic test runs. A trip may consist of only a key cycle to power up the PCM, allow the diagnostic to run, then cycle the key off to power down the PCM. A trip may also involve a PCM power up, meeting specific conditions to run the diagnostic test, then powering down the PCM. The definition of a trip depends upon the diagnostic. Some diagnostic tests run only once per trip (i.e., catalyst monitor) while other tests run continuously during each trip (i.e. misfire). WARM-UP CYCLE The PCM uses warm-up cycles to run some diagnostics and to clear any diagnostic trouble codes (DTCs). A warm-up cycle occurs when the engine coolant temperature increases 22°C (40°F) from the start-up temperature. The engine coolant must also achieve a minimum temperature of 71°C (160°F). The PCM counts the number of warm-up cycles in order to clear the malfunction indicator lamp (MIL). The PCM will clear the DTCs when 40 consecutive warm-up cycles occur without a malfunction. DIAGNOSTIC TROUBLE CODES (DTCS) The PCM is programmed with test routines that test the operation of the various systems the PCM controls. Some tests monitor internal PCM functions. Many tests are run continuously. Other tests run only under specific conditions, referred to as Conditions for Running the DTC. When the vehicle is operating within the conditions for running a particular test, the PCM monitors certain parameters and determines if the values are within an expected range. The parameters and values considered outside the range of normal operation are listed as Conditions for Setting the DTC. When the Underhood Electrical Center or Junction Block Replacement Fuse Block: Service and Repair Underhood Electrical Center or Junction Block Replacement UNDERHOOD ELECTRICAL CENTER OR JUNCTION BLOCK REPLACEMENT REMOVAL PROCEDURE 1. Disconnect the negative battery cable. 2. Remove the left fender upper brace. 3. Remove the electrical center brace cover assemble by lifting the cover (3) outwards to clear the tabs. 4. Remove all fuses and relays. Page 6027 2. Install the 2-3 shift solenoid (367A) and the 2-3 shift solenoid retainer (395). 3. Install the 1-2 shift solenoid (267A) and the 1-2 shift solenoid retainer (395). 4. Important: When installing the pressure control solenoid, the electrical connector (2) must be in the position shown. Install the pressure control solenoid (377). 5. Notice: Refer to Fastener Notice in Service Precautions. Install the pressure control solenoid retainer (378) and retainer bolt (364A). ^ Tighten the bolt to 11 Nm (97 inch lbs.). Page 8618 Yukon XL vehicles built within the VIN breakpoints shown. Important: Dealers should confirm vehicle eligibility through GMVIS (GM Vehicle Inquiry System) before beginning recall repairs. [Not all vehicles within the above breakpoints may be involved.] For US For dealers with involved vehicles, a Campaign Initiation Detail Report containing the complete Vehicle Identification Number, customer name and address data has been prepared and will be loaded to the GM DealerWorld, Recall Information website. Dealers that have no involved vehicles currently assigned will not have a report available in GM DealerWorld. For Canada For dealers with involved vehicles, a Campaign Initiation Detail Report containing the complete Vehicle Identification Number, customer name and address data has been prepared and is being furnished to involved dealers. Dealers that have no involved vehicles currently assigned will not receive a report with the recall bulletin. For Export For dealers with involved vehicles, a Campaign Initiation Detail Report containing the complete Vehicle Identification Number, customer name and address data has been prepared and is being furnished to involved dealers. Dealers that have no involved vehicles currently assigned will not receive a report with the recall bulletin. The Campaign Initiation Detail Report may contain customer names and addresses obtained from Motor Vehicle Registration Records. The use of such motor vehicle registration data for any other purpose other than follow-up necessary to complete this recall is a violation of law in several states/provinces/countries. Accordingly, you are urged to limit the use of this report to the follow-up necessary to complete this program. Parts Information A very small number of vehicles (less than 90 world-wide) will require the replacement of the hydraulic brake booster. Do not order boosters for shelf stock. When a replacement is required, order the appropriate booster from GMSPO. All replaced boosters (excluding Export) must be returned to the Warranty Parts Center. Hold the booster until you receive the request for return. Special Tool Beginning February 18, 2005, each dealer was shipped a Hydro-Boost Checking Tool, CH 47950, for use in this recall. This tool is being furnished at no charge. Additional tools, if required, may be purchased by contacting SPX Kent-Moore at 1-800-468-6657. Courtesy Transportation The General Motors Courtesy Transportation program is intended to minimize customer inconvenience when a vehicle requires a repair that is covered by the New Vehicle Limited Warranty. The availability of courtesy transportation to customers whose vehicles are within the warranty coverage period and involved in a product recall is very important in maintaining customer satisfaction. Dealers are to ensure that these customers understand that shuttle service or some other form of courtesy transportation is available and will be provided at no charge. Dealers should refer to the General Motors Service Policies and Procedures Manual for Courtesy Transportation guidelines. Page 12112 Circuit/System Testing Component Testing Page 1691 Vehicle Speed Sensor: Service and Repair Manual Transmission - NV 4500 Vehicle Speed Sensor (VSS) Replacement Removal Procedure 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. Disconnect the vehicle speed sensor (VSS) electrical connector (3). 3. Remove the VSS and seal. Installation Procedure 1. Coat the NEW O-ring seal with a thin film of transmission fluid, use GM P/N 12346190 (Canadian P/N 10953477), or equivalent. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the VSS. ^ Tighten the VSS to 16 Nm (12 ft. lbs.). Page 11145 1. Install the evaporator core (1) to the HVAC module assembly (2). 2. Install the evaporator cowl gasket (1) to the evaporator (2). Page 517 Driver Door Module (DDM) - C4 (With RPO Code YE9) Part 1 Drivetrain - Transfer Case Control Module Replacement Control Module: All Technical Service Bulletins Drivetrain - Transfer Case Control Module Replacement Bulletin No.: 05-04-21-002 Date: March 10, 2005 INFORMATION Subject: Guidelines for Replacement of Transfer Case Control Module (TCCM) Models: 2005 and Prior Light Duty Trucks with New Venture Gear (NVG) Transfer Case (RPOs NP1, NP4, NP8) Dealers are replacing the TCCM unnecessarily. Dealers are replacing the TCCM with codes stored in HISTORY only. The TCCM does not have a current fault condition when tested. Parts reviewed at the Warranty Parts Center (WPC) have a 75% No Trouble Found (NTF) rate. The only two legitimate reasons to replace the TCCM are: ^ Diagnostic Trouble Code (DTC) C0550 ^ NO Communication with a scan tool. DTC C0550 This DTC indicates that the module has an internal fault and should be replaced. No Communication ^ The no communication conditions referenced here are also caused by a module internal fault to a point where the module physically will not talk. A technician cannot pull DTCs from the module because it will not communicate. The module is electrically dead. ^ No communication is not to be confused with a U1026 code. This code tells the technician that the module may still be functioning but is temporarily off line. This code may be set by the Instrument Panel (IP) or the Powertrain Control Module (PCM) against the TCCM. The technician needs to figure out why the module went off line. These are typically caused by connection concerns. There is no need to replace a TCCM for a U1026 DTC. Diagnostic Aids ^ When diagnosing a transfer case electrical control system, ALWAYS check power and ground wiring first. ^ Test the connections for intermittent or poor connections, complete plug insertion, bent pins, pushed out terminals and water contamination. Page 12724 5. Choose the outstanding core you wish to process, by selecting the Virtual Core Button on the far right side of the screen. 6. Enter the information in the required fields and select the submit button. Record the confirmation number. Canadian Dealers 1. Return the removed Analog / Digital-Ready OnStar(R) VCIM to the Parts Manager. 2. The Parts Manager will log onto https://adt.onstar.gm.mass.ca and enter information as prompted. All Dealers If the website indicates that the VCIM needs to be physically returned to the distributor, please use the pre-paid shipping label that was included in the kit to return the removed VCIM. Important: To avoid a $250 core non-return charge, you must do one of the following within 30 days of kit shipment: 1. Submit the necessary VCIM data through the website, as indicated above. 2. Mail the removed core from the customer's vehicle back to the distributor. 3. Return the unused digital upgrade kit back to the distributor using the pre-paid shipping label that is included in the kit box. Returning the Upgraded Vehicle to the Customer Returning the Upgraded Vehicle to the Customer 1. Place the new OnStar Subscriber Information (Owner's Manual kit) in the customer's vehicle where they can review some of the new features of the Digital-Capable system. The continuous digit dialing feature should be highlighted to the customer to avoid a return to the dealership for dialing instructions. Advise the customer to discard any existing OnStar(R) Owner's Manuals that may be in the vehicle. 2. Have the Service Advisor, Service Manager or Sales Consultant review the new OnStar(R) Hands-Free Calling procedure with the customer. The customer is uses to their analog OnStar(R) Hands-Free Calling system, which uses individual digit dial to make a call. The Generation 6 Digital-Capable system uses continuous digit dial, and the customer needs to be made aware of this change. 3. U.S. Dealers Only: Staple the "Tip Sheet - OnStar(R) Generation 6 Digitally-Capable System", that was included in the kit, to the customer's copy of the repair order. This tip sheet will help your customer better understand their new OnStar(R) system. 4. Canadian Dealers Only: Refer the customer to the Hands-Free Calling Quick Review Card from the new OnStar(R) Owner's Manual kit for help with the new dialing procedure. 5. Fill out the form entitled "GM Limited Warranty for Upgraded OnStar(R) Digital Equipment Program Participants" and staple a copy of this to the customer's repair order. You may want to keep a copy for your records. 6. Encourage your customer to press their blue OnStar(R) button the next day. The OnStar(R) Advisor will be able to review some of the new features of their digital OnStar(R) system. Closing the Onstar(R) Upgrade Exchange Closing the OnStar(R) Upgrade Exchange 1. Collect payment from the customer. Your dealership's open account (sales) will be charged for the cost of the chosen subscription plan, any applicable subscription taxes, and the $15 upgrade charge after the vehicle has been configured through the TIS2WEB process. 2. None of the costs associated with the OnStar Digital Upgrade program may be claimed as a GM goodwill event. These costs must be paid by the customer, and may not be included in any goodwill offered to the customer. GM employees or representatives or field personnel are not able to offer goodwill for this program. If the dealership decides to pay for the upgrade for their customer, be aware that your GM or OnStar(R) contact will not be able to reimburse you for this cost. 3. Use labor code Z2096 to submit your claim for the labor time published below plus 0.2 hr Administrative Allowance and an additional $20.00 Net Amount. ^ For all dealer claim submissions (excluding U.S. Saturn), use Complaint Code MH - Technical Bulletin, and Failure Code 93 - Technical Service Bulletin. Page 8175 2. Important: Use a small flat-bladed tool and lift the inner edge caliper boot next to the piston to release any trapped air. Ensure that the piston boot is below the level of the piston face. 3. Install the brake pad retainers to the caliper bracket. 4. Important: Ensure that the wear sensor is positioned at the leading edge, upward, of the inner pad during forward wheel rotation. Install the brake pads over the brake pad retainers and onto the caliper bracket. 5. Install the caliper to the caliper mounting bracket. 6. Notice: Refer to Fastener Notice in Service Precautions. Install 2 new caliper guide pin bolts. ^ Tighten the 2 caliper guide pin bolts to 42 Nm (31 ft. lbs.). 7. Install the tire and wheel assembly. 8. Lower the vehicle. 9. With the engine OFF, gradually apply the brake pedal to approximately 2/3 of its travel distance. 10. Slowly release the brake pedal. 11. Wait 15 seconds, then repeat steps 9-10 until a firm pedal is obtained. This will properly seat the brake caliper pistons and brake pads. 12. Fill the master cylinder reservoir to the proper level with clean brake fluid. Refer to Master Cylinder Reservoir Filling in Hydraulic Brakes. 13. Burnish the pads and the rotors. Refer to Burnishing Pads and Rotors. Page 2737 4. Push on the top part until it clicks in place. 5. Connect the harness to the front of the junction block. 6. Install the cover to the junction block until it clicks in place. 7. Hand tighten the retaining nut until seated. Page 2672 Junction Block - I/P - C4 Part 1 Page 13287 ^ Pay the dealer the regular retail price (no discounts are available) for one of the following 1-year, non-refundable OnStar(R) Analog-to-Digital Transition (ADT) Service Subscription Plans: ^ 1-year Safe & Sound Subscription: $199 ($289 in Canada) ^ 1-year Directions & Connections Subscription: $399 ($579 in Canada) ^ Pay the dealer the applicable state and local sales taxes on the subscription: ^ U.S. Dealers: Taxes only apply in these states: CT, DC, FL, HI, ND, NJ, NM, NY, SC, SD, TX, and WV ^ Canadian Dealers: All applicable taxes ^ Pay the dealer a one-time charge of $15 for the upgrade: ^ U.S. Dealers: Do not collect taxes on the $15 ^ Canadian Dealers: Collect all applicable taxes on the $15 Note: Dealers should NOT remit OnStar(R) ADT-related taxes to their taxing authority as OnStar(R) is responsible for tax remittance. Please Be Sure To Read these Important Points: ^ The 1-year OnStar(R) subscription is not refundable or transferable to another person. Upgraders can apply unused subscription months to a new or Certified Pre-Owned digital OnStar-equipped GM vehicle purchase or lease. As noted above, the digital upgrade program requires the subscriber to purchase a one-year prepaid OnStar(R) subscription. Assuming the subscriber intends to keep their vehicle, but subsequently purchases or leases a 2006 model year or newer OnStar(R)-equipped new or certified used GM vehicle, in the interest of subscriber satisfaction, they may apply remaining unused whole months of the subscription to the new vehicle. The subscription may not be applied to another person's vehicle. Important: This is a customer satisfaction measure that would usually occur several months after an upgrade. It is not intended to be leveraged as part of a new/used vehicle purchase or lease transaction. ^ The $15 charge is not refundable. ^ Dealer ADT kit orders are VIN specific. Dealer kit orders require a VIN and must be exchanged with the OnStar(R) unit in the vehicle with that VIN. Proper activation and enrollment depends on this step. ^ You must put the actual miles on the Repair Order. Do not estimate. ^ Customers will receive a Hands-Free Calling number once the digital hardware is installed and configured. ^ Any nametags that were stored in the old system will need to be re-set by the subscriber once the new hardware is installed. ^ Customers are responsible for the charges described above regardless of whether their vehicle is in or out of the New Vehicle Warranty period. In addition, customers should not be charged labor costs. Dealers can charge GM the labor for the upgrade as specified at the end of this bulletin using the listed labor operation. ^ Vehicles eligible for an OnStar(R) hardware upgrade are listed in this bulletin. Vehicle upgradeability can also be determined by typing the VIN into the field entitled "Determine VIN Hardware Functionality" on the OnStar(R) Online Enrollment website, located in the sales or service workbench tab of GM GlobalConnect. Canadian Dealers can use a similar tool that is available within InfoNET. ^ Access to the sales and/or service workbench in the GM GlobalConnect website can be granted by the dealership's Partner Security Coordinator (PSC). If you are unsure who the PSC is, check with the Sales Manager. Ordering the Upgrade Kit/Upgrade kit Installation Ordering the Upgrade Kit 1. To order a kit, you will need to access the OnStar(R) Online Enrollment webpage, located under the sales or service workbench of GM GlobalConnect (infoNET for Canadian upgrade orders). These kits cannot be ordered from GMSPO. Page 2680 Junction Block - Rear Lamps - C2 Page 2996 ACCESSORY WHEEL AND TIRE INFORMATION FORM You have just modified your vehicle by installing an "Accessory Package" which includes Wheels and Tires. This form contains important information about your accessory installation. In an effort to provide superior service to you, our customer, we ask that you please present this form to your Servicing Dealer when removing or installing wheels and tires on your vehicle. This form contains important information necessary to service your vehicle. Disclaimer Page 15093 Front Door Weatherstrip: Service and Repair Weatherstrip Replacement - Side Door Opening Weatherstrip Replacement - Side Door Opening Removal Procedure 1. Open both doors. 2. Remove the sill plate. 3. Remove the hinge pillar trim pillar. 4. Remove the windshield pillar molding. 5. Remove the weather-strip from the rear side door pinch-weld flange. Installation Procedure 1. Install the weather-strip from the rear side door opening fully seating the weather-strip into the pinch-weld flange. 2. Install the windshield pillar molding. 3. Install the hinge pillar trim pillar. 4. Install the sill plate. 5. Inspect the door closing effort and seal to door fit. Page 11558 7. Disconnect the SDM wiring harness connector (1) from the SDM (3). 8. Remove the SDM mounting fasteners. 9. Remove the SDM from the vehicle. IMPORTANT: The following repair procedures should only be used in the event that the inflatable restraint sensing and diagnostic module (SDM) mounting studs and/or fasteners are damaged to the extent that the SDM may no longer be properly mounted. 10. Repair the fasteners using the following procedure: 10.1. Remove the stripped nut and discard the nut. 10.2. Drill out the weld spots to the weld stud from the floor pan side, then remove and discard the stud. 10.3. Condition the floor panel attaching surface where the new stud is to be installed. 10.4. Install new weld stud GM P/N 115115602 and clamp the weld stud. 10.5. Migweld the stud at the drilled holes from above or below the floor pan, as required. 10.6. Apply body sealer GM P/N 9984248 around any exposed openings. 10.7. Install a new fastener GM P/N 11515933. INSTALLATION PROCEDURE 1. Remove any dirt, grease, or other contaminants from the mounting surface. 2. Install the SDM (3) horizontally to the vehicle. 3. Point the arrow on the SDM toward the front of the vehicle. NOTE: Refer to Fastener Notice in Service Precautions. 4. Install the SDM mounting fasteners. Tighten Tighten fasteners to 10 N.m (89 lb in). 5. Connect the SDM wiring harness connector (1) to the SDM. Page 1885 7. Remove the control lever to the manual shaft nut. 8. Remove the control lever from the manual shaft. 9. Remove the PNP switch bolts. 10. Remove the PNP switch from the manual shaft. If the PNP switch does not slide off the manual shaft, file the outer edge of the manual shaft in order to remove any burrs. Installation Procedure 1. Install the PNP switch to the manual shaft by aligning the switch hub flats with the manual shaft flats. 2. Slide the PNP switch onto the manual shaft until the switch mounting bracket contacts the mounting bosses on the transmission. 3. Important: If a new PNP switch is being installed, the switch will come with a positive assurance bracket. The positive assurance bracket aligns the new switch in its proper position for installation and the use of the park neutral switch aligner will not be necessary. Install the PNP switch bolts finger tight. Page 16032 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Micro-Pack 100W Connectors MICRO-PACK 100W CONNECTORS TOOLS REQUIRED J 38125-D Terminal Repair Kit REMOVAL PROCEDURE There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2)has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. IMPORTANT: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Page 8123 Important: After drilling the holes, apply the appropriate anti-corrosion primer. Refer to the GM Refinish Material Booklet # 4901 M-D (English) or # 4901-D-F (French) for additional information. 6. Center punch the marked location and drill a 6.35 mm (1/4 in) hole. Install the plastic retainer in the hole (1) of the mud flap. 7. Tighten fastener at the hole (2) location of the mud flap. Tighten Tighten the fastener to 25 N.m (18 lb ft). 8. For vehicles with short box, use the following procedure: 8.1. Push the mud flap to make contact with the rear side of the underbody cross sill and mark the location of the hole (3) of the mud flap. 8.2. Center punch the marked location and drill a 5.159 mm (13/64 in) hole. 8.3. Install the screw. Tighten Tighten the screw to 4 N.m (35 lb in). 8.4. Repeat the above steps for hole locations 4 and 6. 9. For vehicles with long box, use the following procedure: Page 4320 Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips SPLICING COPPER WIRE USING SPLICE CLIPS IMPORTANT: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. TOOLS REQUIRED J 38125-D Terminal Repair Kit 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-D in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. Page 10717 18. Inspect and add axle lubricant to the axle housing, if necessary. 19. Lower the vehicle. Page 4307 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the cover up until the dress cover releases. Repeat this procedure for the other locking tab. 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. 5. If the connector has a nose piece, use a small flat-blade tool to remove the nose piece by inserting the blade into the slot on the front of the connector and prying up on the nose piece. IMPORTANT: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 6. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. IMPORTANT: Be careful not to angle or rock the J 38125-13A tool when inserting it into the connector or the tool may break. Page 13530 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground TESTING FOR SHORT TO GROUND NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting With A Digital Multimeter TROUBLESHOOTING WITH A DIGITAL MULTIMETER NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TROUBLESHOOTING WITH A TEST LAMP A/T - 4L60/65E, No Reverse/2nd or 4th Gear Sun Gear: All Technical Service Bulletins A/T - 4L60/65E, No Reverse/2nd or 4th Gear TECHNICAL Bulletin No.: 00-07-30-022D Date: June 10, 2008 Subject: No Reverse, Second Gear or Fourth Gear (Replace Reaction Sun Shell with More Robust Heat Treated Parts) Models: 1993 - 2005 GM Passenger Cars and Light Duty Trucks 2003 - 2005 HUMMER H2 with 4L60/65-E Automatic Transmission (RPOs M30 or M32) Supercede: This bulletin is being revised to add 2005 model year to the parts information. Please discard Corporate Bulletin Number 00-07-30-022C (Section 07 - Transmission/Transaxle). Condition Some customers may comment on a no reverse, no second or no fourth gear condition. First and third gears will operate properly. Cause The reaction sun gear (673) may not hold inside the reaction sun shell (670). Correction Important: There are FOUR distinct groups of vehicles and repair procedures involved. Vehicles built in the 2001 model year and prior that make use of a reaction shaft to shell thrust washer: ^ The sun shell can be identified by four square holes used to retain the thrust washer. Use reaction sun shell P/N 24228345, reaction carrier to shell thrust washer (699B) P/N 8642202 and reaction sun gear shell thrust washer (674) P/N 8642331er (674) P/N 8642331along with the appropriate seals and washers listed below. ^ Vehicles built in the 2001 model year and prior that have had previous service to the reaction sun shell: It is possible that some 2001 and prior model year vehicles have had previous service to the reaction sun shell. At the time of service, these vehicles may have been updated with a Reaction Sun Shell Kit (Refer to Service Bulletin 020730003) without four square holes to retain the thrust washer. If it is found in a 2001 model year and prior vehicles that the reaction sun shell DOES NOT have four square holes to retain the thrust washer, these vehicles must be serviced with P/Ns 24229825 (674), 24217328 and 8642331 along with the appropriate seals and washers listed below. ^ Vehicles built in the 2001 model year and later that make use of a reaction shaft to shell thrust bearing: The sun shell can be identified by no holes to retain the thrust washer. Use reaction sun shell, P/N 24229825, reaction carrier shaft to shell thrust bearing (669A), P/N 24217328 and reaction sun gear shell thrust washer (674), P/N 8642331 along with the appropriate seals and washers listed below. ^ Vehicles built from November, 2001 through June, 2002: These vehicles should have the reaction carrier shaft replaced when the sun shell is replaced. Use shell kit P/N 24229853, which contains a sun shell (670), a reaction carrier shaft (666), a reaction carrier shaft to shell thrust bearing (669A) and a reaction sun gear shell thrust washer (674). The appropriate seals and washers listed below should also be used. When servicing the transmission as a result of this condition, the transmission oil cooler and lines MUST be flushed. Refer to Corporate Bulletin Number 02-07-30-052. Follow the service procedure below for diagnosis and correction of the no reverse, no second, no forth condition. Important: If metallic debris is found on the transmission magnet, the transmission must be completely disassembled and cleaned. Metallic debris is defined as broken parts and pieces of internal transmission components. This should not be confused with typical "normal" fine particles found on all transmission magnets. Failure to properly clean the transmission case and internal components may lead to additional repeat repairs. 1. Remove the transmission oil pan and inspect the magnet in the bottom of the pan for metal debris. Refer to SI Document ID # 825141. Page 7665 4. Inspect the rear output shaft bushing for scoring or wear. 5. Remove the rear output shaft bushing if required, using the J 45380 ^ Install the finger section of the J 45380 in front of the bushing. ^ Install the tube and forcing screw to the finger section. Ensure the forcing screw is backed out. ^ Using a wrench on the forcing screw, remove the rear output shaft bushing. Installation Procedure 1. Install a NEW rear output shaft bushing, if required using the J 45380 ^ Install the bushing or the finger section of the J 45380 ^ Install the finger section to the main body of the J 45380 ^ Position the bushing and tool to the case. ^ Using a hammer and the J 45380, install the bushing. Page 6329 Pressure Regulating Solenoid: Service and Repair Automatic Transmission - 4L80-E/4L85-E Pressure Regulator Replacement ^ Tools Required J 36850 Transjel Removal Procedure 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. Remove the transmission filter. 3. Caution: Valve springs can be tightly compressed. Use care when removing retainers and plugs. Personal injury could result. Remove the reverse boost valve bushing retainer ring (2). 4. Remove the following from the reverse boost valve cylinder: ^ The reverse boost valve bushing ^ The reverse boost valve ^ The pressure regulator spring retainer ^ The pressure regulator spring ^ The pressure regulator valve ^ The reverse boost valve bushing Installation Procedure 1. Install the pressure regulator valve using J 36850. 2. Pre-assemble the following parts: Page 12968 Speaker - RF - Tweeter - With RPO Code UQ7 Page 16164 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves SPLICING COPPER WIRE USING SPLICE SLEEVES TOOLS REQUIRED J 38125-D Terminal Repair Kit IMPORTANT: Use only GM splice sleeves, other splice sleeves may not protect the splice from moisture or a provide good electrical connection. Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. Page 3712 Exhaust Manifold: Service and Repair Exhaust Manifold Replacement - Right Exhaust Manifold Replacement - Right (4.8L, 5.3L, and 6.0L Engines) 1. Raise and suitably support the vehicle. 2. Remove the exhaust manifold pipe nuts. 3. Lower the vehicle. 4. Remove the spark plugs. 5. Remove the exhaust manifold bolts, manifold, and gasket. 6. Discard the gasket. 7. Remove the heat shield bolts (1), and shield (2) from the exhaust manifold (1), if necessary. 8. Clean and inspect the exhaust manifold. Installation Procedure Notice: Refer to Fastener Notice in Service Precautions. Page 11753 Steps 4-5 Steps 1-5 Page 10457 Wheel Bearing: Adjustments Rear Wheel Bearing Adjustment (With Full Floating 10.5" or 11.5" Ring Gear) IMPORTANT: Ensure the brakes are fully released and do not drag. ^ Pull or push the tire at the top back and forth in order to test the wheel bearing play. ^ Use a pry bar under the tire as an alternative. ^ If the wheel bearing adjustment is correct, the movement will be barely noticeable. ^ If the movement is excessive, adjust the bearings. Adjustment Procedure Tools Required J 2222-C Wheel Bearing Nut Wrench 1. Raise the vehicle. 2. Remove the axle shaft. 3. Remove the hub adjuster nut retaining ring. 4. Remove the adjuster nut lock key. Tire Monitor System - TPM Sensor Information Tire Pressure Monitor Receiver / Transponder: Technical Service Bulletins Tire Monitor System TPM Sensor Information INFORMATION Bulletin No.: 08-03-16-003 Date: May 12, 2008 Subject: Warranty Reduction - Transfer of Tire Pressure Monitoring (TPM) Sensors to Replacement Wheels and Allowable TPM Sensor Replacements Models: 2000-2009 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2009 HUMMER H2 2006-2009 HUMMER H3 2005-2009 Saab 9-7x with On-Wheel TPM Sensors TPM Sensor / Wheel Warranty Reviews During the last warranty review period it was noted that wheels being returned under the GM New Vehicle Warranty were being shipped back to General Motors with the TPM sensor still attached to the wheel. Return rates ran as high as 60% with the TPM sensors still attached. Operational TPM sensors should not be returned to GM and are to be transferred to replacement wheels if they become necessary. Important: Operational TPM Sensors that are returned under warranty to General Motors will be charged back to the dealer.Sensors have a 10 year /150,000 mile (240,000 km) battery life, and should be transferred if one or more wheels are replaced. TPM Valve Stem / Grommet (0-ring) Replacement When the TPM sensors are transferred to new wheels you should replace the component used to seal the TPM sensor stem to the wheel. On sensors with an aluminum stem and visible nut on the outside of the wheel a replacement grommet (0-ring) should be used to assure a proper seal. The sensor retaining nut (except Aveo) should be tightened to 7 N.m (62 lb in) for all vehicles except Pontiac Vibe (4.0 N.m (35.4 lb in)). Important: ^ DO NOT overtorque the retaining nut. Notice: ^ Factory installed TPM Sensors come with plastic aluminum or nickel-plated brass stem caps. These caps should not be changed. Chrome plated steel caps may cause corrosion of aluminum valve stems due to incompatibility of the metals. On current style sensors the entire rubber stem is replaceable. The service interval on the revised TPM sensor with replaceable stem is the same as for any other traditional valve stem. Replace the stem at the time of tire replacement sensor transfer or whenever air seepage is suspected at the valve stem. When replacing the valve stem tighten the screw to 1.3 N.m (11.5 lb in). For either style of TPM sensor see the service parts guide for the correct GM part numbers to order and use. Disclaimer Page 16126 Electrical Symbols ELECTRICAL SYMBOLS Electrical Symbols Part 1 Page 6783 43. Install the right inner axle shaft housing assembly to the differential carrier assembly. 44. Install the inner axle shaft housing bolts. Tighten Tighten the inner axle shaft housing bolts to 40 N.m (30 lb ft). 45. Install the inner axle shaft housing washers and nuts to the bracket. Tighten Tighten the inner axle shaft housing nuts to 100 N.m (75 lb ft). 46. Connect the wheel drive shaft inboard flange to the inner axle shaft. 47. Install the wheel drive shaft inboard flange to the inner axle shaft bolts. Tighten Tighten the wheel drive shaft inboard flange to the inner axle shaft bolts to 79 N.m (58 lb ft). 48. Connect the wire harness to the inner axle shaft housing and differential carrier. 49. Connect the electrical connector to the front axle actuator. 50. Fill the differential carrier assembly with axle lubricant. Use the proper fluid. Refer to Lubricant Replacement - Front Drive Axle in the Front Axle sub-section of the Service Manual. 51. Install the front engine protection shield. Refer to Engine Protection Shield Replacement in the Frame and Underbody sub-section of the service manual. 52. Lower the vehicle. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Page 7232 Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA and/or the secondary locks. Micro .64 Connectors MICRO .64 CONNECTORS TOOLS REQUIRED J 38125-D Terminal Repair Kit REMOVAL PROCEDURE Follow the steps below in order to remove terminals from Micro 64 connectors. 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. 2. Disconnect the connector from the component. Interior - Power Seat Switch Knobs Loose/Missing Power Seat Switch: All Technical Service Bulletins Interior - Power Seat Switch Knobs Loose/Missing Bulletin No.: 05-08-50-017 Date: December 14, 2005 TECHNICAL Subject: Power Front Seat (RPO AN3) Switch Knobs Loose or Missing (Replace Switch Knobs) Models: 2002-2006 Cadillac Escalade, Escalade EXT 2003-2006 Cadillac Escalade ESV 2002-2006 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2002-2006 GMC Sierra, Yukon, Yukon XL with Individual Front Seat Non-Bucket (RPO AN3) and Driver Front Seat Power Adjuster (AG1) and/or Passenger Front Seat Power Adjuster (AG2) Condition Some customers may comment that the power front seat adjuster switch knobs are loose and fall off or are missing. Correction Replace the front seat adjuster switch knob. These knobs were formerly available only as part of the power seat adjuster switch. DO NOT replace the switch if the knob only needs to be replaced. Parts Information Warranty Information Page 5780 7. Remove the transmission control lever from the manual shaft. 8. Remove the PNP switch bolts. 9. Remove the PNP switch from the manual shaft. If the PNP switch did not slide off the manual shaft, file the outer edge of the manual shaft in order to remove any burrs. Installation Procedure 1. Install the PNP switch to the transmission manual shaft by aligning the switch hub flats with the manual shaft flats. 2. Slide the PNP switch onto the transmission manual shaft until the switch mounting bracket contacts the mounting bosses on the transmission. 3. Important: If a NEW PNP switch is being installed, the switch will come with a positive assurance bracket. The positive assurance bracket aligns the new switch in its proper position for installation and the use of the park neutral switch aligner will not be necessary. Install the PNP switch bolts finger tight. 4. Install J 41364-A onto the PNP switch. Ensure that the two slots on the switch where the manual shaft is inserted are lined up with the lower two tabs on the tool. 5. Notice: Refer to Fastener Notice in Service Precautions. Rotate the tool until the upper locator pin on the tool is lined up with the slot on the top of the switch. ^ Tighten the bolts to 25 Nm (18 ft. lbs.). 6. Remove the J 41364-A from the switch. If installing a new switch, remove the positive assurance bracket at this time. 7. Install the transmission control lever to the manual shaft with the nut. ^ Tighten the nut to 25 Nm (18 ft. lbs.). Locations Windshield Washer Reservoir Procedures Seat Heater: Procedures Seat Back Heater Element Replacement - Front SEAT BACK HEATER ELEMENT REPLACEMENT - FRONT REMOVAL PROCEDURE 1. Remove the seat from the vehicle. 2. Remove the seat back trim cover. 3. Peel the seat back heater off the foam pad. 4. Disconnect the seat back heater harness. INSTALLATION PROCEDURE 1. Connect the seat back heater harness. 2. Install the seat back heater. 3. Install the seat back trim cover. 4. Install the seat in the vehicle. Seat Cushion Heater Element Replacement - Front SEAT CUSHION HEATER ELEMENT REPLACEMENT - FRONT REMOVAL PROCEDURE CAUTION: If the passenger seat cushion foam is damaged when you remove the heater element, replace the passenger pressence system in order to prevent personal injury. 1. Remove the seat trim panel. 2. Remove the seat cushion trim cover. Page 326 Page 4372 1. If installing the old sensor, coat the threads with sealant GM P/N 12346004 (Canadian P/N 10953480) or equivalent. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the ECT sensor. Tighten Tighten the sensor to 20 N.m (15 lb ft). 3. Connect the ECT sensor electrical connector (5). 4. Refill the cooling. Refer to Draining and Filling Cooling System in Cooling System. A/T Control - DTC P0756 Diagnostic Tips Valve Body: All Technical Service Bulletins A/T Control - DTC P0756 Diagnostic Tips INFORMATION Bulletin No.: 01-07-30-036H Date: January 29, 2009 Subject: Diagnostic Tips for Automatic Transmission DTC P0756, Second, Third, Fourth Gear Start Models: 2009 and Prior GM Passenger Cars and Light Duty Trucks 2009 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X with 4L60-E, 4L65-E or 4L70E Automatic Transmission (RPOs M30, M32 or M70) Supercede: This bulletin is being revised to add the 2009 model year and add details regarding spacer plates. Please discard Corporate Bulletin Number 01-07-30-036G (Section 07 - Transmission/Transaxle). Some dealership technicians may have difficulty diagnosing DTC P0756, 2-3 Shift Valve Performance on 4L60-E, 4L65-E or 4L70E automatic transmissions. As detailed in the Service Manual, when the PCM detects a 4-3-3-4 shift pattern, DTC P0756 will set. Some customers may also describe a condition of a second, third or fourth gear start that may have the same causes but has not set this DTC yet. Below are some tips when diagnosing this DTC: ^ This is a performance code. This means that a mechanical malfunction exists. ^ This code is not set by electrical issues such as a damaged wiring harness or poor electrical connections. Electrical problems would cause a DTC P0758, P0787 or P0788 to set. ^ The most likely cause is chips/debris plugging the filtered AFL oil at orifice # 29 on the top of the spacer plate (48). This is a very small hole and is easily plugged by a small amount of debris. It is important to remove the spacer plate and inspect orifice # 29 and the immediate area for the presence of chips/debris. Also, the transmission case passage directly above this orifice and the valve body passage directly below should be inspected and cleaned of any chips/debris. For 2003 and newer vehicles the spacer plate should be replaced. The service replacement spacer plate is a bonded style with gaskets and solenoid filter screens bonded to the spacer plate. These screens can help to prevent plugging of orifice # 29 caused by small debris or chips. ^ This code could be set if the 2-3 shift valve (368) were stuck or hung-up in its bore. Inspect the 2-3 shift valve (368) and the 2-3 shuttle valve (369) for free movement or damage and clean the valves, the bore and the valve body passages. ^ This code could be set by a 2-3 shift solenoid (367b) if it were cracked, broken or leaking. Refer to Shift Solenoid Leak Test in the appropriate Service Manual for the leak test procedure. Based on parts return findings, a damaged or leaking shift solenoid is the least likely cause of this condition. Simply replacing a shift solenoid will not correct this condition unless the solenoid has been found to be cracked, broken or leaking. It is important to also refer to the appropriate Service Manual or Service Information (SI) for further possible causes of this condition. Disclaimer Page 5456 13. If necessary, lower the vehicle. 14. Using a scan tool, clear the DTCs. 15. Start the vehicle and inspect for leaks. Important: Advise the customer that a similar condition may occur if the vehicle is fueled with the engine running AND the rear tank is fueled first. The engine must be shut off (as required by law) during vehicle refueling. Parts Information Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 2614 Fuse Block - Underhood - Secondary Wire Entry (With RPO Code HP2) Part 4 Page 8078 The information shown is for the 1999-2002 wiring harnesses and for the 2003-05 wiring harness. To modify a 12171982, 15366255 or 15086884 harness for use in a 2003-05 vehicle, switch the wires in cavities "A" and "D". To modify a 15085418 harness for use in a 1999-2002 vehicle (see model list at the front of this bulletin for applicable models), switch the wires in cavities "A" and "D". Warranty Information When the correct wiring harness P/N is matched to the specific model year of the vehicle, everything works properly. Therefore, conversion of an incorrect wiring jumper to match the vehicle would not be considered a warrantable repair. Disclaimer Page 10739 The wheel hubs illustrated above are intended to provide enough visual details to identify subtle differences between the Gen II and Gen III replacement hubs. The various colors used in the graphics are not indicative of any difference or feature, but are used to increase the detail and clarity of the assembly. The associated part number is listed with each illustration. Please refer to the chart above for the specific application for each hub. Page 4212 Disclaimer Page 12355 Control Module References Part 4 C100 - C198 Multiple Junction Connector: Diagrams C100 - C198 C100 I/P Harness To Engine Harness Part 1 Page 8463 Driveline - Bump/Clunk/Squawking Noises Slip Yoke: Customer Interest Driveline - Bump/Clunk/Squawking Noises Bulletin No.: 01-04-17-004B Date: January 05, 2005 TECHNICAL Subject: Clunk, Bump or Squawk when Vehicle Comes to Complete Stop or Accelerating from Complete Stop (Replace Rear Drive Shaft Nickel-Plated Slip Yoke) Models Supercede: This bulletin is being revised to add Cadillac Escalade (Old Style) to the Models section. Please discard Corporate Bulletin Number 01-04-17-004A (Section 04 - Driveline/Axle). Condition Some customers may comment on a clunk, bump or squawk noise when the vehicle comes to a stop or when accelerating from a complete stop. Cause A slip/stick condition between the transfer case output shaft and the driveshaft slip yoke may cause this condition. Diagnostic Tips There are several resources in the electronic Service Information System which can provide the technician with information on diagnosis and repair of clunk conditions, and fix the customer's vehicle right the first time without unnecessary parts replacement. Some of the documents available in SI include: ^ Symptoms - Propeller Shaft Page 10951 Parts required to complete this special coverage are to be obtained from General Motors Customer Care and Aftersales (GMCC&A;). Service Procedure Note The resistor module connector and blower motor resistor will need to be replaced if one or more of the symptoms below is present. - The HVAC blower may not function on certain or all blower speed settings - A burning plastic smell or smoke may be present in the vehicle - The HVAC blower may run continually with the ignition in the OFF position Determine if one or more of the above symptoms is present. If required refer to HVAC diagnostic information in SI. Refer to Resistor Module Connector and Blower Motor Resistor Replacement in this bulletin if one or more of the symptoms is present. Other HVAC repairs are NOT covered in this product safety special coverage bulletin. Resistor Module Connector and Blower Motor Resistor Replacement 1. Remove the blower fuses (Htr A/C & HVAC 1 fuses). 2. Lower the close-out panel enough to gain access to the resistor module connector. 3. Disconnect the connector from the resistor module. Note Connector replacement is required even if the connector was replaced on a previous service repair. 4. Remove the tape from the wiring harness to expose the wiring. 5. Cut the wires back far enough from the connector to eliminate any melted insulation on the wire. Note Use the old connector as a map for splicing the wires for the new connector. Be sure to use the correct crimping tool from the terminal repair kit J 38125. Use only Duraseal splice sleeves. Other splice sleeves may not protect the splice from moisture or provide a good electrical connection. 6. Install the new connector. Use the yellow splice sleeves provided with the connector. 7. Install the new blower motor resistor. 8. Reinstall the fuses. Test the blower motor to make sure all speeds are functional. 9. Reinstall the hush panel/close-out panel. Customer Reimbursement Customer requests for reimbursement of previously paid repairs to correct the condition described in this bulletin are to be submitted to the dealer prior to or by December 31, 2012. Repairs must have occurred within the 10 years of the date the vehicle was originally placed in service, or 240,000 kilometres, whichever occurs first. When a customer requests reimbursement, they must provide the following: Page 14642 For vehicles repaired under warranty, use the table. Disclaimer Page 13573 Door Control Module Diagram 3 Part 1 Page 12174 ^ An OnStar(R) Call Center button press WILL NOT connect the vehicle with OnStar(R). The vehicle must be upgraded to reactivate the account. The customer will hear a demo message stating that there is not a current OnStar(R) subscription for the vehicle. The message will also instruct the customer how to upgrade and reactivate services. ^ OnStar(R) personal calling (OPC) will not be available, as this feature requires the customer to have a current OnStar(R) account. Attempts to use this feature will result in cellular connection failure messages and the inability to connect to the number dialed. Note For deactivated vehicles, a no connect response should be considered normal system operation. Further diagnosis and subsequent repair is only necessary should the customer elect to become an active OnStar(R) subscriber and upgrade the account subscription. OnStar(R) Cellular, GPS, and Diagnostic Limitations The proper operation of the OnStar(R) System is dependent on several elements outside the components integrated into the vehicle. These include the National Cellular Network Infrastructure, the cellular telephone carriers within the network, and the GPS. The cellular operation of the OnStar(R) system may be inhibited by factors such as the users range from a digital cellular tower, the state of the cellular carrier's equipment, and the location where the call is placed. Making an OnStar(R) key press in areas that lack sufficient cellular coverage or have a temporary equipment failure will result in either the inability of a call to complete with a data transfer or the complete inability to connect to the OnStar(R) Call Center. The OnStar(R) system may also experience connection issues if the identification numbers for the module, station identification number (STID), electronic serial number (ESN) or manufacturers electronic ID (MEID), are not recognized by the cellular carriers local signal receiving towers. The satellites that orbit earth providing the OnStar system with GPS data have almost no failures associated with them. In the event of a no GPS concern, the failure will likely lie with the inability of the system to gain GPS signals because of its location, i.e. in a parking structure, hardware failure, or being mistaken with an OnStar(R) call which has reached the Call Center without vehicle data. During diagnostic testing of the OnStar(R) system, the technician should ensure the vehicle is located in an area that has a clear unobstructed view of the open sky, and preferably, an area where digital cellular calls have been successfully placed. These areas can be found by successfully making an OnStar(R) keypress in a known good OnStar(R) equipped vehicle and confirming success with the OnStar(R) Call Center advisor. Such places can be used as a permanent reference for future OnStar(R) testing. Mobile Identification Number and Mobile Directory Number The vehicle communication interface module (VCIM) utilizes 2 numbers for cellular device identification, call routing and connection. They are: ^ A mobile identification number (MIN) ^ A mobile directory number (MDN) Note The MIN represents the number used by the cellular carrier for call routing purposes. The MDN represents the number dialed to reach the cellular device. Diagnostic Information Symptoms - Cellular Communication The following steps must be completed before using the symptom table. 1. Perform the Diagnostic System Check - Vehicle, before using the Symptom Tables in order to verify that the following are true: ^ There are no DTCs set. ^ The control modules can communicate via the serial data link. 2. Review the system operation in order to familiarize yourself with the system functions. Refer to Radio/Audio System Description and Operation in SI. Diagnostic Starting Point - Displays and Gages Begin the displays and gages system diagnosis with Diagnostic System Check - Vehicle or the audible warning system diagnosis with Diagnostic System Page 9660 Ground Strap: Service and Repair GROUND STRAP REPLACEMENT REMOVAL PROCEDURE 1. If necessary, remove the engine sight shield. 2. Remove the engine wiring harness ground bolt. 3. Reposition the engine wiring harness ground and ground strap. 4. Remove the ground strap nut from the stud at the front of dash. 5. Remove the ground strap from the stud. INSTALLATION PROCEDURE NV3500/NV4500 Transmissions Clutch Slave Cylinder: Service and Repair NV3500/NV4500 Transmissions Clutch Actuator Cylinder Replacement (NV3500/NV4500 Transmissions) Removal Procedure 1. Remove the manual transmission. 2. Remove the clutch actuator cylinder bolts. 3. Remove the clutch actuator cylinder. If required, the clutch release bearing can be removed from the clutch actuator cylinder for replacement. Installation Procedure 1. Install the clutch actuator cylinder. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the clutch actuator cylinder bolts. ^ Tighten the bolts to 8 Nm (71 inch lbs.). 3. Install the manual transmission. Page 2475 8. Install the transmission support. 9. Install the transmission support side bracket and bolts. 10. Install the transmission support bolts and nuts. ^ Tighten the bolts/nuts to 95 Nm (70 ft. lbs.). 11. Install the transmission mount nuts. ^ Tighten the nuts to 40 Nm (30 ft. lbs.). 12. Remove the transmission jack. 13. Lower the vehicle. 14. Fill the transmission to the proper level with DEXRON® III transmission fluid. Page 12525 ^ SP303 The following modules, components, and splice pack are connected to the star portion of the class 2 serial data circuit: ^ SP300 ^ Audio amplifier ^ Driver door module (DDM) ^ Driver door switch assembly (DDSA) ^ Memory seat module (MSM) ^ Left rear door module (LRDM) AND ^ SP303 ^ Antenna module ^ Front passenger door module (FPDM) ^ Rear integration module (RIM) ^ Right rear door module (RRDM) ^ Theft deterrent module (TDM) ^ Vehicle communication interface module (VCIM). Refer to Data Communication Schematics and Data Link Communications Description and Operation in SI. Part 2 Conditions for Running the DTC Voltage supplied to the module is in the normal operating voltage range of 9 - 16 volts. DTCs B1327, B1328, U1300, U1301, U1305 are not set as current. The vehicle power mode requires serial data communication to occur. Conditions for Setting the DTC A message containing a critical operating parameter has not been received within the last 5 seconds after establishing class 2 serial data communication. Action Taken When the DTC Sets The module uses a default value for the missing parameter. Conditions for Clearing the DTC A current DTC clears when the malfunction is no longer present. A history DTC clears when the module ignition cycle counter reaches the reset threshold, without a repeat of the malfunction. Diagnostic Aids When a malfunction such as an open fuse to a module occurs while modules are communicating, a DTC U1001-1254 Loss of XXX Communications is set current. When the modules stop communicating the current DTC U1001-1254 Loss of XXX Communications is cleared but the history DTC remains. When the modules begin to communicate again, the module with the open fuse will not be learned by the other modules so U1000 or U1255 is set current by the other modules. If the malfunction occurs when the modules are not communicating, only U1000 or U1255 is set. Page 13139 1. To receive credit, submit a claim with the information above. Disclaimer 2001 and Older Model Year Vehicles (Except Saab Vehicles) 2001 and Older Model Year Vehicles (Except Saab Vehicles) Important: 2001 and older model year vehicles require the removal of the battery power from the OnStar(R) vehicle interface unit (VIU) to eliminate the possibility of an inadvertent OnStar(R) or emergency/airbag call. 1. Locate and gain access to the OnStar® VIU. Refer to OnStar Vehicle Interface Unit Replacement in SI. Important: Complete removal of the VIU is usually not required. Perform only the steps required to gain access to the C2 32-way blue connector. Residing in the C2 connector are the battery positive (+) circuits. Removal of the C2 connector will deactivate the unit and eliminate the possibility of an inadvertent OnStar(R) or emergency/airbag call. Page 9618 Location View Page 2685 Relay Block - I/P C1 Part 3 Page 910 Control Module References Part 5 Page 7936 Transmission Speed Sensor: Service and Repair Output Shaft Speed Sensor Replacement Output Shaft Speed Sensor Replacement Removal Procedure Important: This procedure is for 2-wheel drive (2WD) vehicles only. If the vehicle is equipped with 4-wheel drive (4WD), the output speed sensor is located on the transfer case. 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. Disconnect the output speed sensor (2) electrical connector. 3. Remove the output speed sensor bolt. 4. Remove the output speed sensor (2). 5. Inspect the output speed sensor (2) for any evidence of damage. Installation Procedure Automatic Transmission - 4L60-E/4L65-E Pressure Regulating Solenoid: Service and Repair Automatic Transmission - 4L60-E/4L65-E Pressure Regulator Replacement Removal Procedure 1. Remove the transmission filter. 2. Compress the reverse boost valve sleeve into the bore of the oil pump to release tension on the reverse boost valve retaining ring. 3. Remove the reverse boost valve retaining ring, then slowly release tension on the reverse boost valve sleeve. 4. Remove the reverse boost valve sleeve (5) and the reverse boost valve (4). 5. Remove the pressure regulator isolator spring (3) and the pressure regulator valve spring (2). 6. Remove the pressure regulator valve (1). Installation Procedure 1. Install the pressure regulator valve (1). 2. Install the pressure regulator isolator spring (3) and the pressure regulator valve spring (2). 3. Install the reverse boost valve (4) in the reverse boost valve sleeve (5). 4. Install the reverse boost valve (4) and sleeve (5) in the oil pump cover. Page 12811 Page 3313 6. Important: Do not manually depress the retaining clip when installing the plastic cap. Snap the plastic cap onto the quick connect fitting. 7. Ensure that the plastic cap is fully seated against the fitting. 8. Ensure that no gap is present between the cap and the fitting. 9. Inspect and fill the engine oil to the proper level. Page 4918 4. Position the J 41364-A onto the PNP switch. Ensure that the two slots on the switch where the manual shaft is inserted are lined up with the lower two tabs on the tool. 5. Notice: Refer to Fastener Notice in Service Precautions. Rotate J 41364-A until the upper locator pin on the tool is lined up with the slot on the top of the switch. ^ Tighten the bolts to 25 Nm (18 ft. lbs.). 6. Remove J 41364-A from the PNP switch. If installing a new switch, remove the positive assurance bracket at this time. 7. Install the control lever to the manual shaft with the nut. 8. Install the manual shaft nut. ^ Tighten the nut to 25 Nm (18 ft. lbs.). 9. Install the range selector cable end (2) to the range selector lever ball stud (1). Page 14394 Driver Door Module (DDM) - C4 (With RPO Code YE9) Part 1 Page 15201 Electrical Symbols Part 9 Page 12331 TOOLS REQUIRED J 34142-B 12 V Unpowered Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. When testing for voltage: 1. Attach 1 lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach 1 lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Using Connector Test Adapters USING CONNECTOR TEST ADAPTERS NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-B Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires USING FUSED JUMPER WIRES TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Connector Position Assurance Locks CONNECTOR POSITION ASSURANCE LOCKS The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Terminal Position Assurance Locks TERMINAL POSITION ASSURANCE LOCKS The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Push to Seat Connectors PUSH TO SEAT CONNECTORS TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Page 13533 Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA and/or the secondary locks. Micro .64 Connectors MICRO .64 CONNECTORS TOOLS REQUIRED J 38125-D Terminal Repair Kit REMOVAL PROCEDURE Follow the steps below in order to remove terminals from Micro 64 connectors. 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. 2. Disconnect the connector from the component. Page 9442 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-8 (12085115) crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-8 (12085115) until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes SPLICING INLINE HARNESS DIODES Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate Service Data wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. 9. Tape the diode to the harness or connector using electrical tape. Page 2626 Fuse: Application and ID Junction Block - I/P Location View Location View Page 3924 Accelerator Pedal Position Sensor: Description and Operation ACCELERATOR PEDAL POSITION (APP) SENSOR The accelerator pedal assembly contains 2 individual APP sensors within the assembly. The APP sensors 1 and 2 are potentiometer type sensors, each with the following circuits: - A 5-volt reference circuit - A low reference circuit - A signal circuit The APP sensors are used to determine the pedal angle. The control module provides each APP sensor a 5-volt reference circuit and a low reference circuit. The APP sensors then provide the control module with signal voltage proportional to pedal movement. Both APP sensor signal voltages are low at rest position and increase as the pedal is applied. Page 6587 Page 2647 Fuse Block - Underhood C2 Part 3 Page 11964 If you are unsure who the PSC is, check with the Sales Manager. General Information 1. The first step is to verify if the OnStar(R) account is active or not. This can be done by pressing the blue OnStar(R) button and connecting to the OnStar(R) call center. Analog only accounts are no longer active. Only digital upgraded accounts will be active. On Gen 6 digital systems, a clear, or "dark" LED may indicate that the OnStar(R) system has been deactivated or may possibly have a no power/no communication condition. 2. If the account isn't active, the next step is to verify what version of OnStar(R) module is in the vehicle. This can be done via the Tech 2 (Body>VCIM>Module ID Information>Module Information 2) or by using www.onstarenrollment.com. 3. A Generation 5 or older analog module can be diagnosed by following the original electronic Service Information developed for the model year of the vehicle. Note: If the customer has an old analog module, the vehicle can be repaired by replacing the module, but the customer cannot have an active account without upgrading to a digital module. 4. Modules, antennas, brackets, and other equipment are in the same location, whether original analog production or digital upgrade. 5. An upgraded vehicle may also have a new vehicle communication interface module (VCIM) bracket. If it does, order the new bracket when replacing the bracket. Don't order the original bracket. The kit may also include a small wiring jumper cable. If it does, this jumper will be required for a new module replacement. Do not discard. 6. After replacing the VCIM, it is essential to configure the new OnStar(R) system. Failure to configure the system will result in an additional customer visit for repair. DO NOT press and hold the white dot or phone button on the keypad as it will not reset this version of the OnStar(R) system and may result in a DTC being set. Use of the TIS2WEB and SPS applications, along with the Tech2(R), are required in order to perform the VCIM configuration and setup procedure for this vehicle. The configuration and set-up procedure is now a two-step process which enables an automated activation by the OnStar(R) Center, without a button press by the technician to the OnStar(R) Call Center. Page 14677 Door Window Weatherstrip Rear Door Window Glass Weatherstrip: Service and Repair Door Window Weatherstrip Weatherstrip Replacement - Rear Door Window Removal Procedure 1. Remove the window. 2. Pull the weatherstrip from the front window run channel. 3. Pull the weatherstrip from the rear window run channel. 4. Pull the weatherstrip from the window frame flange. Installation Procedure 1. Align the weatherstrip in the window frame flange. 2. Press the weatherstrip into the window frame flange until fully seated. 3. Press the weatherstrip into the rear window run channel until fully seated. 4. Press the weatherstrip into the front window run channel until fully seated. 5. Install the window. Page 11977 Keyless Entry - Inoperative Keyless Entry Module: All Technical Service Bulletins Keyless Entry - Inoperative Bulletin No.: 04-08-52-005 Date: June 15, 2004 TECHNICAL Subject: Remote Keyless Entry (RKE) System Inoperative (Reprogram Passenger Door Module (PDM)) Models: 2004 Cadillac Escalade, Escalade ESV, Escalade EXT 2004 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2004 GMC Sierra, Yukon, Yukon XL Condition Some customers may comment on any of the following conditions: ^ The RKE key fob does not function. ^ The "Service Tire Pressure Monitoring System" message is displayed, if equipped. ^ The passenger door will not unlock from the passenger's or driver's door switches. ^ The passenger door window is inoperative. Correction Reprogram the PDM with the Tech 2(R). Currently the Tech 2(R) software is not available for the 2004 model year. Engineering is aware of this and are working to release a new service calibration. In the meantime, build the Tech 2(R) as a 2003 model year and perform the reprogram using the procedure listed below. 1. Turn the ignition switch to the ON position. 2. Connect the Tech 2(R) to the vehicle's diagnostic link connector (DLC), power it up and press enter. ^ Select: Diagnostics. ^ Select model year: 2003. ^ Select: Light truck. ^ Select: Body. ^ Select the proper Product line. ^ Select the proper HVAC Type. ^ Select the proper Radio System type. ^ Select: Passenger Door Module. ^ Select: Special Functions. ^ Select: Refresh. Important: You must remove the described fuse in the next step for the "Refresh" program to be performed. If you do not remove the fuse for five seconds, the Tech 2 will continue to display "Test in Progress" and the program will not complete. ^ Remove the PDM fuse for 5 seconds from the fuse center located behind the panel on the left end of the instrument panel. Page 10449 11. Remove the torsion bars from the vehicle. Important: Note the position of the torsion bars as the left and right bars are different. Installation Procedure 1. Install the torsion bars to the lower control arm. 2. Install the torsion bar crossmember. 3. Install the torsion bar crossmember bolts (1) to the weld nuts (4). ^ Tighten the bolt to 95 Nm (70 ft. lbs.). Page 4980 4. Remove the EVAP canister purge solenoid bolt (2). 5. Remove the EVAP canister purge solenoid (3) and insulator (1). INSTALLATION PROCEDURE 1. Install the insulator (1) onto the EVAP canister purge solenoid (3). 2. Install the EVAP canister purge solenoid (3). NOTE: Refer to Fastener Notice in Service Precautions. 3. Install the EVAP canister purge solenoid bolt (2). Tighten Tighten the bolt to 10.5 N.m (93 lb in). Page 5955 Park Neutral Position (PNP) Switch C175 Page 2763 Location View Location View Page 12119 2. Skip to the next step if the vehicle to be upgraded is not shown above. 3. Skip to the next step if the vehicle to be upgraded is not a 2005 Cadillac STS. The 2005 Cadillac STS kit may include a new inside rearview (ISRV) mirror assembly and a new ISRV mirror wiring cover. If the kit you receive includes these parts, please remove the existing ISRV mirror and wire cover from the vehicle and install the ones provided in the kit per the instructions in SI. 4. Skip this step if the vehicle to be upgraded is not listed below. ^ 2003-2004 Saturn L-Series ^ 2003 Saturn ION ^ 2002-2003 Saturn VUE 1. Locate and remove the Right Audio output signal terminal 7 from Connector C2 at the Vehicle Communication Interface Module (VCIM). 2. Remove the terminal end and strip the wire. 3. Locate the Left Audio output signal wire from terminal 1 in Connector C2. 4. Splice the Right Audio output signal wire from terminal 7 with the Left Audio output signal wire from terminal 1. 5. See Wiring Repairs in SI for approved splicing methods. Description and Operation Shift Indicator: Description and Operation PRNDL DISPLAY The IPC displays the selected gear position as determined by the PCM. The IPC receives a class 2 message from the PCM indicating the gear position. The PRNDL display blanks if: - The IPC receives a class 2 message indicating the park position and the column park switch indicates a position other than park, open input. - The IPC detects a loss of class 2 communications with the PCM. Page 10242 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Weather Pack Connectors WEATHER PACK CONNECTORS The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. Page 9238 C320 Seat Jumper Harness To Seat Harness (With RPO Code AN3) Part 2 Page 3694 Important: All gaskets surfaces are to be free of oil or other foreign material during assembly. 1. Install the water pump and NEW gaskets. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the water pump bolts. 1. Tighten the bolts a first pass to 15 Nm (11 ft. lbs.). 2. Tighten the bolts a final pass to 30 Nm (22 ft. lbs.). 3. Install the heater inlet hose to the water pump. 4. Position the heater inlet hose clamp at the water pump. 5. Install the surge tank outlet hose to the water pump. 6. Position the surge tank outlet hose clamp at the water pump. Page 2767 1. Install the engine electrical center bracket assembly to the front fender. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the 4 retaining bolts (1). Tighten Tighten the 4 retaining bolts (1) to 9 N.m (80 lb in). 3. Align the electrical center block (1) stubs in the slots so that the tabs (2) retains it in place. Page 5563 Ignition Coil 3 Page 15675 Headlamp Switch: Service and Repair HEADLAMP SWITCH REPLACEMENT REMOVAL PROCEDURE 1. Remove the instrument cluster bezel. 2. Unsnap the switch from the housing. 3. Disconnect the electrical connectors. 4. Remove the switch. INSTALLATION PROCEDURE Page 9443 IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. Splicing Twisted or Shielded Cable SPLICING TWISTED OR SHIELDED CABLE Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. - Rewrap the conductors with the mylar tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with mylar tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Control Module References Page 2529 Engine Oil: Fluid Type Specifications Engine Oil API Classification ................................................................................................................................. ........................................ Look for Starburst Symbol Above -18° C (0° F) ......................................... .......................................................................................................................... 10W-30, 5W-30 (preferred) Below -29° C (-20° F) ................................................................................................................................................. 5W-30 synthetic (preferred) , 0W-30 Instruments - Service Tire Monitor Message is Displayed Low Tire Pressure Indicator: All Technical Service Bulletins Instruments - Service Tire Monitor Message is Displayed Bulletin No.: 05-08-49-018A Date: May 11, 2006 ADVANCE SERVICE INFORMATION RESOLUTION Subject: EI 05065 - Service Tire Monitor Message Displayed (Pull/Reinstall IPC Fuse or Verify Correct Passenger Door Module (PDM) and Tires) Models: 2004 Chevrolet Silverado 2004 GMC Sierra Supercede: This bulletin is being revised to provide correction action. Please discard Corporate Bulletin Number 05-08-49-018 (Section 08 - Body and Accessories). Condition Some customers may comment that the "SERVICE TIRE MONITOR" message is being displayed on the DIC. Correction DO NOT REPLACE THE INSTRUMENT PANEL CLUSTER. If the DIC is displaying the SERVICE TIRE MONITOR message: 1. Verify if the vehicle has an electronic aftermarket module spliced into the ALDL Class 2 data line (purple wire). 2. If the vehicle HAS an aftermarket module spliced into the Class 2 line, pull the IPC fuse (located underhood) for 25 seconds. Important: Due to the electronic aftermarket module, the SERVICE TIRE MONITOR message may reoccur. 3. Reinstall the IPC fuse. This will clear the SERVICE TIRE MONITOR message from the display. 4. If the vehicle DOES NOT have an aftermarket module spliced into the Class 2 line, verify the vehicle is equipped with the correct PDM (Passenger Door Module) and tires. Warrant Information This repair is not covered under the vehicle warranty due to the installation of an aftermarket module. Disclaimer Page 14114 Driver Door Module (DDM) - C3 (With RPO Code YE9) Part 2 Page 9439 Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips SPLICING COPPER WIRE USING SPLICE CLIPS IMPORTANT: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. TOOLS REQUIRED J 38125-D Terminal Repair Kit 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-D in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. Page 13558 Control Module References Part 7 Page 1776 Tighten Tighten the bolt to 9 N.m (79 lb in). 4. Connect the electrical connector to the sensor (2). 5. Install the CPA. 6. Enable the SIR system. Refer to SIR Disabling and Enabling Zone 1. Page 1984 Electrical Symbols Part 11 OnStar(R) - Re-establishing OnStar(R) Communications Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Re-establishing OnStar(R) Communications Bulletin No.: 00-08-46-004C Date: January 17, 2008 INFORMATION Subject: Re-establishing Communications with OnStar(R) Center After Battery Disconnect Models: 2000-2008 GM Passenger Cars and Trucks (Including Saturn and Saab) with Digital OnStar(R) (RPO UE1) Supercede: This bulletin is being revised to add models and model years. Please discard Corporate Bulletin Number 00-08-46-004B (Section 08 - Body and Accessories). When servicing any of the above models and a battery cable is disconnected or power to the OnStar(R) Vehicle Communication Interface Module (VCIM) is interrupted for any reason the following procedure must be performed to verify proper Global Positioning System (GPS) function. Never swap OnStar(R) Vehicle Communication Interface Modules (VCIM) from other vehicles. Transfer of OnStar(R) modules from other vehicles should not be done. Each OnStar(R) module has a unique identification number. The VCIM has a specific Station Identification (STID). This identification number is used by the National Cellular Telephone Network and OnStar(R) systems and is stored in General Motors Vehicle History files by VIN. After completing ALL repairs to the vehicle you must perform the following procedure: Move the vehicle into an open area of the service lot. Sit in the vehicle with the engine running and the radio turned on for five minutes. Press the OnStar(R) button in the vehicle. When the OnStar(R) advisor answers ask the advisor to verify the current location of the vehicle. If the vehicle location is different than the location the OnStar(R) advisor gives contact GM Technical Assistance (TAC) and choose the OnStar(R) prompt. GM OnStar(R) TAC will assist in the diagnosis of a failed VCIM and, if appropriate, order a replacement part. Replacement parts are usually shipped out within 24 hours, and a pre-paid return package label will be included for returning the faulty part. By returning the faulty part, you will avoid a non-return core charge. Disclaimer Page 2644 Fuse Block - Underhood C1 Part 5 Fuse Block - Underhood C2 Page 11113 Air Temperature Sensor - Lower Left Page 6638 Chips or debris plugging the bleed orifice of the 2-3 shift solenoid (367). This will cause the transmission to stay in 2nd gear when 3rd gear is commanded and return to 1st gear when 4th gear is commanded. A 2-3 shift valve (368) or 2-3 shuttle valve (369) that is stuck, restricted and/or hung-up in its bore. This condition may also be an indication of a damaged 2-4 band or 3-4 clutches. This clutch damage may generate debris causing the 2-3 shift valve line-up to stick in the valve body bore and set DTC P0757. Correction Inspect the condition of the transmission fluid for signs of overheat or a burnt odor. If either is noted, the transmission should be disassembled for further investigation and repaired as needed. Inspect the inside of the oil pan for signs of clutch friction material. A small amount of friction material in the bottom of the pan is normal. If a large amount of clutch material is noted in the fluid or bottom pan, the transmission should be disassembled for further investigation and repaired as needed. Inspect and clean the 2-3 shift valve (368), the 2-3 shuttle valve (369) and the valve bore of debris/metal chips. Inspect and clean the 2-3 shift solenoid (367B) opening of debris/metal chips. While inspecting the 2-3 shift solenoid (367B), look for a screen over the solenoid opening. If the solenoid DOES NOT have a screen, replace the solenoid. All current GMSPO stock shift solenoids have a screen over the solenoid opening. If clutch debris is found, it is also very important to inspect the pressure control (PC) solenoid valve fluid screens. Clean or replace the PC solenoid as necessary. It is also important to flush and flow check the transmission oil cooler using J 45096. Refer to SI "Automatic Transmission Oil Cooler Flushing and Flow Test" for the procedure. Refer to the appropriate Service Manual for additional diagnostic information and service procedures. Warranty Information For repairs performed under warranty, use the applicable published labor code and information. Disclaimer Component Locations Fluid Pressure Sensor/Switch: Component Locations Automatic Transmission - 4L60-E/4L65-E Automatic Transmission Electronic Component Views (M30/M32) Electronic Components Page 12071 monitor the Tech2(R) for the current time and date. REMINDER - Keep in mind that the time displayed on the Tech2(R) is in Greenwich Mean Time (GMT) and the offset is based on the time zones relationship to GMT. If replacement of the VIU/VCIM is necessary, you MUST reconfigure the OnStar® system. Failure to reconfigure the system will result in an additional customer visit for repair. OnStar® VIU, Generations 2 and 3, will require the technician to press the blue OnStar® button to reconfigure the vehicle with an OnStar® advisor. OnStar(R) VCIM, Generations 4-7 will require the technician to reconfigure the vehicle with the use of the TIS2WEB and SPS applications (pass thru only), along with the Tech2(R). The configuration and set-up procedure is a two-step process that must be completed step-by-step without interruption or delay in between each step. This procedure enables an automated activation without a button press by the technician to the OnStar(R) Call Center. Following this procedure, it may take up to 24 hours for all OnStar(R) services to be fully activated. How to Order Parts If the OnStar(R) GPS date/time stamp is non-recoverable and the unit needs to be replaced, dealers in the U.S. should contact Autocraft Electronics select the catalog item that contains this bulletin number. Canadian dealers should contact MASS Electronics. Dealers DO NOT need to call the GM Technical Assistance Center (TAC) for replacement approval. Autocraft Electronics and MASS Electronics will be responsible for verifying that the subject vehicle is a candidate for a replacement VIU/VCIM. Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use the table. Warranty Information (Saab U.S. Models) Page 12976 Speaker: Service and Repair Speaker Replacement - Front Door SPEAKER REPLACEMENT - FRONT DOOR REMOVAL PROCEDURE 1. Remove the trim panel. 2. Remove the speaker by pushing down on the top retainer. 3. Disconnect the electrical connector. INSTALLATION PROCEDURE 1. Connect the electrical connector. 2. Install the speaker. Snap the speaker into place and ensure that the speaker is fully seated. 3. Install the trim panel. 4. Inspect the component's operation. Page 9441 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves SPLICING COPPER WIRE USING SPLICE SLEEVES TOOLS REQUIRED J 38125-D Terminal Repair Kit IMPORTANT: Use only GM splice sleeves, other splice sleeves may not protect the splice from moisture or a provide good electrical connection. Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. HVAC System - Manual Control Module HVAC: Description and Operation HVAC System - Manual HVAC CONTROL MODULE The HVAC control module is a class 2 device that interfaces between the operator and the HVAC system to maintain air temperature and distribution settings. The battery positive voltage circuit provides power that the control module uses for keep alive memory (KAM). If the battery positive voltage circuit loses power, all HVAC DTCs and settings will be erased from KAM. The body control module (BCM), which is the vehicle mode master, provides a device on signal. The control module supports the above features. The HVAC control module is a class 2 device that interfaces between the operator and the HVAC system to maintain air temperature and distribution settings. The battery positive voltage circuit provides power that the control module used for keep alive memory (KAM). If the battery positive voltage circuit loses power, all HVAC DTCs and settings will be erased from KAM. The body control module (BCM), which is the vehicle mode master, provides a device on signal. The control module supports the above features. Recall 04V045000: Possible Hydro-Boost Defect Power Steering Pump: Recalls Recall 04V045000: Possible Hydro-Boost Defect DEFECT: Certain sport utility vehicles, pickup trucks, and passenger vans fail to comply with the requirements of Federal Motor Vehicle Safety Standard No. 135, "Passenger Car Brake Systems." Some of these vehicles were produced with an out-of-specification brake hydro-boost housing relief valve bore. Consequently, the valve O-ring seal may fracture. Steering efforts may be slightly increased while braking or parking. Under certain driving conditions, a fractured seal may also require an increase in the applied brake pedal effort to achieve the same vehicle deceleration. REMEDY: Dealers are to replace the hydro-boost relief valve. The manufacturer has reported that owner notification is expected to begin during the second quarter of 2004. Owners may contact Cadillac at 1-866-982-2339; Chevrolet at 1-800-630-2438; GMC at 1-866-996-9463; or Hummer at 1-866-486-6376. Page 15160 Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA and/or the secondary locks. Micro .64 Connectors MICRO .64 CONNECTORS TOOLS REQUIRED J 38125-D Terminal Repair Kit REMOVAL PROCEDURE Follow the steps below in order to remove terminals from Micro 64 connectors. 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. 2. Disconnect the connector from the component. Page 3862 results from the alteration or modification of a vehicle using non-GM approved parts or accessories. Dealers should be especially cautious of accessory companies that claim the installation of their product will not void the factory warranty. Many times these companies have even given direction on how to quickly disassemble the accessory in an attempt to preclude the manufacturer from finding out that is has been installed. Any suspect repairs should be reviewed by the Fixed Operations Manager (FOM), and in Canada by the Warranty Manager (WM) for appropriate repair direction. If it is decided that a goodwill repair is to be made on the vehicle, even with the installation of such non-GM approved components, the customer is to be made aware of General Motors position on this issue and is to sign the appropriate goodwill documentation required by General Motors. It is imperative for dealers to understand that by installing such devices, they are jeopardizing not only the warranty coverage, but also the performance and reliability of the customer's vehicle. Disclaimer Page 1066 Control Module: Locations NVG 263-NP1 Transfer Case Shift Control Module Transfer Case Shift Control Module 1 - I/P Harness 2 - Transfer Case Shift Control Module Connectors 3 - Transfer Case Shift Control Module 4 - Instrument Panel Page 2155 Steps 1 - 11 The number(s) below refer to the step(s) in the diagnostic table. 2. This test is to verify that the vibration is present during diagnosing. Other vehicle components may cause a similar symptom such as the exhaust system, or the drivetrain. 3. This test is to verify that the drive belt(s) or accessory drive components may be causing the vibration. Remove the drive belt(s) and operate the engine for a few seconds, this will verify if the vibration is related to the drive belt(s) or not. With the drive belt(s) removed the water pump will not operate and the engine may overheat. Also diagnostic trouble codes (DTCs) may set when the engine is operated with the drive belt(s) removed. 4. The drive belt(s) may cause a vibration. While the drive belt(s) is removed this is the best time to inspect the condition of the drive belt(s). 6. Inspection of the fasteners can eliminate the possibility that a incorrect bolt, nut, spacer, or washer was installed. 8. This step should only be performed if the fan is driven by the drive belt. Inspect the engine cooling fan for bent, twisted, loose, or cracked blades. Page 6402 Page 324 ^ Audio amplifier ^ Driver door module (DDM) ^ Driver door switch assembly (DDSA) ^ Front passenger door module (FPDM) ^ Left rear door module (LRDM) ^ Memory seat module (MSM) ^ Radio antenna module (listed as remote function actuation in scan tool display) ^ Rear integration module (RIM) ^ Right rear door module (RRDM) ^ Theft deterrent module (TDM) ^ TV antenna module ^ Vehicle communication interface module (VCIM) The star has 4 splice packs: ^ SP200 located in the left side of the instrument panel, near the steering column , taped to the instrument panel harness ^ SP201 located in the center of the instrument panel, near the radio ^ SP300 located in the left side middle of the passenger compartment, taped to the body harness, near the carpet seam ^ SP303 located in the right rear of the passenger compartment, taped to the body harness, approximately 24 cm (9.5 in) from the fuse block - right rear. Refer to Data Communication Schematics in SI. The following modules, components, and splice packs are connected to the ring portion of the class 2 serial data circuit: ^ Dash integration module (DIM) ^ Electronic brake control module (EBCM) ^ Engine control module (ECM) ^ Inflatable restraint sensing and diagnostic module (SDM) ^ Instrument panel cluster (IPC) ^ HVAC control module ^ Radio ^ Rear integration module (RIM) ^ Vehicle communication interface module (VCIM) OR ^ Communication interface module (CIM) ^ SP200 ^ SP201 ^ SP300 Engine Controls - MIL ON/Rough Idle/Misfire/DTC's Set Oxygen Sensor: All Technical Service Bulletins Engine Controls - MIL ON/Rough Idle/Misfire/DTC's Set Bulletin No.: 05-06-04-063 Date: October 12, 2005 TECHNICAL Subject: LM7, L59 or L33 Engines with Cold Start Rough or Incorrect Idle, Misfire, Malfunction Indicator Lamp (MIL) or Flashing Requiring 02 Sensor Replacement (Reprogram PCM) Models: 2004-2005 Cadillac Escalade 2004-2005 Chevrolet Avalanche, Silverado 1500, Suburban, Tahoe 2005 Chevrolet Silverado Hybrid (HP2) 2004-2005 GMC Sierra 1500, Yukon, Yukon XL 2005 GMC Sierra Hybrid (PH2) with Vortec 5300 5.3L V-8 Engine (VINs T, Z, B - RPOs LM7, L59, L33) Condition Some customers may comment on a Malfunction Indicator Lamp (MIL) On or that the MIL is flashing. An actual engine misfire may or may not be felt along with an incorrect idle speed. Typically this occurs during cold winter months, on cold engine starts. Some vehicles may have been previously serviced for the same condition. Technicians may also find the following DTCs stored with the Tech 2(R) P0131, P0133, P0134, P0137, P0138, P0140, P0151, P0153, P0154, P0157, P1133, which may be in conjunction with P0171, P0174, P0300 and P1138. Cause Water shock occurs when water droplets are present in the exhaust. The water in the exhaust contacts the sensor element inside the H02 sensor, causing the H02 sensor element to crack. Correction Upon diagnostic investigation, the technician may find that the H02 sensor requires replacement. In addition to replacing the affected H02 sensor, these vehicles should also be reflashed with the latest PCM calibration. An updated PCM calibration will be available to dealerships as part of TIS 2000 incremental satellite update 11.0 (NAO version 25.010) or greater. Always, make sure your Tech 2 is updated with the latest software version. Important: If a DTC P0420 or P0430 is stored along with DTC(s) P0300, the catalytic converter diagnostics in Service Information (SI) must be followed to determine if the catalytic converters are operating properly. Warranty Information For vehicles repaired under warranty, use the table. Page 4504 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Weather Pack Connectors WEATHER PACK CONNECTORS The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. Page 10641 Parts Information Warranty Information For vehicles repaired under warranty use, the table. Disclaimer Page 13835 3. Remove the masking tape from the painted surface surrounding the emblem. Emblem Replacement - Grille (Chevrolet) Emblem Replacement - Grille (Chevrolet) Removal Procedure 1. Remove the upper grille baffle. 2. Remove the retaining nuts (3) from the rear of the grille emblem (1). 3. Separate and remove the emblem (1) from the grille (2). Installation Procedure Page 3394 2. Install the intake manifold. 3. Apply a 5 mm (0.20 inch) band of threadlock GM P/N 12345382 (Canadian P/N 10953489), or equivalent to the threads of the intake manifold bolts. 4. Notice: Refer to Fastener Notice in Service Precautions. ^ Tighten the intake manifold bolts. 1. Tighten the bolts a first pass in sequence to 5 Nm (44 inch lbs.). 2. Tighten the bolts a final pass in sequence to 10 Nm (89 inch lbs.). Page 11819 ^ Reinstall the fuse and fuse panel cover. ^ Press the "Enter" button to perform the "Refresh" function. ^ "Test in Progress" will be displayed and the right front passenger door lock will cycle once. ^ The screen will display "Procedure Completed". ^ Press the "Exit" button as necessary to return to the main menu screen. 3. Using the switches in the right front passenger door, verify that the power window and power door lock located in that door function properly. Important: The calibrations required for performing SPS reprogram in the next step are based on the type of exterior rearview mirror the vehicle has. To determine the correct calibration, check the Service Parts Identification Label on the vehicle for the RPO code for exterior mirrors. 4. Follow normal Service Programming System (SPS) to reprogram the passenger door module with the current calibration available in TIS 2000. 5. After reprogramming is complete, using the switches in the right front passenger door, verify that the power window and power door lock located in that door function properly. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Engine Controls - MIL ON/Misfire/Misfire DTC's Set Engine Control Module: All Technical Service Bulletins Engine Controls - MIL ON/Misfire/Misfire DTC's Set Bulletin No.: 06-06-04-046 Date: September 12, 2006 INFORMATION Subject: Information on Engine Misfire MIL/SES Light Illuminated or Flashing DTC P0300, P0301, P0302, P0303, P0304, P0305, P0306, P0307, P0308, P0420 or P0430 Models: 1999-2007 Cadillac, Chevrolet, GMC Full-Size Pickup and/or Utility Trucks with 4.8L, 5.3L, 5.7L, 6.0L or 6.2L VORTEC GEN III, GEN IV, V-8 Engine (VINs V, C, T, Z, B, 3, M, 0, J, R, U, N, Y, K, 8 - RPOs LR4, LY2, LM7, L59, L33, LC9, LH6, LMG, LY5, L31, LQ4, LQ9, L76, LY6, L92) with Active Fuel Management(TM) and E85 Flex Fuel If you encounter vehicles that exhibit the above conditions, refer to SI for the appropriate DTC(s) set. If no trouble is found, the cause may be due to an ECM ground terminal that has corroded with rust over time. Inspect the main engine wiring harness ground terminal (G103) for this condition. The wire terminal (G103) attaches either to the front or to the rear of the right side cylinder head, depending on the model year of the Full Size Pickup and/or Utility Trucks. If the ECM ground terminal has been found to be corroded, then follow the service procedure outlined in this bulletin to correct the corrosion issue. Remove either the nut or bolt securing the main engine wiring harness ground terminal (G103) to the right cylinder head. Refer to the above illustration to determine where the ground is located on the vehicle (1). Page 10238 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly, Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Pull to Seat Connectors PULL TO SEAT CONNECTORS TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Page 15336 4. Wait 1 minute before working on the system. Enabling Procedure - Air Bag Fuse 1. Place the ignition in the OFF position. 2. Install the fuse(s) supplying power to the SDM. 3. Turn the ignition switch to the ON position. The AIR BAG indicator will flash then turn OFF. 4. Perform the Diagnostic System Check - Vehicle if the AIR BAG warning indicator does not operate as described. Disabling Procedure - Negative Battery Cable 1. Turn the steering wheel so that the vehicles wheels are pointing straight ahead. 2. Place the ignition in the OFF position. 3. Disconnect the negative battery cable from the battery. 4. Wait 1 minute before working on system. Enabling Procedure - Negative Battery Cable 1. Place the ignition in the OFF position. 2. Connect the negative battery cable to the battery. 3. Turn the ignition switch to the ON position. The AIR BAG indicator will flash then turn OFF. 4. Perform the Diagnostic System Check - Vehicle if the AIR BAG warning indicator does not operate as described. Page 2664 Fuse Block- I/P C1 Part 5 Page 10102 7. Remove the bolts (2) retaining the power steering pump to the bracket. 8. Remove the power steering pump from the vehicle. Installation Procedure 1. Install the power steering pump (1) to the vehicle. 2. Notice: Refer to Fastener Notice in Service Precautions. Install the bolts retaining the power steering pump to the power steering pump bracket. ^ Tighten the power steering pump mounting bolts to 25 Nm (18 ft. lbs.). Page 8749 Positive: Vehicle Damage Warnings BATTERY DISCONNECT CAUTION CAUTION: Unless directed otherwise, the ignition and start switch must be in the OFF or LOCK position, and all electrical loads must be OFF before servicing any electrical component. Disconnect the negative battery cable to prevent an electrical spark should a tool or equipment come in contact with an exposed electrical terminal. Failure to follow these precautions may result in personal injury and/or damage to the vehicle or its components. OnStar(R) - Incorrect GPS Position Reported During Call Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Incorrect GPS Position Reported During Call Bulletin No.: 02-08-46-006C Date: January 08, 2008 INFORMATION Subject: Incorrect OnStar(R) Global Positioning System (GPS) Location Reported During OnStar(R) Call Models: 2000-2008 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2008 HUMMER H2 2006-2008 HUMMER H3 2005-2008 Saab 9-7X with OnStar(R) Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 02-08-46-006B (Section 08 - Body and Accessories). A small number of the above-mentioned vehicles may exhibit a condition in which the vehicle reports an inaccurate location to the OnStar(R) Call Center. This condition can only be identified via a button press to the OnStar(R) Call Center by the customer. Call Center personnel will be able to identify this inaccurate location condition. Customers will then be notified through the mail by OnStar(R) if their vehicle exhibits this condition. Once this condition has been identified OnStar(R) will instruct the customer to return to the dealership to have this condition corrected. It is not necessary to reconfigure the vehicle after the following procedure. In order to correct this condition you must cycle power to the OnStar(R) system. This can be done by either removing the fuses powering the OnStar(R) system or disconnecting the OnStar(R) module (VCIM) from the vehicle. As a last resort you can disconnect the vehicle's battery. The power needs to be removed from the system for approximately 15 minutes. After completing this procedure the vehicle should be taken to an area with an unobstructed view of the sky. The vehicle should be kept running for approximately 10 minutes to allow the vehicle to reacquire the global positioning system (GPS). Then contact the OnStar(R) Call Center via the blue OnStar(R) button and ask the advisor to verify the GPS position. If the OnStar(R) advisor still has an inaccurate GPS location refer to the Navigation Systems and Cellular Communications sub-sections in the Service Manual in order to diagnose and repair the concern. If the normal diagnostics lead to module replacement you will need to contact Technical Assistance (TAC) and choose the OnStar(R) prompt. GM OnStar(R) TAC will assist in the diagnosis and if appropriate order a replacement part. Replacement parts are usually shipped out within 24 hours and a pre-paid return package label will be included for returning the faulty part. By returning the faulty part you will avoid a significant non-return core charge. Warranty Information (excluding Saab US Models) For vehicles repaired under warranty, use the table. Warranty Information (Saab US Models) Page 7720 2. Connect the speed sensor electrical connector (4). 3. Lower the vehicle. Page 3941 Camshaft Position Sensor: Description and Operation CAMSHAFT POSITION (CMP) SENSOR The CMP sensor is also a magneto resistive sensor, with the same type of circuits as the CKP sensor. The CMP sensor signal is a digital ON/OFF pulse, output once per revolution of the camshaft. The CMP sensor information is used by the PCM to determine the position of the valve train relative to the CKP. Page 3392 9. Remove the evaporative emission (EVAP) purge solenoid vent tube by performing the following: 1. Remove the EVAP tube end from the solenoid (1). 2. Remove the EVAP tube end from the vapor pipe (2). 10. Remove the EVAP purge solenoid bolt (2), solenoid (3), and isolator (1) from the intake manifold. Page 13142 5.2 Cut off the cable tie (B), detach the connector's rear end face (C) and pull out the connecting rail (D). 5.3. Remove pin 39, cut off the cable terminal and insulate the end with tape (E). Fold back the cable and secure it with tape (F). 5.4. Fit the connecting rail and end face. 5.5. Plug in the connector (A) and secure the cables with cable ties (B). 6. Install the floor console over the handbrake. Do not press the console down into place, but instead allow it to fit loosely. 7. Install the switch: 7.1. Install the switch for the roof lighting (B) and plug in its connector. 7.2. Guide the connectors for the window lift module and rear seat heater, if equipped, through the hole for each respective unit. Plug in the window lift module's connector and install the module (A). Page 11994 Models The service procedure in this bulletin has been revised. Step 11 in the procedure for the 2004-2005 Saab 9-3 (9440) Convertible has been revised. Discard all copies of bulletin 08089B, issued September 2008. Condition In November 2002, the U.S. Federal Commissions (FCC) ruled that wireless carriers would no longer be required to support the analog wireless network beginning in 2008. As a result, On Star(R) is unable to continue analog service. OnStar(R) has deactivated most of the systems operating in the analog mode; however, there are some vehicles that OnStar(R) could not deactivate. Although the analog OnStar(R) hardware in these vehicles can no longer communicate with OnStar(R), the hardware in the vehicle is still active. If the OnStar(R) emergency button is pressed, or in the case of an airbag deployment, or near deployment, the customer may hear a recording that OnStar(R) is being contacted. However, since analog service is no longer available, the call will not connect to OnStar(R). To end the call, the customer must press the white phone or white dot button. If the call is not ended, the system will continue to try to connect to OnStar(R) until the vehicle battery is drained. Special Policy Adjustment At the customer's request, dealers/retailers are to deactivate the OnStar(R) system. The service will be made at no charge to the customer. This special coverage covers the condition described above until December 31, 2008 for all non-Saab vehicles; April 30, 2009 for all Saab vehicles. Vehicles Involved Page 4658 Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. 1. Disconnect the connector from the component. 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. Page 12381 Global Positioning System Antenna: Service and Repair Antenna Assembly Replacement - Cellular and Navigation ANTENNA ASSEMBLY REPLACEMENT - CELLULAR AND NAVIGATION REMOVAL PROCEDURE 1. Lower the headliner. Refer to Headliner Replacement in Interior Trim 2. Disconnect the cables from the antenna. 3. Loosen the retaining nut until the antenna assembly can be pulled from the top of the roof. INSTALLATION PROCEDURE 1. Place the antenna assembly on the roof opening. NOTE: Refer to Fastener Notice in Service Precautions. 2. Tighten the retaining nut. Tighten Tighten the nut to 6 N.m (53 lb in). 3. Connect the antenna cables. 4. Install the headliner. TPMS System - Service And Re-Learning Sensor IDs Tire Pressure Module: Technical Service Bulletins TPMS System - Service And Re-Learning Sensor IDs INFORMATION Bulletin No.: 10-03-16-001 Date: July 19, 2010 Subject: TPMS System Service and Re-Learning Sensor IDs Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks 2010 and Prior HUMMER H2 2009 and Prior HUMMER H3 2010 and Prior Saturn Models 2009 and Prior Saab 9-7X with Wheel-Mounted Tire Pressure Sensors In the event that the spare tire, which is normally not equipped with a tire pressure monitor (TPM) sensor, is installed in place of one of the road tires and the vehicle is driven above 40 km/h (25 mph) for 20 minutes or more, the TPM indicator icon on the instrument panel cluster (IPC) will flash for approximately one minute and then remain on steady each time the ignition is turned ON, indicating a diagnostic trouble code (DTC) has been set. The driver information center (DIC), if equipped, will also display a SERVICE TIRE MONITOR type message. When the road tire is repaired and reinstalled in the original location, the TPM indicator icon illumination and DIC message may remain displayed until the DTC is cleared. To ensure that the TPM indicator and the DIC message are cleared after service, it is necessary to clear any TPM DTCs using a scan tool. If a scan tool is unavailable, performing the TPM relearn procedure using a TPM diagnostic tool will provide the same results. It is advised to perform the relearn procedure away from other vehicles to prevent picking up a stray sensor signal. If one or more of the TPM sensors are missing or damaged and have been replaced, then the relearn procedure must be performed. Disclaimer Page 13513 Electrical Symbols Part 3 Page 10845 1. Remove the floor air outlet duct extension (1) from the floor duct (2). 2. Remove the center console. 3. Remove the screws from the center console duct. 4. Remove the center console duct. 5. Disconnect the electrical connection from the mode actuator (10). 6. Remove the mode actuator mounting screws from the HVAC module. 7. Remove the mode actuator as an assembly with the actuator cam. INSTALLATION PROCEDURE Page 14699 Page 12213 switch lighting connector. 3.3. Undo the floor console's retaining bolts (C). 3.4. Take out the rear ashtray/cover (D). 3.5. Remove the screw (E) for the rear cover. 3.6. Remove the floor console's retaining nuts (E). 3.7. Detach the floor console (G) by pulling it straight back and lifting it slightly. 3.8. If required, detach the switch for the rear seat heater and unplug the connector. 4. Remove the switch and the floor console: 4.1. Detach the window lift module (A) by loosening it in the front edge (snap fastener). Unplug the window lift module's connector. 4.2. Detach the switch for the roof lighting (B) and unplug its connector. Lift away the floor console. 5. Pry out the signal line from the SRS control module to the OnStar(R) control module and secure it: 5.1. Unplug the SRS control module's connector (A). Lower Left of the I/P Lower Left Of The I/P Page 8385 Removal Procedure 1. Release the park brake. 2. Raise and support the vehicle. Refer Vehicle Lifting 3. Relieve the tension from the park brake cable by pulling down on the park brake cable in front of the equalizer and removing the right park brake cable from the equalizer bar. 4. Remove the cable from the mounting bracket by depressing the locking tabs. 5. Remove the park brake cable from the differential clip.Remove the bolt retaining the park brake cable from the rear axle clip. 6. Remove the rear brake cable mounting bracket bolt. Page 5227 Important: Clean the fuel filler cap and surrounding areas prior to removing the fuel filler housing in order to avoid possible contamination. 1. Remove the fuel fill cap. 2. Remove the fuel tank filler housing to fuel tank fill pipe screws. 3. Remove the fuel tank filler housing to body TORX® screws (1) and retainer (2). Important: It is NOT necessary to raise the vehicle in order to remove and/or install the fuel filler housing. 4. Remove the fuel filler housing from under the vehicle. 5. Install the new fuel filler housing, P/N 15289921, from under the vehicle. 6. Install the fuel tank filler housing to fuel tank fill pipe screws. Tighten Tighten the screws to 2.3 N.m (20 lb in). 7. Install the fuel tank filler housing to body TORX(R) screws and retainer. Tighten Tighten the screws to 2.3 N.m (20 lb in). Important: The new fuel cap, P/N 15225005 "tether strap" installs in the elongated hole in the fuel filler housing. DO NOT install the new fuel cap tether in the round hole in the fuel filler housing. Page 11058 Parts required to complete this special coverage are to be obtained from General Motors Customer Care and Aftersales (GMCC&A;). Service Procedure Note The resistor module connector and blower motor resistor will need to be replaced if one or more of the symptoms below is present. - The HVAC blower may not function on certain or all blower speed settings - A burning plastic smell or smoke may be present in the vehicle - The HVAC blower may run continually with the ignition in the OFF position Determine if one or more of the above symptoms is present. If required refer to HVAC diagnostic information in SI. Refer to Resistor Module Connector and Blower Motor Resistor Replacement in this bulletin if one or more of the symptoms is present. Other HVAC repairs are NOT covered in this product safety special coverage bulletin. Resistor Module Connector and Blower Motor Resistor Replacement 1. Remove the blower fuses (Htr A/C & HVAC 1 fuses). 2. Lower the close-out panel enough to gain access to the resistor module connector. 3. Disconnect the connector from the resistor module. Note Connector replacement is required even if the connector was replaced on a previous service repair. 4. Remove the tape from the wiring harness to expose the wiring. 5. Cut the wires back far enough from the connector to eliminate any melted insulation on the wire. Note Use the old connector as a map for splicing the wires for the new connector. Be sure to use the correct crimping tool from the terminal repair kit J 38125. Use only Duraseal splice sleeves. Other splice sleeves may not protect the splice from moisture or provide a good electrical connection. 6. Install the new connector. Use the yellow splice sleeves provided with the connector. 7. Install the new blower motor resistor. 8. Reinstall the fuses. Test the blower motor to make sure all speeds are functional. 9. Reinstall the hush panel/close-out panel. Customer Reimbursement Customer requests for reimbursement of previously paid repairs to correct the condition described in this bulletin are to be submitted to the dealer prior to or by December 31, 2012. Repairs must have occurred within the 10 years of the date the vehicle was originally placed in service, or 240,000 kilometres, whichever occurs first. When a customer requests reimbursement, they must provide the following: Page 5437 5. Remove the fuel level sensor retaining clip. 6. Remove the fuel level sensor. INSTALLATION PROCEDURE 1. Install the fuel level sensor. Page 15951 Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA and/or the secondary locks. Micro .64 Connectors MICRO .64 CONNECTORS TOOLS REQUIRED J 38125-D Terminal Repair Kit REMOVAL PROCEDURE Follow the steps below in order to remove terminals from Micro 64 connectors. 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. 2. Disconnect the connector from the component. Page 7759 Speed Sensor: Service and Repair Transfer Case - NVG 246-NP8 Transfer Case Speed Sensor Replacement - Front Transfer Case Speed Sensor Replacement - Front Removal Procedure 1. Remove the transfer case shield, if equipped. 2. Disconnect the front speed sensor electrical connector (5). 3. Remove the front speed sensor. Installation Procedure 1. Notice: Refer to Fastener Notice in Service Precautions. Install the front speed sensor. ^ Tighten the speed sensor to 15 Nm (11 ft. lbs.). Locations Forward Lamp Harness Page 1656 Oxygen Sensor: Service and Repair Heated Oxygen Sensor (HO2S) Replacement Bank 2 Sensor 1 HEATED OXYGEN SENSOR (HO2S) REPLACEMENT BANK 2 SENSOR 1 REMOVAL PROCEDURE 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. Disconnect the connector position assurance (CPA) retainer. 3. Remove the heated oxygen sensor (HO2S) from the clips NOTE: Refer to Heated Oxygen and Oxygen Sensor Notice in Service Precautions. 4. If equipped with a 4.8L or 5.3L engine, disconnect the HO2S electrical connector. Page 5192 Flexible Fuel Sensor: Service and Repair FUEL COMPOSITION SENSOR REPLACEMENT REMOVAL PROCEDURE 1. Relieve the fuel system pressure. Refer to Fuel Pressure Relief Procedure. 2. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 3. Disconnect the fuel composition sensor electrical connector. 4. Remove the fuel line retainers (1). 5. Disconnect the fuel pipes from the fuel composition sensor. 6. Remove the fuel composition sensor nuts. 7. Remove the fuel composition sensor. 8. If required, remove the fuel composition sensor bolts and remove the sensor from the bracket. Page 9284 Location View Location View Page 13297 Parts Information Page 6841 19. Remove the pinion. 20. Remove the collapsible spacer. 21. Remove the inner pinion bearing from the pinion using the J 22912-01 and a hydraulic press. 22. Remove the outer pinion bearing cup using a hammer and a brass drift in the slots provided.Move the drift back and forth between one side of the cup and the other in order to work the cups out of the retainer evenly. 23. Remove the inner pinion bearing cup using a hammer and a brass drift in the slots provided.Move the drift back and forth between one side of the cup and the other in order to work the cups out of the retainer evenly. Installation Procedure Page 13831 1. Install the emblem (1) onto the grille (2). Notice: Refer to Fastener Notice in Service Precautions. 2. Install the retaining nuts (3) and tighten. Tighten the retaining nuts to 3 N.m (27 lb in). 3. Reinstall the upper grille baffle. Page 11630 Remove all rust from the ground terminal, the cylinder head and the retaining nut or bolt. Position the main engine wiring harness ground terminal and install the nut or bolt. Tighten: Tighten the retaining nut or bolt to 16 N.m (12 lb ft). Apply some type of electrical moisture sealant to protect the harness terminal from further corrosion. Disclaimer Interior - Erratic Memory Seat Operation Memory Positioning Module: All Technical Service Bulletins Interior - Erratic Memory Seat Operation Bulletin No.: 04-08-50-016C Date: August 12, 2005 TECHNICAL Subject: Memory Seat May Not Return to Requested Position (Reprogram Driver Seat Module) Models: 2003-2005 Cadillac Escalade, Escalade ESV, Escalade EXT 2003-2005 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2003-2005 GMC Sierra, Yukon, Yukon XL, Yukon Denali All with Seat FRT, Individual (Non BKT) (RPO AN3) 2003-2005 HUMMER H2 with Seat, Front Bucket Deluxe (RPO AR9) Supercede: This bulletin is being revised to update the correction information. Please discard Corporate Bulletin Number 04-08-50-016B (Section 08 - Body and Accessories). Condition Some customers may comment that with repeated cycling of the memory seat between the "exit" and one of the "presets", the position of the seat may "creep" forward or rearward out of expected adjustment. Cause There is a coding deficiency in the software for the memory seat module. Correction Technicians are to reprogram the driver seat module with an updated software calibration. The previous bulletin stated to use a service calibration that was released with TIS satellite data update version 4.5. Feedback has proved that calibration to be ineffective in eliminating the memory seat creep condition. An updated service calibration was released with TIS satellite data update version 6.5 available June 13, 2005. This new calibration has additional memory seat creep protection. As always, make sure your Tech 2(R) is updated with the latest software version. Important: After programming is complete, move the seat all the way rearward and down, then bump the seat slightly forward and up. This position will be just off the end of travel hard stops. Reset both memory seat exit positions at this position. Having the seat set at just off the hard stops will aid in reducing the creep condition. Warranty Information Page 6176 4. Install the ground, then the washer and then the bolt to the frame. Important: It is important to use the bolts, washers and nuts specified in this bulletin. These parts have been identified due to their conductive finish. 5. Install a washer and nut to the back side of the frame. Tighten Tighten the nut to 9 Nm (79 lb in). 6. Cover the front and back side of the repair area using Rubberized Undercoating. An additional check can be made to ensure a good connection for the battery cable to frame ground. It is possible for this ground to cause similar symptoms with the ABS as described above. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Parts Information Warranty Information Disclaimer Brakes/Wheels - Excessive Debris Build Up Brake Caliper: All Technical Service Bulletins Brakes/Wheels - Excessive Debris Build Up Bulletin No.: 04-05-23-005 Date: June 22, 2004 INFORMATION Subject: Availability of Rear Wheel Mud Flaps to Reduce Debris Build-up on Rear Brake Calipers and/or Rear Wheels Models: 1999-2004 Chevrolet Silverado Pickup Models 1999-2004 GMC Sierra Pickup Models This bulletin is to inform dealers of the release of rear wheel mud flaps. The above models that are exposed to extensive off-paved roads may benefit from the mud flaps. The mud flaps have been developed to minimize the amount of stones and/or mud that can impact and collect on the rear caliper and/or wheel rim. Please advise customers that the installation of these mud flaps and following the recommended off-road driving information provided in their Owner's Manual should greatly reduce the possibility of accelerated rear brake component wear and/or rim damage. Install the mud flap forward of each rear wheel using the following procedure. Important: Always work from outboard to inboard, drilling one hole at a time and securing with a fastener. Follow the sequence of the procedure. This will prevent distortion of the mud flap. 1. Raise the vehicle. Support the vehicle. 2. Locate the pickup box side panel rear brace. 3. Remove the existing outboard upper fastener on the brace. 4. Install the mud flap through the "V" of the brace. Install the previously removed fastener in the hole (2) of the mud flap to the brace. Do not tighten the fastener at this time. 5. Using the mud flap as a template, locate and mark the location of the hole (1) in the pickup box wheel house. Page 11203 14. Install the evaporator tube nut to the evaporator. Tighten Tighten the nut to 16 N.m (12 lb ft). 15. Evacuate and recharge the A/C system. Refer to Refrigerant Recovery and Recharging. 16. Leak test the fittings of the components using the J 39400-A. Page 9821 Relay Box: Service and Repair I/P Electrical Center or Junction Block Replacement - Right INSTRUMENT PANEL ELECTRICAL CENTER OR JUNCTION BLOCK REPLACEMENT - RIGHT REMOVAL PROCEDURE 1. Remove the right side end panel. 2. Push in the tabs in order to remove the fuse block. 3. Pull out the fuse block out of the I/P in order to remove the retaining bolt. 4. Loosen the bolt. 5. Insert a screw driver between the wire harness block and fuse block in order to separate. 6. Separate the fuse block from the I/P harness block. 7. Remove the I/P wiring harness block from the vehicle. INSTALLATION PROCEDURE 1. Install the fuse block to the I/P wire harness block. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the retaining bolt. Tighten Tighten the bolt to 6 N.m (53 lb in) 3. Install the fuse block to the I/P until it clicks in place. Page 12849 5.2 Cut off the cable tie (B), detach the connector's rear end face (C) and pull out the connecting rail (D). 5.3. Remove pin 39, cut off the cable terminal and insulate the end with tape (E). Fold back the cable and secure it with tape (F). 5.4. Fit the connecting rail and end face. 5.5. Plug in the connector (A) and secure the cables with cable ties (B). 6. Install the floor console over the handbrake. Do not press the console down into place, but instead allow it to fit loosely. 7. Install the switch: 7.1. Install the switch for the roof lighting (B) and plug in its connector. 7.2. Guide the connectors for the window lift module and rear seat heater, if equipped, through the hole for each respective unit. Plug in the window lift module's connector and install the module (A). Page 315 Page 3908 Steps 4 - 5 Page 12042 Parts Information Description and Operation Malfunction Indicator Lamp: Description and Operation MALFUNCTION INDICATOR LAMP (MIL) OPERATION The malfunction indicator lamp (MIL) is located in the instrument panel cluster. The MIL will display as either SERVICE ENGINE SOON or one of the following symbols when commanded ON: The MIL indicates that an emissions related fault has occurred and vehicle service is required. The following is a list of the modes of operation for the MIL: The MIL illuminates when the ignition is turned ON, with the engine OFF. This is a bulb test to ensure the MIL is able to illuminate. - The MIL turns OFF after the engine is started if a diagnostic fault is not present. - The MIL remains illuminated after the engine is started if the control module detects a fault. A diagnostic trouble code (DTC) is stored any time the control module illuminates the MIL due to an emissions related fault. The MIL turns OFF after three consecutive ignition cycles in which a Test Passed has been reported for the diagnostic test that originally caused the MIL to illuminate. - The MIL flashes if the control module detects a misfire condition which could damage the catalytic converter. - When the MIL is illuminated and the engine stalls, the MIL will remain illuminated as long as the ignition is ON. - When the MIL is not illuminated and the engine stalls, the MIL will not illuminate until the ignition is cycled OFF and then ON. Page 8579 visible in the clear adapter tube). If fluid is seen coming out of the inlet port adapter up to 65 Nm (48 lb-ft) maximum torque, the hydro-boost booster assembly is "OK", Proceed to Step 19. A. If NO fluid is seen exiting from the inlet port adapter, complete Steps 19-27 and then repeat Steps 1-18. B. If no fluid is visible from the second evaluation, replace the hydro-boost unit. Proceed to the appropriate procedure found in this bulletin. 19. Loosen the clamp bolt, remove the clamp containment bolt, and remove the accumulator pressure clamp. Remove the inlet port adapter from the supply port of the booster. Wipe the excess power steering fluid off of the adapter with a clean, lint-free shop cloth. Store the adapter in a clean location, such as a plastic bag. 20. Reinstall the supply hose/tube to the booster. Tighten Tighten to 28 N.m (21 lb-ft). 21. Clean any spilled fluid from the outside of the booster. 22. For Express/Savana only: ^ Connect the reservoir outlet hose to the booster unit. Keeping the hose end higher than reservoir, reposition the reservoir onto the mounting studs. A. Install the remote power steering reservoir mounting nuts. Tighten Tighten to 7 Nm (58 lb in). 23. Start the engine and run at idle. Depress the brake pedal 5 times. Turn the steering wheel to the "steering lock" position. Hold for 1-2 seconds. Check to see if there is any leakage from the ports/fittings. 24. Turn the engine off. 25. If leaks were observed, re-check that the fittings are at the recommended torque values. Repeat Steps 17 and 18. 26. Check the power steering reservoir fluid level, add fluid if necessary. 27. Close the hood. Hydro-Boost(R) Replacement - Avalanche, Express, Savana, Silverado, Sierra, Suburban, Yukon XL Tools Required ^ J 35555 Metal Mityvac ^ J 43485 Power Steering Bleeder Adapter Removal 1. Apply the park brake and block the wheels. Page 10049 Power Steering Line/Hose: Service and Repair Power Brake Booster Outlet Hose Replacement Power Brake Booster Outlet Hose Replacement Removal Procedure 1. Notice: Refer to Power Steering Hose Disconnected Notice in Service Precautions. Install a drain pan under the vehicle. 2. Remove the brake booster outlet hose (1) from the brake booster (2). 3. Remove the clamp retaining the brake booster outlet hose to the power steering pump. 4. Remove the brake booster outlet hose from the vehicle. Installation Procedure 1. Notice: The inlet and outlet hoses must not be twisted during installation. Do not bend or distort the inlet or outlet hoses to make installation easier. Failure to follow these procedures could result in component damage. Route the hose in the same position the hose occupied prior to removal. 2. Install the brake booster outlet hose (1) to the brake booster (2).Position the clamp at the end of the hose. 3. Install the brake booster outlet hose to the power steering pump (4).Position the clamp at the end of the hose. 4. Remove the drain pan from under the vehicle. 5. Bleed the power steering system. Refer to Bleeding the Power Steering System. Page 443 Important The following information MUST be documented on the repair order. Failure to do so may result in a chargeback. - Customer vehicle condition. - Was a Service Lamp or Service Message illuminated? If yes, specify which Service Lamp or Service Message. - Was a DTC(s) set? If yes, specify which DTC(s) were set. - After following the procedure contained within this bulletin, could the condition be duplicated? ‹› If the condition was not duplicated, then document the affected module/component connector name and number on the repair order. - If the condition was duplicated after the procedure contained within this bulletin was followed, and additional diagnosis led to the replacement of a module or component, the SI Document ID Number MUST be written on the repair order. Parts Information Alternate Distributor For All of North America Note NyoGel(R) 760G Lubricant* is equivalent to GMSPO P/N 12377900, and P/N 10953529 (Canada), specified for use to correct the condition in this bulletin. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to: Warranty Information (Saab Models) Page 13537 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Micro-Pack 100W Connectors MICRO-PACK 100W CONNECTORS TOOLS REQUIRED J 38125-D Terminal Repair Kit REMOVAL PROCEDURE There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2)has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. IMPORTANT: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Front Impact Sensor: Service and Repair Front INFLATABLE RESTRAINT FRONT END SENSOR REPLACEMENT REMOVAL PROCEDURE CAUTION: Do not strike or jolt the inflatable restraint front end sensor. Before applying power to the front end sensor make sure that it is securely fastened. Failure to observe the correct installation procedure could cause SIR deployment, personal injury, or unnecessary SIR system repairs. 1. Disable the SIR system. Refer to SIR Disabling and Enabling Zone 1. 2. Disconnect the electrical connector. 3. Remove the connector position assurance (CPA) from the connector. 4. Remove the sensor bolt. 5. Remove the sensor (2) from the vehicle. INSTALLATION PROCEDURE 1. Remove any dirt, grease, or other contaminants from the mounting surface (1). IMPORTANT: Refer to SIR Service Precautions. 2. Point the arrow on the sensor toward the front of the vehicle. NOTE: Refer to Fastener Notice in Service Precautions. 3. Install the sensor (2) horizontally to the radiator support. Page 4833 1. Apply sealant GM P/N 12346004, (Canadian P/N 10953480), or equivalent, to the threads of the oil pressure sensor. Notice: Refer to Fastener Notice in Service Precautions. 2. Using J 41712 or equivalent, install the oil pressure sensor. ^ Tighten the oil pressure sensor to 30 Nm (22 ft. lbs.). 3. Connect the oil pressure sensor electrical connector (1). 4. If necessary, install the engine sight shield. Description and Operation Electronic Throttle Control Module: Description and Operation THROTTLE ACTUATOR CONTROL MODULE The TAC module is the control center for the throttle actuator control system. The TAC system is self-diagnosing and provides diagnostic information to the PCM through a dedicated serial data line. The TAC achieves throttle positioning by providing a pulse width modulated voltage to the TAC, as directed by the PCM. Page 13561 Body Control Module (BCM) - C2 Part 2 Page 3883 Recall - Brake Booster Pressure Accumulator Cracking Technical Service Bulletin # 05006 Date: 050323 Recall - Brake Booster Pressure Accumulator Cracking Product Safety - Hydro-Boost Accumulator Over-Pressurization # 05006 - (Mar 23, 2005) Models: 2004 Chevrolet Kodiak 2004-2005 Chevrolet Avalanche, Express, Silverado, Suburban 2004 GMC TopKick 2004-2005 GMC Savana, Sierra, Yukon XL Condition General Motors has decided that a defect, which relates to motor vehicle safety, exists in certain 2004 Chevrolet Kodiak and GMC TopKick; 2004-2005 Chevrolet Avalanche, Express, Silverado, Suburban; GMC Savana, Sierra, Yukon XL vehicles. On some of these vehicles, the hydraulic brake booster's pressure accumulator may crack and/or separate from the Hydro-Boost(R) assembly during normal vehicle operating conditions. If a separation were to occur and the hood of the vehicle were open, fragments from the accumulator could cause injury to people in the immediate area. In addition, the presence of this crack or fractured surface could allow the hydraulic fluid to leak from the accumulator circuit of the booster assembly. The loss of fluid would cause increased steering and braking effort. Correction Dealers are to inspect the hydraulic brake booster, and replace it if necessary. Vehicles Involved Involved are certain 2004 Chevrolet Kodiak and GMC TopKick; 2004-2005 Chevrolet Avalanche, Express, Silverado, Suburban; GMC Savana, Sierra, A/C - Window Defroster Contact/Tab Repair Information Heated Glass Element: All Technical Service Bulletins A/C - Window Defroster Contact/Tab Repair Information INFORMATION Bulletin No.: 03-08-48-006H Date: April 11, 2011 Subject: Repair Information for Reconnection of Rear Window Defroster Contact or Tab Models: 2000-2012 GM Passenger Cars and Trucks 2003-2009 HUMMER H2 2006-2010 HUMMER H3 2005-2009 Saab 9-7X 2007-2010 Opel GT 2007-2008 Daewoo G2X Equipped With Electric Rear Window Defroster - RPO C49 Supercede: This bulletin is being revised to add the 2012 model year. Please discard Corporate Bulletin Number 03-08-48-006G (Section 08 - Body and Accessories). Repair Suggestions Soldering Defroster Contact Tabs In many cases the terminal tab will still be in the connector when you examine the vehicle. For Chevrolet Tahoe, Suburban, GMC Yukon, and Cadillac Escalade vehicles (with moveable glass), always replace the defroster tab (GM P/N 25916031) and the defroster electrical power connector (P/N 12034110). For all other vehicles, reconnect the original defroster tab. In most applications it is preferable to create a new solder connection to reattach a separated rear defroster tab. If you take note of the steps below, it is possible to create a new solder joint that is equal to, or stronger than, the original. The generic procedure below is not very time intensive, but does include minor preparation work to create a good bonding surface. Be sure to follow each of the steps, as combined they will produce the strongest bond possible. Please consider the following before attempting the repair: - Soldering introduces significant heat to the glass window of the vehicle. When performing the re-connection of the tab, use only the heat required to do the job. Pre-heat the soldering iron and have the solder in your other hand, ready to go, the moment you have enough heat to melt the solder. - If it is winter, bring the vehicle into the service garage and remove any snow from the back window area. Allow time for the glass to warm to the temperature inside the building. Soldering creates a "hot spot" in the glass. DO NOT solder on cold glass. Caution Heating the glass excessively, or repeatedly without time to cool, may result in glass breakage. ALWAYS wear safety glasses when performing this repair! - You MUST use a silver-bearing solder to make the connection. DO NOT attempt this repair with conventional tin/lead alloy solders. Silver bearing solder will adhere to the electrical buss bar, making a strong and lasting repair. - Protect surfaces under the area to be soldered. It is very easy to drip solder when performing this repair. Placing a shop towel under the soldering area is sufficient protection. Soldering Procedure 1. It is imperative to remove and replace the rear defroster electrical power connector by crimping a new connector to the feed wire. The proper connector P/N 12034110 can be found in the Packard Electrical Assortment, Tray 18, Position 5. - Insert Delphi pick 12094430 to depress the locking tab on the terminal. - Insert Delphi pick 12094429 to release the secondary lock tab. Important DO NOT re-use the existing defroster tab on new-style full-size utility vehicles with moveable glass. 2. Connect the electrical connector to the defroster tab. Fully engage the connector. An improperly seated connector may cause excessive resistance and impede the proper operation of the defroster. Add a small bead of solder to mate the electrical connector tab to the defroster tab. Page 1599 Knock Sensor: Description and Operation KNOCK SENSOR (KS) SYSTEM DESCRIPTION PURPOSE The knock sensor (KS) system enables the control module to control the ignition timing for the best possible performance while protecting the engine from potentially damaging levels of detonation. The control module uses the KS system to test for abnormal engine noise that may indicate detonation, also known as spark knock. SENSOR DESCRIPTION This KS system uses one or two broadband one-wire sensors. The sensor uses piezo-electric crystal technology that produces an AC voltage signal of varying amplitude and frequency based on the engine vibration, or noise, level. The amplitude and frequency are dependant upon the level of knock that the KS detects. The control module receives the KS signal through a signal circuit. The KS ground is supplied by the engine block through the sensor housing. One way the control module monitors the system is by output of a bias voltage on the KS signal wire. The bias voltage creates a voltage drop that the control module monitors and uses to help diagnose KS faults. The KS noise signal rides along this bias voltage, and due to the constantly fluctuating frequency and amplitude of the signal, will always be outside of the bias voltage parameters. Another way the control module monitors the system is by learning the average normal noise output from the KS. The control module learns a minimum noise level, or background noise, at idle from the KS and uses calibrated values for the rest of the RPM range. The control module uses the minimum noise level to calculate a noise channel. The control module uses this noise channel, and the KS signal that rides along the noise channel, in much the same way as the bias voltage type does. As engine speed and load change, the noise channel upper and lower parameters will change to accommodate the normal KS signal. In order to determine which cylinders are knocking, the control module only uses KS signal information when each cylinder is near top dead center (TDC) of the firing stroke. If the control module has determined that knock is present, it will retard the ignition timing to attempt to eliminate the knock. The control module will always try to work back to a zero compensation level, or no spark retard. An abnormal KS signal will fall within the noise channel or will not be present. KS diagnostics are calibrated to detect faults with the KS circuitry inside the control module, the KS wiring, or the KS voltage output. Steering - 'Service Rear Wheel Steering' Message Body Control Module: All Technical Service Bulletins Steering - 'Service Rear Wheel Steering' Message Bulletin No.: 05-02-118-002 Date: February 03, 2005 TECHNICAL Subject: DTC C0455, "Service Rear Wheel Steering", System Jumps from 4-Wheel Steer to 2-Wheel Steer (Reprogram BCM) Models: 2003-2005 Chevrolet Silverado, Suburban 2003-2005 GMC Sierra, Yukon XL with 4-Wheel Steer (RPO NYS) Condition Some customers may comment that the system will jump from 4-wheel steer to 2-wheel steer and the DIC displays the message "Service Rear Wheel Steering". Diagnosis will show DTC C0455-Front Steering Position Sensor malfunction. Cause This condition may be caused by a Class2 communication issue. Correction Reprogram the BCM. 2005 Model Year Vehicles: New software calibration, P/N 15248410, was released on TIS version 12 - broadcast to dealers on December 4, 2004. 2003-2004 Model Year Vehicles: New software calibration, P/N 15259330 ('03 Model Year) and P/N 15259331 ('04 04 Model Year), was released on TIS version 1.75 - broadcast to dealers on January 24, 2005. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer OnStar(R) - Negative Impact of Cloth/Vinyl Roofs Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Negative Impact of Cloth/Vinyl Roofs INFORMATION Bulletin No.: 02-08-44-007D Date: May 12, 2009 Subject: Negative Impact of Dealer-Installed Cloth/Vinyl Roofs on XM Radio and/or OnStar(R) Systems Models: 2002-2009 Passenger Cars and Trucks (Including Saturn) 2003-2009 HUMMER H2 2006-2009 HUMMER H3 2005-2009 Saab 9-7X with XM Radio (RPO U2K) and/or OnStar(R) (RPO UE1) .............................................................................................................................................................. .................................................................................. Supercede: This bulletin is being revised to include the 2009 model year. Please discard Corporate Bulletin Number 02-08-44-007C (Section 08 - Body and Accessories). .............................................................................................................................................................. .................................................................................. Dealers should not install a cloth or vinyl roof on vehicles that have been ordered with the XM radio option (RPO U2K) and/or OnStar(R) (RPO UE1). The performance of these systems may be negatively impacted by the installation of the cloth/vinyl roof. Additionally, water leaks may result from installing a cloth or vinyl roof on vehicles with roof-mounted antenna systems. Relocating the antenna to another spot on the vehicle exterior, in order to install a cloth or vinyl roof, is not advised either. The performance of the OnStar(R) and XM Radio antennas has been optimized for their current locations. Relocating the antennas may result in a performance degradation. Disclaimer Page 11884 When the maximum value is reached, the trip odometer will roll over to 0.0. TIMER The Timer is displayed as XX (hours) : XX (minutes) : XX (seconds). The Timer is started and stopped using the DIC Select button. Holding the Select button for longer than 1 second while the Timer parameter is displayed will reset the Timer to 00:00:00. The Timer status and data value is retained in memory when the ignition is turned OFF. When the ignition is turned ON again, the Timer status and data value is resumed. The Timer maximum value is 99:59:59. When the maximum is reached, the Timer rolls over to 00:00:00 and continues to operate. FUEL INFORMATION DIC Fuel Information / Reset Capabilities The available DIC Fuel Information and reset capabilities are as follows: Range. Can not be reset - Avg. Fuel Economy. Can be reset - Inst. Fuel Economy. Can not be reset - Engine Oil Life. Can be reset Range The range display is the estimated distance that the vehicle can travel under current fuel economy and fuel level conditions. This range is calculated from odometer information and class 2 messages. Fuel Range is capable of displaying values from 0-999 mi or km. Display appears as: RANGE: XXX MILES (English), RANGE: XXX km (Metric). If the range is less than 40 miles, RANGE: LOW will be displayed. Average Fuel Economy The Average Fuel Economy (AFE) value is calculated by the cluster based on Trip Distance and Trip Fuel Used. Pressing the Select button for longer than 1 second while the Average Fuel Economy is displayed in the DIC will reset to 0.0. Average Fuel Economy is capable of displaying values from 0.0-99.9. Display appears as: AVG ECON XX.X (English) MPG, AVG ECON XX.X L/100km (Metric). Trip Distance and Trip Fuel Used accumulated values are stored in memory when the ignition is turned OFF. Instantaneous Fuel Economy Instantaneous Fuel Economy values are calculated by the cluster from odometer information and class 2 messages. The cluster calculates instantaneous fuel economy based on distance and fuel. Instantaneous fuel economy is capable of displaying values from 0.0 - 99.9. Display appears as INST ECON XX.X (English), INST ECON XX.X L/100km (Metric). Values for the Instantaneous fuel economy are not stored when the ignition is turned OFF. Engine Oil Life Engine Oil Life percentage values are based on class 2 messages to the IPC. The IPC requests this value when Engine Oil Life is selected on the DIC. Engine Oil Life is capable of displaying values from 0-100 percent and the OIL LIFE RESET driver warning will be displayed. Pressing the Select button for longer than 5 seconds while Engine Oil Life is displayed on the DIC the value will reset to 100 percent. Display appears as ENGINE OIL LIFE: XXX%. Page 9256 C410 Right Rear Lamp Harness To Chassis Harness (With RPO Code T79) Engine - Revised Connecting Rod Bolt Torque Connecting Rod: Technical Service Bulletins Engine - Revised Connecting Rod Bolt Torque Bulletin No.: 07-06-01-002 Date: March 05, 2007 INFORMATION Subject: Information on Revised Connecting Rod Bolt Torque for Small Block GEN III and GEN IV Vortec(TM) V8 Engines Models A new connecting rod bolt torque specification was introduced to the GEN III and GEN IV Vortec(TM) small block V8 engines. The connecting rod bolts should continue to be tightened using two passes. The second pass value has been increased from 75 degrees to 85 degrees. Install the connecting rod bolts and tighten. Refer to Piston, Connecting Rod, and Bearing Installation in SI. Tighten Tighten the connecting rod bolts a first pass to 20 N.m (15 lb ft). Tighten the connecting rod bolts a final pass to 85 degrees using the J 45059 Angle Meter. Service and Repair Torque Converter Clutch: Service and Repair Torque Converter Clutch (TCC) Valve and Spring Replacement Removal Procedure 1. Remove the transmission filter. Caution: Valve springs can be tightly compressed. Use care when removing retainers and plugs. Personal injury could result. 2. Remove the valve bore plug retainer ring (1). 3. Remove the following parts: ^ The valve bore plug ^ The TCC valve ^ The TCC valve spring Installation Procedure 1. Install the following parts: ^ The TCC valve spring ^ The TCC valve ^ The valve bore plug Page 8920 Cigar Lighter/Auxiliary Outlets Diagram 4 (1 Of 2) Service and Repair Maintenance Indicator - A/T: Service and Repair This vehicle does not use a Trans Fluid Life index, and has no monitor to reset. Page 9790 Junction Block - I/P Wire Entry Part 1 Page 14064 Electrical Symbols Part 3 Service and Repair Maintenance Indicator - A/T: Service and Repair This vehicle does not use a Trans Fluid Life index, and has no monitor to reset. Rear Axle Shaft Replacement Axle Shaft: Service and Repair Rear Axle Shaft Replacement 8.6 Inch, 9.5 Inch Axles Rear Axle Shaft Replacement (8.6 Inch, 9.5 Inch Axles) Removal Procedure 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Remove the tire and wheel assembly. 3. Remove the brake caliper. 4. Remove the rear cover and the gasket. 5. Remove the pinion shaft locking bolt. 6. On axles without a locking differential, remove the pinion shaft. Page 9817 Relay Box: Service and Repair Body Wiring Harness Junction Block Replacement BODY WIRING HARNESS JUNCTION BLOCK REPLACEMENT REMOVAL PROCEDURE 1. Remove the cover retaining nut. 2. Remove the cover by pushing in the tabs. 3. Remove the harness from the front of the junction block. 4. Remove the junction block from the bracket by pressing to release the tabs. 5. Remove the junction block in order to gain access to the rear of the block to remove the retaining bolts. 6. Remove the retaining bolts. 7. Separate the wire harness block from the junction block by inserting a screw driver in between. 8. Remove the junction block from the vehicle. INSTALLATION PROCEDURE 1. Install the wire harness block to the junction block. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the retaining bolts. Tighten Tighten the bolts to 6 N.m (53 lb in). 3. Install the junction block to the bracket. Service and Repair Glove Box Lamp Switch: Service and Repair INSTRUMENT PANEL (I/P) COMPARTMENT LAMP SWITCH REPLACEMENT REMOVAL PROCEDURE 1. Lower the instrument panel storage compartment door by pressing in the tab. 2. With one hand holding the plunger of the switch, use a small screw driver to push in the tabs on each side while pulling outwards. 3. Pull the switch assembly from the I/P. 4. Disconnect the electrical connector. 5. Remove the bulb (1). INSTALLATION PROCEDURE Page 12679 Test Description DTC U1001 and U1254 Circuit/System Description Modules connected to the Class 2 serial data circuit monitor for serial data communications during normal vehicle operation. Operating information and commands are exchanged among the modules. When a module receives a message for a critical operating parameter, the module records the identification number of the module which sent the message for State of Health monitoring. A critical operating parameter is one which, when not received, requires that the module use a default value for that parameter. Once an identification number is learned by a module, it will monitor for that module's Node Alive message. Each module on the class 2 serial data circuit which is powered and performing functions that require detection of a communications malfunction is required to send a Node Alive message every 2 seconds. When no message is detected from a learned identification number for 5 seconds, a DTC U1XXX where XXX is equal to the 3-digit identification number is set. Page 4765 Intake Air Temperature (IAT)/Mass Air Flow (MAF) Sensor Description and Operation Pedal Positioning Switch: Description and Operation Brake Pedal Position Sensor Calibration Description and Operation Calibration Criteria The brake pedal position (BPP) sensor receives a low reference signal and a 5-volt reference signal from the electro-hydraulic power steering (EHPS). Whenever the brake pedal is applied, the brake pedal position sensor applies a variable voltage signal to the EHPS through the BPP sensor signal circuit. Brake pedal position sensor calibration must be performed after the brake pedal position sensor or EHPS system have been serviced. The calibration procedure will set brake pedal position sensor home value. This value is used by the EHPS to determine the brake pedal position and the brake pedal rate. These two outputs are provided to the hybrid control module (HCM) via GMLAN. Calibration Procedure 1. Install a scan tool. 2. Turn ON the ignition, with the engine OFF. 3. Important: Make sure the brake pedal is not depressed before sending BPP sensor calibration command. Navigate to the Special Functions screen on the scan tool and select BPP Sensor Calibration in order to perform the brake pedal position sensor calibration. Page 14402 Front Passenger Door Module (FPDM) - C3 (With RPO Code YE9) Part 2 Page 2761 Relay Box: Application and ID Relay Block - I/P Location View Page 16018 Electrical Symbols Part 14 Page 12993 Steps 1-5 Page 9554 Fuse Block - Underhood C2 Part 3 Page 10054 1. Remove the power steering outlet hose (4) from the power steering gear (3). 2. Remove the power steering outlet hose (4) from the power steering cooler (5). Installation Procedure 1. Connect the power steering outlet hose (4) to the power steering cooler (5). 2. Connect the power steering outlet hose (4) to the power steering gear (3). Hand tighten only. 3. Notice: Refer to Fastener Notice in Service Precautions. Connect the power steering outlet hose (2) to the power steering pump (1). ^ Tighten both hose connections to 28 Nm (20 ft. lbs.). 4. Bleed the power steering system. Refer to Bleeding the Power Steering System. 5. Inspect all the hose connections for leaks. Power Brake Booster Inlet Hose Replacement Power Brake Booster Inlet Hose Replacement Removal Procedure 1. Notice: Refer to Power Steering Hose Disconnected Notice in Service Precautions. Install a drain pan under the vehicle. Instruments - Service Tire Monitor Message is Displayed Low Tire Pressure Indicator: All Technical Service Bulletins Instruments - Service Tire Monitor Message is Displayed Bulletin No.: 05-08-49-018A Date: May 11, 2006 ADVANCE SERVICE INFORMATION RESOLUTION Subject: EI 05065 - Service Tire Monitor Message Displayed (Pull/Reinstall IPC Fuse or Verify Correct Passenger Door Module (PDM) and Tires) Models: 2004 Chevrolet Silverado 2004 GMC Sierra Supercede: This bulletin is being revised to provide correction action. Please discard Corporate Bulletin Number 05-08-49-018 (Section 08 - Body and Accessories). Condition Some customers may comment that the "SERVICE TIRE MONITOR" message is being displayed on the DIC. Correction DO NOT REPLACE THE INSTRUMENT PANEL CLUSTER. If the DIC is displaying the SERVICE TIRE MONITOR message: 1. Verify if the vehicle has an electronic aftermarket module spliced into the ALDL Class 2 data line (purple wire). 2. If the vehicle HAS an aftermarket module spliced into the Class 2 line, pull the IPC fuse (located underhood) for 25 seconds. Important: Due to the electronic aftermarket module, the SERVICE TIRE MONITOR message may reoccur. 3. Reinstall the IPC fuse. This will clear the SERVICE TIRE MONITOR message from the display. 4. If the vehicle DOES NOT have an aftermarket module spliced into the Class 2 line, verify the vehicle is equipped with the correct PDM (Passenger Door Module) and tires. Warrant Information This repair is not covered under the vehicle warranty due to the installation of an aftermarket module. Disclaimer Page 12851 Important: Secure the wiring harness so that there is no risk of chafing and rattling. 9.4. Fold back the wiring harness and tape over the connectors (C). Fold back the wiring harness once more and secure with cable ties (D). 9.5. Install the right-hand rear luggage compartment in accordance with WIS - 8. Body - Interior equipment - Adjustment/Replacement. 10. Install the ground cable to the battery's negative terminal. 11. Clear the diagnostic trouble codes. 12. Set the date and time, see WIS - 3. Electrical system - Information display (SID_ - Technical description. 2003-2005 Saab 9-3 (9400) 4D/5D; 2004-2005 Saab 9-3 (9400) CV 2003-2005 Saab 9-3 (9440) 4D/5D; 2004-2005 Saab 9-3 (9440) CV Notice: Handle the fiber optic cables with care or the signal may be distorted. ^ It is very important that the two leads in the connector are not confused with one another. ^ Do not splice the cables. ^ Do not bend the cable in a radius smaller than 25 mm (1 in). ^ Do not expose the cable to temperatures exceeding 185°F (85°C). ^ Keep the cable ends free from dirt and grime. ^ Do not expose the cable to impact as this may cause the transparent plastic to whiten, thereby reducing the intensity of the light and causing possible communication interruptions. ^ The cable should not lie against any sharp edges as this may cause increased signal attenuation. 1. Remove the ECU CU with a Tech 2(R) according to the following: Fault diagnosis - Select model year - Select Saab 9-3 Sport (9440) - All - Add/Remove - Control Module - CU/PU - Remove. 2. Remove the ground cable from the battery's negative terminal. 3. Remove the floor console in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 4. Pry out the signal line from the SRS control module to the OnStar(R) control module and secure it: Service and Repair Exhaust Pipe Gasket: Service and Repair Exhaust Seal Replacement Removal Procedure 1. Raise and suitably support the vehicle. 2. If equipped with a 4.3L, 4.8L, or 5.3L engine, perform the following: 1. Remove the clip from around the engine harness and the oxygen sensor pigtail. 2. Disconnect the connector position assurance (CPA) retainer. 3. Disconnect the forward oxygen sensor electrical connector. 3. If equipped with a 4.3L, 4.8L, or 5.3L engine, perform the following: 1. Unclip the oxygen sensor electrical connector from the hose clip. 2. Disconnect the CPA retainer. 3. Disconnect the oxygen sensor electrical connector (1). 4. If equipped with a 6.0L or 8.1L engine, perform the following: 1. Disconnect the CPA retainer. 2. Disconnect the oxygen sensor electrical connector (1). 5. Support the catalytic converter or exhaust manifold pipe with adjustable jackstands. A/T - Torque Converter Replacement Information Torque Converter: Technical Service Bulletins A/T - Torque Converter Replacement Information INFORMATION Bulletin No.: 01-07-30-010C Date: May 12, 2008 Subject: Automatic Transmission/Transaxle Torque Converter Replacement Models: 2009 and Prior GM Passenger Cars and Trucks 2009 and Prior HUMMER H2, H3 2009 and Prior Saturn Cars and Light Duty Trucks (Except VTi Equipped Vehicles (RPO M16 and M75) 2009 and Prior Saab 9-7X with ALL Automatic Transmissions and Transaxles Supercede: This bulletin is being revised to add the 2007-2009 model years. Please discard Corporate Bulletin Number 01-07-30-010B (Section 07 - Transmission/Transaxle). The purpose of this bulletin is to help technicians determine when a torque converter should be replaced. Below is a list of general guidelines to follow. The converter should NOT be replaced if the following apply: ^ DTC P0742 - TCC stuck on is set. This code is almost always the result of a controls condition (i.e. stuck TCC solenoid/valve). Experience has shown that this code rarely indicates a mechanical concern within the torque converter. ^ The fluid has an odor or is discolored but no evidence of metal contamination. ^ Fine metal particles (traces of metal flakes/gray color to fluid ) are found in the converter. This is not harmful to the torque converter. ^ The vehicle has been exposed to high mileage. ^ A small amount of wear appears on the hub where the oil pump drive gear mates to the converter (RWD only). A certain amount of such wear is normal for both the hub and oil pump gear. Neither the converter nor the front pump assembly should be replaced. The torque converter should be replaced under any of the following conditions: ^ The vehicle has TCC shudder and/or no TCC apply. First complete all electrical and hydraulic diagnosis and check for proper engine operation. The converter clutch may be damaged. Also the converter bushing and/or internal 0-ring may be damaged. ^ Evidence of damage to the oil pump assembly pump shaft turbine shaft drive sprocket support and bearing or metal chips/debris in the converter. ^ Metal chips/debris are found in the converter or when flushing the cooler and the cooler lines. ^ External leaks in the hub weld area lug weld or closure weld. ^ Converter pilot is broken damaged or fits poorly into the crankshaft. ^ The converter hub is scored or damaged. ^ The transmission oil is contaminated with engine coolant engine oil or water. ^ If excessive end play is found after measuring the converter for proper end play (refer to Service Manual). ^ If metal chips/debris are found in the fluid filter or on the magnet and no internal parts in the unit are worn or damaged. This indicates that the material came from the converter. ^ The converter has an unbalanced condition that results in a vibration that cannot be corrected by following Converter Vibration Procedures. ^ Blue converter or dark circular ring between lugs. This condition will also require a complete cleaning of the cooler and a check for adequate flow Page 2628 Junction Block - I/P Wire Entry Part 2 Page 15749 Backup Lamp Switch: Service and Repair ZF S6-650 Backup Lamp Switch Replacement Removal Procedure 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. If equipped with a 6.6L engine, disconnect the backup lamp switch electrical connector (3). 2. If equipped with a 8.1L engine, disconnect the backup lamp switch electrical connector (4). 3. Remove the backup lamp switch. Installation Procedure Drivetrain - Wheel Drive Shaft Nut Torque Revision Axle Nut: Technical Service Bulletins Drivetrain - Wheel Drive Shaft Nut Torque Revision Bulletin No.: 04-04-95-001 Date: March 02, 2004 SERVICE MANUAL UPDATE Subject: Revised Wheel Drive Shaft Nut Torque Specification Models: 2002-2004 Cadillac Escalade, Escalade EXT 2003-2004 Cadillac Escalade ESV 1999-2004 Chevrolet Silverado 2000-2004 Chevrolet Suburban 2002-2004 Chevrolet Avalanche 2003-2004 Chevrolet Astro, Express 1999-2004 GMC Sierra 2000-2004 GMC Yukon, Yukon XL 2003-2004 GMC Safari, Savana 2003-2004 HUMMER H2 This bulletin is being issued to revise the torque specification for the wheel drive shaft nut in the Wheel Drive Shafts sub-section of the Service Manual. Please replace the current information in the Service Manual with the following information. The following information has been updated within SI. If you are using a paper version of this Service Manual, please make a reference to this bulletin on the affected page. Page 10198 Looking at the FRONT of the sensor, align the sensor with the steering shaft and install into the adapter and bearing assembly. 24. Install the connector to the sensor. Page 11341 1. Install the blower motor control processor (2) to the HVAC module (1). NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the blower motor control processor retaining screws. Tighten Tighten the screws to 1.6 N.m (14 lb in). 3. Connect the electrical connector (4) to the blower motor control processor (2). 4. Connect the electrical connector at the blower motor. 5. If equipped, install the sound insulator panel. HVAC Control Module Replacement HVAC CONTROL MODULE REPLACEMENT REMOVAL PROCEDURE Vehicle Speed Sensor (VSS) Vehicle Speed Sensor: Diagrams Vehicle Speed Sensor (VSS) Page 8893 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. REPLACEMENT PROCEDURE After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Insure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the Terminal Removal Procedure. Repairing Connector Terminals REPAIRING CONNECTOR TERMINALS TOOLS REQUIRED J 38125-D Terminal Repair Kit Use the following repair procedures in order to repair the following: - Push to Seat terminals - Pull to Seat terminals - Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-D contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100 World terminals. Soldering Micro-Pack 100 World terminals may damage the terminal. Circuit Protection - Circuit Breakers CIRCUIT PROTECTION - CIRCUIT BREAKERS A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Page 13239 High OR Low The above conditions are met for more than 3 seconds. Circuit/System Verification These DTCs cannot be retrieved with a current status. To diagnose use the Scan Tool Does Not Communicate with a Class 2 Device. Refer to SI. An intermittent condition is likely to be caused by a short on the Class 2 serial data circuit. To diagnose use the Scan Tool Does Not Communicate with a Class 2 Device. Refer to SI. DTC B2455 DTC Descriptors DTC B2455 01: Cellular Phone Microphone Circuit Short to Battery DTC B2455 02: Cellular Phone Microphone Circuit Short to Ground DTC B2455 04: Cellular Phone Microphone Circuit Open Circuit Circuit/System Description Without RPO UAV The vehicle communication interface module (VCIM) uses the cellular phone microphone to allow driver communication with OnStar(R). With RPO UAV The vehicle communication interface module (VCIM) and navigation radio use the cellular phone microphone to allow driver communication with OnStar(R), as well as to operate the voice recognition/voice guidance feature of the navigation radio. Conditions for Running the DTC The ignition is in RUN or ACC position. System voltage is between 9.5 - 15.5 volts. The above conditions are met for more than 10 seconds. Conditions for Setting the DTC B2455 01: A short to battery is detected on the cellular microphone signal circuit. B2455 02: A short to ground is detected on the cellular microphone signal circuit. B2455 04: An open circuit is detected on the cellular microphone signal circuit. Action Taken When the DTC Sets The VCIM and/or navigation radio (RPO UAV) will not receive any signal from the microphone. The OnStar(R) status LED turns red. Voice recognition will not function. Conditions for Clearing the DTC Page 9749 C250 Brake/Clutch Harness To Brake Clutch Jumper Harness (With RPO Code ZX3) Page 14109 Control Module References Part 7 Fuel Pressure Gage Installation and Removal Fuel Pressure Release: Service and Repair Fuel Pressure Gage Installation and Removal FUEL PRESSURE GAGE INSTALLATION AND REMOVAL INSTALLATION PROCEDURE TOOLS REQUIRED J 34730-1A Fuel Pressure Gage CAUTION: - Refer to Gasoline/Gasoline Vapors Caution in Service Precautions. - Refer to Fuel Gage Leak Caution in Service Precautions. 1. Remove the engine sight shield. 2. Remove the fuel rail pressure fitting cap. 3. Connect the J 34730-1A to the fuel pressure valve. Wrap a shop towel around the fitting while connecting the gage in order to avoid spillage. 4. Install the bleed hose on J 34730-1A into an approved container. REMOVAL PROCEDURE 1. Remove the bleed hose on the J 34730-1A from the approved container. 2. Remove the shop towel from around the fitting and discard into an approved container. 3. Disconnect the J 34730-1A from the fuel pressure valve. 4. Install the fuel rail pressure fitting cap. 5. Install the engine sight shield. Page 14930 Seat Memory Switch: Diagrams Driver Door Module (DDM) - C5 (Memory/Heated Seat Switch) Part 1 Page 4604 Oxygen Sensor: Service and Repair Heated Oxygen Sensor (HO2S) Replacement Bank 1 Sensor 2 HEATED OXYGEN SENSOR (HO2S) REPLACEMENT BANK 1 SENSOR 2 REMOVAL PROCEDURE 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. If equipped, disconnect the fuel composition sensor electrical connector. 3. Disconnect the connector position assurance (CPA) retainer. NOTE: Refer to Heated Oxygen and Oxygen Sensor Notice in Service Precautions. 4. If equipped with a fuel composition sensor, remove the heated oxygen sensor (HO2S) electrical connector from the fuel line clip. 5. If equipped with a 4.8L or 5.3L engine, disconnect the HO2S electrical connector (2). 6. If equipped with a 6.0L engine, disconnect the HO2S electrical connector (2). Page 2120 - Worn ignition wires - Incorrect spark plug gap - Excessive idling or slow speeds under light loads can keep spark plug temperatures so low that normal combustion deposits may not burn off. - Deposit fouling - Oil, coolant, or additives that include substances such as silicone, very white coating, reduces the spark plug intensity. Most powdery deposits will not affect spark plug intensity unless they form into a glazing over the electrode. Page 5482 Important: The intake plenum should also be checked for excessive warpage that may cause an uneven clamping pressure of the seal. If the plenum is found to be warped it will need to be replaced. Service Information states, "An intake manifold with warpage in excess of 3 mm (0.118 in) over a 200 mm (7.87 in) area should be replaced." Intake warpage is measured at the gasket sealing surfaces and should be measured within a 200 mm (7.87 in) area. This measurement is across only two of the intake runner port openings. Measurements taken across the entire distance of all four intake runner ports will lead to unnecessary manifold replacements. Important: Measurements taken across the entire distance of all four intake runner ports will lead to unnecessary intake manifold replacements. 1. Locate a straight edge across the intake manifold cylinder head deck surface. Position the straight edge across two runner port openings. 2. Insert a feeler gauge between the intake manifold and the straight edge. An intake manifold with warpage in excess of 3 mm (0.118 in) over a 200 mm (7.87 in) area is warped and should be replaced. Do not replace intake manifolds with warpage that measures less than 3 mm (0.118 in) over a 200 mm (7.87 in). Parts Information Warranty Information For vehicles repaired under warranty, use the table. Page 14346 Electrical Symbols Part 6 Page 11070 The new calibrations have been updated to compensate for the actuator overtravel condition, the actuator hunting and the ticking/clicking noises. The new calibrations effectively eliminate the codes listed above, the default position of the doors associated with the DTCs and opens up the feedback position value. The new calibrations should not be used unless the vehicle has one or more of the customer concerns listed above or a DTC listed above has been set. The new calibrations will not correct any other DTC or NC system performance concern. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 12026 7.2. Remove the console (A). 7.3. Disconnect the connector (B) from the OnStar(R) control module. Important: Secure the cable harness to prevent the risk of scraping and rattling. 7.4. Fold back the cable harness and tape down the connector (C). Fold back the cable harness again and secure with cable ties (D). 7.5. 5D: Assemble the right-hand cover for the luggage compartment floor. 8. Fit the ground cable on the battery's negative cable. Page 12023 Important: The optic cable must not be bent with a radius less than 25 mm (1 in). 12.5. Cars with brackets for e.g. an amplifier: Fit the cable tie (11 900 515) to the wiring harness approx. 100 mm (4 in) from H2-9, fit the cable tie (H) to the bracket. Gather the optic cable in a gentle loop (I) and then place the loop behind the bracket. Important: The optic cable must not be bent with a radius less than 25 mm (1 in). 12.6. Cars without brackets for e.g. an amplifier: Gather the optic cable in a gentle loop (J) and secure with cable tie. 13. CV: Fit the left-hand, rear side hatch trim in accordance with WIS - 8. Body - Interior equipment - Adjustment/Replacement. 14. Fit the ground cable to the battery's negative terminal. 15. Carry out procedures after disconnecting the battery, see WIS - 3. Electrical System - Charging system - Adjustment/Replacement. Important: Follow Tech 2(R) on-screen instructions. 16. Add ECU ICM, choose without OnStar(R). See WIS-General-Tech 2(R) - Description and Operation - Add/Remove. 2000-2004 Saab 9-5 2000-2004 Saab 9-5 Page 6563 7. Remove the control lever to the manual shaft nut. 8. Remove the control lever from the manual shaft. 9. Remove the PNP switch bolts. 10. Remove the PNP switch from the manual shaft. If the PNP switch does not slide off the manual shaft, file the outer edge of the manual shaft in order to remove any burrs. Installation Procedure 1. Install the PNP switch to the manual shaft by aligning the switch hub flats with the manual shaft flats. 2. Slide the PNP switch onto the manual shaft until the switch mounting bracket contacts the mounting bosses on the transmission. 3. Important: If a new PNP switch is being installed, the switch will come with a positive assurance bracket. The positive assurance bracket aligns the new switch in its proper position for installation and the use of the park neutral switch aligner will not be necessary. Install the PNP switch bolts finger tight. Wheels/Tires - Slow Tire Leak/Vibration Wheels: Customer Interest Wheels/Tires - Slow Tire Leak/Vibration Bulletin No.: 03-03-10-001D Date: January 17, 2008 TECHNICAL Subject: Tire Slowly Goes Flat and/or Excessive wheel Vibration Caused By Bead Splits (Replace wheels with New Heavy Duty Rim Version) Models: 1999-2006 Chevrolet Silverado 1500 Series Pickup Models (Classic) 1999-2006 Chevrolet Express 1500 Series Vans 2000-2006 Chevrolet Suburban Tahoe 1999-2006 GMC Sierra 1500 Series Pickup Models (Classic) 1999-2006 GMC Savana 1500 Series Vans 2002-2006 GMC Yukon Yukon XL 2007 GMC Sierra Denali Crew Cab with 6-Bolt, 16 X 6.5 Full Face Steel wheel (Base and RPO PY2) Supercede: This bulletin is being revised to add the Express and Savana models and add information to the Correction section. Please discard Corporate Bulletin Number 03-03-10-001C (Section 03 Suspension). Implementation of this service bulletin by "GM of Canada" dealers requires prior District Service Manager approval. Condition Some customers may comment on a tire that slowly goes flat and/or excessive wheel vibration. This condition is more apparent on vehicles in which customer usage typically involves frequent severe conditions such as: High load (at or above gross vehicle weight) Rough road/off road usage Fleet/Commercial usage Cause The wheel may experience a crack or split in the outboard bead seat weld area. A weld attaches the rim and disc together on full-face wheels in this area. To identify this wheel it is offered in a silver painted version P/N 9593915 code "TZA" and a chrome-clad version, P/N 9593150 code "RSC" (these codes are stamped into the wheel's disc near the bolt holes). Correction Wheel replacement should only be done for air loss and/or vibration caused by bead splits. A new heavy-duty rim version of these wheels has been released for service. The new heavy-duty painted wheel is P/N 9595245 code "FFU" used as a road wheel and spare. The new heavy-duty chrome clad version is P/N 9595306 code "FFW" used as a road wheel only (these codes are stamped into the inboard rim flange balance weight area and are also on a sticker near the bolt holes). If a condition of a crack or split as described above occurs all (5) five of the original wheels on the vehicle should be replaced with the new heavy-duty wheels as follows: Replace road wheel P/N 9593915 with P/N 9595245. Replace road wheel PIN 9593150 with P/N 9595306. Replace the spare wheel with P/N 9595245 on all vehicles. Page 3753 2. Connect the CPA retainer. 3. Install the clip around the engine harness and the oxygen sensor pigtail. 11. Lower the vehicle. Page 2312 6. Install the discharge hose (1) to the A/C compressor using new sealing washers. 7. Install the discharge hose mounting bolt. Tighten Tighten the bolt to 16 N.m (12 lb ft). 8. Evacuate and recharge the A/C system. Refer to Refrigerant Recovery and Recharging. 9. Leak test the fittings of the component using the J 39400-A. Page 5957 Filler Tube Replacement (Cab/Chassis - Front) Fuel Filler Hose: Service and Repair Filler Tube Replacement (Cab/Chassis - Front) FILLER TUBE REPLACEMENT (CAB/CHASSIS - FRONT) REMOVAL PROCEDURE 1. Relieve the fuel system pressure. Refer to Fuel Pressure Relief Procedure. 2. If equipped with a rear auxiliary tank, disconnect the fuel and evaporative emission (EVAP) quick connect fittings. 3. Cap the fuel feed and EVAP pipes in order to prevent possible system contamination. 4. Loosen the fuel fill pipe clamp (2) at the tank. 5. Loosen the vent pipe clamp (1) at the tank. 6. Remove the fuel fill pipe and vent pipe from the tank. 7. Cap the fuel and vent openings in the tank in order to prevent possible system contamination. INSTALLATION PROCEDURE Page 9734 C210 Brake/Clutch Harness To Beacon Harness (With RPO Codes 5G4/TRW) Page 9537 Junction Block - I/P Wire Entry Part 4 Page 11473 Right Side Impact Sensor (With RPO Code HP2) Page 15271 Door Switch: Diagrams Door Latch Assembly (Door Jamb Switch) - LR C2 (Crew Cab Only) Door Latch Assembly (Door Jamb Switch) - LR C2 (Crew Cab Only) Page 9632 Junction Block - I/P Wire Entry Part 4 Page 13389 Electrical Symbols ELECTRICAL SYMBOLS Electrical Symbols Part 1 Page 11554 Inflatable Restraint Sensing and Diagnostic Module (SDM) - Part 2 Page 3203 6. Rotate the crankshaft until the number one piston is at top dead center (TDC) of the compression stroke.In this position, cylinder number one rocker arms will be off lobe lift, and the crankshaft sprocket key will be at the 1:30 position.The engine firing order is 1, 8, 7, 2, 6, 5, 4, 3.Cylinders 1, 3, 5 and 7 are the left bank.Cylinder 2, 4, 6 and 8 are the right bank. Notice: Refer to Fastener Notice in Service Precautions. 7. With the engine in the number one firing position, tighten the following valve rocker arm bolts: ^ Tighten the cylinders 1, 2, 7 and 8 exhaust valve rocker arm bolts to 30 Nm (22 ft. lbs.). ^ Tighten the cylinders 1, 3, 4 and 5 intake valve rocker arm bolts to 30 Nm (22 ft. lbs.). 8. Rotate the crankshaft 360 degrees. 9. Tighten the following valve rocker arm bolts: ^ Tighten the cylinders 3, 4, 5 and 6 exhaust valve rocker arm bolts to 30 Nm (22 ft. lbs.). ^ Tighten the cylinders 2, 6, 7 and 8 intake valve rocker arm bolts to 30 Nm (22 ft. lbs.). 10. Install the valve rocker arm cover. Page 8403 After installing the cable to the rear axle holding clip, verify that clip is securely retaining the cable. If not, crimp the clip by hand taking care not to pinch or kink the cable. Install the cable to the differential clip. 7. For 25/35 series vehicles, connect the cable at the equalizer. 8. For 25/35 series vehicles, enable the park brake cable automatic adjuster. Refer to Enabling the Park Brake Cable Automatic Adjuster. 9. For all 15 series vehicles, pull down on the park brake cable in front of the equalizer and install the left park brake cable to the equalizer bar. 10. Remove the safety stands. 11. Remove the safety stands and lower the vehicle. 12. Adjust the park brake cable. (W/NYS) Park Brake Cable Replacement - Right Rear (w/NYS) Removal Procedure 1. Release the park brake. Page 11083 HVAC Control Module - C2 Part 1 HVAC Control Module - C2 Part 2 Page 15955 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Micro-Pack 100W Connectors MICRO-PACK 100W CONNECTORS TOOLS REQUIRED J 38125-D Terminal Repair Kit REMOVAL PROCEDURE There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2)has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. IMPORTANT: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Page 8306 7. Remove the caliper pin boots (4) from the disc brake caliper mounting bracket (3). Installation Procedure 1. Lubricate the front brake caliper bushings, bolts and seals with high temperature silicone brake lubricant. 2. Install the caliper pin boots (4) to the disc brake caliper mounting bracket (3). 3. Install the disc brake pad retainers to the disc brake caliper mounting bracket. 4. Install the disc brake pads to the disc brake caliper mounting bracket. 5. Install the disc brake caliper to the caliper mounting bracket. Refer to Brake Caliper Replacement - Front. 6. With the engine OFF, gradually apply the brake pedal approximately 2/3 of its travel distance. 7. Slowly release the brake pedal. 8. Wait 15 seconds, then repeat steps 6-7 until a firm brake pedal is obtained. This will properly seat the brake caliper pistons and brake pads. Disc Brake Hardware Replacement - Rear Disc Brake Hardware Replacement - Rear Caution: Refer to Brake Dust Caution in Service Precautions. Removal Procedure 1. Raise and support the vehicle. Refer Vehicle Lifting 2. Remove the tire and wheel assembly. Page 6271 Fluid Line/Hose: Service and Repair Automatic Transmission - 4L80-E/4L85-E Transmission Fluid Cooler Hose/Pipe Replacement Removal Procedure 1. Remove the grille assembly. 2. Remove the transmission fluid cooler hose from the Auxiliary oil cooler. 3. Remove the transmission fluid cooler hose from the radiator. 4. Raise the vehicle. Refer to Vehicle Lifting. 5. Remove the engine protection shield. 6. Remove the transmission fluid cooler hoses from the transmission. 7. Remove the transmission fluid cooler hoses from the retainer on the engine. 8. Remove the transmission fluid cooler hoses from the vehicle. Installation Procedure Page 6773 31. Install the ring gear onto the differential case. 32. Install the ring gear bolts. Hand start each bolt to ensure that the ring gear is properly seated to the differential case. 33. Tighten the ring gear bolts. Tighten the ring gear bolts alternately and in stages, gradually pulling the ring gear onto the differential case. Tighten Tighten the ring gear bolts in sequence to 120 N.m (88 lb ft). 34. Install the differential side bearings by performing the following steps: 34.1. In order to protect the differential case, install the J 8107-2 in the case on the side opposite the bearing installation. 34.2. Install the J 22761(2) and the J 8092 (1) onto the differential case bearing as shown. 34.3. Drive the differential case bearing onto the case using the J 22761 and the J 8092. 35. Install the new differential case assembly into the carrier. 36. Clean the sealing surface of each half of the differential carrier case and the inner axle housing to differential carrier assembly. The surfaces must be clean of all grease and oil. 37. Apply a bead of sealer, P/N 1052942 (Canadian P/N 10953466), or equivalent, to one differential carrier case half sealing surface. 38. Install the right differential carrier case half. 39. Install the differential carrier case bolts Tighten Tighten the differential carrier case bolts to 47 N.m (35 lb ft). 40. Install the front drive axle clutch shaft to the differential carrier. 41. Install the left side inner axle shaft by doing the following steps: 41.1. Install the left side inner shaft into the differential carrier assembly until the inner shaft is seated against the differential side gear. 41.2. While holding the inner shaft against the differential side gear, turn the inner shaft in order to align the splines of the inner shaft with the splines on the differential side gear. 41.3. Drive the inner into the differential case side gear using a soft-faced mallet until the retaining ring on the inner shaft is fully seated within the groove in the differential case side gear. Pull back on the inner shaft to ensure that the inner shaft is properly retained in the differential case side gear. 42. Apply sealant, P/N 1052942 (Canadian P/N 10953466), or equivalent, to the inner axle housing to differential carrier sealing surface. Page 8521 8. Inspect the machined surface that was covered by the master cylinder on the front of the hydraulic brake booster at the location (1) shown for a stamped number. The stamped number will be a number 1, 2, 3, or 4. ^ If a stamped number 1 is visible, then the relief valve must be replaced. Proceed to the next step. ^ If a stamped number 2, 3, or 4 is visible, then no further action is required. Proceed to Step 14 and reinstall the master cylinder. ^ If no stamped number is visible, then no further action is required. Proceed to Step 14 and reinstall the master cylinder. 9. Cover the master cylinder with a clean shop towel in order to protect it from fluids or cleaners. Also, place a shop towel under the hydraulic brake booster to absorb any fluid that may leak out of the unit when the relief valve is removed in the next step. 10. Using the tool (2) included with the new relief valve, unscrew the original relief valve (1) from the hydraulic brake booster. Notice DO NOT blow compressed air into the bore or use any commercially available cleaners to flush the valve bore in the next step. This could damage the booster or master cylinder. 11. Inspect the two 0-rings on the original valve for signs of damage. If an 0-ring is missing, broken, or damaged, inspect the bore in the hydraulic brake booster for any pieces or debris using a non-metallic type tool or a clean "lint-free" towel. Important A torque wrench must be used when tightening the valve in the next step. In addition, a 3/8 inch drive to 1/4 inch drive adapter will be needed if your torque wrench is a 3/8 inch drive. Important After tightening the NEW relief valve in the next step, a small gap may exist between the head on the valve and the hydraulic brake booster. This condition is normal. 12. Insert the NEW relief valve into the bore. Tighten Tighten to 17 Nm (13 lb ft). Page 13104 Diagnostic Trouble Codes DTC U1000 and U1255 Circuit/System Description Modules connected to the Class 2 serial data circuit monitor for serial data communications during normal vehicle operation. Operating information and commands are exchanged among the modules. When a module receives a message for a critical operating parameter, the module records the identification number of the module which sent the message for State of Health monitoring. A critical operating parameter is one which, when not received, requires that the module use a default value for that parameter. When a module does not associate an identification number with at least one critical parameter within 5 seconds of beginning serial data communication, DTC U1000 or U1255 DTC is set. When more than one critical parameter does not have an identification number associated with it, the DTC will only be reported once. The Class 2 serial data communications circuit on this vehicle are in a hybrid ring and star configuration. Each module on the ring has 2 serial data circuits connected to it, except the following modules which have only 1 serial data circuit connected them: Page 6707 Notice: Refer to Fastener Notice in Service Precautions. 2. Install the clutch pedal to brake module bolts. ^ Tighten the bolts to 50 Nm (37 ft. lbs.). 3. Install the clutch pedal to clutch pedal bracket bolt. ^ Tighten the bolt to 36 Nm (27 ft. lbs.). 4. Push the clutch master cylinder in until the pushrod socket is touching the clutch pedal. 5. Push in and rotate the clutch master cylinder 45 degrees counterclockwise to the locked position. 6. If equipped with a ZF S6-650 transmission, connect the clutch master cylinder to clutch actuator cylinder quick connect fitting. 7. If equipped with a NV 3500 or NV 4500 transmission, connect the clutch master cylinder to clutch actuator cylinder quick connect fitting. Page 12177 ^ Audio amplifier ^ Driver door module (DDM) ^ Driver door switch assembly (DDSA) ^ Front passenger door module (FPDM) ^ Left rear door module (LRDM) ^ Memory seat module (MSM) ^ Radio antenna module (listed as remote function actuation in scan tool display) ^ Rear integration module (RIM) ^ Right rear door module (RRDM) ^ Theft deterrent module (TDM) ^ TV antenna module ^ Vehicle communication interface module (VCIM) The star has 4 splice packs: ^ SP200 located in the left side of the instrument panel, near the steering column , taped to the instrument panel harness ^ SP201 located in the center of the instrument panel, near the radio ^ SP300 located in the left side middle of the passenger compartment, taped to the body harness, near the carpet seam ^ SP303 located in the right rear of the passenger compartment, taped to the body harness, approximately 24 cm (9.5 in) from the fuse block - right rear. Refer to Data Communication Schematics in SI. The following modules, components, and splice packs are connected to the ring portion of the class 2 serial data circuit: ^ Dash integration module (DIM) ^ Electronic brake control module (EBCM) ^ Engine control module (ECM) ^ Inflatable restraint sensing and diagnostic module (SDM) ^ Instrument panel cluster (IPC) ^ HVAC control module ^ Radio ^ Rear integration module (RIM) ^ Vehicle communication interface module (VCIM) OR ^ Communication interface module (CIM) ^ SP200 ^ SP201 ^ SP300 Page 12216 Important: Secure the wiring harness so that there is no risk of chafing and rattling. 9.4. Fold back the wiring harness and tape over the connectors (C). Fold back the wiring harness once more and secure with cable ties (D). 9.5. Install the right-hand rear luggage compartment in accordance with WIS - 8. Body - Interior equipment - Adjustment/Replacement. 10. Install the ground cable to the battery's negative terminal. 11. Clear the diagnostic trouble codes. 12. Set the date and time, see WIS - 3. Electrical system - Information display (SID_ - Technical description. 2003-2005 Saab 9-3 (9400) 4D/5D; 2004-2005 Saab 9-3 (9400) CV 2003-2005 Saab 9-3 (9440) 4D/5D; 2004-2005 Saab 9-3 (9440) CV Notice: Handle the fiber optic cables with care or the signal may be distorted. ^ It is very important that the two leads in the connector are not confused with one another. ^ Do not splice the cables. ^ Do not bend the cable in a radius smaller than 25 mm (1 in). ^ Do not expose the cable to temperatures exceeding 185°F (85°C). ^ Keep the cable ends free from dirt and grime. ^ Do not expose the cable to impact as this may cause the transparent plastic to whiten, thereby reducing the intensity of the light and causing possible communication interruptions. ^ The cable should not lie against any sharp edges as this may cause increased signal attenuation. 1. Remove the ECU CU with a Tech 2(R) according to the following: Fault diagnosis - Select model year - Select Saab 9-3 Sport (9440) - All - Add/Remove - Control Module - CU/PU - Remove. 2. Remove the ground cable from the battery's negative terminal. 3. Remove the floor console in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 4. Pry out the signal line from the SRS control module to the OnStar(R) control module and secure it: Page 11641 Seat Belt Buckle: Service and Repair Seat Belt Buckle and Latch - Rear (Extended Cab) SEAT BELT BUCKLE AND LATCH REPLACEMENT - REAR (EXTENDED CAB) CAUTION: To avoid personal injury to the occupants of the vehicle, observe the following precautions: - More than one supplier's seat belts are used, therefore, install ONLY the seat belt components specified in the GM parts catalog. - To verify that the correct seat belt components were installed, insert the seat belt latch in the seat belt buckle. The latch must be fully seated and be retained in the buckle until purposely released. REMOVAL PROCEDURE 1. Pull the seat belt buckles through the rear seat cushion. Fold the rear seat up. 2. Remove the rear seat belt buckle nuts. 3. Remove the buckle assembly. INSTALLATION PROCEDURE 1. Position the buckle assembly to the floor panel stud. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the rear seat belt buckle nuts. Tighten Tighten the nuts to 53 N.m (39 lb ft). Page 12519 OnStar(R) Microphone The OnStar(R), or cellular microphone, can be a part of the rearview mirror assembly, or on some vehicle lines, a separate, stand alone unit. In either case, the VCIM supplies approximately 10 volts to the microphone on the cellular microphone signal circuit, and voice data from the user is sent back to the VCIM over the same circuit. A cellular microphone low reference circuit or a drain wire provides a ground for the microphone. Cellular and GPS Antennas The vehicle will be equipped with one of the following types of antennas: ^ Separate, stand-alone cellular and navigation (GPS) antennas. ^ A combination cellular and navigation (GPS) antenna, which brings the functions of both into a single part. ^ A cellular, GPS, and digital radio receiver (DRR) antenna, which also incorporates the functionality of the DRR satellite antenna (XM). The cellular antenna is the component that allows the OnStar(R) system to send and receive data using electromagnetic waves by means of cellular technology. The antenna is connected at the base to a coax cable that plugs directly into the VCIM. The GPS antenna is used to collect the signals of the orbiting GPS satellites. Within the antenna is housed a low noise amplifier that allows for a more broad and precise reception of this data. The antenna is connected at the base to a coax cable that plugs directly into the VCIM. The cable also provides a path for DC current for powering the antenna. The OnStar(R) Call Center also has the capability of communicating with the vehicle during an OnStar(R) call to retrieve the latest GPS location and transmit it to the OnStar(R) Call Center. A history location of the last recorded position of the vehicle is stored in the module and marked as aged, for as long as the module power is not removed. Actual GPS location may take up to 10 minutes to register in the event of a loss of power. Audio System Interface When the OnStar(R) requires audio output, a serial data message is sent to the audio system to mute all radio functions and transmit OnStar(R) originated audio. The OnStar(R) audio is transmitted to the vehicle audio system by a dedicated signal circuit and a low reference circuit. The audio system will mute and an audible ring will be heard though the speakers if the vehicle receives a call with the radio ON. On some vehicles, the HVAC blower speed may be reduced when the OnStar(R) system is active to aid in reducing interior noise. When the system is no longer active, the blower speed will return to its previous setting. OnStar(R) Steering Wheel Controls Some vehicles may have a button on the steering wheel, that when pushed can engage the OnStar(R) system. The button may be a symbol of a face with sound waves, or may say MUTE, or be a symbol of a radio speaker with a slash through it. By engaging the OnStar(R) system with this feature, the user can interact with the system by use of voice commands. A complete list of these commands is supplied in the information provided to the customer. If the information is not available for reference, at any command prompt, the user can say "HELP" and the VCIM will return an audible list of available commands. The steering wheel controls consist of multiple momentary contact switches and a resistor network. The switches and resistor network are arranged so that each switch has a different resistance value. When a switch is pressed, a voltage drop occurs in the resistor network. This produces a specific voltage value unique to the switch selected, to be interpreted by the radio or the body control module (BCM). OnStar(R) Power Moding (DRX or Sleep Cycle) The OnStar(R) system uses a unique sleep cycle to allow the system to receive cellular calls while the ignition is in the OFF position and retained accessory power (RAP) mode has ended. A green status LED on the OnStar(R) keypad normally indicates an active OnStar(R) account. The OnStar(R) system will stay powered up after ignition off for an extended time in order to allow for remote services like door unlock, horn honk, light flash, etcetera to take place as requested by the customer. Power cycle (also referred to as DRX) times vary depending on the generation of the OnStar(R) system. Technicians may identify the OnStar(R) system generation by using a Tech 2 and following this menu path: (Body>VCIM>Module ID Information>Module Information 2) or by accessing www.onstarenrollment.com All Generation 6 digital systems are powered up continuously for 48 hours from ignition OFF. After 48 hours, the Generation 6 systems will enter a 9 minute OFF, 1 minute ON power cycle for an additional 72 hours. At the beginning and end of the 1 minute ON stage, you may or may not experience a short spike of current at the beginning and at the end. This allows for calls from OnStar to be received by the system. After 120 hours from ignition OFF, Page 1570 1. Install the CKP sensor. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the CKP sensor bolt. Tighten Tighten the bolt to 25 N.m (18 lb ft). 3. Connect the CKP sensor electrical connector. 4. Install the starter. 5. Perform the CKP system variation learn procedure. See: Testing and Inspection/Programming and Relearning Page 13064 Disclaimer Page 2066 1. Loosen the jam nut on the tie rod (2). 2. Rotate the inner tie rod (1) to the required toe specification setting. Refer to Wheel Alignment Specifications. 3. Notice: Refer to Fastener Notice in Service Precautions. ^ Tighten the jam nut on the tie rod. ^ Tighten the tie rod jam to 68 Nm (50 ft. lbs.). 4. Check the toe setting after tightening. 5. Re-adjust the toe setting if necessary. Rear Toe Adjustment Rear Toe Adjustment 1. Loosen the jam nut on the tie rod (1). 2. Rotate the inner tie rod to the required toe specification setting. Refer to Wheel Alignment Specifications. 3. Notice: Refer to Fastener Notice in Service Precautions. ^ Tighten the jam nut on the tie rod. ^ Tighten the tie rod jam to 65 Nm (48 ft. lbs.). 4. Check the toe setting after tightening. 5. Re-adjust the toe setting if necessary. Page 12597 4.2. Release the back end of the connector (C) and remove from the contact rail (D). 4.3. M00-01: Disconnect pin 39, cut off the cable terminal and insulate the end using tape (E). Fold back the cable and secure using tape (F). 4.4. M02-04: Disconnect pin 58, cut off the cable terminal and insulate the end using tape (E). Fold back the cable and secure using tape (F). 4.5. Assemble the contact rail and end. 4.6. Connect connector (A) and secure the cable using a cable tie (B). 5. Assemble the gear shift housing (A). AUT: Connect connector (B). 6. Assemble the center console, see WIS - Body - Interior. 7. Remove the OnStar(R) control module and secure the cable harness: 7.1. 5D: Remove the right-hand cover from the luggage compartment floor. Page 10246 9. Use J 38125-12A to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. REPAIR PROCEDURE The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. 1. Cut the wire as close to the terminal as possible. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. Page 1433 Ambient Light Sensor: Diagrams Ambient Light Sensor Steering - 'Service Rear Wheel Steering' Message Body Control Module: Customer Interest Steering - 'Service Rear Wheel Steering' Message Bulletin No.: 05-02-118-002 Date: February 03, 2005 TECHNICAL Subject: DTC C0455, "Service Rear Wheel Steering", System Jumps from 4-Wheel Steer to 2-Wheel Steer (Reprogram BCM) Models: 2003-2005 Chevrolet Silverado, Suburban 2003-2005 GMC Sierra, Yukon XL with 4-Wheel Steer (RPO NYS) Condition Some customers may comment that the system will jump from 4-wheel steer to 2-wheel steer and the DIC displays the message "Service Rear Wheel Steering". Diagnosis will show DTC C0455-Front Steering Position Sensor malfunction. Cause This condition may be caused by a Class2 communication issue. Correction Reprogram the BCM. 2005 Model Year Vehicles: New software calibration, P/N 15248410, was released on TIS version 12 - broadcast to dealers on December 4, 2004. 2003-2004 Model Year Vehicles: New software calibration, P/N 15259330 ('03 Model Year) and P/N 15259331 ('04 04 Model Year), was released on TIS version 1.75 - broadcast to dealers on January 24, 2005. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 10762 The information shown is for the 1999-2002 wiring harnesses and for the 2003-05 wiring harness. To modify a 12171982, 15366255 or 15086884 harness for use in a 2003-05 vehicle, switch the wires in cavities "A" and "D". To modify a 15085418 harness for use in a 1999-2002 vehicle (see model list at the front of this bulletin for applicable models), switch the wires in cavities "A" and "D". Warranty Information When the correct wiring harness P/N is matched to the specific model year of the vehicle, everything works properly. Therefore, conversion of an incorrect wiring jumper to match the vehicle would not be considered a warrantable repair. Disclaimer Page 10890 Electrical Symbols Part 13 Page 16061 Electrical Symbols Part 3 Diagrams Inside Air Temperature Sensor Assembly Locations SEO Harness Routing Page 491 Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. 1. Disconnect the connector from the component. 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. Page 14990 to provide these burdensome remedies, every effort must be made to promptly schedule an appointment with each customer and to repair their vehicle as soon as possible. In the recall notification letters, customers are told how to contact the US National Highway Traffic Safety Administration if the recall is not completed within a reasonable time. Dealer Recall Responsibility - All All unsold new vehicles in dealers possession and subject to this recall MUST be held and inspected/repaired per the service procedure of this recall bulletin BEFORE customers take possession of these vehicles. Dealers are to service all vehicles subject to this recall at no charge to customers, regardless of mileage, age of vehicle, or ownership, from this time forward. Customers who have recently purchased vehicles sold from your vehicle inventory, and for which there is no customer information indicated on the dealer listing, are to be contacted by the dealer. Arrangements are to be made to make the required correction according to the instructions contained in this bulletin. A copy of the customer letter is shown in this bulletin for your use in contacting customers. Recall follow-up cards should not be used for this purpose, since the customer may not as yet have received the notification letter. In summary, whenever a vehicle subject to this recall enters your vehicle inventory, or is in your dealership for service in the future, please take the steps necessary to be sure the recall correction has been made before selling or releasing the vehicle. GENERAL MOTORS PRODUCT PROGRAM CUSTOMER REIMBURSEMENT PROCEDURE If you have paid to have this recall condition corrected prior to receiving this notification, you may be eligible to receive reimbursement. Requests for reimbursement may include parts, labor, fees and taxes. Reimbursement may be limited to the amount the repair would have cost if completed by an authorized General Motors dealer. Your claim will be acted upon within 60 days of receipt. If your claim is: ^ Approved, you will receive a check from General Motors. ^ Denied, you will receive a letter from General Motors with the reason(s) for the denial, or ^ Incomplete, you will receive a letter from General Motors identifying the documentation that is needed to complete the claim and offered the opportunity to resubmit the claim when the missing documentation is available. Please follow the instructions on the claim Form previously show to file e a claim for reimbursement. If you have questions about this reimbursement procedure, please contact the toll free telephone number provided at the bottom of the form. If you need assistance with any other concern, please contact the appropriate Customer Assistance Center at the number shown. The Customer Assistance Center hours of operation are from 8:00 AM - 11:00 PM eastern standard time Monday through Friday. Disclaimer Service and Repair Suspension Mode Switch: Service and Repair Electronic Suspension Ride Control Switch Replacement Removal Procedure 1. Remove the instrument panel trim bezel. 2. Remove the switch from the lower opening of the switch plate panel. 3. Disconnect the electrical connector. Installation Procedure 1. Connect the electrical connector. 2. Install the switch into the lower opening of the switch plate panel. 3. Install the instrument panel trim bezel. Page 15810 Headlamp Switch Part 2 Page 12183 The module uses a default value for the missing parameter. Conditions for Clearing the DTC A current DTC clears when the malfunction is no longer present. A history DTC clears when the module ignition cycle counter reaches the reset threshold, without a repeat of the malfunction. Diagnostic Aids When multiple Loss of Communication DTCs are set concurrently, the cause is likely to be 2 opens in the ring portion of the class 2 serial data circuit. Use the Control Modules and Devices ‐ Description and Identification Number table in order to determine which modules are not communicating. Use the class 2 serial data circuit schematic in order to determine the location of the opens. Test Description Page 15205 Electrical Symbols Part 13 Page 15602 Daytime Running Lamp (DRL) - Right (Domestic) Diagrams Headlamp Leveling Switch (Export) Page 9079 Location View Page 2009 SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-D. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: - The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair Tools Required J 38125-D Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-D. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Page 1399 Important The new canister vent valve will be installed in a new location, outside of the frame. 7. Position and secure the new valve assembly to the frame bracket on the outside of the frame using the existing hole and mounting bolt. Tighten Tighten the bracket mounting bolt to 12 Nm (106 lb in). 8. Connect the vent valve pipe to the EVAP canister. 9. Install the two vent valve pipe clips into the existing underbody holes. 10. Connect the EVAP canister vent valve electrical connector, if equipped. 11. Attach bulk 5/8" heater hose to the vent valve port and secure using a clamp. Run a length as needed along the frame rail routing to the area above the transmission. 12. Cut the hose to determined length and install the supplied filter box. Secure using a clamp. 13. Remove the transmission support and lower the transmission assembly as necessary to allow for access to the new filter box location. 14. Secure the filter box to the transmission vent hose just forward of the hose tee-section using a tie strap. DO NOT pinch or restrict the transmission vent hose. The filter box opening should be pointing downward. 15. Raise the transmission and reinstall the transmission support. 16. Tie strap the hose as needed along the frame rail in order to keep the hose away from pinch-points and heat sources. 17. Lower the vehicle. 2004-2007 Model Year (Use Service Kit P/N 19152349) 1. Raise the vehicle. Suitably support the vehicle. 2. Disconnect the EVAP canister vent valve electrical connector. 3. Disconnect the canister pipe from the vent valve. 4. Push in the retainer and remove the existing canister vent valve from the fuel tank clip or mounting bracket. Discard the old valve. 5. Cut back the existing canister pipe approximately 51 mm (2 in) to remove the quick connect end. Crew Cab Short Box Shown Below, Other Configurations Similar Page 6908 8. Pack the tripot seal (4) and the tripot housing (1) with the grease supplied in the kit. The amount of grease supplied in this kit has been pre-measured for this application. Page 2208 Extended Cab Short Box Shown Below, Other Configurations Similar 6. Install the new canister vent valve solenoid to the fuel tank clip or mounting bracket as shown above. The valve port closest to the electrical connector must point towards the canister. 7. Cut bulk 5/8" heater hose to a length of approximately 76 mm (3 in). Install the hose between the solenoid and the canister pipe and secure using clamps. 8. Attach bulk 5/8" heater hose to the vent port and secure using a clamp. Run a length as needed along the frame rail routing to the area above the transmission. 9. Cut the hose to determined length and install the supplied filter box. Secure using a clamp. 10. Remove the transmission support and lower the transmission assembly as necessary to allow for access to the new filter box location. 11. Secure the filter box to the transmission vent hose just forward of the hose tee-section using a tie strap. DO NOT pinch or restrict the transmission vent hose. The filter box opening should be pointing downward. 12. Raise the transmission and reinstall the transmission support. 13. Connect the EVAP canister vent valve electrical connector. 14. Tie strap the hose as needed along the frame rail in order to keep the hose away from pinch-points and heat sources. 15. Lower the vehicle. Correction (2007-2010 New Style Models) After following the published SI diagnostics and determining that the EVAP canister vent valve is the cause of the MIL light, replace the EVAP canister vent valve assembly and relocate the remote filter box. To ensure correct installation, follow the procedures below. Important DO NOT replace the EVAP canister assembly for this concern unless it fails the leak test. Use Service Kit P/N 19207763 1. Raise the vehicle. Suitably support the vehicle. 2. Disconnect the EVAP canister vent valve electrical connector. Page 1202 Seat Heater Switch: Service and Repair Heated Seat Switch Replacement - Rear HEATED SEAT SWITCH REPLACEMENT - REAR REMOVAL PROCEDURE 1. Remove the center console end panel. 2. Disconnect the electrical connector. 3. Remove the seat heater switch retaining screws. 4. Remove the switch from the vehicle. INSTALLATION PROCEDURE 1. Install the switch to the console panel. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the retaining screw. Tighten Tighten the screws to 1.6 N.m (14 lb in). 3. Connect the electrical connector. 4. Install the center console end panel. Page 10472 8. Separate the wheel drive shaft from the wheel hub and bearing using J 45859 (2) or equivalent. 9. Remove the wheel hub and bearing (1) from the vehicle. Installation Procedure HVAC System - Manual Control Module HVAC: Diagrams HVAC System - Manual HVAC Control Module - C1 Part 1 Page 16141 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors USING CONNECTOR TEST ADAPTERS IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-B Connector Test Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Page 1524 Turn Signal Multifunction Switch - C3 Page 14556 Disclaimer Page 14073 Electrical Symbols Part 13 Description and Operation CD Changer: Description and Operation REMOTE CD CHANGER (CDX) The remote CD changer allows for multiple compact disks to be played continuously without having to manually change compact discs. Normal size discs may be played using the slots supplied in the magazine. The magazine must first be loaded with discs before it can played. To load CDs, insert the CDs from bottom to top, placing the discs in the magazine label side up. If a disc is loaded label side down, the disc will not play and an error will occur. Care should be used to align and insert the disc into one disc tray only. Repeat this procedure for loading all of the discs in the magazine. Once the discs are loaded into the magazine, push the magazine into the changer in the direction of the arrow marked on the magazine. When the CD magazine is loaded, the changer will begin checking for discs in the magazine. This will continue for up to one and a half minutes, depending on the number of discs loaded. To eject the magazine from the player, push the CD changer door. The door will open. Then press the eject button. NOTICE: If the CD magazine fails to eject after the EJECT button has been pressed, do not attempt to pry the magazine from the CD changer. Whenever a CD magazine with discs is loaded in the changer, the CD changer symbol will appear on the radio display. If the CD changer is checking the magazine for CDs, the CD symbol will flash on the display until the changer is ready to play. Fuel Level Sensor Replacement - 1 Fuel Level Sensor: Service and Repair Fuel Level Sensor Replacement - 1 FUEL LEVEL SENSOR REPLACEMENT REMOVAL PROCEDURE 1. Remove the sending unit. 2. Disconnect the fuel pump electrical connector. 3. Remove the fuel lever sensor electrical connector retaining clip. 4. Disconnect the fuel level sensor electrical connector. 5. Remove the fuel level sensor retaining clip. 6. Remove the fuel level sensor (1). INSTALLATION PROCEDURE 1. Install the fuel level sensor (1). 2. Install the fuel level sensor retaining clip. 3. Connect the fuel level sensor electrical connector. 4. Install the fuel lever sensor electrical connector retaining clip. 5. Connect the fuel pump electrical connector. 6. Install the sending unit. Page 12527 With Full Floating 10.5 8. Remove the adjusting nut. 9. Remove the hub from the axle housing. 10. Remove the rotor, if necessary. 11. Remove the oil seal from the wheel hub using a suitable seal removal tool. 12. Remove the inner hub bearing. 13. Remove the inner hub bearing cup using a brass drift and a hammer. Page 877 Electrical Symbols Part 14 Page 4476 Splice Pack - SP207 Page 3922 Accelerator Pedal Position Sensor: Diagrams Accelerator Pedal Position (APP) Sensor Part 1 Quick Connect Fitting(S) Service (Metal Collar) Fuel Line Coupler: Service and Repair Quick Connect Fitting(S) Service (Metal Collar) QUICK CONNECT FITTING(S) SERVICE (METAL COLLAR) TOOLS REQUIRED - J 41769 Fuel Line Quick Disconnect Tool - J 43178 Fuel Line Disconnect Tool REMOVAL PROCEDURE 1. Relieve the fuel system pressure. Refer to Fuel Pressure Relief Procedure. 2. Remove the retainer from the fuel feed line to engine quick-connect fitting. 3. If equipped with the 5.3L (L59) engine, remove the retainers from the fuel feed and return line to engine quick-connect fittings. CAUTION: Wear safety glasses when using compressed air, as flying dirt particles may cause eye injury. Page 7708 Disclaimer Page 14380 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-8 (12085115) crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-8 (12085115) until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes SPLICING INLINE HARNESS DIODES Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate Service Data wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. 9. Tape the diode to the harness or connector using electrical tape. Page 3198 Fuel Pressure Release: Service and Repair Fuel Pressure Relief Procedure FUEL PRESSURE RELIEF PROCEDURE TOOLS REQUIRED J 34730-1A Fuel Pressure Gage CAUTION: Relieve the fuel system pressure before servicing fuel system components in order to reduce the risk of fire and personal injury. After relieving the system pressure, a small amount of fuel may be released when servicing the fuel lines or connections. In order to reduce the chance of personal injury, cover the regulator and the fuel line fittings with a shop towel before disconnecting. This will catch any fuel that may leak out. Place the towel in an approved container when the disconnection is complete. 1. Disconnect the negative battery cable. 2. Install the J 34730-1A. 3. Loosen the fuel fill cap in order to relieve fuel tank vapor pressure. 4. Open the valve on J 34730-1A in order to bleed the system pressure. The fuel connections are now safe for servicing. 5. Drain any fuel remaining in the gage into an approved container. 6. Once the system pressure is completely relieved, remove the J 34730-1A. Page 3578 3. Install the coolant air bleed pipe (2) and gaskets (3) onto the cylinder heads. Notice: Refer to Fastener Notice in Service Precautions. 4. Install the coolant air bleed pipe bolts/studs (1). Tighten the bolts/studs to 12 Nm (106 inch lbs.). 5. Install the coolant air bleed pipe covers (2) and bolts (1). Tighten the bolts to 12 Nm (106 inch lbs.). 6. Fill the cooling system. Page 4482 Electrical Symbols Part 4 Page 11251 Refrigerant Oil: Service and Repair A/C REFRIGERANT SYSTEM OIL CHARGE REPLENISHING If oil was removed from the A/C system during the recovery process or due to component replacement, the oil must be replenished. Oil can be injected into a charged system using J 45037 . For the proper quantities of oil to add to the A/C refrigerant system, refer to Refrigerant System Capacities. Page 15450 Door Latch Assembly (Door Jamb Switch) - Front Passenger - C2 Page 7833 ^ TCC PWM solenoid (5) ^ 3-2 control solenoid (6) 9. Install the 1-2 accumulator. 10. Connect the transmission harness 20-way connector (1) to the transmission pass-through connector. Align the arrows on each half of the connector and insert straight down. 11. Install the transmission filter. Page 974 Interior - Intermittent Seat Heater Operation Seat Heater Control Module: Customer Interest Interior - Intermittent Seat Heater Operation Bulletin No.: 05-08-50-008 Date: August 19, 2005 TECHNICAL Subject: Intermittent Heated Seats Inoperative, DTC B3941 Set (Reprogram Driver Seat Module) Models: 2003-2005 Cadillac Escalade, Escalade ESV, Escalade EXT 2003-2005 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2003-2005 GMC Sierra, Yukon, Yukon XL, Yukon Denali All with Seat FRT, Individual (Non BKT) (RPO AN3) 2003-2005 HUMMER H2 with Seat, Front Bucket Deluxe (RPO AR9) Condition Some customers may comment that occasionally the seat heater will not operate when activated. If the ignition key is cycled OFF and back ON again, the heated seat will operate correctly. Also, on some LB7 diesel engine vehicles, the seat heater may turn itself off during the first 10 minutes of operation. This occurs only with the first activation for the day and works correctly with subsequent activations immediately after the event. These conditions are intermiffent and DTC B3941 may be set. Correction Technicians are to reprogram the driver seat module with an updated software calibration. This new service calibration was released with TIS satellite data update version 6.5 available June 13, 2005. As always, make sure your Tech 2(R) is updated with the latest software version. Warranty Information Drivetrain - Growl/Moan Noise From Front Axle Differential Case: All Technical Service Bulletins Drivetrain - Growl/Moan Noise From Front Axle Bulletin No.: 03-04-19-004B Date: December 12, 2005 TECHNICAL Subject: Growl or Moan Noise Coming From Front Axle (Replace Front Axle Differential Case) Models: 2003-2006 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2003-2006 GMC Sierra, Yukon, Yukon XL with 4WD and Active Transfer Case (RPO NP8) and 8.25 Inch Front Axle Supercede: This bulletin is being revised to update the model years. Please discard Corporate Bulletin Number 03-04-19-004A (Section 04 - Driveline/Axle). Condition Some customers may comment on a growl or moan-type noise coming from the front axle above 50 km/h (30 mph). This condition may be described as a noise that phases or cycles in and out. This noise is present in the 2WD mode only, and may be present whether the vehicle is accelerating, decelerating, or at a steady speed. The noise goes away in 4WD or Auto 4WD modes. Cause This noise may be caused by a low clearance condition within the differential in the front axle assembly. In the 2WD mode, the front differential has a large amount of relative motion between the differential pinion and side gears. In the 4WD or Auto 4WD modes, the transfer case motors the front propeller shaft, and the relative motion between the differential gears is reduced or eliminated, so the noise is eliminated. Correction Replace the front differential case, P/N 26018131. This is the component bolted to the ring gear. It is NOT necessary to replace the differential gears unless unusual wear is observed. Use the procedure listed below. 1. Raise the vehicle. 2. Remove the front engine protection shield. Refer to Engine Protection Shield Replacement in the Frame and Underbody sub-section of the Service Manual. 3. Drain the differential carrier assembly. 4. Disconnect the electrical connector from the actuator and wire harness from the right inner axle shaft housing and differential carrier. 5. Remove the right wheel driveshaft inboard flange bolts from the inner axle shaft. 6. Disconnect the right wheel driveshaft from the inner axle shaft. 7. Remove the inner axle shaft housing nuts from the bracket. 8. Remove the inner axle shaft housing bolts from the differential carrier assembly. 9. Carefully remove the inner axle shaft housing assembly from the differential carrier. 10. Remove the left wheel driveshaft inboard flange bolts from the inner axle shaft. 11. Remove the left inner axle shaft from the differential carrier assembly. 12. Remove the front drive axle clutch shaft from the differential carrier assembly. 13. Remove the differential carrier assembly bolts. Page 13548 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Page 7183 1. Install the shift lever seal and lever. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the shift lever bolts. ^ Tighten the bolts to 20 Nm (15 ft. lbs.). 3. Install the insulator. 4. Raise the transmission. 5. Install the transmission support. 6. Install the control lever and boot. Page 924 Body Control Module: Electrical Diagrams Door Control Module Diagram 1 Fuel System - SES Lamp ON/Gauge Reads Empty/DTC's Set Fuel Tank Vent: Customer Interest Fuel System - SES Lamp ON/Gauge Reads Empty/DTC's Set Bulletin No.: 05-06-04-008A Date: April 14, 2005 TECHNICAL Subject: Diagnostic Trouble Code (DTC) P1172 or P2636, Fuel Gauge Reads Empty, Service Engine Soon (SES) Light On (Relocate Auxiliary Fuel Tank Vent Hose) Models: 2001-2005 Chevrolet Silverado (Cab Chassis Models Only) 2001-2005 GMC Sierra (Cab Chassis Models Only) with Auxiliary Fuel Tank Supercede: This bulletin is being revised to clarify the difference between the auxiliary fuel tank balance hose and vent hose. Please discard Corporate Bulletin Number 05-06-04-008 (Section 06 Engine/Propulsion System). Condition Some customers may comment that the SES light comes on and the fuel gauge reads empty. when This may occur when the vehicle is parked on an incline with the engine running. Diagnosis with a scan tool may reveal a DTC P1172 and/or P2636. Cause Important: A similar condition may occur if the vehicle is fueled with the engine running AND the rear tank is fueled first. The engine must be shut off (as required by law) during vehicle refueling. The auxiliary fuel tank vent hose is located in the same "T" connection on the main tank vent hose as the auxiliary tank balance hose. During fuel transfer, the fuel is pumped out of the auxiliary tank to the main tank via the balance hose. The fuel is then sucked back into the auxiliary tank via the vent hose rather then dumping the fuel into the main tank. When the Powertrain Control Module (PCM) does not detect a fluid level transfer between the main tank and the auxiliary tank, the PCM shuts off the auxiliary tank pump and the fuel gauge goes to empty. Correction Follow the service procedure below to correct this condition. 1. Depending on the body upfitter, it may be necessary to raise the vehicle in order to gain access to the auxiliary tank balance hose. 2. Depending on the body upfitter, it may be necessary to remove the left rear tire/wheel assemblies in order to gain access to the auxiliary tank balance hose. Page 5119 6. Remove the fuel pipe bracket nut. 7. Remove the fuel pipe bracket from the bellhousing stud. 8. Remove the heated oxygen (HO2S) sensor connector from the bracket. 9. Remove the fuel line clips from the brackets on the transmission. 10. Remove the fuel line clip from the bracket on the transfer case, if equipped with 4 wheel drive (4WD). 11. Remove the clip from the bracket on the frame. 12. Remove the transfer case harness from the clip bracket. IMPORTANT: The area around the electro-hydraulic control unit (EHCU) MUST be free from loose dirt to prevent contamination of disassembled anti-lock brake (ABS) components. 13. Thoroughly wash all contaminants from around the EHCU. 14. Disconnect the chassis electrical harness connectors from the electronic brake control module (EBCM). 15. Disconnect the brake lines from the brake pressure modulator valve (BPMV). Service and Repair Maintenance Indicator - A/T: Service and Repair This vehicle does not use a Trans Fluid Life index, and has no monitor to reset. Page 2350 Refer to Fastener Notice in Service Precautions. Install the power steering cooler (1) to the radiator support. ^ Tighten the bolts retaining the power steering cooler to 5 Nm (44 inch lbs.). 2. Install the power steering cooler outlet hose (2) to the power steering pump (1). 3. Install the retaining clamp. 4. Install the power steering inlet hose (3) to the power steering gear (1). 5. Install the retaining clamp. 6. Fill and bleed the power steering system. Refer to Bleeding the Power Steering System. 7. Inspect all the hose connections for leaks. 8. Install the front grille. Refer to Grille Replacement (GMC) Grille Replacement (Chevrolet) in Exterior Trim. 9. Connect the energy storage box after servicing the vehicle. Engine Controls - MIL ON/Misfire/Misfire DTC's Set Ground Strap: All Technical Service Bulletins Engine Controls - MIL ON/Misfire/Misfire DTC's Set Bulletin No.: 06-06-04-046 Date: September 12, 2006 INFORMATION Subject: Information on Engine Misfire MIL/SES Light Illuminated or Flashing DTC P0300, P0301, P0302, P0303, P0304, P0305, P0306, P0307, P0308, P0420 or P0430 Models: 1999-2007 Cadillac, Chevrolet, GMC Full-Size Pickup and/or Utility Trucks with 4.8L, 5.3L, 5.7L, 6.0L or 6.2L VORTEC GEN III, GEN IV, V-8 Engine (VINs V, C, T, Z, B, 3, M, 0, J, R, U, N, Y, K, 8 - RPOs LR4, LY2, LM7, L59, L33, LC9, LH6, LMG, LY5, L31, LQ4, LQ9, L76, LY6, L92) with Active Fuel Management(TM) and E85 Flex Fuel If you encounter vehicles that exhibit the above conditions, refer to SI for the appropriate DTC(s) set. If no trouble is found, the cause may be due to an ECM ground terminal that has corroded with rust over time. Inspect the main engine wiring harness ground terminal (G103) for this condition. The wire terminal (G103) attaches either to the front or to the rear of the right side cylinder head, depending on the model year of the Full Size Pickup and/or Utility Trucks. If the ECM ground terminal has been found to be corroded, then follow the service procedure outlined in this bulletin to correct the corrosion issue. Remove either the nut or bolt securing the main engine wiring harness ground terminal (G103) to the right cylinder head. Refer to the above illustration to determine where the ground is located on the vehicle (1). Page 364 4.1. Unplug the SRS control module's connector (A). 4.2. Cut off the cable tie (B), detach the connector's rear end face (C), and pull out the connecting rail (D). 4.3. Extract pin 15, cut off the cable terminal and insulate the end with tape (E). Fold back the cable and secure it with tape (F). 4.4. Fit the connecting rail and end face. 4.5. Plug in the connector (A) and secure the cables with cable ties (B). 5. Remove the parcel shelf trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6. M03: Replace the optic cable on the right-hand side Page 10755 Disclaimer Page 15165 Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. 1. Disconnect the connector from the component. 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. Discharge Hose Replacement Hose/Line HVAC: Service and Repair Discharge Hose Replacement DISCHARGE HOSE REPLACEMENT TOOLS REQUIRED J 39400-A Halogen Leak Detector REMOVAL PROCEDURE 1. Recover the refrigerant. Refer to Refrigerant Recovery and Recharging. 2. Remove the discharge hose mounting bolt (2) from the A/C compressor. 3. Remove the discharge hose (1) from the A/C compressor. 4. Remove the upper radiator baffle. 5. Remove the discharge hose nut from the condenser. 6. Remove the discharge hose from the condenser. 7. Disconnect the electrical connector from the A/C recirculation switch. 8. Remove the discharge hose from the vehicle. 9. Discard all of the used sealing washers. Cap the system openings. INSTALLATION PROCEDURE Page 10828 Recirculation Actuator Page 8732 8.3. Attempt to start the engine of the vehicle with the discharged battery. 9. Reverse the steps exactly when removing the jumper cables. The negative battery cable must first be disconnected from the engine that was jump started. Page 7945 Park Neutral Position (PNP) Switch C175 AWD/4WD - AWD/4WD Lamps/System Inop./DTC C0550 Control Module: All Technical Service Bulletins AWD/4WD - AWD/4WD Lamps/System Inop./DTC C0550 Bulletin No.: 02-04-21-006E Date: July 20, 2006 TECHNICAL Subject: Inoperative 4WD/AWD Lamps, Inoperative 4WD/AWD System, DTC C0550 Set, No Communication with TCCM (Reprogram Transfer Case Control Module) Models: 2004 Buick Rainier 2002-2004 Chevrolet TrailBlazer, TrailBlazer EXT 2003-2004 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2002-2004 GMC Envoy, Envoy XL 2003-2004 GMC Sierra, Yukon, Yukon XL 2004 GMC Envoy XUV 2002-2004 Oldsmobile Bravada with Electronic Shift or Active Transfer Case (RPOs NP1, NP4 or NP8) Supercede: This bulletin is being revised to add Subject information and change the labor operation. This bulletin cancels and supersedes Bulletin Number 03-04-21-006. Please discard Corporate Bulletin Numbers 02-04-21-006D and 03-04-21-006 (Section 04 - Driveline/Axle). Condition Some customers may comment that the 4WD/AWD indicator lights on the selector switch do not work, or the 4WD/AWD system may be inoperative and/or the service 4WD light is illuminated. The condition is typically intermittent and always occurs at key-up. Upon investigation, the technician may find DTC C0550 set. Cause The Transfer Case Control Module (TCCM) has not received the wake-up call during key-up and has remained in the "sleep mode". When the TCCM is in the "sleep mode", it will not communicate with the class II bus or the Tech 2(R). Correction 1. Try to communicate with the TCCM. If no communication, go to step 2. If communication is possible, go to step 5. 2. Remove the underhood (ATCM or TREC) TCCM fuse. 3. Wait 30 seconds. 4. Reinstall the fuse. The module should wake up and communicate with the Tech 2(R). 5. Check for codes in the TCCM. If a C0550 is found current or in history with or without other codes, replace the module and go to step 6. 6. Reprogram the TCCM with the latest TIS software using normal SPS procedures. 7. Verify operation and that no codes are present. Important: For the 2002 model year, the TCCM must be replaced and reprogrammed. Warranty Information Page 2855 Important The new canister vent valve will be installed in a new location, outside of the frame. 7. Position and secure the new valve assembly to the frame bracket on the outside of the frame using the existing hole and mounting bolt. Tighten Tighten the bracket mounting bolt to 12 Nm (106 lb in). 8. Connect the vent valve pipe to the EVAP canister. 9. Install the two vent valve pipe clips into the existing underbody holes. 10. Connect the EVAP canister vent valve electrical connector, if equipped. 11. Attach bulk 5/8" heater hose to the vent valve port and secure using a clamp. Run a length as needed along the frame rail routing to the area above the transmission. 12. Cut the hose to determined length and install the supplied filter box. Secure using a clamp. 13. Remove the transmission support and lower the transmission assembly as necessary to allow for access to the new filter box location. 14. Secure the filter box to the transmission vent hose just forward of the hose tee-section using a tie strap. DO NOT pinch or restrict the transmission vent hose. The filter box opening should be pointing downward. 15. Raise the transmission and reinstall the transmission support. 16. Tie strap the hose as needed along the frame rail in order to keep the hose away from pinch-points and heat sources. 17. Lower the vehicle. 2004-2007 Model Year (Use Service Kit P/N 19152349) 1. Raise the vehicle. Suitably support the vehicle. 2. Disconnect the EVAP canister vent valve electrical connector. 3. Disconnect the canister pipe from the vent valve. 4. Push in the retainer and remove the existing canister vent valve from the fuel tank clip or mounting bracket. Discard the old valve. 5. Cut back the existing canister pipe approximately 51 mm (2 in) to remove the quick connect end. Crew Cab Short Box Shown Below, Other Configurations Similar With Full Floating 10.5 4. Drive the bearing cup into the wheel hub using the J 44419 (2) and the J 8092 (1). 5. Install the retaining ring into the groove. Make sure the retaining ring is fully and evenly seated in the groove. 6. Install the inner bearing cup. 7. Drive the inner bearing cup into the wheel hub using the J 24427 (2) and the J 8092 (1). Page 11908 1. To receive credit, submit a claim with the information above. Disclaimer 2001 and Older Model Year Vehicles (Except Saab Vehicles) 2001 and Older Model Year Vehicles (Except Saab Vehicles) Important: 2001 and older model year vehicles require the removal of the battery power from the OnStar(R) vehicle interface unit (VIU) to eliminate the possibility of an inadvertent OnStar(R) or emergency/airbag call. 1. Locate and gain access to the OnStar® VIU. Refer to OnStar Vehicle Interface Unit Replacement in SI. Important: Complete removal of the VIU is usually not required. Perform only the steps required to gain access to the C2 32-way blue connector. Residing in the C2 connector are the battery positive (+) circuits. Removal of the C2 connector will deactivate the unit and eliminate the possibility of an inadvertent OnStar(R) or emergency/airbag call. CKP System Variation Learn Procedure Crankshaft Position Sensor: Service and Repair CKP System Variation Learn Procedure CKP SYSTEM VARIATION LEARN PROCEDURE 1. Install a scan tool. 2. Monitor the powertrain control module (PCM) for DTCs with a scan tool. If other DTCs are set, except DTC P0315, refer to Diagnostic Trouble Code (DTC) List for the applicable DTC that set. 3. Select the crankshaft position (CKP) variation learn procedure with a scan tool. 4. The scan tool instructs you to perform the following: 4.1. Accelerate to wide open throttle (WOT). 4.2. Release throttle when fuel cut-off occurs. 4.3. Observe fuel cut-off for applicable engine. 4.4. Engine should not accelerate beyond calibrated RPM value. 4.5. Release throttle immediately if value is exceeded. 4.6. Block drive wheels. 4.7. Set parking brake. 4.8. DO NOT apply brake pedal. 4.9. Cycle ignition from OFF to ON. 4.10. Apply and hold brake pedal. 4.11. Start and idle engine. 4.12. Turn A/C OFF. 4.13. Vehicle must remain in Park or Neutral. 4.14. The scan tool monitors certain component signals to determine if all the conditions are met to continue with the procedure. The scan tool only displays the condition that inhibits the procedure. The scan tool monitors the following components: - CKP sensors activity-If there is a CKP sensor condition, refer to the applicable DTC that set. - Camshaft position (CMP) sensor activity-If there is a CMP sensor condition, refer to the applicable DTC that set. - Engine coolant temperature (ECT)-If the ECT is not warm enough, idle the engine until the engine coolant temperature reaches the correct temperature. 5. Enable the CKP system variation learn procedure with a scan tool. IMPORTANT: While the learn procedure is in progress, release the throttle immediately when the engine starts to decelerate. The engine control is returned to the operator and the engine responds to throttle position after the learn procedure is complete. 6. Accelerate to WOT. 7. Release when the fuel cut-off occurs. 8. Test in progress 9. The scan tool displays Learn Status: Learned this ignition. If the scan tool indicates that DTC P0315 ran and passed, the CKP variation learn procedure is complete. If the scan tool indicates DTC P0315 failed or did not run, refer to DTC P0315. If any other DTCs set, refer to Diagnostic Trouble Code (DTC) List for the applicable DTC that set. 10. Turn OFF the ignition for 30 seconds after the learn procedure is completed successfully. 11. The CKP system variation learn procedure is also required when the following service procedures have been performed, regardless of whether DTC P0315 is set: - A CKP sensor replacement - An engine replacement - A PCM replacement - A harmonic balancer replacement - A crankshaft replacement - Any engine repairs which disturb the CKP sensor relationship Electrical - MIL ON/DTC's Set By Various Control Modules Wiring Harness: Customer Interest Electrical - MIL ON/DTC's Set By Various Control Modules TECHNICAL Bulletin No.: 09-06-03-004D Date: December 08, 2010 Subject: Intermittent No Crank/No Start, No Module Communication, MIL, Warning Lights, Vehicle Messages or DTCs Set by Various Control Modules - Diagnosing and Repairing Fretting Corrosion (Disconnect Affected Connector and Apply Dielectric Lubricant) Models: 2011 and Prior GM Passenger Cars and Trucks Attention: This repair can be applied to ANY electrical connection including, but not limited to: lighting, body electrical, in-line connections, powertrain control sensors, etc. DO NOT over apply lubricant to the point where it prevents the full engagement of sealed connectors. A light coating on the terminal surfaces is sufficient to correct the condition. Supercede: This bulletin is being revised to update the Attention statement and add the 2011 model year. Please discard Corporate Bulletin Number 09-06-03-004C (Section 06 Engine/Propulsion System). Condition Some customers may comment on any of the following conditions: - An intermittent no crank/no start - Intermittent malfunction indicator lamp (MIL) illumination - Intermittent service lamp illumination - Intermittent service message(s) being displayed The technician may determine that he is unable to duplicate the intermittent condition. Cause This condition may be caused by a buildup of nonconductive insulating oxidized debris known as fretting corrosion, occurring between two electrical contact surfaces of the connection or connector. This may be caused by any of the following conditions: - Vibration - Thermal cycling - Poor connection/terminal retention - Micro motion - A connector, component or wiring harness not properly secured resulting in movement On low current signal circuits this condition may cause high resistance, resulting in intermittent connections. On high current power circuits this condition may cause permanent increases in the resistance and may cause a device to become inoperative. Representative List of Control Modules and Components The following is only a representative list of control modules and components that may be affected by this connection or connector condition and DOES NOT include every possible module or component for every vehicle. - Blower Control Module - Body Control Module (BCM) - Communication Interface Module (CIM) - Cooling Fan Control Module - Electronic Brake Control Module (EBCM) - Electronic Brake and Traction Control Module (EBTCM) - Electronic Suspension Control (ESC) Module - Engine Control Module (ECM) - Heating, Ventilation and Air Conditioning (HVAC) Control Module Page 5205 Fuel: Technical Service Bulletins Fuel System - E85 Refueling Station Information Bulletin No.: 06-06-04-030 Date: May 15, 2006 INFORMATION Subject: Locations of E85 Refueling Stations and Expanded E85 Information Models: 2007 and Prior GM Cars and Trucks Equipped for Flexible Fuel (E85) Attention: U.S. dealers - This bulletin should be directed to the Sales Manager as well as the Service Manager. Copies of this bulletin may be given to customers purchasing or considering the purchase of E85 capable vehicles, and may be left or posted in customer waiting areas. Canadian dealers - This bulletin is intended for the U.S. Market and provides only limited information relevant to the Canadian market. Customer Questions, Concerns and Refueling Locations for E85 Fuel Extensive information on E85 Ethanol based fuels can be found at www.livegreengoyellow.com . This General Motors site contains vital information that anticipates and answers customer questions and concerns about E85 fuel. Part of the information is a useful link that provides the location nationally of all E85 refueling stations. Disclaimer Page 5015 supported, only J2534. 1. BEFORE the original IPC is disconnected from the vehicle, record the odometer and engine hour values. 2. Replace the IPC with a replacement part obtained from the ESC. Refer to Instrument Cluster Replacement in SI. 3. Using the TIS2WEB SPS application, select either: J2534 Tech 2 or J2534 MDI, when available and build the vehicle. 4. Select: IPC Setup J2534. 5. After selecting IPC Setup J2534, the user will be prompted to: install the new controller. Ignore this prompt if the new IPC was already installed. This prompt is just to remind the user that this application is only for a new IPC. Important FOR 2003 FULLSIZE TRUCKS, UTILITIES AND H2, THE ENGINE MUST BE STARTED AND RUNNING PRIOR TO ENTERING THE MILEAGE AND ENGINE HOURS. After the odometer value is programmed, the engine must remain running for 6 minutes 15 seconds before the ignition can be turned off. Failure to do so will result in engine hours not being programmed and a new IPC will have to be ordered. 6. Enter the odometer and engine hour values, when applicable. By default the application will be set to miles. For metric units, click the button on the left next to: Kilometers. The IPC odometer and engine hour meter setup procedure is now complete. 7. The IPC calibration files can now be programmed into the IPC. Refer to SPS in SI. Disclaimer Page 13556 Control Module References Part 5 Page 4661 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. REPLACEMENT PROCEDURE After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Insure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the Terminal Removal Procedure. Repairing Connector Terminals REPAIRING CONNECTOR TERMINALS TOOLS REQUIRED J 38125-D Terminal Repair Kit Use the following repair procedures in order to repair the following: - Push to Seat terminals - Pull to Seat terminals - Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-D contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100 World terminals. Soldering Micro-Pack 100 World terminals may damage the terminal. Circuit Protection - Circuit Breakers CIRCUIT PROTECTION - CIRCUIT BREAKERS A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Page 8296 5. Install the caliper guide pin bolts. 6. Notice: Refer to Fastener Notice in Service Precautions. ^ Tighten the caliper guide pin bolts. ^ Tighten the caliper guide pin bolts to 42 Nm (31 ft. lbs.). 7. Remove the rubber cap or plug from the exposed brake hose fitting end. 8. Important: Install 2 new copper brake hose gaskets. Assemble the 2 new copper brake hose gaskets and the brake hose to caliper bolt to the brake hose. 9. Connect the brake hose at the caliper by installing the brake hose to caliper bolt. ^ Tighten the bolt to 40 Nm (30 ft. lbs.). 10. Bleed the hydraulic brake system. 11. Install the tire and wheel assembly. 12. Lower the vehicle. 13. Fill the master cylinder reservoir to the proper level with clean brake fluid. Refer to Master Cylinder Reservoir Filling in Hydraulic Brakes. Brake Caliper Overhaul - Rear Brake Caliper Overhaul - Rear (15 Series) Caution: Refer to Brake Dust Caution in Service Precautions. Caution: Refer to Brake Fluid Irritant Caution in Service Precautions. Disassembly Procedure Important: Page 4746 Engine Control Module: Description and Operation Electronic Ignition (EI) System POWERTRAIN CONTROL MODULE (PCM) The PCM controls all ignition system functions, and constantly corrects the basic spark timing. The PCM monitors information from various sensor inputs that include the following: - The throttle position (TP) sensor - The engine coolant temperature (ECT) sensor - The mass air flow (MAF) sensor - The intake air temperature (IAT) sensor - The vehicle speed sensor (VSS) - The transmission gear position or range information sensors - The engine knock sensors (KS) Page 13566 Body Control Module (BCM) - C4 Part 2 Keyless Entry - Inoperative Keyless Entry Module: All Technical Service Bulletins Keyless Entry - Inoperative Bulletin No.: 04-08-52-005 Date: June 15, 2004 TECHNICAL Subject: Remote Keyless Entry (RKE) System Inoperative (Reprogram Passenger Door Module (PDM)) Models: 2004 Cadillac Escalade, Escalade ESV, Escalade EXT 2004 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2004 GMC Sierra, Yukon, Yukon XL Condition Some customers may comment on any of the following conditions: ^ The RKE key fob does not function. ^ The "Service Tire Pressure Monitoring System" message is displayed, if equipped. ^ The passenger door will not unlock from the passenger's or driver's door switches. ^ The passenger door window is inoperative. Correction Reprogram the PDM with the Tech 2(R). Currently the Tech 2(R) software is not available for the 2004 model year. Engineering is aware of this and are working to release a new service calibration. In the meantime, build the Tech 2(R) as a 2003 model year and perform the reprogram using the procedure listed below. 1. Turn the ignition switch to the ON position. 2. Connect the Tech 2(R) to the vehicle's diagnostic link connector (DLC), power it up and press enter. ^ Select: Diagnostics. ^ Select model year: 2003. ^ Select: Light truck. ^ Select: Body. ^ Select the proper Product line. ^ Select the proper HVAC Type. ^ Select the proper Radio System type. ^ Select: Passenger Door Module. ^ Select: Special Functions. ^ Select: Refresh. Important: You must remove the described fuse in the next step for the "Refresh" program to be performed. If you do not remove the fuse for five seconds, the Tech 2 will continue to display "Test in Progress" and the program will not complete. ^ Remove the PDM fuse for 5 seconds from the fuse center located behind the panel on the left end of the instrument panel. Page 8223 5. Install the rotor by slowly turning the rotor while pushing the rotor towards the axle. 6. If the brake rotor was removed and installed as part of a brake system repair, measure the assembled lateral runout (LRO) of the brake rotor to ensure optimum performance of the disc brakes. Refer to Brake Rotor Assembled Lateral Runout (LRO) Measurement. 7. If the brake rotor assembled LRO measurement exceeds the specification, bring the LRO to within specifications. Refer to Brake Rotor Assembled Lateral Runout (LRO) Correction. 8. Install the brake caliper and the brake caliper mounting bracket as an assembly to the vehicle. 9. Perform the following procedure before installing the 2 brake caliper bracket mounting bolts. 1. Remove all traces of the original adhesive patch. 2. Clean the threads of the bolts with brake parts cleaner or the equivalent and allow to dry. 3. Apply Threadlocker GM P/N 12345493 (Canadian P/N 10953488) to the threads of the bolts. 10. Notice: Refer to Fastener Notice in Service Precautions. Install the brake caliper bracket mounting bolts. ^ Tighten the brake caliper bracket mounting bolts to 200 Nm (148 ft. lbs.). 11. Install the quarter shaft shield. 12. Install the quarter shaft shield nut and the bolt. ^ Tighten the quarter shaft shield nut and the bolt to 25 Nm (18 ft. lbs.). 13. Install the tire and wheel assembly. 14. Lower the vehicle. 15. With the engine OFF gradually apply the brake pedal to approximately 2/3 of it's travel distance. 16. Slowly release the brake pedal. 17. Wait 15 seconds then repeat steps 15-16 until a firm pedal is obtained. This will properly seat the brake caliper pistons and brake pads. Disc Brake Splash Shield Replacement - Front Disc Brake Splash Shield Replacement - Front Page 715 - Proof of ownership at time of repair. - Original paid receipt confirming the amount of unreimbursed repair expense(s) (including Service Contract deductibles), a description of the repair, and the person or entity performing the repair. If the work was done by someone other than a GM dealership, the amount of reimbursement will be limited to the amount that the repair would have cost GM to have it completed by a GM dealership. Courtesy Transportation The General Motors Courtesy Transportation program is intended to minimize customer inconvenience when a vehicle requires a repair that is covered by the New Vehicle Limited Warranties. The availability of courtesy transportation to customers whose vehicles are within the warranty coverage period and involved in a product program is very important in maintaining customer satisfaction. Dealers are to ensure that these customers understand that shuttle service or some other form of courtesy transportation is available and will be provided at no charge. Dealers should refer to the General Motors Service Policies and Procedures Manual for Courtesy Transportation guidelines. Warranty Transaction Information Submit a transaction using the table below. * The amount identified in "Net Item" should represent the dollar amount reimbursed to the customer. Disclaimer Page 2648 Fuse Block - Underhood C2 Part 4 Page 11899 Page 1835 24. From the technicians point of view, the FRONT of the sensor will have: ^ A flush rotor flange cuff (4) ^ A pin hole (2) for the centering pin. Note the location of the pin hole. ^ An alignment mark (3) on the flush rotor flange cuff (4) for installation ^ A foam ring (1) 25. Remove the connector from the sensor. 26. Remove the sensor from the adapter and bearing assembly. 27. To install the sensor, proceed to step 21 in the installation procedure. Installation Procedure 1. Important: If reusing the existing sensor, no centering of the sensor is required. If installing a new sensor, it will come with a pin installed in the sensor. Do not remove the pin until the sensor is seated. 2. From the technicians point of view, the FRONT of the sensor (1) connector will be on your right.From the technicians point of view, the BACK of the sensor (2) connector will be on your left. 3. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install into the adapter and bearing assembly. 4. Install the connector to the sensor. 5. From the technicians point of view, the FRONT of the sensor will have: ^ A foam ring (4) ^ A pin hole (7) for the centering pin. Note the location of the pin hole. ^ A flushed rotor flange cuff (6) ^ An alignment mark (5) for installation 6. From the technicians point of view, the BACK of the sensor will have: ^ Double D flats (1) Page 11831 Technicians are to inspect the HVAC actuator harness for contact with the instrument panel support brace. Repair any damage to the actuator harness wiring and install protective plastic conduit over the harness. Install friction tape over the sharp edge of the instrument panel brace. Clear the diagnostic trouble codes and verify proper HVAC system operation. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 3514 Disclaimer Page 2505 2. For the 9.5 inch and the 10.5 inch axles, remove the rear axle fill plug. 3. For the 11.5 inch axle, remove the fill plug. 4. Remove the rear axle drain plug. 5. Drain the lubricant into a suitable container. 6. Inspect the drain plug for excessive metal particle accumulation. This accumulation is symptomatic of extreme wear. 7. Clean the drain plug. Installation Procedure 1. Notice: Refer to Fastener Notice in Service Precautions. Install the rear axle drain plug. Page 11093 1. Install the blower motor control processor (2) to the HVAC module (1). NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the blower motor control processor retaining screws. Tighten Tighten the screws to 1.6 N.m (14 lb in). 3. Connect the electrical connector (4) to the blower motor control processor (2). 4. Connect the electrical connector at the blower motor. 5. If equipped, install the sound insulator panel. HVAC Control Module Replacement HVAC CONTROL MODULE REPLACEMENT REMOVAL PROCEDURE Page 7579 Page 11393 Solar Sensor: Diagrams Sunload Sensor Page 9761 C306 Infotainment Jumper Harness To Console Harness (With RPO Code Y91) Part 3 Page 14602 Driver Seat (2 Of 2) Service and Repair Front Door Striker: Service and Repair Striker Replacement - Door Removal Procedure Important: If both of the door striker bolts are removed at the same time, the striker backing plate will fall into the body. This will result in additional time to perform the repair. 1. Remove the lower striker bolt. 2. Loosen the upper striker bolt enough in order to rotate the striker and the spacer (if equipped) away from the lower bolt hole. 3. Install the lower striker bolt. Tighten the lower striker bolt sufficiently in order to hold the striker backing plate in place. 4. Remove the upper striker bolt. 5. Remove the spacer, if equipped. 6. Remove the striker. Installation Procedure 1. Install the striker. 2. Install the spacer, if equipped. 3. Install the upper striker bolt. 4. If the striker backing plate has moved, rotate the lower striker bolt until the upper threaded hole is properly aligned. 5. Remove the lower bolt. 6. Rotate the striker and the spacer, (if equipped) in order to align the lower threaded hole in the striker backing plate. Notice: Refer to Fastener Notice in Service Precautions. 7. Tighten the striker bolts. Tighten the door striker bolts to 24 N.m (18 lb ft). Page 5682 6. Remove the 1-2 shift solenoid retainer (395) and the 1-2 shift solenoid (267A). 7. Remove the 2-3 shift solenoid retainer (395) and the 2-3 shift solenoid (367A). 8. Remove the 3-2 control solenoid retainer (395) and the 3-2 control solenoid (394). Installation Procedure 1. Install the 3-2 control solenoid (394) and the 3-2 control solenoid retainer (395). Page 11261 Low Pressure Sensor / Switch: Locations Right Side Of The Engine Compartment Page 6367 17. Remove the oil level indicator tube. 18. Remove the seal from the transmission, if necessary. 19. Remove the oil level indicator tube, if equipped with RPO HP2. 20. Remove the seal from the transmission, if necessary. Installation Procedure Steering - Underhood Clunk Heard/Felt in Steering Wheel Steering Column Bearing: Customer Interest Steering - Underhood Clunk Heard/Felt in Steering Wheel TECHNICAL Bulletin No.: 00-02-35-003N Date: March 26 2008 Subject: Clunking Noise Under Hood and Can Be Felt in Steering Wheel and/or Steering Column (Replace Upper Intermediate Steering Shaft [I-Shaft] Assembly) Models: 2002-2006 Cadillac Escalade Models 1999-2007 Chevrolet Silverado Models (Classic) 2000-2006 Chevrolet Suburban, Tahoe Models 2002-2006 Chevrolet Avalanche 1999-2007 GMC Sierra Models (Classic) 2000-2006 GMC Yukon, Yukon XL Models 2003-2006 HUMMER H2 Attention: This Service Bulletin DOES NOT include Mid-Size Utilities such as Buick Rainier, Chevrolet TrailBlazer Models, GMC Envoy Models or Oldsmobile Bravada. Refer to Service Bulletin 02-02-35-006A or newer for Mid-Size Utilities. Supercede: This bulletin is being revised to add diagnostic information (refer to Diagnostic Tips) to check the lower steering column bearing as a potential source of the noise. Please discard Corporate Bulletin Number 00-02-35-003M (Section 02-Steering). Condition Some customers may comment on a clunk-type noise coming from under the hood that also can be felt in the steering wheel. These conditions may be more noticeable when turning at low speeds on rough road surfaces. Diagnostic Tips Use the information below to help diagnose the source of the noise. ^ The lower steering column bearing may create the same noise as the intermediate shaft. Before replacing the I-shaft, verify the noise isn't being caused by movement from the lower steering column bearing. Check the bearing for movement by pushing up and down on the I-shaft where it attaches to the steering column. ^ Frame Snap and/or Popping Type Noise - A frame snap or popping type noise can be duplicated on rough or smooth road surfaces with steering wheel input to the left or the right. This type of noise can be HEARD and is typically louder with the windows rolled down. For additional information refer to Corporate Bulletin Number 03-08-61-002F or newer - Snap/Popping Type Noise Coming from Front of Vehicle (Remove Front Crossmember Change Fastener Orientation). ^ Intermediate Shaft Clunk - Intermediate shaft clunk is heard and FELT in the steering wheel and/or steering column area typically while driving on rough road surfaces with steering wheel input. Correction Important: ^ I-shaft P/N 19153614 has been designed to replace previous designed dampened and non-dampened I-shafts. The physical difference in the yoke size will accommodate all vehicles listed in this bulletin. ^ Due to the design of the new I-shaft, it is not possible to lubricate/grease the I-shaft. Replace the steering column upper intermediate shaft with an improved design shaft that will eliminate the clunk noise using the procedure listed below. Page 9622 Location View Page 2342 Removal Procedure 1. Disconnect the energy storage box before servicing the vehicle. 2. Install a drain pan under the vehicle. Notice: Refer to Power Steering Hose Disconnected Notice in Service Precautions. 3. Remove the power steering gear inlet hose (4) from the brake booster. 4. Remove the power brake booster outlet hose (3) retaining clamp (2) to remove the power brake booster hose outlet hose from the brake booster. 5. Remove the power brake booster inlet hose (1) from the brake booster. 6. Remove the power steering gear inlet hose (5) from the power steering gear. 7. Remove the power brake booster outlet hose (2) retaining clamp (3) to remove the power brake booster outlet hose from the power steering pump. 8. Remove the power brake booster inlet hose (5) from the power steering pump. 9. Remove the power steering hose assembly from the vehicle. Page 14345 Electrical Symbols Part 5 Page 15778 Door Latch Assembly (Door Jamb Switch) - Front Passenger - C2 Page 7112 Flywheel: Service and Repair Engine Flywheel Replacement Removal Procedure 1. Remove the automatic transmission, if equipped. Important: Note the position and direction of the engine flywheel before removal. 2. Remove the engine flywheel bolts. 3. Remove the automatic transmission engine flywheel, if applicable. 4. Remove the clutch, if equipped with a manual transmission. Important: Note the position and direction of the engine flywheel before removal. 5. Remove the engine flywheel bolts. 6. Remove the manual transmission engine flywheel, if applicable. 7. If required, clean and inspect the engine flywheel. Power Steering Gear Inlet Pipe/Hose Power Steering Line/Hose: Service and Repair Power Steering Gear Inlet Pipe/Hose (Rack and Pinion) Power Steering Gear Inlet Pipe/Hose Replacement (Rack and Pinion) Removal Procedure Notice: Refer to Power Steering Hose Disconnected Notice in Service Precautions. 1. Remove the power steering inlet hose (2) from the power steering pump (1). 2. Remove the power steering inlet hose (2) from the power steering gear (3). Installation Procedure 1. Connect the power steering inlet hose (2) to the power steering gear (3). 2. Notice: Refer to Fastener Notice in Service Precautions. Connect the power steering inlet hose (2) to the power steering pump (1). ^ Tighten the hose connections to 28 Nm (20 ft. lbs.). 3. Bleed the power steering system. Refer to Bleeding the Power Steering System. 4. Inspect all the hose connections for leaks. (With Hydroboost) Power Steering Gear Inlet Pipe/Hose Replacement (With Hydroboost) Removal Procedure Page 4931 1. Coat a NEW O-ring seal with a thin film of Synchro-mesh transmission fluid GM P/N 12345349 (Canadian P/N 10953465), or equivalent. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the VSS and O-ring seal. ^ Tighten the VSS to 16 Nm (12 ft. lbs.). 3. Connect the VSS electrical connector (1). 4. Lower the vehicle. Page 2055 Alignment: Specifications Fastener Tightening Specifications Fastener Tightening Specifications Electrical - Trailer Brakes Apply With Headlamps ON Trailer Lighting Module: All Technical Service Bulletins Electrical - Trailer Brakes Apply With Headlamps ON Bulletin No.: 02-05-22-004C Date: April 05, 2005 TECHNICAL Subject: Trailer Brakes Applied When Headlights/Park Lamps Are On, Brake Controller Illumination (Modify Brake Controller Wiring Harness) Models: 2002-2005 Cadillac Escalade, Escalade EXT 1999-2005 Chevrolet Silverado 2000-2005 Chevrolet Suburban, Tahoe 2002-2005 Chevrolet Avalanche 1999-2005 GMC Sierra 2000-2005 GMC Yukon, Yukon XL 2003-2005 HUMMER H2 Supercede: This bulletin is being revised to add additional model years. Please discard Corporate Bulletin Number 02-05-22-004B (Section 05 - Brakes). Condition Some customers may comment that when the headlamps or park lamps are on, the brakes on the trailer are always applied, or that the back lighting for the trailer brake controller only illuminates when the brakes are applied. Cause The cause of this condition may be due to wiring changes within the vehicle electrical system for the 2003 model year. Correction Inspect the brake controller wiring harness jumper that is plugged into the vehicle relay block-body. The relay block-body is located under the left side of the instrument panel near the left kick panel, behind a plastic cover. Page 1751 Knock Sensor: Description and Operation KNOCK SENSOR (KS) SYSTEM DESCRIPTION PURPOSE The knock sensor (KS) system enables the control module to control the ignition timing for the best possible performance while protecting the engine from potentially damaging levels of detonation. The control module uses the KS system to test for abnormal engine noise that may indicate detonation, also known as spark knock. SENSOR DESCRIPTION This KS system uses one or two broadband one-wire sensors. The sensor uses piezo-electric crystal technology that produces an AC voltage signal of varying amplitude and frequency based on the engine vibration, or noise, level. The amplitude and frequency are dependant upon the level of knock that the KS detects. The control module receives the KS signal through a signal circuit. The KS ground is supplied by the engine block through the sensor housing. One way the control module monitors the system is by output of a bias voltage on the KS signal wire. The bias voltage creates a voltage drop that the control module monitors and uses to help diagnose KS faults. The KS noise signal rides along this bias voltage, and due to the constantly fluctuating frequency and amplitude of the signal, will always be outside of the bias voltage parameters. Another way the control module monitors the system is by learning the average normal noise output from the KS. The control module learns a minimum noise level, or background noise, at idle from the KS and uses calibrated values for the rest of the RPM range. The control module uses the minimum noise level to calculate a noise channel. The control module uses this noise channel, and the KS signal that rides along the noise channel, in much the same way as the bias voltage type does. As engine speed and load change, the noise channel upper and lower parameters will change to accommodate the normal KS signal. In order to determine which cylinders are knocking, the control module only uses KS signal information when each cylinder is near top dead center (TDC) of the firing stroke. If the control module has determined that knock is present, it will retard the ignition timing to attempt to eliminate the knock. The control module will always try to work back to a zero compensation level, or no spark retard. An abnormal KS signal will fall within the noise channel or will not be present. KS diagnostics are calibrated to detect faults with the KS circuitry inside the control module, the KS wiring, or the KS voltage output. Junction Block - I/P Relay Box: Application and ID Junction Block - I/P Location View Location View Engine Controls - Aftermarket Accessory Usage Engine Control Module: All Technical Service Bulletins Engine Controls - Aftermarket Accessory Usage INFORMATION Bulletin No.: 04-06-04-054B Date: November 18, 2010 Subject: Info - Non-GM Parts and Accessories (Aftermarket) Models: 2011 and Prior GM Passenger Cars and Trucks Supercede: This bulletin is being revised to add model years and update to the new U.S. Fixed Operation Manager (FOM) and Canada Warranty Manager (WM) names. Please discard Corporate Bulletin Number 04-06-04-054A (Section 06 - Engine/Propulsion System). The recent rise and expansion of companies selling non-GM parts and accessories has made it necessary to issue this reminder to dealers regarding GM's policy on the use and installation of these aftermarket components. When a dealer is performing a repair under the New Vehicle Limited Warranty, they are required to use only genuine GM or GM-approved parts and accessories. This applies to all warranty repairs, special policy repairs or any repairs paid for by GM. Parts and accessories advertised as being "the same" as parts manufactured by GM, but not sold through GM, do not qualify for use in warranty repairs, special policy repairs or any repairs paid for by GM. During a warranty repair, if a GM original equipment part is not available through GM Customer Care and Aftersales (GM CC&A;), ACDelco(R) distributors, other GM dealers or approved sources, the dealer is to obtain comparable, non-GM parts and clearly indicate, in detail, on the repair order the circumstances surrounding why non-GM parts were used. The dealer must give customers written notice, prior to the sale or service, that such parts or accessories are not marketed or warranted by General Motors. It should also be noted that dealers modifying new vehicles and installing equipment, parts and accessories obtained from sources not authorized by GM are responsible for complying with the National Traffic and Motor Vehicle Safety Act. Certain non-approved parts or assemblies, installed by the dealer or its agent not authorized by GM, may result in a change to the vehicle's design characteristics and may affect the vehicle's ability to conform to federal law. Dealers must fully understand that non-GM approved parts may not have been validated, tested or certified for use. This puts the dealer at risk for potential liability in the event of a part or vehicle failure. If a GM part failure occurs as the result of the installation or use of a non-GM approved part, the warranty will not be honored. A good example of non-authorized modification of vehicles is the result of an ever increasing supply of aftermarket devices available to the customer, which claim to increase the horsepower and torque of the Duramax(TM) Diesel Engines. These include the addition of, but are not limited to one or more of the following modifications: - Propane injection - Nitrous oxide injection - Additional modules (black boxes) that connect to the vehicle wiring systems - Revised engine calibrations downloaded for the engine control module - Calibration modules which connect to the vehicle diagnostic connector - Modification to the engine turbocharger waste gate Although the installation of these devices, or modification of vehicle components, can increase engine horsepower and torque, they may also negatively affect the engine emissions, reliability and/or durability. In addition, other powertrain components, such as transmissions, universal joints, drive shafts, and front/rear axle components, can be stressed beyond design safety limits by the installation of these devices. General Motors does not support or endorse the use of devices or modifications that, when installed, increase the engine horsepower and torque. It is because of these unknown stresses, and the potential to alter reliability, durability and emissions performance, that GM has adopted a policy that prevents any UNAUTHORIZED dealer warranty claim submissions to any remaining warranty coverage, to the powertrain and driveline components whenever the presence of a non-GM (aftermarket) calibration is confirmed - even if the non-GM control module calibration is subsequently removed. Refer to the latest version of Bulletin 09-06-04-026 (V8 Gas Engines) or 06-06-01-007 (Duramax(TM) Diesel Engines) for more information on dealer requirements for calibration verification. These same policies apply as they relate to the use of non-GM accessories. Damage or failure from the use or installation of a non-GM accessory will not be covered under warranty. Failure resulting from the alteration or modification of the vehicle, including the cutting, welding or disconnecting of the vehicle's original equipment parts and components will void the warranty. Additionally, dealers will NOT be reimbursed or compensated by GM in the event of any legal inquiry at either the local, state or federal level that Fuel System - TOP TIER Detergent Gasoline (Canada) Fuel: Technical Service Bulletins Fuel System - TOP TIER Detergent Gasoline (Canada) INFORMATION Bulletin No.: 05-06-04-022G Date: October 27, 2010 Subject: TOP TIER Detergent Gasoline Information and Available Brands (Deposits, Fuel Economy, No Start, Power, Performance, Stall Concerns) - Canada ONLY Models: 2011 and Prior GM Passenger Cars and Trucks (Canada Only) Supercede: This bulletin is being revised to update the model years and include an additional gasoline brand as a TOP TIER source. Please discard Corporate Bulletin Number 05-06-04-022F (Section 06 - Engine/Propulsion System). In the U.S., refer to the latest version of Corporate Bulletin Number 04-06-04-047I. A new class of fuel called TOP TIER Detergent Gasoline is appearing at retail stations of some fuel marketers. This gasoline meets detergency standards developed by six automotive companies. All vehicles will benefit from using TOP TIER Detergent Gasoline over gasoline containing the "Lowest Additive Concentration" recommended by the Canadian General Standards Board (CGSB). Those vehicles that have experienced deposit related concerns may especially benefit from use of TOP TIER Detergent Gasoline. Intake valve: 16,093 km (10,000 mi) with TOP TIER Detergent Gasoline Intake valve: 16,093 km (10,000 mi) with Minimum Additive recommended by the CGSB Top Tier Fuel Availability Chevron was the first to offer TOP TIER Detergent Gasoline in Canada. Shell became the first national gasoline retailer to offer TOP TIER Detergent Gasoline across Canada. Petro-Canada began offering TOP TIER Detergent Gasoline nationally as of October 1, 2006. Sunoco began offering TOP TIER Detergent Gasoline in March of 2007. Esso began offering TOP TIER Detergent Gasoline in May of 2010. Page 15185 Control Module References Part 7 Wheels - Changing Procedures/Precautions Wheels: All Technical Service Bulletins Wheels - Changing Procedures/Precautions INFORMATION Bulletin No.: 06-03-10-010A Date: June 09, 2010 Subject: Information on Proper Wheel Changing Procedures and Cautions Models: 2011 and Prior GM Passenger Cars and Trucks 2010 and Prior HUMMER Models 2005-2009 Saab 9-7X 2005-2009 Saturn Vehicles Attention: Complete wheel changing instructions for each vehicle line can be found under Tire and Wheel Removal and Installation in Service Information (SI). This bulletin is intended to quickly review and reinforce simple but vital procedures to reduce the possibility of achieving low torque during wheel installation. Always refer to SI for wheel lug nut torque specifications and complete jacking instructions for safe wheel changing. Supercede: This bulletin is being revised to include the 2011 model year and update the available special tool list. Please discard Corporate Bulletin Number 06-03-10-010 (Section 03 Suspension). Frequency of Wheel Changes - Marketplace Driven Just a few years ago, the increasing longevity of tires along with greater resistance to punctures had greatly reduced the number of times wheels were removed to basically required tire rotation intervals. Today with the booming business in accessory wheels/special application tires (such as winter tires), consumers are having tire/wheel assemblies removed - replaced - or installed more than ever. With this increased activity, it opens up more of a chance for error on the part of the technician. This bulletin will review a few of the common concerns and mistakes to make yourself aware of. Proper Servicing Starts With the Right Tools The following tools have been made available to assist in proper wheel and tire removal and installation. - J 41013 Rotor Resurfacing Kit (or equivalent) - J 42450-A Wheel Hub Resurfacing Kit (or equivalent) Corroded Surfaces One area of concern is corrosion on the mating surfaces of the wheel to the hub on the vehicle. Excessive corrosion, dirt, rust or debris built up on these surfaces can mimic a properly tightened wheel in the service stall. Once the vehicle is driven, the debris may loosen, grind up or be washed away from water splash. This action may result in clearance at the mating surface of the wheel and an under-torqued condition. Caution Before installing a wheel, remove any buildup on the wheel mounting surface and brake drum or brake disc mounting surface. Installing wheels with poor metal-to-metal contact at the mounting surfaces can cause wheel nuts to loosen. This may cause a wheel to come off when the vehicle is moving, possibly resulting in a loss of control or personal injury. Whenever you remove the tire/wheel assemblies, you must inspect the mating surfaces. If corrosion is found, you should remove the debris with a die grinder equipped with a fine sanding pad, wire brush or cleaning disc. Just remove enough material to assure a clean, smooth mating surface. The J 41013 (or equivalent) can be used to clean the following surfaces: - The hub mounting surface - The brake rotor mounting surface - The wheel mounting surface Use the J 42450-A (or equivalent) to clean around the base of the studs and the hub. Lubricants, Grease and Fluids Locations Engine Oil Pressure (EOP) Sensor And CMP Sensor Locations Ambient Air Temperature Sensor Page 2338 1. Notice: The inlet and outlet hoses must not be twisted during installation. Do not bend or distort the inlet or outlet hoses to make installation easier. Failure to follow these procedures could result in component damage. Route the hose in the same position the hose occupied prior to removal. 2. Install the brake booster outlet hose (1) to the brake booster (2).Position the clamp at the end of the hose. 3. Install the brake booster outlet hose to the power steering pump (4).Position the clamp at the end of the hose. 4. Remove the drain pan from under the vehicle. 5. Bleed the power steering system. Refer to Bleeding the Power Steering System. (Non Rack and Pinion) Power Steering Hose Assembly Replacement (Non Rack and Pinion) Removal Procedure 1. Disconnect the energy storage box before serving the vehicle. 2. Install a drain pan under the vehicle. Notice: Refer to Power Steering Hose Disconnected Notice in Service Precautions. 3. Remove the power steering gear inlet hose (4) from the brake booster. 4. Remove the power brake booster outlet hose (3) retaining clamp (2) to remove the power brake booster hose outlet hose from the brake booster. 5. Remove the power brake booster inlet hose (1) from the brake booster. Page 5944 1. The shift lock control actuator must lock the shift lever clevis when the shift lever clevis is put into the park position. 2. Depress the brake pedal to move the shift lever out of the park position. 3. The actuator will be energized. 4. Readjust the shift lock control actuator if needed. 5. Install the BCM. 6. Enable the SIR system. Page 2936 Important: After drilling the holes, apply the appropriate anti-corrosion primer. Refer to the GM Refinish Material Booklet # 4901 M-D (English) or # 4901-D-F (French) for additional information. 6. Center punch the marked location and drill a 6.35 mm (1/4 in) hole. Install the plastic retainer in the hole (1) of the mud flap. 7. Tighten fastener at the hole (2) location of the mud flap. Tighten Tighten the fastener to 25 N.m (18 lb ft). 8. For vehicles with short box, use the following procedure: 8.1. Push the mud flap to make contact with the rear side of the underbody cross sill and mark the location of the hole (3) of the mud flap. 8.2. Center punch the marked location and drill a 5.159 mm (13/64 in) hole. 8.3. Install the screw. Tighten Tighten the screw to 4 N.m (35 lb in). 8.4. Repeat the above steps for hole locations 4 and 6. 9. For vehicles with long box, use the following procedure: Page 12186 ^ I/O check Any faults detected during the initialization self-test shall generate a DTC. All nodes also continuously perform a self-test while in an active state. DTCs and their associated telltales will set as a result of unprogrammed or unlearned information. DTCs, which are defined for system configuration (e.g. Vehicle Option Content not programmed) do not support the history status bit (set =0). Warning indicator bit is also set, when applicable, while this DTC is present. Action Taken When the DTCs Sets The module suspends all message transmission. The module uses default values for all parameters received on the serial data circuits. The module inhibits the setting of all other communication DTCs. Conditions for Clearing the DTC A current DTC clears when the malfunction is no longer present. A history DTC clears when the module ignition cycle counter reaches the reset threshold of 50, without a repeat of the malfunction. Circuit/System Verification Refer to Data Link References to determine which serial data system is used for a specific module. The DTCs cannot be retrieved with a current status. Diagnosis is accomplished using the following symptom procedures: Scan Tool Does Not Communicate with High Speed GMLAN Device in SI. OR Scan Tool Does Not Communicate with Low Speed GMLAN Device in SI. DTC U1300, U1301, or U1305 Circuit Description Modules connected to the Class 2 serial data circuit monitor for serial data communications during normal vehicle operation. Operating information and commands are exchanged among the modules. In addition to this, Node Alive messages are transmitted by each module on the Class 2 serial data circuit about once every 2 seconds. When the module detects one of the following conditions on the Class 2 serial data circuit for approximately 3 seconds, the setting of all other Class 2 serial communication DTCs is inhibited and a DTC will set. Conditions for Running the DTCs Voltage supplied to the module is in the normal operating voltage range. The vehicle power mode requires serial data communication to occur. Conditions for Setting the DTCs No valid messages are detected on the Class 2 serial data circuit. The voltage level detected on the Class 2 serial data circuit is in one of the following conditions: Page 14739 9. Unclip the seat trim cover from the seat cushion frame. 10. Using a side motion, carefully separate the seat cushion trim cover from the seat cushion pad. Caution: Replace the passenger presence system as a complete assembly to prevent possible injury to the occupant. The bladder, the pressure sensor, the seat cushion, and the control module are assembled and calibrated as a unit. Using only some of the components in the service kit will cause the passenger presence system to operate improperly. 11. If replacing the front passenger seat cushion you must also replace the Inflatable Restraint Passenger Presence System. Refer to Inflatable Restraint Passenger Presence System Replacement - Front in SIR. 12. Remove the pad from the seat cushion frame. 13. Remove the seat cushion heater element, if equipped. Installation Procedure 1. Install the seat cushion heater element, if equipped. 2. Install the Inflatable Restraint Passenger Presence System. 3. Install the seat cushion pad to the seat cushion frame. 4. Using a side motion, carefully pull the seat cushion cover onto the frame pad. 5. Attach the seat trim cover to the seat cushion frame. Page 867 Electrical Symbols Part 3 Page 12172 OnStar(R) Microphone The OnStar(R), or cellular microphone, can be a part of the rearview mirror assembly, or on some vehicle lines, a separate, stand alone unit. In either case, the VCIM supplies approximately 10 volts to the microphone on the cellular microphone signal circuit, and voice data from the user is sent back to the VCIM over the same circuit. A cellular microphone low reference circuit or a drain wire provides a ground for the microphone. Cellular and GPS Antennas The vehicle will be equipped with one of the following types of antennas: ^ Separate, stand-alone cellular and navigation (GPS) antennas. ^ A combination cellular and navigation (GPS) antenna, which brings the functions of both into a single part. ^ A cellular, GPS, and digital radio receiver (DRR) antenna, which also incorporates the functionality of the DRR satellite antenna (XM). The cellular antenna is the component that allows the OnStar(R) system to send and receive data using electromagnetic waves by means of cellular technology. The antenna is connected at the base to a coax cable that plugs directly into the VCIM. The GPS antenna is used to collect the signals of the orbiting GPS satellites. Within the antenna is housed a low noise amplifier that allows for a more broad and precise reception of this data. The antenna is connected at the base to a coax cable that plugs directly into the VCIM. The cable also provides a path for DC current for powering the antenna. The OnStar(R) Call Center also has the capability of communicating with the vehicle during an OnStar(R) call to retrieve the latest GPS location and transmit it to the OnStar(R) Call Center. A history location of the last recorded position of the vehicle is stored in the module and marked as aged, for as long as the module power is not removed. Actual GPS location may take up to 10 minutes to register in the event of a loss of power. Audio System Interface When the OnStar(R) requires audio output, a serial data message is sent to the audio system to mute all radio functions and transmit OnStar(R) originated audio. The OnStar(R) audio is transmitted to the vehicle audio system by a dedicated signal circuit and a low reference circuit. The audio system will mute and an audible ring will be heard though the speakers if the vehicle receives a call with the radio ON. On some vehicles, the HVAC blower speed may be reduced when the OnStar(R) system is active to aid in reducing interior noise. When the system is no longer active, the blower speed will return to its previous setting. OnStar(R) Steering Wheel Controls Some vehicles may have a button on the steering wheel, that when pushed can engage the OnStar(R) system. The button may be a symbol of a face with sound waves, or may say MUTE, or be a symbol of a radio speaker with a slash through it. By engaging the OnStar(R) system with this feature, the user can interact with the system by use of voice commands. A complete list of these commands is supplied in the information provided to the customer. If the information is not available for reference, at any command prompt, the user can say "HELP" and the VCIM will return an audible list of available commands. The steering wheel controls consist of multiple momentary contact switches and a resistor network. The switches and resistor network are arranged so that each switch has a different resistance value. When a switch is pressed, a voltage drop occurs in the resistor network. This produces a specific voltage value unique to the switch selected, to be interpreted by the radio or the body control module (BCM). OnStar(R) Power Moding (DRX or Sleep Cycle) The OnStar(R) system uses a unique sleep cycle to allow the system to receive cellular calls while the ignition is in the OFF position and retained accessory power (RAP) mode has ended. A green status LED on the OnStar(R) keypad normally indicates an active OnStar(R) account. The OnStar(R) system will stay powered up after ignition off for an extended time in order to allow for remote services like door unlock, horn honk, light flash, etcetera to take place as requested by the customer. Power cycle (also referred to as DRX) times vary depending on the generation of the OnStar(R) system. Technicians may identify the OnStar(R) system generation by using a Tech 2 and following this menu path: (Body>VCIM>Module ID Information>Module Information 2) or by accessing www.onstarenrollment.com All Generation 6 digital systems are powered up continuously for 48 hours from ignition OFF. After 48 hours, the Generation 6 systems will enter a 9 minute OFF, 1 minute ON power cycle for an additional 72 hours. At the beginning and end of the 1 minute ON stage, you may or may not experience a short spike of current at the beginning and at the end. This allows for calls from OnStar to be received by the system. After 120 hours from ignition OFF, Interior - Heated Seats Intermittently Inoperative Seat Heater Control Module: All Technical Service Bulletins Interior - Heated Seats Intermittently Inoperative Bulletin No.: 05-08-05-008 Date: August 18, 2005 TECHNICAL Subject: Intermittent Heated Seats Inoperative, DTC B3941 Set (Reprogram Driver Seat Module) Models: 2003-2005 Cadillac Escalade, Escalade ESV, Escalade EXT 2003-2005 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2003-2005 GMC Sierra, Yukon, Yukon XL, Yukon Denali All with Seat FRT, Individual (Non BKT) (RPO AN3) 2003-2005 HUMMER H2 with Seat, Front Bucket Deluxe (RPO AR9) Condition Some customers may comment that occasionally the seat heater will not operate when activated. If the ignition key is cycled OFF and back ON again, the heated seat will operate correctly. Also, on some LB7 diesel engine vehicles, the seat heater may turn itself off during the first 10 minutes of operation. This occurs only with the first activation for the day and works correctly with subsequent activations immediately after the event. These conditions are intermiffent and DTC B3941 may be set. Correction Technicians are to reprogram the driver seat module with an updated software calibration. This new service calibration was released with TIS satellite data update version 6.5 available June 13, 2005. As always, make sure your Tech 2(R) is updated with the latest software version. Warranty Information Disclaimer Page 14235 Memory Positioning Module: Service and Repair Memory Seat Control Module Replacement MEMORY SEAT CONTROL MODULE REPLACEMENT REMOVAL PROCEDURE 1. Remove the seat cushion. 2. Disconnect the upper electrical harness connectors (3). 3. Remove the module (2) retaining screws (1). 4. Slide the module to the right to disengage the lower retainers. 5. Disconnect the lower electrical harness connectors (2). 6. Remove the module from the vehicle. INSTALLATION PROCEDURE Instruments - Service Tire Monitor Message is Displayed Fuse: All Technical Service Bulletins Instruments - Service Tire Monitor Message is Displayed Bulletin No.: 05-08-49-018A Date: May 11, 2006 ADVANCE SERVICE INFORMATION RESOLUTION Subject: EI 05065 - Service Tire Monitor Message Displayed (Pull/Reinstall IPC Fuse or Verify Correct Passenger Door Module (PDM) and Tires) Models: 2004 Chevrolet Silverado 2004 GMC Sierra Supercede: This bulletin is being revised to provide correction action. Please discard Corporate Bulletin Number 05-08-49-018 (Section 08 - Body and Accessories). Condition Some customers may comment that the "SERVICE TIRE MONITOR" message is being displayed on the DIC. Correction DO NOT REPLACE THE INSTRUMENT PANEL CLUSTER. If the DIC is displaying the SERVICE TIRE MONITOR message: 1. Verify if the vehicle has an electronic aftermarket module spliced into the ALDL Class 2 data line (purple wire). 2. If the vehicle HAS an aftermarket module spliced into the Class 2 line, pull the IPC fuse (located underhood) for 25 seconds. Important: Due to the electronic aftermarket module, the SERVICE TIRE MONITOR message may reoccur. 3. Reinstall the IPC fuse. This will clear the SERVICE TIRE MONITOR message from the display. 4. If the vehicle DOES NOT have an aftermarket module spliced into the Class 2 line, verify the vehicle is equipped with the correct PDM (Passenger Door Module) and tires. Warrant Information This repair is not covered under the vehicle warranty due to the installation of an aftermarket module. Disclaimer Page 15008 Page 12810 Page 16044 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves SPLICING COPPER WIRE USING SPLICE SLEEVES TOOLS REQUIRED J 38125-D Terminal Repair Kit IMPORTANT: Use only GM splice sleeves, other splice sleeves may not protect the splice from moisture or a provide good electrical connection. Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. Page 13519 Electrical Symbols Part 10 Page 10725 Disclaimer Page 12443 Page 12815 Page 4137 Accelerator Pedal Position (APP) Sensor Part 2 Page 12441 Recall - Aftermarket Leather Seat Cover Kit Technical Service Bulletin # 06102B Date: 071019 Recall - Aftermarket Leather Seat Cover Kit Subject: Product Safety - Aftermarket Leather Seat Cover Kits # 06102B - (10/19/2007) 2005-2006 Buick LaCrosse, Rendezvous 2004 Chevrolet Silverado 2005 Chevrolet Tahoe 2005-2006 Chevrolet TrailBlazer, TrailBlazer EXT 2006 Chevrolet HHR, Malibu 2005 GMC Sierra 2005-2006 GMC Envoy 2006 GMC Envoy XL 2006 HUMMER H3 2005 Pontiac Montana 2006 Pontiac G6 The telephone number for contacting General Motors has been changed. To assist customers with initiating the vehicle repurchase process, dealers should contact the GM Reacquired Vehicle Disclosure Center (RVDC). With dealer assistance, the RVDC will work with the customer to reach an agreement on the purchase and physical transfer of the vehicle. Condition General Motors has decided that a defect that relates to motor vehicle safety exists in aftermarket front passenger leather cover kits that were installed at its request on certain vehicles with the Passenger Sensing System. Recently, testing on these seat covers indicated that they can cause the Passenger Sensing system to malfunction. If the Passenger Sensing System malfunctions, the front airbag on the passenger side may be disabled when it should be enabled, or enabled when it should be disabled. In either case, in the event of a crash that requires airbag deployment, a front passenger's level of injury may be increased. The airbag status indicator displays the status of the airbag. Whenever the front passenger seat is occupied, the driver should always check the airbag indicator to see if the airbag is on or off as explained in the owner manual. If it is not correct for the situation, the passenger should be moved to a different seat. Correction Because a replacement leather seat cover that is compatible with the Passenger Sensing System is not available, General Motors will repurchase the vehicle for the full price the customer paid for it (not exceeding the fair market value at the time the customer purchased it), including taxes and fees, if the vehicle is returned to General Motor's possession by January 31, 2007. There will be no deductions for mileage or use unless the vehicle has sustained substantial damage beyond normal wear and tear. General Motors reserves the right to handle each transaction on a case-by-case basis relative to the application of a reasonable depreciation allowance for mileage or use and/or reduction in repurchase price if the vehicle has sustained substantial damage beyond normal wear and tear. General Motors will also pay for the removal of any aftermarket accessories the customer may have installed before they were notified of this recall and return them to the customer. If they no longer have a use for those accessories or they cannot be removed, General Motors will reimburse the customer for the purchase price of those accessories. The customer's local GM dealer will contact General Motors to begin the repurchase process. General Motors will work with the customer to reach an agreement on the purchase of the vehicle. Dealers will be asked by General Motors to assist in the removal of any aftermarket accessories, inspection of the vehicle, obtaining titles and other documentation required to transfer ownership to General Motors, presenting the customer with a check for the purchase, and taking possession of the vehicle. General Motors will arrange for transportation of the vehicle from the dealer. If any of these vehicles are in the used car inventory of your dealership or were sold by you, or a customer brings in an involved vehicle for service, please contact the GM Reacquired Vehicle Disclosure Center (RVCD). If any of these vehicles are in the used car inventory of your dealership or were sold by you, please contact General Motors. Recall - 2nd Row Center Seat Belt Loop Modification Technical Service Bulletin # 05037 Date: 050714 Recall - 2nd Row Center Seat Belt Loop Modification Second Row Center Safety Belt # 05037 - (Jul 14, 2005) Models: 2003-2005 CADILLAC ESCALADE, ESCALADE ESV, ESCALADE EXT 2003-2005 CHEVROLET AVALANCIE, SILVERADO CREW CAB, SUBURBAN, TAHOE 2003-2005 GMC SIERRA CREW CAB, YUKON, YUKON XL 2004-2005 HUMMER H2 Condition General Motors has decided that a defect, which relates to motor vehicle safety, exists in certain 2003-2005 Cadillac Escalade, Escalade ESV, Escalade EXT; Chevrolet Avalanche, Silverado Crew Cab, Suburban, Tahoe; GMC Sierra Crew Cab, Yukon, Yukon XL; and 2004-2005 HUMMER H2 vehicles. On these vehicles, the seat loop in the second row center seating position may make it difficult to position the lap portion of the safety belt low around the hips of the occupant. In the event of a vehicle accident, if the lap portion of the safety belt routing is not low and snug on the hips, it may not properly restrain the occupant and could increase the risk of abdominal injury. Correction Dealers are to eliminate the seat loop by removing the safety belt from the loop and stitching the loop closed. Vehicles Involved Page 6906 5. Install the convolute retainer tool over the inboard joint seal, being sure to capture the following convolutions: ^ 2-5 for the 1500 model (except 1500 HD) ^ 2-4 for the 1500 HD, 2500, 3500, and Hummer H2 models. Important: Assemble the tripot joint with the convolute retainer in the correct position, as illustrated. Page 2499 Installation Procedure 1. Install the drain plug. ^ Tighten the drain plug to 33 Nm (24 ft. lbs.). Notice: Refer to Fastener Notice in Service Precautions. 2. Fill the differential carrier assembly with axle lubricant. Use the correct fluid. 3. Install the fill plug. ^ Tighten the fill plug to 33 Nm (24 ft. lbs.). 4. Install the front differential carrier shield, if equipped. 5. Lower the vehicle. Page 5592 Knock Sensor: Description and Operation KNOCK SENSOR (KS) SYSTEM DESCRIPTION PURPOSE The knock sensor (KS) system enables the control module to control the ignition timing for the best possible performance while protecting the engine from potentially damaging levels of detonation. The control module uses the KS system to test for abnormal engine noise that may indicate detonation, also known as spark knock. SENSOR DESCRIPTION This KS system uses one or two broadband one-wire sensors. The sensor uses piezo-electric crystal technology that produces an AC voltage signal of varying amplitude and frequency based on the engine vibration, or noise, level. The amplitude and frequency are dependant upon the level of knock that the KS detects. The control module receives the KS signal through a signal circuit. The KS ground is supplied by the engine block through the sensor housing. One way the control module monitors the system is by output of a bias voltage on the KS signal wire. The bias voltage creates a voltage drop that the control module monitors and uses to help diagnose KS faults. The KS noise signal rides along this bias voltage, and due to the constantly fluctuating frequency and amplitude of the signal, will always be outside of the bias voltage parameters. Another way the control module monitors the system is by learning the average normal noise output from the KS. The control module learns a minimum noise level, or background noise, at idle from the KS and uses calibrated values for the rest of the RPM range. The control module uses the minimum noise level to calculate a noise channel. The control module uses this noise channel, and the KS signal that rides along the noise channel, in much the same way as the bias voltage type does. As engine speed and load change, the noise channel upper and lower parameters will change to accommodate the normal KS signal. In order to determine which cylinders are knocking, the control module only uses KS signal information when each cylinder is near top dead center (TDC) of the firing stroke. If the control module has determined that knock is present, it will retard the ignition timing to attempt to eliminate the knock. The control module will always try to work back to a zero compensation level, or no spark retard. An abnormal KS signal will fall within the noise channel or will not be present. KS diagnostics are calibrated to detect faults with the KS circuitry inside the control module, the KS wiring, or the KS voltage output. Page 7245 - Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-D in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-D if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Tire Monitor System - TPM Sensor Information Tire Pressure Monitor Receiver / Transponder: Technical Service Bulletins Tire Monitor System TPM Sensor Information INFORMATION Bulletin No.: 08-03-16-003 Date: May 12, 2008 Subject: Warranty Reduction - Transfer of Tire Pressure Monitoring (TPM) Sensors to Replacement Wheels and Allowable TPM Sensor Replacements Models: 2000-2009 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2009 HUMMER H2 2006-2009 HUMMER H3 2005-2009 Saab 9-7x with On-Wheel TPM Sensors TPM Sensor / Wheel Warranty Reviews During the last warranty review period it was noted that wheels being returned under the GM New Vehicle Warranty were being shipped back to General Motors with the TPM sensor still attached to the wheel. Return rates ran as high as 60% with the TPM sensors still attached. Operational TPM sensors should not be returned to GM and are to be transferred to replacement wheels if they become necessary. Important: Operational TPM Sensors that are returned under warranty to General Motors will be charged back to the dealer.Sensors have a 10 year /150,000 mile (240,000 km) battery life, and should be transferred if one or more wheels are replaced. TPM Valve Stem / Grommet (0-ring) Replacement When the TPM sensors are transferred to new wheels you should replace the component used to seal the TPM sensor stem to the wheel. On sensors with an aluminum stem and visible nut on the outside of the wheel a replacement grommet (0-ring) should be used to assure a proper seal. The sensor retaining nut (except Aveo) should be tightened to 7 N.m (62 lb in) for all vehicles except Pontiac Vibe (4.0 N.m (35.4 lb in)). Important: ^ DO NOT overtorque the retaining nut. Notice: ^ Factory installed TPM Sensors come with plastic aluminum or nickel-plated brass stem caps. These caps should not be changed. Chrome plated steel caps may cause corrosion of aluminum valve stems due to incompatibility of the metals. On current style sensors the entire rubber stem is replaceable. The service interval on the revised TPM sensor with replaceable stem is the same as for any other traditional valve stem. Replace the stem at the time of tire replacement sensor transfer or whenever air seepage is suspected at the valve stem. When replacing the valve stem tighten the screw to 1.3 N.m (11.5 lb in). For either style of TPM sensor see the service parts guide for the correct GM part numbers to order and use. Disclaimer Page 8758 22. If equipped with a 8.1L engine, remove the starter lead nut. 23. Remove the positive cable from the starter. 24. Remove the positive cable clip nut. 25. Remove the positive cable from the engine harness clip. 26. Remove the positive battery cable. INSTALLATION PROCEDURE 1. If equipped with a 8.1L engine, install the positive battery cable. 2. install the positive cable to the engine harness clip. NOTE: Refer to Fastener Notice in Service Precautions. 3. Install the positive cable clip nut. Tighten Tighten the nut to 8 N.m (71 lb in). 4. Install the positive cable to the starter. 5. Install the starter lead nut. Tighten Tighten the starter lead nut to 9 N.m (80 lb in). Page 7258 Power Take-Off: Connector Views Power Take Off (PTO) Relay Page 3902 Fuel Pump (FP) Relay-Secondary (w/Dual Tanks) Page 15164 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Micro-Pack 100W Connectors MICRO-PACK 100W CONNECTORS TOOLS REQUIRED J 38125-D Terminal Repair Kit REMOVAL PROCEDURE There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2)has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. IMPORTANT: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Page 2287 Heater Hose: Service and Repair Heater Hose Replacement - Inlet (With RPO Code HP2 Front) HEATER HOSE REPLACEMENT - INLET (W/ HP2 FRONT) REMOVAL PROCEDURE 1. Drain the cooling system. Refer to Draining and Filling Cooling System (with HP2)Draining and Filling Cooling System (without HP2) in Cooling System. 2. Loosen the air cleaner outlet duct clamps at the following locations: - Throttle body - Mass airflow/intake air temperature (MAF/IAT) sensor 3. Remove the radiator inlet hose clip from the outlet duct. 4. Remove the air cleaner outlet duct. 5. Reposition the inlet heater hose clamp from the engine. 6. Remove the inlet heater hose from the engine. Page 5657 ^ The reverse boost valve bushing ^ A new reverse boost valve ^ A new pressure regulator spring retainer ^ The added isolator pressure regulator spring ^ The pressure regulator spring 3. Install the pre-assembled parts into the pump bore. 4. Install the reverse boost valve bushing retainer ring while holding the reverse boost valve bushing in place. Ensure the retainer ring (2) is in the groove. 5. Install the transmission filter. 6. Fill the transmission to the proper level with Dexron® III transmission fluid. Page 4578 1. Apply sealant GM P/N 12346004, (Canadian P/N 10953480), or equivalent, to the threads of the oil pressure sensor. Notice: Refer to Fastener Notice in Service Precautions. 2. Using J 41712 or equivalent, install the oil pressure sensor. ^ Tighten the oil pressure sensor to 30 Nm (22 ft. lbs.). 3. Connect the oil pressure sensor electrical connector (1). 4. If necessary, install the engine sight shield. Page 8442 1. Install the park brake warning lamp switch. 2. Notice: Refer to Fastener Notice in Service Precautions. Install the park brake warning lamp switch mounting bolt. ^ Tighten the bolt to 3 Nm (25 inch lbs.). 3. Connect the park brake warning lamp switch electrical connector. 4. Install the MID-bussed electrical center to the bracket. 5. Connect the negative battery cable. Page 4865 Oxygen Sensor: Service and Repair Heated Oxygen Sensor (HO2S) Replacement Bank 2 Sensor 2 HEATED OXYGEN SENSOR (HO2S) REPLACEMENT BANK 2 SENSOR 2 REMOVAL PROCEDURE 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. Disconnect the connector position assurance (CPA) retainer. NOTE: Refer to Heated Oxygen and Oxygen Sensor Notice in Service Precautions. 3. Remove the heated oxygen sensor (HO2S) connector clip from the frame. 4. If equipped with a 4.8L or 5.3L engine, disconnect the HO2S electrical connector. Page 12608 ^ On 2002 Sevilles and DeVilles, the GPS jumper cable MUST be unclipped from the back seat cross brace, or unplugged from the VCIM first. DO NOT pull back on the mounting bracket until the GPS antenna jumper cable is unclipped from the back seat cross brace or unplugged from the VCIM. The short length of jumper cable does not allow the VCIM mounting bracket to be pulled back very far, and could lead to a break at the VCIM connector. ^ On 2000-2002 Bonnevilles and LeSabres and 2001-2002 Auroras you will need to follow these steps: 1. Remove the 4 nuts that secure the VCU/VIU bracket assembly to the rear seat back brace. Note: Save these nuts for later use. 2. Remove and discard the plastic VCU/VIU bracket assembly from the vehicle. 3. Remove the upper right stud (1) from the rear seat back brace and re-install in the middle lower slot (2) on the brace. Tighten the fastener to 4 Nm (36 lb in). 4. Position the new VCIM in the vehicle over the studs on the rear seat back brace. 5. Install two of the nuts saved from step (1). Tighten the nuts to 4 Nm (36 lb in). 6. Connect the new OnStar jumper harness supplied in the kit to the VCIM (two white connectors) and the body wiring harness (C345 connector). 7. Connect the small coaxial jumper cable supplied in the kit, to the VCIM, with the end that has a blue plastic housing connector. Plug the other end of this coaxial jumper cable to the OnStar Global Positioning Satellite (GPS) antenna coaxial cable at the right angle connector. Note: The GPS cable in the new OnStar jumper harness is not utilized. 8. Connect the cellular coaxial cable to the OnStar VCIM. On 2001 Impala and Monte Carlos you will need to follow these steps: 9. Remove the Vehicle Communications Unit (VCU) and Vehicle Interface Unit (VIU) following the procedures listed in SI. Save the bracket nuts for later use. Page 12173 these systems will then completely power OFF. OnStar(R) Module Expected Current Draw The expected current draw of the OnStar(R) module in various ignition modes are as follows: ^ Ignition ON ‐ 240 to 400 mA ^ Ignition OFF ‐ 3 to 20 mA for 48 hours ^ Ignition OFF ‐ 0.2 to 0.8 mA after 48 hours (120 hours on specified vehicle communication platforms (VCPs)). Note During extended voltage testing for battery parasitic draw, it is possible to observe a voltage spike caused by the following: ^ A cellular registration call that was triggered by the local cellular system. ^ The OnStar(R) system has set a monthly trigger for a vehicle data upload call for the OnStar(R) Vehicle Diagnostic E‐mail upload. OnStar(R) System States of Readiness The OnStar(R) system will use the following 4 states of readiness, depending upon the type of cellular market the vehicle is in when the ignition is turned OFF. ^ High power ^ Low power ^ Sleep ^ Digital standby The high power state is in effect whenever the ignition is in the ON or RUN position, retained accessory power (RAP) is enabled, and/or the OnStar(R) system is sending or receiving calls or when the system is performing a remote function. The low power state is in effect when the OnStar(R) system is idle with the ignition in the ON or RUN position, or with RAP enabled. The sleep state is entered after the vehicle has been shut OFF and the RAP has timed out. At a predetermined time recorded within the VCIM, the system re-enters the low power state to listen for a call from the OnStar(R) Call Center for 1 minute. After this interval, the system will again return to the sleep state for 9 minutes. If a call is sent during the 1 minute interval, the OnStar(R) system will receive the call and immediately go into the high power mode to perform any requested functions. If a call is not received during the 1 minute interval, the system will go back into the sleep mode for another 9 minutes. This process will continue for up to 48 hours, after which the OnStar(R) system will turn OFF until the ignition is turned to the ON or RUN position. The digital standby power state is entered after the vehicle has been shut off and the RAP has timed out while in a digital cellular area. When in digital standby mode, the OnStar(R) module is able to perform all remote functions as commanded by an OnStar(R) advisor at any time, for a continuous 48 hours. After 48 hours, the OnStar(R) module will go into sleep mode until a wake up signal from the vehicle is seen by the CIM. If the OnStar module loses the digital cellular signal it will revert to analog mode and follow the standard sleep state (9 minutes OFF, 1 minute standby) based on the time of the GPS signals, this will continue until a digital cellular signal is again received. If the OnStar(R) system loses battery power while the system is in a standby or sleep mode, the system will remain OFF until battery power is restored and the ignition is turned to the ON or RUN position. Deactivated OnStar(R) Accounts In the event that a customer has not upgraded their vehicle to a digital system, the account has been deactivated. The customers have been previously notified of the steps required to upgrade their vehicles. After the OnStar(R) account has been deactivated, customers will experience the following: ^ The OnStar(R) status LED will not illuminate ^ The OnStar(R) system will NOT attempt to connect to the OnStar(R) Call Center in the event of a collision or if the vehicle's front air bags deploy for any other reason. ^ An emergency button press will result in a demo message being played, indicating the service has been deactivated and needs to be upgraded. Page 485 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly, Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Pull to Seat Connectors PULL TO SEAT CONNECTORS TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. SRS - Air Bag Lamp ON/DTC B0092 Set Seat Occupant Sensor: All Technical Service Bulletins SRS - Air Bag Lamp ON/DTC B0092 Set Bulletin No.: 02-09-41-002A Date: March 24, 2004 TECHNICAL Subject: Air Bag Lamp On, Passenger Air Bag Indicator Always Reads OFF, DTC B0092 Set (Repair Passenger Presence System (PPS) Sensor Harness) Models: 2003-2004 Cadillac Escalade, Escalade EXT 2003-2004 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2003-2004 GMC Sierra, Yukon, Yukon XL with Sensor Indicator Inflatable Restraint Front Passenger/Child Presence Detector (RPO ALO) Supercede: This bulletin is being revised to add the 2004 model year. Please discard Corporate Bulletin Number 02-09-41-002 (Section 09 - Restraints). Condition Some customers may comment that the Air Bag Lamp is on and the Passenger Air Bag indicator always reads OFF. Upon investigation, the technician may find DTC B0092 set. Cause The cause of this condition may be a shorted Passenger Presence System (PPS) sensor wire. The PPS sensor harness is located under the front passenger seat. This harness may be pinched between the seat frame and the track/riser. Correction Locate the PPS sensor (1) and inspect the harness for proper routing. If the harness is pinched between the seat frame and the track/riser, use the procedure listed below to repair wire(s). 1. Move the front passenger seat to the full rearward and full tilt up position. 2. Loosen the seat frame to track/riser nut and remove the harness. 3. Tighten the seat frame to track/riser nut. 4. Repair any damaged wires. Refer to Wiring Repairs in the Wiring Systems sub-section of the Service Manual. Warranty Information Capacity Specifications Refrigerant Oil: Capacity Specifications REFRIGERANT OIL CAPACITIES ACCUMULATOR REPLACEMENT NOTE: Add 60 ml (2 oz) of PAG oil, plus the equal amount of oil drained from the accumulator. COMPRESSOR REPLACEMENT ......................................................................................................................................................... 60 ml (2.0 oz) NOTE:The Denso replacement compressor is precharged with 237 ml (8.0 oz) of PAG oil. CONDENSER REPLACEMENT ............................................................................................................................................................ 30 ml (1.0 oz) EVAPORATOR REPLACEMENT ......................................................................................................................................................... 90 ml (3.0 oz) NOTE: If more than the specified amount of PAG oil was drained from a component, add the equal amount drained. TOTAL SYSTEM PAG OIL CAPACITY ............................................................................................................................................ 240 ml (8.0 oz) Page 3041 Wheels: Service and Repair Tire and Wheel Removal and Installation Tire and Wheel Removal and Installation ^ Tools Required J 39544-KIT Complete Torque Socket Set Caution: If penetrating oil gets on the vertical surfaces between the wheel and the rotor or drum it could cause the wheel to work loose as the vehicle is driven, resulting in loss of control and an injury accident. Notice: Never use heat to loosen a tight wheel. It can shorten the life of the wheel, studs, or hub and bearing assemblies. Wheel nuts must be tightened in sequence and to the specified torque to avoid bending the wheel or rotor. Notice: Improperly tightened wheel nuts can lead to brake pulsation and rotor damage. In order to avoid expensive brake repairs, evenly tighten the wheel nuts to the proper torque specification. Important: Removing wheels can be difficult because of foreign material or a tight fit between the wheel center hole and the hub or rotor. Excessive force, such as hammering on the wheel or tire, can cause damage. Slightly tapping the tire side wall with a rubber mallet is acceptable. 1. ^ Tighten all wheel nuts on the affected wheel. 2. Loosen each wheel nut 2 turns. 3. Rock the vehicle from side to side in order to loosen the wheel. If this does not loosen the wheel, rock the vehicle front to back applying quick hard jabs to the brake pedal to loosen the wheel. 4. Repeat this procedure if the wheel does not break free. Removal Procedure 1. Raise the vehicle. Support the vehicle with suitable safety stands. Refer to Vehicle Lifting. 2. Remove the wheel center cap. 3. Remove the wheel nuts from the tire and wheel. 4. Mark the location of the tire and wheel to the hub assembly. 5. Remove the tire and wheel from the vehicle. 6. Clean the wheel nuts, studs and the wheel and rotor mounting surfaces. Installation Procedure Caution: Before installing the wheels, remove any buildup of corrosion on the wheel mounting surface and brake drum or disc mounting surface by scraping and wire brushing. Installing wheels with poor metal-to-metal contact at the mounting surfaces can cause wheel nuts to loosen. This can cause a wheel to come off when the vehicle is moving, causing loss of control and possibly personal injury. Notice: A torque wrench or J 39544 must be used to ensure that wheel nuts are tightened to specification. Never use lubricants or penetrating fluids on wheel stud, nuts, or mounting surfaces, as this can raise the actual torque on the nut without a corresponding torque reading on the torque wrench. Wheel nuts, studs, and mounting surfaces must be clean and dry. Failure to follow these instructions could result in wheel, nut, and/or stud damage. Page 5888 For vehicles repaired under warranty, use the table. Disclaimer Page 13552 Control Module References Part 1 Page 15141 Electrical Symbols Part 4 Page 14799 4. Press the button a second time, 2 light bars will glow indicating the MEDIUM temperature setting for the entire seat. 5. Press the button a third time, 1 light bar will glow indicating the LOW temperature setting for the entire seat. 6. Press the button a fourth time to turn the entire heated seat OFF. 7. To heat ONLY the seat back, press the vertical (LH) button one time. ^ An ON/OFF indicator light over the heated seat back symbol will glow to designate that ONLY the seat back is being heated. ^ All 3 light bars over the horizontal (RH) button will glow indicating the HIGH temperature setting for ONLY the seat back. 8. Press the button a second time, 2 light bars will glow indicating the MEDIUM temperature setting for ONLY the seat back. 9. Press the button a third time, 1 light bar will glow indicating the LOW temperature setting for ONLY the seat back. 10. Press the button a fourth time to turn the heated seat back OFF. Switch Diagnostics Important: In order to eliminate unnecessary part replacement and comeback repairs, it is essential that the appropriate diagnostic tables and aids found in the applicable manuals are followed. 1. Verify the condition prior to making any repairs. Refer to Seats and Seat Controls in the applicable Owners Manual or this bulletin for proper heated seat switch operation information. 2. If an improperly operating front heated seat condition exists, refer to the Diagnostic Information and Procedures in the Seats sub-section of the applicable Service Manual in order to diagnose the system accurately. 3. When measuring the resistance of the seat heater elements, ensure the values are within the updated range of 1.5-5.5 ohms. Refer to DTC B2425 or B2430-Clearing the DTC in the Diagnostic Information and Procedures in the Seats sub-section of the applicable Service Manual. Customer Information Some heated seat components from the above listed vehicles have been returned to the Warranty Parts Center (WPC) for heat function not operating properly. Analyses of these parts show 'no out of specification condition' or No Trouble Found (NTF). 1. Provide customers with the knowledge that if bumped, either one of the heated seat switches can be activated/deactivated accidentally. 2. Ensure customers have a thorough understanding of how the heated seat switches function. Disclaimer Page 4062 Important The M6 conductive rivet stud as shown, can accommodate a panel thickness range of 0.7-4.2 mm (0.03-0.17 in). If there are layers of sheet metal, they should be touching without any air gaps to ensure a good ground. 5. Select a M6 conductive rivet stud. Refer to the Parts Information section of this bulletin. Note Use the GE-50317 rivet stud tool kit. 6. Place the M6 conductive rivet stud (1) in the 10 mm (0.40 in) hole. Assemble the rivet stud tool (2) with the groove and flare side facing the rivet stud, then the washer and the M6 nut (3). 7. Using a wrench on the rivet stud tool, and a socket on the M6 nut, secure the M6 conductive rivet stud. 8. Ensure the rivet stud is securely fastened, WITHOUT ANY detectable movement. 9. Completely wrap the threads of the rivet stud with painters tape or equivalent. Note The rivet stud and surrounding panel area MUST BE properly refinished PRIOR to the installation of the ground wire terminal and conductive nut to maintain a secure, stable and corrosion-free electrical ground. 10. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 11. Allow the refinished repair area to cure sufficiently before removing the protective material applied to the rivet stud threads. 12. Remove the painters tape or equivalent from the rivet stud threads. 13. Using GM approved residue-free solvent or equivalent, thoroughly clean the rivet stud threads to remove any adhesive and allow to dry. 14. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive rivet stud. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. Page 16097 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves SPLICING COPPER WIRE USING SPLICE SLEEVES TOOLS REQUIRED J 38125-D Terminal Repair Kit IMPORTANT: Use only GM splice sleeves, other splice sleeves may not protect the splice from moisture or a provide good electrical connection. Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. Page 574 Disclaimer Page 6048 Page 4824 Manifold Absolute Pressure (MAP) Sensor Page 915 Body Control Module (BCM) - C2 Part 2 Page 11300 The new calibrations have been updated to compensate for the actuator overtravel condition, the actuator hunting and the ticking/clicking noises. The new calibrations effectively eliminate the codes listed above, the default position of the doors associated with the DTCs and opens up the feedback position value. The new calibrations should not be used unless the vehicle has one or more of the customer concerns listed above or a DTC listed above has been set. The new calibrations will not correct any other DTC or NC system performance concern. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 2015 IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. Splicing Twisted or Shielded Cable SPLICING TWISTED OR SHIELDED CABLE Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. - Rewrap the conductors with the mylar tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with mylar tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Control Module References Locations Page 12572 Page 9446 Control Module References Part 3 Page 8980 Fuse Block - Underhood - Secondary Wire Entry (With RPO Code HP2) Part 3 Page 12100 Page 12796 The module uses a default value for the missing parameter. Conditions for Clearing the DTC A current DTC clears when the malfunction is no longer present. A history DTC clears when the module ignition cycle counter reaches the reset threshold, without a repeat of the malfunction. Diagnostic Aids When multiple Loss of Communication DTCs are set concurrently, the cause is likely to be 2 opens in the ring portion of the class 2 serial data circuit. Use the Control Modules and Devices ‐ Description and Identification Number table in order to determine which modules are not communicating. Use the class 2 serial data circuit schematic in order to determine the location of the opens. Test Description Page 3462 Rear of the Engine Page 3621 8. Loosen the TCM electrical connector bolts. 9. Disconnect the TCM electrical connectors (1). 10. Remove the TCM and cover. 11. Remove the fan shroud retainers. 12. Remove the fan shroud bolts 13. Remove the upper fan shroud. Installation Procedure 1. Install the upper fan shroud. Page 8830 3. Install the generator cable to the generator, perform the following: 3.1. Install the generator cable. 3.2. Install the generator cable nut to the terminal stud. Tighten Tighten the nut to 9 N.m (80 lb in). 3.3. Slide the boot over the terminal stud. 4. Connect the generator electrical connector (3). 5. If necessary, install the engine sight shield. 6. Install the accessory drive belt. 7. Connect the negative battery cable. Page 16183 INSTALLATION PROCEDURE 1. Install the door module into the switch panel bezel until it snaps into place. 2. Install the switch panel bezel and module to the door panel. NOTE: Refer to Fastener Notice in Service Precautions. 3. Install the screw that retains the switch panel bezel (1) to the front door panel. Tighten Tighten the screw to 2 N.m (18 lb in). 4. Connect the electrical connectors. 5. Install the front door trim panel. 6. If equipped with camper mirrors program the door module. Refer to Service Programming System (SPS) in Programming. Page 7203 Transmission Mount: Service and Repair ZF S6-650 Transmission Mount Replacement Removal Procedure Notice: Broken or deteriorated mounts can cause misalignment and destruction of certain drive train components. When a single mount breaks, the remaining mounts are subjected to abnormally high stresses. 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. Remove the transmission mount to crossmember nuts. 3. Remove the transmission mount bolts to the transmission. 4. Raise the transmission using a suitable transmission jack, just enough in order to permit the removal of the mount. 5. Remove the transmission mount. Installation Procedure 1. Install the rear transmission mount. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the transmission mount bolts. ^ Tighten the transmission mount bolts to 50 Nm (37 ft. lbs.). 3. Lower the transmission. 4. Install the transmission mount to crossmember nuts. ^ Tighten the transmission mount to crossmember nuts to 54 Nm (40 ft. lbs.). 5. Lower the vehicle. Page 4767 1. Locate the air flow direction arrow (2) on the MAF/IAT sensor. 2. Install the MAF/IAT sensor to the air cleaner assembly. NOTE: Refer to Fastener Notice in Service Precautions. 3. Tighten the MAF/IAT clamp. Tighten Tighten the clamp to 7 N.m (62 lb in). 4. Connect the MAF/IAT sensor electrical connector (4). 5. Push in the gray CPA retainer. 6. Install the air cleaner outlet duct. Page 11583 Page 5615 Camshaft Position Sensor: Service and Repair CAMSHAFT POSITION (CMP) SENSOR REPLACEMENT REMOVAL PROCEDURE IMPORTANT: Clean the area around the CMP sensor before removal in order to prevent debris from entering the engine. 1. Remove the camshaft position (CMP) sensor bolt. 2. Remove the CMP sensor. INSTALLATION PROCEDURE 1. Install the CMP sensor. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the CMP sensor bolt. Tighten Tighten the bolt to 29 N.m (21 lb ft). Page 13701 17. Trim hinge extensions (1) so they maintain a wall thickness of 2 mm between the end of the extensions and the body side hinge nuts (3). 18. Measure and maintain a wall thickness of 2 mm around the hole at the end of the extension (4). Important: Prior to refinishing, refer to publication GM 4901M-D-2000 GM Approved Refinish Materials for recommended products. Do not combine paint systems. Refer to paint manufacturer's recommendations. 19. Clean and prepare all surfaces. 20. Refinish as necessary. 21. Install and align all related panels and components. Page 6914 Constant Velocity Joint: Service and Repair Outer Joint and Seal Replacement Wheel Drive Shaft Outer Joint and Seal Replacement ^ Tools Required J 8059 Snap Ring Pliers - J 35910 Seal Clamp Tool - J 36652 Drive Axle Clamp Swage Tool Disassembly Procedure 1. Use a hand grinder to cut through the swage ring (2). Important: Use caution when using the hand grinder by the CV joint outer race (1). 2. Use side cutters to cut off the small boot clamp (4). Page 6708 8. Install the clutch master cylinder clip to the brake pressure module valve pipe. 9. Apply light pressure to the clutch pedal to couple the pushrod socket to the clutch pedal. 10. Connect the clutch pedal position switch electrical connector (1). 11. Pump the clutch pedal 3 time prior to starting the vehicle to ensure connection is complete. 12. Position and connect the junction block. 13. Install the driver's side knee bolster and deflector. Page 14649 Seat Adjuster Switch- Front Passenger (With RPO Code AN3) Part 2 Fuel System - Cranks But No Start/Inaccurate Fuel Gauge Fuel Gauge Sender: All Technical Service Bulletins Fuel System - Cranks But No Start/Inaccurate Fuel Gauge Bulletin No.: 04-08-49-018E Date: January 05, 2005 TECHNICAL Subject: Cranks But No Start, Stall, Inaccurate/Incorrect Fuel Gauge Reading, No Fuel, Vehicle is Out of Fuel and Fuel Gauge Reads Above Empty (Replace Fuel Level Sensor) Models: 2001-2004 Cadillac Trucks 1999-2004 Chevrolet and GMC Trucks with Gasoline Engine (VINs Z, X, V, T, U, N, G, 6, 8 - RPOs LU3, LR4, LM7, LQ4, LQ9, L59, L18,LK5 L52) Attention: Parts are currently available for vehicles with Variable Fuel (VIN Z - RPO L59) vehicles. Please refer to Corporate Bulletin Number 04-06-04-01 2B or newer for Variable Fuel (VIN Z - RPO L59) vehicles. Supercede: This bulletin is being revised to include information on the Chevrolet Colorado and the GMC Canyon. Please discard Corporate Bulletin Number 04-08-49-018D (Section 08 - Body and Accessories). Condition Some customers may comment on the vehicle stalling and will not restart, vehicle ran out of fuel, vehicle appears to be out of fuel but the fuel gauge reads above empty. The fuel gauge may read 1/4 tank. Cause Contamination on the fuel sending card may cause inaccurate/incorrect fuel gauge readings. Correction Follow the service procedure below for diagnosis and repair of this concern. 1. Confirm that the vehicle is actually out of fuel. ^ If the vehicle is not out of fuel but Engine Cranks but Does Not Run, refer to the appropriate Service Information. ^ If the vehicle is out of fuel and the gauge does not read empty, test the fuel gauge. Refer to the following information: - Fuel Gage Inaccurate or Inoperative Single Tank - Fuel Gage Inaccurate or Inoperative Dual Tanks - Fuel Gage Inaccurate or Inoperative Colorado and Canyon 2. If testing reveals that the fuel gauge is operating correctly, replace the fuel sensor assembly and auxiliary tank fuel level sensor if equipped. 3. Replace the fuel level sensor. Refer to the following appropriate service information: ^ Fuel Level Sensor Replacement 4.8L and 5.3L Engines ^ Fuel Level Sensor Replacement 6.0L Engine - Front Tank ^ Fuel Level Sensor Replacement 6.0L Engine - Rear Tank ^ Fuel Level Sensor Replacement 8.1L vehicles with Front Tank ^ Fuel Level Sensor Replacement 8.1 L vehicles with Rear Tank Page 4609 2. Install the HO2S. Tighten Tighten the sensor to 42 N.m (31 lb ft). 3. If equipped with a 6.0L engine, connect the HO2S electrical connector. 4. If equipped with a 4.8L or 5.3L engine, connect the HO2S electrical connector. 5. Install the HO2S to the clips 6. Disconnect the CPA retainer. 7. Lower the vehicle. Page 9021 Fuse Block - Underhood C4 Part 1 OnStar(R) - Loss of GPS Signal/Hands Free Issues Emergency Contact Module: Customer Interest OnStar(R) - Loss of GPS Signal/Hands Free Issues Bulletin No.: 02-08-46-007C Date: November 19, 2007 INFORMATION Subject: Information on OnStar(R) System - Possible Loss of GPS Signal, Hands-Free Calling Minutes Expire Prematurely and/or Inability to Add Hands-Free Calling Minutes Models: 2001-2008 GM Passenger Cars and Light Duty Trucks (Including Saturn) 2003-2008 HUMMER H2 2006-2008 HUMMER H3 2005-2008 Saab 9-7X with OnStar(R) System (RPO UE1) Supercede: This bulletin is being revised to add the 2008 model year, warranty information and to provide GPS signal recovery steps (under Dealer Action heading) to do PRIOR to determining if the VIU/VCIM needs replacement. Please discard Corporate Bulletin Number 02-08-46-007B (Section 08 - Body & Accessories). If the vehicle currently has analog-upgradable OnStar(R) hardware, then the customer should be made aware of the digital upgrade program per the latest version of Service Bulletin # 05-08-46-006. Any analog OnStar system that is not upgraded prior to the end of 2007 will be deactivated due to the upcoming phase-out of the analog cellular network in the U.S. and Canada. If the vehicle has recently been upgraded or has had a service replacement unit installed, this bulletin may not be applicable. Certain 2001-2008 model year vehicles equipped with OnStar(R) may exhibit a condition with the Global Positioning System (GPS) that causes inaccuracies in the GPS clock. The GPS system is internal to the OnStar(R) Vehicle Interface Unit (VIU) or the Vehicle Communication Interface Module (VCIM). This inaccuracy can result in a symptom where the OnStar(R) Call Center is unable to obtain an accurate GPS signal, hands-Free Calling minutes expire prematurely and/or the inability to add Hands-Free calling minutes. Customer Notification OnStar(R) will notify the customer by mail with instructions to contact their dealership service department. Dealer Action Not all vehicles will require VIU/VCIM replacement. The GPS signal in some vehicles may be recoverable. To determine if the signal is recoverable, simply connect the Tech2(R) and using the GPS information data display option, observe the GPS date and time. If the date/time stamps are equal to a date approximately 19 years in the future, the GPS clock has exceeded its capacity and the VIU/VCIM will need to be replaced. If the date/time stamp is in the past or near future, the GPS clock has simply generated an inaccurate value and may be recoverable by performing the following power-up reset. To initiate a power-up reset, battery voltage (batt. +) must be removed from the VIU/VCIM. The preferred methods, in order, of initiating the reset are outlined below. Remove the fuse that supplies Battery positive (Batt. +) voltage to the module (refer to the applicable Service Information schematics for the appropriate fuse). The next preferred method is to remove the connector to the OnStar(R) unit that Batt + is contained. The least preferable method is to remove the negative terminal of the vehicle battery. This will not only initiate the power-up reset, but it may also result in the loss of radio presets and other stored personalization information/settings in other modules as well. After initiating the power-up reset, the GPS data will be set to the defaulted date and time and will require an acquisition of the GPS signal in order to gain the proper date and time. Acquiring the GPS signal requires running the vehicle in an open/unobstructed view of the sky. First, contact OnStar(R) Technical Support by pressing the blue button. Allow the OnStar(R) Technical Advisor to activate the GPS recovery process. This should take approximately 10 minutes. Continue to Fuel Level Sensor Replacement - 1 Fuel Gauge Sender: Service and Repair Fuel Level Sensor Replacement - 1 FUEL LEVEL SENSOR REPLACEMENT REMOVAL PROCEDURE 1. Remove the sending unit. 2. Disconnect the fuel pump electrical connector. 3. Remove the fuel lever sensor electrical connector retaining clip. 4. Disconnect the fuel level sensor electrical connector. 5. Remove the fuel level sensor retaining clip. 6. Remove the fuel level sensor (1). INSTALLATION PROCEDURE 1. Install the fuel level sensor (1). 2. Install the fuel level sensor retaining clip. 3. Connect the fuel level sensor electrical connector. 4. Install the fuel lever sensor electrical connector retaining clip. 5. Connect the fuel pump electrical connector. 6. Install the sending unit. Page 3357 8. Install the transmission bolt and stud on the right side until snug, If equipped with the 4L60-E automatic transmission. 9. Notice: Refer to Fastener Notice in Service Precautions. Install the bottom bolt on the left side until snug. 1. Tighten the oil pan and oil pan-to-oil pan front cover bolts to 25 Nm (18 ft. lbs.). 2. Tighten the oil pan-to-rear cover bolts to 12 Nm (106 inch lbs.). 3. Tighten the bellhousing, converter cover, and transmission bolts/stud to 50 Nm (37 ft. lbs.). 10. Install the positive battery cable clip and bolt to the oil pan. ^ Tighten the bolt to 9 Nm (80 inch lbs.). 11. Install the engine oil cooler lines to the positive battery cable clip. Page 5381 1. Relieve the fuel system pressure. Refer to Fuel Pressure Relief Procedure. 2. Disconnect the fuel feed line (1) at the engine. 3. Disconnect the EVAP canister purge tube line (2). 4. Cap the fuel rail in order to avoid possible system contamination. 5. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 6. Remove the fuel pipe bracket nut. 7. Remove the fuel pipe bracket from the bellhousing stud. 8. Remove the fuel line clips from the brackets on the transmission. 9. If equipped with 4-wheel drive (4WD), remove the fuel line clip from the bracket on the transfer case. Tires/Wheels - Tire Slowly Goes Flat/Warning Light ON Wheels: Customer Interest Tires/Wheels - Tire Slowly Goes Flat/Warning Light ON TECHNICAL Bulletin No.: 08-03-10-006C Date: April 27, 2010 Subject: Tire Slowly Goes Flat, Tire Air Loss, Low Tire Pressure Warning Light Illuminated, Aluminum Wheel Bead Seat Corrosion (Clean and Resurface Wheel Bead Seat) Models: 2000-2011 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2009 HUMMER H2 2006-2010 HUMMER H3 2005-2009 Saab 9-7X Supercede: This bulletin is being revised to update the model years. Please discard Corporate Bulletin Number 08-03-10-006B (Section 03 - Suspension). Condition Some customers may comment on a tire that slowly loses air pressure over a period of days or weeks. Cause Abrasive elements in the environment may intrude between the tire and wheel at the bead seat. There is always some relative motion between the tire and wheel (when the vehicle is driven) and this motion may cause the abrasive particles to wear the wheel and tire materials. As the wear continues, there may also be intrusion at the tire/wheel interface by corrosive media from the environment. Eventually a path for air develops and a 'slow' leak may ensue. This corrosion may appear on the inboard or outboard bead seating surface of the wheel. This corrosion will not be visible until the tire is dismounted from the wheel. Notice This bulletin specifically addresses issues related to wheel bead seat corrosion that may result in an air leak. For issues related to porosity of the wheel casting that may result in an air leak, please refer to Corporate Bulletin Number 05-03-10-006F - Low Tire Pressure, Leaking Cast Aluminum Wheels (Repair with Adhesive Sealant) Correction In most cases, this type of air loss can be corrected by following the procedure below. Important DO NOT replace a wheel for slow air loss unless you have evaluated and/or tried to repair the wheel with the procedure below. Notice The repair is no longer advised or applicable for chromed aluminum wheels. 1. Remove the wheel and tire assembly for diagnosis. Refer to Tire and Wheel Removal and Installation in SI. 2. After a water dunk tank leak test, if you determine the source of the air leak to be around the bead seat of the wheel, dismount the tire to examine the bead seat. Shown below is a typical area of bead seat corrosion.Typical Location of Bead Seat Corrosion Page 4990 Important The new canister vent valve will be installed in a new location, outside of the frame. 7. Position and secure the new valve assembly to the frame bracket on the outside of the frame using the existing hole and mounting bolt. Tighten Tighten the bracket mounting bolt to 12 Nm (106 lb in). 8. Connect the vent valve pipe to the EVAP canister. 9. Install the two vent valve pipe clips into the existing underbody holes. 10. Connect the EVAP canister vent valve electrical connector, if equipped. 11. Attach bulk 5/8" heater hose to the vent valve port and secure using a clamp. Run a length as needed along the frame rail routing to the area above the transmission. 12. Cut the hose to determined length and install the supplied filter box. Secure using a clamp. 13. Remove the transmission support and lower the transmission assembly as necessary to allow for access to the new filter box location. 14. Secure the filter box to the transmission vent hose just forward of the hose tee-section using a tie strap. DO NOT pinch or restrict the transmission vent hose. The filter box opening should be pointing downward. 15. Raise the transmission and reinstall the transmission support. 16. Tie strap the hose as needed along the frame rail in order to keep the hose away from pinch-points and heat sources. 17. Lower the vehicle. 2004-2007 Model Year (Use Service Kit P/N 19152349) 1. Raise the vehicle. Suitably support the vehicle. 2. Disconnect the EVAP canister vent valve electrical connector. 3. Disconnect the canister pipe from the vent valve. 4. Push in the retainer and remove the existing canister vent valve from the fuel tank clip or mounting bracket. Discard the old valve. 5. Cut back the existing canister pipe approximately 51 mm (2 in) to remove the quick connect end. Crew Cab Short Box Shown Below, Other Configurations Similar Page 7006 1. Install the wheel hub and bearing (3) to the vehicle. 2. Install the wheel hub and bearing retaining bolts. ^ Tighten the bolts to 180 Nm (132 ft. lbs.). 3. Notice: Refer to Fastener Notice in Service Precautions. Install the wheel drive shaft retaining nut. ^ Tighten the nut to 250 Nm (184 ft. lbs.). 4. Install the retainer (3) and cotter pin (2) to the wheel drive shaft nut. 5. Install the dust cap (4). 6. Install the brake rotor. 7. Install the tire and wheel. 8. Lower the vehicle. Page 8935 5. If J 42059 tool fails to release the power port/lighter socket from the retainer, perform the following alternate method: 5.1. Insert a small grinding tool with a cutoff wheel into the socket. 5.2. Remove the plastic latches in the 3 mm (0.11 in) square windows. 5.3. Use the J 42059 as directed above to remove the socket. 6. Remove the electrical connector from the socket. INSTALLATION PROCEDURE 1. Insert the plastic ring into the opening and snap the plastic ring into place. 2. Connect the electrical connector to the receptacle. 3. Insert the receptacle through the plastic ring gently by hand until the receptacle ring is sealed. 4. Install the power supply fuse. Page 2931 Parts Information Warranty Information For vehicles repaired under warranty use, the table. Disclaimer Page 10659 9.1. Push the mud flap to make contact with the front side of the underbody cross sill and mark location of the hole (5) of the mud flap. 9.2. Center punch the marked location and drill a 5.159 mm (13/64 in) hole. 9.3. Install the screw. Tighten Tighten the screw to 4 N.m (35 lb in). 9.4. Repeat the above steps for hole location 6. 10. Repeat the above steps for the opposite side. Parts Information Parts are expected to be available from GMSPO on June 30, 2004. Warranty Information Please advise the customer that the mud flaps can be purchased as an accessory. Installation and/or cost of the mud flaps will not be covered under the vehicle's warranty. Disclaimer Page 12312 Electrical Symbols Part 2 Page 14120 Front Passenger Door Module (FPDM) - C2 (With RPO Code YE9) Part 1 Page 4466 Fuel Tank Pressure Sensor: Service and Repair FUEL TANK PRESSURE SENSOR REPLACEMENT REMOVAL PROCEDURE 1. Remove the fuel tank. 2. Using a slight rocking motion, while pulling straight up, remove the fuel tank pressure sensor (1). INSTALLATION PROCEDURE 1. Install the fuel tank pressure sensor (1). 2. Install the fuel tank. Page 12192 Circuit/System Testing Component Testing Page 9588 Junction Block - Rear Lamps - C3 Drivetrain - Updated Transfer Case Speed Sensor Conn. Speed Sensor: All Technical Service Bulletins Drivetrain - Updated Transfer Case Speed Sensor Conn. Bulletin No.: 06-04-21-001 Date: May 17, 2006 INFORMATION Subject: Updated Transfer Case Connector Service Kit Now Available For Transfer Case Speed Sensor Wire Harness Connector that Comes Loose Or Connector Retainer Clip Breaks Models: 2007 and Prior GM Light Duty Trucks 2007 and Prior HUMMER H2, H3 2005-2007 Saab 9-7X with Four-Wheel Drive or All-Wheel Drive Technicians may find that when the transfer case speed sensor wire harness connector is removed, the connector lock flexes/bends and does not return to the original position. The transfer case speed sensor wire harness connector then has no locking device. On older vehicles, the plastic connector retainer becomes brittle and the clip may break as soon as it is flexed. In the past, the only service fix was to install a wire harness connector service pack, P/N 88987183. This repair procedure involved splicing a new service connector with an integral connector lock. This connector service kit is of the same design and was still prone to failure over time. A new connector service repair kit is now available, P/N 15306187, that is an updated design. This new kit should be used whenever the speed sensor wire harness connector requires replacement. Parts Information Disclaimer Page 5600 Steps 4 - 5 Page 3361 25. If equipped with 4WD, install the inner axle housing washers and nuts to the bracket. ^ Tighten the nuts to 100 Nm (75 ft. lbs.). 26. Remove the jack from the front drive axle. 27. Install new engine oil and a new oil filter. 28. If equipped with RPO HP2, refill the cooling system. Page 3555 Spark Plug: Service and Repair SPARK PLUG REPLACEMENT REMOVAL PROCEDURE 1. Remove the spark plug wire. 2. Loosen the spark plug 1 or 2 turns. 3. Brush or using compressed air, blow away any dirt from around the spark plug. 4. Remove the spark plug. If removing more than one plug, place each plug in a tray marked with the corresponding cylinder number. INSTALLATION PROCEDURE 1. Correctly position the spark plug washer. 2. Inspect the spark plug gap. Adjust the gap as needed. Specification Spark plug gap: 1.01 mm (0.040 in) 3. Hand start the spark plug in the corresponding cylinder. NOTE: Refer to Fastener Notice in Service Precautions. 4. Tighten the spark plug. Tighten Tighten the plug to 15 N.m (11 lb ft) for used heads. - Tighten the plug to 20 N.m (15 lb ft) for NEW heads. 1. Install the spark plug wire. Page 1980 Electrical Symbols Part 6 Page 644 5. Remove the mounting screws (1) that fasten the EBCM (2) to the BPMV (3). 6. Remove the EBCM (2) from the BPMV (3). Removal may require a light amount of force. Notice: Do not use a tool to pry the EBCM or the BPMV. Excessive force will damage the EBCM. Junction Block - I/P Relay Box: Locations Junction Block - I/P Location View Location View Page 10816 Air Door Actuator / Motor: Locations Air Temperature Sensors - Lower Left Page 9532 Location View Page 12820 Drivetrain - Transfer Case Control Module Replacement Control Module: All Technical Service Bulletins Drivetrain - Transfer Case Control Module Replacement Bulletin No.: 05-04-21-002 Date: March 10, 2005 INFORMATION Subject: Guidelines for Replacement of Transfer Case Control Module (TCCM) Models: 2005 and Prior Light Duty Trucks with New Venture Gear (NVG) Transfer Case (RPOs NP1, NP4, NP8) Dealers are replacing the TCCM unnecessarily. Dealers are replacing the TCCM with codes stored in HISTORY only. The TCCM does not have a current fault condition when tested. Parts reviewed at the Warranty Parts Center (WPC) have a 75% No Trouble Found (NTF) rate. The only two legitimate reasons to replace the TCCM are: ^ Diagnostic Trouble Code (DTC) C0550 ^ NO Communication with a scan tool. DTC C0550 This DTC indicates that the module has an internal fault and should be replaced. No Communication ^ The no communication conditions referenced here are also caused by a module internal fault to a point where the module physically will not talk. A technician cannot pull DTCs from the module because it will not communicate. The module is electrically dead. ^ No communication is not to be confused with a U1026 code. This code tells the technician that the module may still be functioning but is temporarily off line. This code may be set by the Instrument Panel (IP) or the Powertrain Control Module (PCM) against the TCCM. The technician needs to figure out why the module went off line. These are typically caused by connection concerns. There is no need to replace a TCCM for a U1026 DTC. Diagnostic Aids ^ When diagnosing a transfer case electrical control system, ALWAYS check power and ground wiring first. ^ Test the connections for intermittent or poor connections, complete plug insertion, bent pins, pushed out terminals and water contamination. Page 12547 Diagnostic Tips Review Table Page 9563 Fuse Block - Underhood C4 Part 3 Fuse Block - Underhood C5 Page 4049 of the possible harness chafing/pinching. Also, on any of the above listed vehicles, the PCM wiring harness may be chafing against the precharge pump bracket or the battery tray. Correction On RPO AN3 vehicles, inspect the routing of the seat wiring harness. Reroute the seat wiring harness and attaching harness fastener (1) to the opposite side of the seat module bracket. Repair the harness as necessary. Refer to Wiring Repairs in the Wiring Systems sub-section of SI. The seat may have to be removed for ease of access and proper repair of the wiring harness. Inspect the routing of the PCM wiring harness at the precharge pump bracket and the battery tray. Repair the harness as necessary. Refer to Wiring Repairs in the Wiring Systems sub-section of SI. If any of the above conditions still remain after this repair, refer to SI for further diagnostic information. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 2401 10. Place the J 9522-3 on the open horizontal bearing cups. Press the lower bearing cup out of the yoke ear. 11. If you do not completely remove the bearing cup, lift the cross and insert the J 9522-5 between the seal and the bearing cup you are removing. Continue pressing the bearing cup out of the yoke. 12. Rotate the propeller shaft. Press the opposite bearing cup out of the drive shaft yoke. 13. Remove the old slip yoke and universal joint. 14. Inspect the retaining ring grooves for dirt, corrosion, or pieces of the old ring. 15. Inspect the bearing cup bores for burrs or imperfections. 16. Clean the retaining ring grooves. Corrosion, dirt, rust, or pieces of the old retaining ring may prevent the bearing cups from pressing into place or prevent the bearing retainers from properly seating. 17. Install the new nickel-plated slip yoke and universal joint. See parts table below for parts information. 18. Remove the bearing cups from the universal joint. 19. Assemble one bearing cup part way into one side of the yoke. Turn the yoke ear toward the bottom. 20. Assemble the cross into the yoke so that the trunnion seats freely into the bearing cup. Page 12442 Page 2627 Junction Block - I/P Wire Entry Part 1 Suspension - Squeak Noise From Front of Vehicle Suspension Strut / Shock Absorber: Customer Interest Suspension - Squeak Noise From Front of Vehicle Bulletin No.: 03-03-08-003 Date: November 24, 2003 TECHNICAL Subject: Squeak Noise Coming From Front of Vehicle (Align Shock Absorber Upper Mount) Models: 2004 Chevrolet Silverado 1500 Series Pickups 2004 GMC Sierra 1500 Series Pickups with 4WD and Built at Oshawa Plant (1 in VIN position 11) Prior to VIN Breakpoint 41211859 Condition Some customers may comment on a squeak noise coming from the front of the vehicle. Cause The cause of this condition may be due to the front shock(s) not being centered in the frame hole resulting in metal to metal contact. Correction Align the shock absorber upper mount to the correct location using the procedure listed below. DO NOT replace the shock absorber. 1. Open the hood. 2. Remove the upper shock absorber nut. Hold the tennon end with a wrench while removing the nut. 3. Remove the upper portion (1) of the upper mount from the shock. 4. Center the lower portion (3) of the upper mount in the frame hole. 5. Remove the plastic pilot ring (2) from the upper portion and place on the steel sleeve of the shock to ensure proper alignment. 6. Reinstall the upper portion of the upper mount onto the shock. 7. Reinstall the upper shock absorber nut. Hold the tennon end with a wrench while torquing the nut. Tighten: Tighten the nut to 20 N.m (15 lb ft). 8. Repeat for other side if necessary. Keyless Entry - Inoperative Keyless Entry Module: Customer Interest Keyless Entry - Inoperative Bulletin No.: 04-08-52-005 Date: June 15, 2004 TECHNICAL Subject: Remote Keyless Entry (RKE) System Inoperative (Reprogram Passenger Door Module (PDM)) Models: 2004 Cadillac Escalade, Escalade ESV, Escalade EXT 2004 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2004 GMC Sierra, Yukon, Yukon XL Condition Some customers may comment on any of the following conditions: ^ The RKE key fob does not function. ^ The "Service Tire Pressure Monitoring System" message is displayed, if equipped. ^ The passenger door will not unlock from the passenger's or driver's door switches. ^ The passenger door window is inoperative. Correction Reprogram the PDM with the Tech 2(R). Currently the Tech 2(R) software is not available for the 2004 model year. Engineering is aware of this and are working to release a new service calibration. In the meantime, build the Tech 2(R) as a 2003 model year and perform the reprogram using the procedure listed below. 1. Turn the ignition switch to the ON position. 2. Connect the Tech 2(R) to the vehicle's diagnostic link connector (DLC), power it up and press enter. ^ Select: Diagnostics. ^ Select model year: 2003. ^ Select: Light truck. ^ Select: Body. ^ Select the proper Product line. ^ Select the proper HVAC Type. ^ Select the proper Radio System type. ^ Select: Passenger Door Module. ^ Select: Special Functions. ^ Select: Refresh. Important: You must remove the described fuse in the next step for the "Refresh" program to be performed. If you do not remove the fuse for five seconds, the Tech 2 will continue to display "Test in Progress" and the program will not complete. ^ Remove the PDM fuse for 5 seconds from the fuse center located behind the panel on the left end of the instrument panel. Page 14385 Control Module References Part 4 Actuator Recalibration - HVAC Air Door Actuator / Motor: Service and Repair Actuator Recalibration - HVAC RE-CALIBRATING ACTUATORS When replacing the HVAC control module it will be necessary to allow the HVAC control module to perform a calibration process. When installing the HVAC control module be sure to perform the following: IMPORTANT: Do not adjust any controls on the HVAC control module while the HVAC control module is self-calibrating. If interrupted, improper HVAC performance will result. 1. Place the ignition switch to the OFF position. 2. Disconnect the scan tool. 3. Install the HVAC control module. 4. Connect all previously disconnected components. 5. Start the vehicle. 6. Wait 40 seconds for the HVAC control module to self-calibrate. 7. Verify that no DTCs have set as current DTCs. When replacing the HVAC actuator it will be necessary to allow the HVAC control module to perform a calibration process. When installing the HVAC actuator be sure to perform one of the following: IMPORTANT: Do not adjust any controls on the HVAC control module while the HVAC control module is self-calibrating. If interrupted, improper HVAC performance will result. Preferred Method (w/ Scan Tool) 1. Clear all DTCs. 2. Place the ignition switch in the OFF position. 3. Install the HVAC actuator. 4. Connect all previously disconnected components. 5. Start the vehicle. 6. With the scan tool, initiate the Motor Re-calibration feature of the Heating and Air Conditioning Special Functions menu. 7. Verify that no DTCs have set as current DTCs. IMPORTANT: Do not adjust any controls on the HVAC control module while the HVAC control module is self-calibrating. If interrupted, improper HVAC performance will result. Alternate Method (w/o Scan Tool) 1. Clear all DTCs. 2. Place the ignition switch to the OFF position. 3. Install the HVAC actuator. 4. Connect all previously disconnected components. 5. Remove the HVAC/ECAS fuse for a minimum of 10 seconds. 6. Install the HVAC/ECAS fuse. 7. Start the vehicle. 8. Wait 40 seconds for the HVAC control module to self-calibrate. 9. Verify that no DTCs have set as current DTCs. Page 2563 24. Fill the brake master cylinder reservoir to the maximum-fill level with Delco Supreme 11®, GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. 25. Slowly depress and release the brake pedal. Observe the feel of the brake pedal. 26. If the brake pedal feels spongy perform the following steps: 1. Inspect the brake system for external leaks. 2. Using a scan tool, perform the antilock brake system automated bleeding procedure to remove any air that may have been trapped in the BPMV. Refer to ABS Automated Bleed Procedure in Antilock Brake System. 27. Turn the ignition key ON, with the engine OFF. Check to see if the brake system warning lamp remains illuminated. 28. Important: If the brake system warning lamp remains illuminated, DO NOT allow the vehicle to be driven until it is diagnosed and repaired. If the brake system warning lamp remains illuminated, refer to Symptoms - Hydraulic Brakes. Page 2486 3. Fill the transmission to just below the bottom of the fill plug hole. 4. Install the oil fill plug. ^ Tighten the plug to 37 Nm (27 ft. lbs.). 5. Lower the vehicle. Service and Repair Front Fender Liner: Service and Repair Wheelhouse Panel Replacement Removal Procedure 1. Remove the push-in retainers from the wheelhouse panel. 2. Remove the top clips (2) retaining the harness to the top of the wheelhouse panel. 3. Install the retainers for Avalanche only. 4. Remove the wheelhouse panel from the wheelhouse. Installation Procedure 1. Install the wheelhouse panel to the wheelhouse. 2. Install the top clips (2) retaining the harness to the top of the wheelhouse panel. 3. Install the retainers for Avalanche only. 4. Install the push-in retainers to the wheelhouse panel. Page 9944 Steering and vibration complaints are not always the result of improper alignment. One possible cause is wheel and tire imbalance. Another possibility is tire lead due to worn or improperly manufactured tires. Lead/pull is defined as follows: at a constant highway speed on a typical straight road, lead/pull is the amount of effort required at the steering wheel to maintain the vehicles straight path. Lead is the vehicle deviation from a straight path on a level road without pressure on the steering wheel. Refer to Radial Tire Lead/Pull Correction in Tires and Wheels in order to determine if the vehicle has a tire lead problem. Before performing any adjustment affecting wheel alignment, perform the following inspections and adjustments in order to ensure correct alignment readings: ^ Inspect the tires for the proper inflation and irregular tire wear. ^ Inspect the runout of the wheels and the tires. ^ Inspect the wheel bearings for backlash and excessive play. ^ Inspect the ball joints and tie rod ends for looseness or wear. ^ Inspect the control arms and stabilizer shaft for looseness or wear. ^ Inspect the steering gear for looseness at the frame. Refer to Fastener Tightening Specifications in Power Steering System. ^ Inspect the struts/shock absorbers for wear, leaks, and any noticeable noises. Refer to Struts or Shock Absorbers On-Vehicle Testing in Suspension General Diagnosis. ^ Inspect the vehicle trim height. Refer to Trim Height Inspection Procedure in Suspension General Diagnosis. ^ Inspect the steering wheel for excessive drag or poor return due to stiff or rusted linkage or suspension components. ^ Inspect the fuel level. The fuel tank should be full or the vehicle should have a compensating load added. Give consideration to excess loads, such as tool boxes, sample cases, etc. If normally carried in the vehicle, these items should remain in the vehicle during alignment adjustments. Give consideration also to the condition of the equipment being used for the alignment. Follow the equipment manufacturer's instructions. Satisfactory vehicle operation may occur over a wide range of alignment settings. However, if the setting exceeds the service allowable specifications, correct the alignment to the service preferred specifications. Refer to Wheel Alignment Specifications. Perform the following steps in order to measure the front and rear alignment angles: 1. Install the alignment equipment according to the manufacturer's instructions. 2. Jounce the front and the rear bumpers 3 times prior to checking the wheel alignment. 3. Measure the alignment angles and record the readings. 4. Important: When performing adjustments to vehicles requiring a 4-wheel alignment, set the rear wheel alignment angles first in order to obtain proper front alignment angles. Adjust alignment angles to vehicle specification, if necessary. Refer to Wheel Alignment Specifications. Page 8863 Electrical Symbols ELECTRICAL SYMBOLS Electrical Symbols Part 1 Page 13219 If you are unsure who the PSC is, check with the Sales Manager. General Information 1. The first step is to verify if the OnStar(R) account is active or not. This can be done by pressing the blue OnStar(R) button and connecting to the OnStar(R) call center. Analog only accounts are no longer active. Only digital upgraded accounts will be active. On Gen 6 digital systems, a clear, or "dark" LED may indicate that the OnStar(R) system has been deactivated or may possibly have a no power/no communication condition. 2. If the account isn't active, the next step is to verify what version of OnStar(R) module is in the vehicle. This can be done via the Tech 2 (Body>VCIM>Module ID Information>Module Information 2) or by using www.onstarenrollment.com. 3. A Generation 5 or older analog module can be diagnosed by following the original electronic Service Information developed for the model year of the vehicle. Note: If the customer has an old analog module, the vehicle can be repaired by replacing the module, but the customer cannot have an active account without upgrading to a digital module. 4. Modules, antennas, brackets, and other equipment are in the same location, whether original analog production or digital upgrade. 5. An upgraded vehicle may also have a new vehicle communication interface module (VCIM) bracket. If it does, order the new bracket when replacing the bracket. Don't order the original bracket. The kit may also include a small wiring jumper cable. If it does, this jumper will be required for a new module replacement. Do not discard. 6. After replacing the VCIM, it is essential to configure the new OnStar(R) system. Failure to configure the system will result in an additional customer visit for repair. DO NOT press and hold the white dot or phone button on the keypad as it will not reset this version of the OnStar(R) system and may result in a DTC being set. Use of the TIS2WEB and SPS applications, along with the Tech2(R), are required in order to perform the VCIM configuration and setup procedure for this vehicle. The configuration and set-up procedure is now a two-step process which enables an automated activation by the OnStar(R) Center, without a button press by the technician to the OnStar(R) Call Center. Page 6246 4. Install the oil pan and NEW gasket. 5. Notice: Refer to Fastener Notice in Service Precautions. Install the oil pan bolts. ^ Tighten the bolts alternately and evenly to 11 Nm (97 inch lbs.). 6. If previously removed, install the range selector cable bracket and bolts. ^ Tighten the bolts to 25 Nm (18 ft. lbs.). 7. Apply a small amount of sealant GM P/N 12346004 (Canadian P/N 10953480), or equivalent to the threads of the oil pan drain plug, if equipped. 8. Install the oil pan drain plug, if equipped. ^ Tighten the plug to 18 Nm (13 ft. lbs.). 9. Lower the vehicle. 10. Fill the transmission to the proper level with DEXRON® III transmission fluid. 11. Check the COLD fluid level reading for initial fill only. 12. Inspect the oil pan gasket for leaks. Page 7114 1. Install the spacer (if applicable) onto the rear of the crankshaft. 2. Install the manual transmission engine flywheel to the crankshaft, if applicable. 3. Install the automatic transmission engine flywheel to the crankshaft, if applicable. Important: Longer flywheel bolts must be used on applications using a flywheel spacer. 4. Apply threadlock GM P/N 12345382 (Canadian P/N 10953489), or equivalent to the threads of the flywheel bolts. Page 8874 Electrical Symbols Part 13 Page 5558 3.2. Reinstall any loose boot. Page 1670 Transmission Position Switch/Sensor: Adjustments Automatic Transmission - 4L80-E/4L85-E Park/Neutral Position Switch Adjustment Important: ^ The following procedure is for vehicles that have not had the park/neutral position (PNP) switch removed or replaced. If the switch has been removed or replaced, refer to Park/Neutral Position Switch Replacement for the proper adjustment procedure. ^ Apply the park brake. ^ The engine must start in the park (P) or neutral (N) positions only. ^ Check the PNP switch for proper operation. If adjustment is required, proceed as follows: 1. Place the shift lever in the neutral (N) position. 2. With an assistant in the drivers seat, raise and suitably support the vehicle. Refer to Vehicle Lifting. 3. Loosen the PNP switch bolts. 4. With the vehicle in neutral (N), rotate the PNP switch while the assistant attempts to start the engine. 5. Following a successful start, turn the engine off. 6. Notice: Refer to Fastener Notice in Service Precautions. Tighten the PNP switch bolts. ^ Tighten the bolts to 25 Nm (18 ft. lbs.). 7. Lower the vehicle. 8. Check the PNP switch for proper operation. The engine must start in the park (P) or neutral (N) positions only. 9. Replace the PNP switch if proper operation can not be achieved. Page 6628 Instruments - DIC Perceived Fuel Economy Settings Driver/Vehicle Information Display: Technical Service Bulletins Instruments - DIC Perceived Fuel Economy Settings Bulletin No.: 03-00-89-021 Date: July 30, 2003 INFORMATION Subject: New Vehicle Pre-Delivery Inspection - Perceived Fuel Economy and Driver Information Center (DIC) Settings Models: 2003-2004 Passenger Cars and Trucks 2003-2004 HUMMER H2 with Driver Information Center (DIC) The customer's initial perception of vehicle fuel economy, based upon the information displayed on the Driver Information Center (DIC), may contribute to poor ratings for fuel economy in various automotive surveys. The way the vehicle is handled during the build and shipping process may leave inaccurate values in the history of the DIC. During the pre-delivery inspection, the dealership must reset the "average fuel economy" setting. Reset the average fuel economy setting according to the information in the appropriate Owner's Manual. Once reset, the average fuel economy will then be calculated starting from that point. The data used to determine fuel range is an average of recent driving conditions. This setting cannot be reset. However, as the customer's driving conditions change, the data will be gradually updated to reflect more accurate readings. If a customer inquires about fuel economy, and the fuel consumption information is not on the price sticker, do not exaggerate the vehicle's capabilities. In either case, stress that fuel economy performance is highly dependent upon driving habits and vehicle usage. Disclaimer Page 15950 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly, Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Pull to Seat Connectors PULL TO SEAT CONNECTORS TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Page 3957 Crankshaft Position Sensor: Description and Operation CRANKSHAFT POSITION (CKP) SENSOR The crankshaft position (CKP) sensor is a three wire sensor based on the magneto resistive principle. A magneto resistive sensor uses two magnetic pickups between a permanent magnet. As an element such as a reluctor wheel passes the magnets the resulting change in the magnetic field is used by the sensor electronics to produce a digital output pulse. The PCM supplies a 12-volt, low reference, and signal circuit to the CKP sensor. The sensor returns a digital ON/OFF pulse 24 times per crankshaft revolution. Page 786 The 1999 though early 2003 wiring harness jumper that plugs into the relay block will have a reddish/brown 6-way connector and a tag with the last four digits of the wiring harness part number. Second design 2003-05 may have a white plastic connector with part number 5418 as well. ^ The 1999 jumper is/was P/N 12171982 with a pink/purple tag identifier of 1982. This number has been superseded to 15366255, with a pink/purple tag identifier of 6255. ^ The 2000 jumper harness is P/N 15366255. The pink/purple tag identifier is 6255. ^ The 2001-2002 jumper is P/N 15086884. The orange tag identifier is 6884. ^ The 2003-05 jumper is P/N 15085418. The orange tag identifier is 5418. When transferring the brake controller with the wiring jumper attached from a 2001-2002 vehicle to a 2003-05 vehicle, a change to the jumper harness connector must be performed. Page 14472 Power Seat Control Module: Diagrams Memory Seat Module - C1 Page 6502 2. Install the valve bore plug retainer ring (1). 3. Install the transmission filter. Page 12588 Important: The optic cable must not be bent with a radius less than 25 mm (1 in). 6.12. Place the optic cable in the wiring harness channels on the right-hand side. Thread through the existing cable ties (C) if possible, otherwise, secure with a cable tie to the existing one. Close the cover on the channels. Ensure the catches lock. 6.13. Secure the optic cable along the right-hand rear wheel housing, next to the ordinary wiring harness securing points and by the SRS unit (D). 6.14. Thread the optic cable up next to the safety belt by the old optic cable and place on the parcel shelf. 6.15. Unplug the connectors (E) from the OnStar(R) control modules. 6.16. Remove the console (F) together with the OnStar(R) control modules. Page 10923 Control Module References Part 4 Page 1321 Air Temperature Sensors - Lower Right Locations Page 3996 Top Of Engine Page 16274 Washer Fluid Level Switch: Service and Repair WASHER SOLVENT CONTAINER LEVEL SENSOR REPLACEMENT REMOVAL PROCEDURE 1. Remove the washer solvent container. 2. Using a small flat-bladed tool, remove the washer solvent container level sensor (1) and seal (2) from the container. INSTALLATION PROCEDURE 1. Position the washer solvent container level sensor (1) and the seal (2) to the container by pressing in until fully seated. 2. Install the washer solvent container. Fuel Hose/Pipes Replacement - Chassis 1 Fuel Supply Line: Service and Repair Fuel Hose/Pipes Replacement - Chassis 1 FUEL HOSE/PIPES REPLACEMENT - CHASSIS (PICKUP) REMOVAL PROCEDURE IMPORTANT: Clean the fuel and evaporative emission (EVAP) connections and surrounding areas prior to disconnecting the lines in order to avoid possible system contamination. 1. Relieve the fuel system pressure. Refer to Fuel Pressure Relief Procedure. 2. Disconnect the fuel feed line (1) at the engine. 3. Disconnect the EVAP canister purge tube line (2). 4. Cap the fuel rail and EVAP lines in order to avoid possible system contamination. 5. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 6. Remove the fuel pipe bracket nut. 7. Remove the fuel pipe bracket from the bellhousing stud. 8. Remove the heated oxygen sensor (HO2S) sensor connector from the bracket. Page 1977 Electrical Symbols Part 3 Automatic Transmission - 4L60-E/4L65-E Transmission Position Switch/Sensor: Service and Repair Automatic Transmission 4L60-E/4L65-E Park/Neutral Position Switch Replacement ^ Tools Required J 41364-A Park Neutral Switch Aligner Removal Procedure 1. Apply the park brake. 2. Shift the transmission into neutral. 3. If equipped with 4-wheel drive (4WD), remove the front propeller shaft. 4. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 5. Disconnect the park/neutral position (PNP) switch electrical connector (2). 6. Remove the manual shaft lever nut. Page 11691 Air Bag Deactivation Switch: Description and Operation Inflatable Restraint I/P Module Disable Switch INFLATABLE RESTRAINT I/P MODULE DISABLE SWITCH The instrument panel (I/P) module disable switch is a manual 2-position key switch. The I/P module disable switch allows the vehicle operator the ability to enable or disable the I/P module (passenger frontal air bag). The I/P module disable switch interfaces with the passenger presence system (PPS) module to request the enabling or disabling of the I/P module. The occupants are notified of the enabling or disabling of the I/P module via the I/P module disable switch ON/OFF indicator and the PASSENGER AIR BAG ON/OFF indicators located on the rear view mirror. Page 7632 Page 14863 Seat Front Vertical Position Sensor - Driver (With RPO Code AN3) Locations Steering Column Page 8760 12. Install the positive battery cable to the channel. 13. Slide the channel pin into the oil pan tab. 14. Install the positive battery cable channel bolt. Tighten Tighten the bolt to 12 N.m (106 lb in). 15. Lower the vehicle. 16. If equipped with a 8.1L engine, install the negative cable clip to the positive cable clip. 17. If equipped with a 4.8L, 5.3L, or 6.0L engine, install the negative cable clip to the positive cable clip. Diagram Information and Instructions Heated Glass Element: Diagram Information and Instructions Truck Zoning TRUCK ZONING Truck Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that corresponds to where they are located in the vehicle. The table explains the numbering system. Page 1116 Switch Replacement - Door Lock and Side Window - Passenger Removal Procedure 1. Remove the front door trim panel. 2. Disconnect the electrical connectors. 3. Remove the screw that retains the switch panel bezel (1) from the front door panel. 4. Remove the switch panel bezel from the door panel using a flat-bladed tool. 5. Using a wide plastic flat-bladed tool, release the retaining clips on both sides of the door module. 6. Remove the door module from the switch panel bezel. Installation Procedure Page 5049 3. Disconnect the vent valve pipe quick connect from the canister. 4. Either cut the existing valve vent pipe and leave the remaining section of pipe in the vehicle or remove along with the valve. 5. Push in the retainer and remove the existing canister vent valve from the fuel tank clip or mounting bracket. 6. Cut back the existing canister pipe approximately 51 mm (2 in) and retain the pipe for use with new valve. 7. Connect the canister pipe quick connect to the canister. 2500 Crew Cab Short Box Shown Below, Other Configurations Similar 1500 Extended Cab Short Box Shown Below, Other Configurations Similar 8. Install the new canister vent valve solenoid to the fuel tank clip or mounting bracket as shown above. The valve port closest to the electrical connector must point towards the canister. 9. Cut bulk 5/8" heater hose to a length of approximately 76 mm (3 in). Install the hose between the solenoid and the canister pipe and secure using clamps. 10. Attach bulk 5/8" heater hose to the vent port and secure using a clamp. Run a length as needed along the frame rail routing to the passenger side area above the transmission. 11. Cut the hose to determined length and install the supplied filter box. Secure using a clamp. 12. Remove the transmission heat shield, if necessary. 13. Remove the transmission support and lower the transmission assembly as necessary to allow for access to the new filter box location. 14. Secure the filter box to the transmission vent hose just forward of the hose tee-section using a tie strap. DO NOT pinch or restrict the transmission vent hose. The filter box opening should be pointing downward. 15. Raise the transmission and reinstall the transmission support. 16. Reinstall the transmission heat shield. 17. Connect the EVAP canister vent valve electrical connector. 18. Tie strap the hose as needed along the frame rail in order to keep the hose away from pinch-points and heat sources. 19. Lower the vehicle. Parts Information Page 11965 Page 7630 Control Module: Locations NVG 263-NP1 Transfer Case Shift Control Module Transfer Case Shift Control Module 1 - I/P Harness 2 - Transfer Case Shift Control Module Connectors 3 - Transfer Case Shift Control Module 4 - Instrument Panel Page 9544 LR Of The Engine Compartment (With RPO Code 9L4) Page 6325 Pressure Regulating Solenoid: Connector Locations Page 6590 Park Neutral Position (PNP) Switch C175 Page 8529 Page 12656 Disclaimer Page 11801 INSTALLATION PROCEDURE 1. Connect the extension cable to the radio. 2. Connect the extension cable to the HVAC duct. 3. Connect the extension cable to the antenna. 4. Install the instrument panel trim panel. Page 7450 3. Notice: Refer to Fastener Notice in Service Precautions. Install the transfer case adapter bolts. ^ Tighten the bolts to 50 Nm (37 ft. lbs.). 4. Important: When installing the gasket to the transfer case, make sure that the yellow printing on the gasket is facing toward the transfer case (away from the transmission). The locating tab on the gasket should always be pointing up. Install the new transfer case gasket. 5. Install the transfer case. Drivetrain - Growl/Moan Noise From Front Axle Differential Case: Customer Interest Drivetrain - Growl/Moan Noise From Front Axle Bulletin No.: 03-04-19-004B Date: December 12, 2005 TECHNICAL Subject: Growl or Moan Noise Coming From Front Axle (Replace Front Axle Differential Case) Models: 2003-2006 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2003-2006 GMC Sierra, Yukon, Yukon XL with 4WD and Active Transfer Case (RPO NP8) and 8.25 Inch Front Axle Supercede: This bulletin is being revised to update the model years. Please discard Corporate Bulletin Number 03-04-19-004A (Section 04 - Driveline/Axle). Condition Some customers may comment on a growl or moan-type noise coming from the front axle above 50 km/h (30 mph). This condition may be described as a noise that phases or cycles in and out. This noise is present in the 2WD mode only, and may be present whether the vehicle is accelerating, decelerating, or at a steady speed. The noise goes away in 4WD or Auto 4WD modes. Cause This noise may be caused by a low clearance condition within the differential in the front axle assembly. In the 2WD mode, the front differential has a large amount of relative motion between the differential pinion and side gears. In the 4WD or Auto 4WD modes, the transfer case motors the front propeller shaft, and the relative motion between the differential gears is reduced or eliminated, so the noise is eliminated. Correction Replace the front differential case, P/N 26018131. This is the component bolted to the ring gear. It is NOT necessary to replace the differential gears unless unusual wear is observed. Use the procedure listed below. 1. Raise the vehicle. 2. Remove the front engine protection shield. Refer to Engine Protection Shield Replacement in the Frame and Underbody sub-section of the Service Manual. 3. Drain the differential carrier assembly. 4. Disconnect the electrical connector from the actuator and wire harness from the right inner axle shaft housing and differential carrier. 5. Remove the right wheel driveshaft inboard flange bolts from the inner axle shaft. 6. Disconnect the right wheel driveshaft from the inner axle shaft. 7. Remove the inner axle shaft housing nuts from the bracket. 8. Remove the inner axle shaft housing bolts from the differential carrier assembly. 9. Carefully remove the inner axle shaft housing assembly from the differential carrier. 10. Remove the left wheel driveshaft inboard flange bolts from the inner axle shaft. 11. Remove the left inner axle shaft from the differential carrier assembly. 12. Remove the front drive axle clutch shaft from the differential carrier assembly. 13. Remove the differential carrier assembly bolts. Page 8460 3. Remove the master cylinder nuts. Do not remove the pipes from the master cylinder. Position the master cylinder away from the booster head. Secure the master cylinder in an upright position. 4. Disconnect the power brake booster inlet hose, the steering gear inlet hose, and the power brake booster outlet hose from the booster assembly. 5. Remove the booster pump rod retainer from the lever. 6. Remove the stop lamp switch from the lever. 7. Remove the booster pump rod from the lever. 8. Remove the nuts at the booster. 9. Remove the booster assembly. Installation 1. Install the booster assembly to the vehicle. 2. Install the nuts at the booster. Page 14647 Seat Adjuster Switch - Driver (AG1) Locations Power Take-Off: Locations Power Take Off (PTO) Relay Page 15923 3. Prepare the surface of the used defroster tab (not required for new tabs on new-style full-size utility models) and the defroster buss bar with fine grain (500 grit) sandpaper or Emery cloth. It is not necessary to remove all of the original solder, but it should be scuffed sufficiently so that no oxidation is present. The photo above shows a close up of a properly prepared surface. Tip You may want to mask the glass around the contact area with tape. This is easy to do and will allow you to safely prepare the contact surface without the risk of scratching the glass or the black painted shading. Important Most rear glass has a black painted masking around the edge of the glass. When cleaning up the connection surface, be very careful not to damage the surface of the black shading or the surface of the glass. 4. Wipe the newly prepared contact area with Kent Automotive* Acrysol(TM) (or equivalent) to remove any residual oil or dirt. Important Page 894 9. Use J 38125-12A to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. REPAIR PROCEDURE The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. 1. Cut the wire as close to the terminal as possible. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. Page 7518 Control Module: Service and Repair NVG 263-NP1 Transfer Case Shift Control Module Replacement Transfer Case Shift Control Module Replacement Removal Procedure 1. Disconnect the shift control module electrical connectors. 2. Unsnap and remove the shift control module from the bracket. Installation Procedure Locations Impact Sensor: Locations Front End Sensors Page 8189 13. Use a Dial Indicator to measure the rotor to verify the LRO is within specification. 14. If using, BENCH LATHE - DO NOT remove conical washers and lug nuts at this time. ON-CAR LATHE - You must remove adapter and install conical washers and lug nuts to retain rotor position. Important For Hubless rotor design, while removing the adapter, you must hold the rotor tight to the hub and install the top conical washer and lug nut first to ensure no debris falls between the surface while removing the adapter. Then, install the remaining conical washers and lug nuts. Otherwise, LRO will be comprised. 15. Perform Steps 1 through 7 on the opposite side of the vehicle (steps 1-12, if performing LRO). 16. Reinstall the rotors on both sides of the vehicle and perform the following steps: 1. Reinstall the calipers and pads. 2. Pump the brakes to pressurize the calipers. 3. Remove the lug nuts/conical washers. 4. Install and properly torque the wheels. Important It is critical to follow the star pattern wheel torque procedure and use the proper tools (torque stick or torque wrench) as referenced in SI. 17. Road test the vehicle to verify the repairs. Brake Lathe Calibration Procedure BRAKE LATHE CALIBRATION PROCEDURE Calibration of the brake lathe should be performed and recorded monthly or whenever post-service brake rotor LRO measurements are consistently reading above specification. BENCH-TYPE LATHE Use the following procedure to calibrate a Bench-type brake lathe: 1. After refinishing a rotor, loosen the arbor nut and while holding the inside bell clamp to keep it from rotating, rotate the rotor 180 degrees. 2. Retighten the arbor nut and set the dial indicator on the rotor using the same instructions as checking the run out on the vehicle. 3. Rotate the arbor and read the runout. 4. Divide the reading by two and this will give you the amount of runout the lathe is cutting into the rotor. Important If there is any runout, you will need to machine the inside bell clamp in place on the lathe (this procedure is for a Bench type lathe ONLY, DO NOT machine inside the bell clamp on an On-Car type lathe). Machining the Inside Bell Clamp (Bench Type Lathe Only) Any nicks or burrs on the shoulder of the arbor must be removed. An 80-grit stone can be used to accomplish this. Spray WD-40(R) on the shoulder and with the lathe running, hold the stone flat against the shoulder surface using slight pressure. When the burrs are gone, clean the surface. Burrs must also be removed from the hub of the inside bell clamp. This can be accomplished with the stone and WD-40(R). Keep the stone flat on the hub while removing the burrs. After removing the burrs, clean the hub. Place the bell clamp on the arbor of the lathe and use the small radius adapters first and then spacers to allow you to tighten the arbor nut to secure the bell clamp to the lathe. Position the tool bit in the left hand of the rotor truer so you can machine the face of the bell clamp. Machine the face of the bell clamp taking just enough off of it to cut the full face of the clamp the full 360 degrees. Before you loosen the arbor nut, match mark the hub of the bell clamp to the arbor and line up these marks before machining a rotor. A magic marker can be used to make the match marks. Machine a rotor and recheck the calibration. Repeat this procedure on all Inside Bell Clamps used. Page 5667 Page 8186 If performing routine Brake Service for worn pads only, and the rotors are not damaged and measure within specification - DO NOT REFINISH ROTORS. 1. Remove the rotor(s). 2. Measure the rotor for original thickness using a brake micrometer. Multiple measure points should be taken and the lowest measurement should be recorded. 3. Reference the Minimum Thickness specification stamped on the backside of the rotor or SI for Minimum Thickness specification/other. In most cases, the rotor should be refinished unless the measurement taken makes it obvious that refinishing the rotor would take the measurement under the Minimum Thickness specification (then replacement is necessary). DO NOT use any other manufacturers rotor specifications. 3. ***Record the lowest ORIGINAL rotor thickness measurement on the repair order hard copy as noted in the "Repair Order Documentation - Rotor Refinish" section of this bulletin. 4. Clean all of the mating surfaces between the hub, the rotor and the wheel using the J 42450A Wheel Hub Cleaning Kit and J 41013 - Whiz Wheel(R). If rotors are not to be refinished - Go To Step 8. Important Cleaning all mating surfaces and making them free of corrosion, burrs and other debris (which includes removal of Hubless rotors) is critical and MUST be performed whether using an On-Car or Bench Lathe Refinish Procedure. 5. Be sure to follow the appropriate refinishing procedure listed below for the type of lathe you are using. Important Only replace the rotors if they do not meet the Minimum Thickness specification. Important DO NOT REFINISH NEW ROTORS. Important Only remove the necessary amount of material from each side of the rotor and note that equal amounts of material do not have to be removed from both sides on any brake system using a floating caliper. Important Prior to making the cut, install the recommended clip-on style disc silencer supplied with the lathe. Use of this silencer is critical to prevent chatter from occurring during the cut. Bench Type Lathe 1. Refinish the existing rotor on an approved, well-maintained lathe to guarantee smooth, flat and parallel surfaces. 2. Check for clean and true lathe adapters and make sure the arbor shoulder is clean and free of debris or burrs. For more information, see the "Brake Lathe Calibration Procedure (Bench-Type)" section in this bulletin. 3. On the outboard area of the rotor, position the cutting tools one eighth of an inch into the brake pad area of the rotor. Feed the cutting tools into the rotor until they cut the rotor to new metal, a full 360 degrees. Zero each dial and back off a full turn 4. Move the cutting bits to the middle of the rotor and do the same procedure. If zero is passed during the process, reset zero. Back off a full turn. 5. Position the cutting bits one eighth of an inch inside the inboard (closest to the hub) edge of the brake pad contact area. Do the same procedure. If zero is passed during the process, reset zero. 6. Back off a full turn and position the cutting bits all the way inboard in preparation to refinish the full rotor surface. Advance both tool cutters to the zero setting plus just enough to clean up the entire rotor surface. 7. After completing the refinish, sand both sides of the rotor for approximately one minute per side using a sanding block and 130-150 grit sandpaper to obtain a non-directional finish. On-Car Type Lathe 1. Reinstall the rotor(s). Important Page 319 OnStar(R) Microphone The OnStar(R), or cellular microphone, can be a part of the rearview mirror assembly, or on some vehicle lines, a separate, stand alone unit. In either case, the VCIM supplies approximately 10 volts to the microphone on the cellular microphone signal circuit, and voice data from the user is sent back to the VCIM over the same circuit. A cellular microphone low reference circuit or a drain wire provides a ground for the microphone. Cellular and GPS Antennas The vehicle will be equipped with one of the following types of antennas: ^ Separate, stand-alone cellular and navigation (GPS) antennas. ^ A combination cellular and navigation (GPS) antenna, which brings the functions of both into a single part. ^ A cellular, GPS, and digital radio receiver (DRR) antenna, which also incorporates the functionality of the DRR satellite antenna (XM). The cellular antenna is the component that allows the OnStar(R) system to send and receive data using electromagnetic waves by means of cellular technology. The antenna is connected at the base to a coax cable that plugs directly into the VCIM. The GPS antenna is used to collect the signals of the orbiting GPS satellites. Within the antenna is housed a low noise amplifier that allows for a more broad and precise reception of this data. The antenna is connected at the base to a coax cable that plugs directly into the VCIM. The cable also provides a path for DC current for powering the antenna. The OnStar(R) Call Center also has the capability of communicating with the vehicle during an OnStar(R) call to retrieve the latest GPS location and transmit it to the OnStar(R) Call Center. A history location of the last recorded position of the vehicle is stored in the module and marked as aged, for as long as the module power is not removed. Actual GPS location may take up to 10 minutes to register in the event of a loss of power. Audio System Interface When the OnStar(R) requires audio output, a serial data message is sent to the audio system to mute all radio functions and transmit OnStar(R) originated audio. The OnStar(R) audio is transmitted to the vehicle audio system by a dedicated signal circuit and a low reference circuit. The audio system will mute and an audible ring will be heard though the speakers if the vehicle receives a call with the radio ON. On some vehicles, the HVAC blower speed may be reduced when the OnStar(R) system is active to aid in reducing interior noise. When the system is no longer active, the blower speed will return to its previous setting. OnStar(R) Steering Wheel Controls Some vehicles may have a button on the steering wheel, that when pushed can engage the OnStar(R) system. The button may be a symbol of a face with sound waves, or may say MUTE, or be a symbol of a radio speaker with a slash through it. By engaging the OnStar(R) system with this feature, the user can interact with the system by use of voice commands. A complete list of these commands is supplied in the information provided to the customer. If the information is not available for reference, at any command prompt, the user can say "HELP" and the VCIM will return an audible list of available commands. The steering wheel controls consist of multiple momentary contact switches and a resistor network. The switches and resistor network are arranged so that each switch has a different resistance value. When a switch is pressed, a voltage drop occurs in the resistor network. This produces a specific voltage value unique to the switch selected, to be interpreted by the radio or the body control module (BCM). OnStar(R) Power Moding (DRX or Sleep Cycle) The OnStar(R) system uses a unique sleep cycle to allow the system to receive cellular calls while the ignition is in the OFF position and retained accessory power (RAP) mode has ended. A green status LED on the OnStar(R) keypad normally indicates an active OnStar(R) account. The OnStar(R) system will stay powered up after ignition off for an extended time in order to allow for remote services like door unlock, horn honk, light flash, etcetera to take place as requested by the customer. Power cycle (also referred to as DRX) times vary depending on the generation of the OnStar(R) system. Technicians may identify the OnStar(R) system generation by using a Tech 2 and following this menu path: (Body>VCIM>Module ID Information>Module Information 2) or by accessing www.onstarenrollment.com All Generation 6 digital systems are powered up continuously for 48 hours from ignition OFF. After 48 hours, the Generation 6 systems will enter a 9 minute OFF, 1 minute ON power cycle for an additional 72 hours. At the beginning and end of the 1 minute ON stage, you may or may not experience a short spike of current at the beginning and at the end. This allows for calls from OnStar to be received by the system. After 120 hours from ignition OFF, Page 14900 Power Seat Switch: Removal and Replacement Seat Switch Replacement - Power Removal Procedure 1. Remove the power seat switch bezel from the seat. 2. Remove the power seat switch to bezel screws. 3. Remove the power seat switch. Installation Procedure Notice: Refer to Fastener Notice in Service Precautions. 1. Install the power seat switch to bezel screws. Tighten the screws to 2 N.m (18 lb in). 2. Install the power seat switch bezel to the seat. Page 2688 Relay Block - I/P C1 Part 6 Page 11202 7. Position the SGCM coolant pump (1) to the radiator core support (3). 8. Install the bolts (2) to the SGCM coolant pump (1). Tighten Tighten the nut to 16 N.m (12 lb ft). 9. Install the push pin to the right side radiator air baffle. 10. Install the air cleaner assembly. 11. Install the rear evaporator tube (3) to the vehicle. 12. Connect the nut to the evaporator tube fitting. Tighten Tighten the nut to 9 N.m (80 lb in). 13. Install the evaporator tube to the evaporator. Interior - Front Heated Seat(s) Inoperative Seat Heater Switch: All Technical Service Bulletins Interior - Front Heated Seat(s) Inoperative Bulletin No.: 04-08-50-007 Date: March 12, 2004 INFORMATION Subject: Service Information for Front Heated Seat Inoperative/Cold Models: 2003-2004 Cadillac Escalade/ESV/EXT 2003-2004 Chevrolet Avalanch/Silverado/Suburban/Tahoe 2003-2004 GMC Denali/Sierra/Yukon/Yukon XL 2003-2004 Hummer H2 The purpose of this bulletin is to provide the technician with the following service information: ^ Heated Seats Switch Operation ^ Heated Seats Switch Diagnostics ^ Heated Seats Switch Customer Information Switch Operation 1. The engine must be running for the heated seat feature to work. The heated seats will shut off automatically when the ignition is turned off. 2. Two buttons, located on the door, are used to control the heated seat. ^ Press the horizontal (RH) button to heat the entire seat, back and cushion. ^ Press the vertical (LH) button to heat ONLY the seat back. ^ The three light bars are an indicator of the level of heat selected for either the entire seat (horizontal button) or ONLY the seat back (vertical button). 3. To heat both the seat back and seat cushion at the same time, press the horizontal (RH) button with the heated seat symbol one time. ^ All 3 light bars will glow indicating the HIGH temperature setting. ^ The horizontal (RH) button does NOT have an ON/OFF indicator light. Description and Operation Malfunction Indicator Lamp: Description and Operation MALFUNCTION INDICATOR LAMP (MIL) OPERATION The malfunction indicator lamp (MIL) is located in the instrument panel cluster. The MIL will display as either SERVICE ENGINE SOON or one of the following symbols when commanded ON: The MIL indicates that an emissions related fault has occurred and vehicle service is required. The following is a list of the modes of operation for the MIL: The MIL illuminates when the ignition is turned ON, with the engine OFF. This is a bulb test to ensure the MIL is able to illuminate. - The MIL turns OFF after the engine is started if a diagnostic fault is not present. - The MIL remains illuminated after the engine is started if the control module detects a fault. A diagnostic trouble code (DTC) is stored any time the control module illuminates the MIL due to an emissions related fault. The MIL turns OFF after three consecutive ignition cycles in which a Test Passed has been reported for the diagnostic test that originally caused the MIL to illuminate. - The MIL flashes if the control module detects a misfire condition which could damage the catalytic converter. - When the MIL is illuminated and the engine stalls, the MIL will remain illuminated as long as the ignition is ON. - When the MIL is not illuminated and the engine stalls, the MIL will not illuminate until the ignition is cycled OFF and then ON. Page 7827 Torque Converter Clutch Solenoid: Connector Locations Page 11580 Policies and Procedures Manual for courtesy transportation guidelines. Claim Information Submit a Product Recall Claim with the information shown. Customer Notification -- For US and Canada General Motors will notify customers of this recall on their vehicle (see copy of customer letter shown this bulletin). Customer Notification -- For Export Letters will be sent to known owners of record located within areas covered by the US National Traffic and Motor Vehicle Safety Act. For owners outside these areas, dealers should notify customers using the sample letter. Dealer Recall Responsibility -- For US and Export (US States, Territories, and Possessions) The US National Traffic and Motor Vehicle Safety Act provides that each vehicle which is subject to a recall of this type must be adequately repaired within a reasonable time after the customer has tendered it for repair. A failure to repair within sixty days after tender of a vehicle is prima facie evidence of failure to repair within a reasonable time. If the condition is not adequately repaired within a reasonable time, the customer may be entitled to an identical or reasonably equivalent vehicle at no charge or to a refund of the purchase price less a reasonable allowance for depreciation. To avoid having to provide these burdensome remedies, every effort must be made to promptly schedule an appointment with each customer and to repair their vehicle as soon as possible. In the recall notification letters, customers are told how to contact the US National Highway Traffic Safety Administration if the recall is not completed within a reasonable time. Dealer Recall Responsibility -- All All unsold new vehicles in dealers' possession and subject to this recall MUST be held and inspected/repaired per the service procedure of this recall bulletin BEFORE customers take possession of these vehicles. Dealers are to service all vehicles subject to this recall at no charge to customers, regardless of mileage, age of vehicle, or ownership, from this time forward. Customers who have recently purchased vehicles sold from your vehicle inventory, and for which there is no customer information indicated on the dealer listing, are to be contacted by the dealer. Arrangements are to be made to make the required correction according to the instructions contained in this bulletin. A copy of the customer letter is shown in this bulletin for your use in contacting customers. Recall follow-up cards should not be used for this purpose, since the customer may not as yet have received the notification letter. Page 7226 Refer to the table as a guide in selecting the correct test adapter for frontprobing connectors: Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure SCAN TOOL SNAPSHOT PROCEDURE Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: - Snapshot - taken from the Snapshot menu choice - Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information Page 4745 Conditions for Setting the DTC occur, the PCM executes the Action Taken When the DTC Sets. Some DTCs alert the driver via the MIL or a message. Other DTCs do not trigger a driver warning, but are stored in memory. The PCM also saves data and input parameters when most DTCs are set. This data is stored in the Freeze Frame and/or Failure Records. The DTCs are categorized by type. The DTC type is determined by the MIL operation and the manner in which the fault data is stored when a particular DTC fails. In some cases there may be exceptions to this structure. Therefore, when diagnosing the system it is important to read the Action Taken When the DTC Sets and the Conditions for Clearing the DTC in the supporting text. There are different types of DTCs and different actions taken when the DTCs set. Refer to Diagnostic Trouble Code (DTC) Type Definitions for a description of the general characteristics of each DTC type. DTC STATUS When the scan tool displays a DTC, the status of the DTC is also displayed. The following DTC statuses are indicated only when they apply to the DTC that is set. Fail This Ign. (Fail This Ignition): Indicates that this DTC failed during the present ignition cycle. Last Test Fail: Indicates that this DTC failed the last time the test ran. The last test may have run during a previous ignition cycle if an A or B type DTC is displayed. For type C DTCs, the last failure must have occurred during the current ignition cycle to appear as Last Test Fail. MIL Request: Indicates that this DTC is currently requesting the MIL. This selection will report type B DTCs only when they have requested the MIL (failed twice). Test Fail SCC (Test Failed Since Code Clear): Indicates that this DTC that has reported a failure since the last time DTCs were cleared. History: Indicates that the DTC is stored in the PCM History memory. Type B DTCs will not appear in History until they have requested the MIL (failed twice). History will be displayed for all type A DTCs and type B DTCs (which have requested the MIL) that have failed within the last 40 warm-up cycles. Type C DTCs that have failed within the last 40 warm-up cycles will also appear in History. Not Run SCC (Not Run Since Code Clear): DTCs will be listed in this category if the diagnostic has not run since DTCs were last cleared. This status is not included with the DTC display since the DTC can not be set if the diagnostic has not run. This information is displayed when DTC Info is requested using the scan tool. Page 6857 2. Install the new axle shaft seal using the J 45225 (1) and the J 8092 (2). 3. Install the inner axle shaft into the inner axle shaft housing. - Carefully tap the inner axle shaft into place with a soft-faced mallet. 4. Install the inner axle shaft and clutch fork assembly components into the inner shaft housing. 5. Install the inner axle shaft and housing assembly to the differential carrier case assembly. 6. If both the left side bearing and seal was removed, perform the follow step. Install the left side bearing with the square shoulder in using the J 36609 (1) and the J 8092 (2). 7. If both the left side bearing and seal was removed, perform the following step. Install the new axle shaft seal using the J 45225 (1) and the J 8092 (2). Page 12463 7.1. Remove the console (A) together with the OnStar(R) control modules. 7.2. Remove the connectors (B). Important: The optic cable must not be bent with a radius less than 25 mm (1 in). Important: Secure the wiring harness so that there is no risk of chafing and rattling. 7.3. Fold back the wiring harness and tape over the connectors (C). Fold back the wiring harness once more and secure with cable ties (D). 7.4. Fit the parcel shelf trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 8. CV: Removing the OnStar(R) control modules and securing the wiring: Adjustment/Replacement. 8.1. Open the luggage compartment floor. Page 6775 Disclaimer Page 13663 Front Door Panel: Service and Repair Panel Replacement Trim Panel Replacement - Side Front Door (With YE9 Early Production) Trim Panel Replacement - Side Front Door (With YE9 Early Production) Removal Procedure 1. Remove the door handle bezel. 2. Remove the door trim panel upper extension. 3. Using a suitable flat-bladed tool, gently pry the manual lock lever from the door trim panel. 4. Remove the trim panel screws. * Remove the screw (2) from within the opening where the manual door lock lever resides. * Remove the screw (3) from the opening in front of the armrest. 5. Carefully slide the trim panel up in order to release the retainers from the door. 6. Disconnect the electrical connectors. Installation Procedure Page 4324 IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. Splicing Twisted or Shielded Cable SPLICING TWISTED OR SHIELDED CABLE Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. - Rewrap the conductors with the mylar tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with mylar tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Control Module References Page 338 DTC B2476 04: Cellular Phone Select Service Switch Open Circuit DTC B2476 59: Cellular Phone Select Service Switch Stuck Button DTC B2482 00: Cellular Phone Select Service Switch Range/Performance Circuit Short to Ground Open / High Resistance Short to Voltage Signal Performance Circuit/System Description The OnStar(R) button assembly consists of 3 buttons, Call/Answer, OnStar(R) Call Center, and OnStar(R) Emergency. The vehicle communication interface module (VCIM) supplies the OnStar(R) button assembly with 10 volts via the keypad supply voltage circuit. Each of the buttons, when pressed, completes the circuit across a resistor allowing a specific voltage to be returned to the VCIM over the keypad signal circuit. Depending upon the voltage range returned, the VCIM is able to identify which button has been activated. Conditions for Running the DTCs The ignition is ON. System voltage is between 9 - 16 volts. Conditions for Setting the DTCs B2476 04: The VCIM detects an open/high resistance on the keypad supply voltage circuit. B2482 and B2476 59: The VCIM detects a valid signal on the keypad signal circuit for more than 15 seconds. If one of the OnStar(R) buttons is held or stuck for 15 seconds or more, the VCIM will set these DTCs. Action Taken When the DTCs Set The OnStar(R) status LED turns red. No calls can be placed. The VCIM will ignore all inputs from the OnStar® button assembly. Conditions for Clearing the DTCs The condition responsible for setting the DTC no longer exists. A history DTC will clear once 100 consecutive malfunction-free ignition cycles have occurred. Page 4645 High Temperature Conditions Tools Required J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency MEASURING FREQUENCY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage MEASURING VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop MEASURING VOLTAGE DROP NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Page 15983 Steps 1-3 Page 14039 Notice: Refer to Fastener Notice in Service Precautions. 3. Install the quarter panel trim screws. Tighten the quarter panel trim screws to 2 N.m (18 lb in). 4. Install the sill trim plates. 5. Install the armrest. 6. Install the armrest screw. Tighten the armrest screw to 2 N.m (18 lb in). 7. Install the rear window molding. 8. Install the rear seat if necessary. Trim Panel Replacement - Rear Quarter (Regular Cab) Trim Panel Replacement - Rear Quarter (Regular Cab) Removal Procedure 1. Remove the coat hook. 2. Remove the jack and tool stowage. 3. Remove the rear window lower molding. Page 8534 Vehicle Speed Sensor (VSS) Tow/Haul Switch Location Page 8843 What if I input the VIN incorrectly? If an incorrect VIN is entered into the system (meaning that the system does not recognize the VIN or that the VIN has been entered incorrectly) the system will return an error message. If I am an authorized user for the KeyCode application, can I access the application from home? Yes. What if I suspect key code misuse? Your dealership should communicate the proper procedures for requesting key codes. Any suspicious activity either within the dealership or externally should be reported to Dealer Systems Support at 1-800-265-0573 or GM of Canada Key Code Inquiry Desk at 1-905-644-4892. Whose key codes can I access through the system? At this time the following Canadian vehicle codes are available through the system: Chevrolet, Cadillac, Buick, Pontiac, GMC, HUMMER (H2 and H3 only), Oldsmobile, Saturn, Saab and Isuzu (up to 2002 model year) for a maximum of 17 model years. What should I do if I enter a valid VIN and the system does not produce any key code information? Occasionally, the KeyCode Look Up application may not produce a key code for a valid VIN. This may be the result of new vehicle information not yet available. In addition, older vehicle information may have been sent to an archive status. If you do not receive a key code returned for valid VIN, you should contact GM of Canada Key Code Inquiry Desk at 1-905-644-4892. How do I access KeyCodes if the KeyCode Look-up system is down? If the KeyCode Look-up system is temporarily unavailable, you can contact the original selling dealer who may have it on file or contact GM of Canada Key Code Inquiry Desk at 1-905-644-4892. If the customer is dealing with an emergency lock-out situation, you need to have the customer contact Roadside assistance, OnStar if subscribed, or 911. What should I do if the KeyCode from the look-up system does not work on the vehicle? On occasion a dealer may encounter a KeyCode that will not work on the vehicle in question. In cases where the KeyCode won't work you will need to verify with the manufacturer of the cutting equipment that the key has been cut correctly. If the key has been cut correctly you may be able to verify the proper KeyCode was given through the original selling dealer. When unable to verify the KeyCode through the original selling dealer contact GM of Canada Key Code Inquiry Desk at 1-905-644-4892. If the key has been cut correctly and the code given does not work, the lock cylinder may have been changed. In these situations following the proper SI document for recoding a key or replacing the lock cylinder may be necessary. How long do I have to keep KeyCode Records? Dealership KeyCode documentation must be retained for two years. Can I get a KeyCode changed in the Look-Up system? Yes, KeyCodes can be changed in the Look-Up system if a lock cylinder has been changed. Contact GM of Canada Key Code Inquiry Desk at 1-905-644-4892. What information do I need before I can provide a driver of a company fleet vehicle Keys or KeyCode information? The dealership should have a copy of the individual's driver's license, proof of employment and registration. If there is any question as to the customer's employment by the fleet company, the dealer should attempt to contact the fleet company for verification. If there is not enough information to determine ownership and employment, this information should not be provided. How do I document a request from an Independent Repair facility for a KeyCode or Key? The independent must provide a copy of their driver's license, proof of employment and signed copy of the repair order for that repair facility. The repair order must include customer's name, address, VIN, city, province and license plate number. Copies of this information must be included in your dealer KeyCode file. Page 15033 Tailgate Shock / Support: Service and Repair Support Cable Replacement - Endgate Support Cable Replacement - Endgate Removal Procedure 1. Lower the end gate. 2. Remove the end gate support cable on each side from the cable restrain bolt. 3. Remove the retainer from the end gate striker. 4. Remove the end gate support cable from the end gate. Installation Procedure 1. Install the end gate support cable onto the end gate. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the latch fastener. Tighten the latch fasteners to 25 N.m (18 lb ft). Front End Sensors Impact Sensor: Description and Operation Front End Sensors INFLATABLE RESTRAINT FRONT END SENSORS The front end sensors are equipped on vehicles to supplement the SIR system performance. The front end sensors are electronic and are not part of the deployment loops, but instead provide inputs to the sensing and diagnostic module (SDM). The front end sensors can assist in determining the severity of some frontal collisions. The SDM uses the input from the front end sensors to assist in determining the severity of a frontal collision further supporting air bag deployment. If the SDM determines a deployment is warranted, the SDM will cause current to flow through the deployment loops deploying the frontal air bags. Page 4264 Intake Air Temperature (IAT)/Mass Air Flow (MAF) Sensor Page 12503 THIS PROGRAM IS IN EFFECT UNTIL APRIL 30, 2011. Condition Certain 2002-2009 model year vehicles equipped with OnStar(R) may have a condition in which the vehicle's OnStar(R) system repeatedly makes incomplete calls to OnStar(R) without the vehicle's occupant(s) input or knowledge. Customer initiated Blue Button call, Emergency calls, and Automatic Crash Notification calls will also fail to establish a data connection with the OnStar(R) Call Center. Eventually, the customer's call will connect as a voice only line and the customer will be able to talk with an OnStar(R) advisor; however, the advisor will not get crucial customer data such as vehicle identification and location. Correction Dealers/retailers are to replace the OnStar(R) module (VCIM). Vehicles Involved Involved are certain 2002-2009 model year vehicles equipped with OnStar(R), and built within these VIN breakpoints: Note: Some model years/models have only one vehicle involved. Important Dealers/retailers are to confirm vehicle eligibility prior to beginning repairs by using GMVIS (dealers/retailers using WINS) or the Investigate Vehicle History link (dealers/retailers using GWM). Not all vehicles within the above breakpoints may be involved. For dealers/retailers with involved vehicles, a listing with involved vehicles containing the complete vehicle identification number, customer name, and address information has been prepared and will be provided to dealers/retailers through the GM GlobalConnect Recall Reports. Dealers/retailers will not have a report available if they have no involved vehicles currently assigned. The listing may contain customer names and addresses obtained from Motor Vehicle Registration Records. The use of such motor vehicle registration data for any purpose other than follow-up necessary to complete this program is a violation of law in several states/provinces/countries. Accordingly, you are urged to limit the use of this report to the follow-up necessary to complete this program. Parts Information US: OnStar(R) modules required for this program are to be obtained by contacting Autocraft Electronics via the web at www.autocraft.com, and selecting the catalog item that contains bulletin number 10037 (or PIC 4893B), or by calling 1-800-336-3998. Dealer must provide the VIN, R.O. number, and the current vehicle mileage. Canada: OnStar(R) modules required for this program are to be obtained by contacting MASS Electronics at 1-877-410-6277. Dealer must provide the VIN, R.O. number, and the current vehicle mileage. DO NOT ORDER ONSTAR(R) MODULES FROM GENERAL MOTORS CUSTOMER CARE AND AFTERSALES (GMCC&A;), SATURN SERVICE PARTS OPERATION (SSPO), OR THE TECHNICAL ASSISTANCE CENTER (TAC). Courtesy Transportation The General Motors Courtesy Transportation program is intended to minimize customer inconvenience when a vehicle requires a repair that is covered by the New Vehicle Limited Warranties. The availability of courtesy transportation to customers whose vehicles are within the warranty coverage period and involved in a product program is very important in maintaining customer satisfaction. Dealers/retailers are to ensure that these customers understand that shuttle service or some other form of courtesy transportation is available and will be provided at no charge. Dealers should refer to the General Motors Service Policies and Procedures Manual for Courtesy Transportation guidelines. Claim Information 1. Submit a claim using the table below. 2. Courtesy Transportation - For dealers/retailers using WINS, submit using normal labor code; for dealers/retailers using GWM - submit as Net Item under the repair labor code. Page 12109 DTC B2483: Global Positioning System (GPS) Antenna Malfunction Short to Ground DTC B2484: Global Positioning System (GPS) Antenna Malfunction Open Circuit Conditions for Running the DTCs The ignition is in RUN or ACC position System voltage is between 9.5 - 15.5 volts. The above conditions are met for more than 1 second. Conditions for Setting the DTCs B2462 02: The CIM detects a short to ground on the navigation antenna signal circuit. B2462 04: The CIM detects an open/high resistance on the navigation antenna signal circuit. B2483: The CIM detects a short to ground on the navigation antenna signal circuit. B2484: The CIM detects an open/high resistance on the navigation antenna signal circuit. Action Taken When the DTCs Set The OnStar(R) status LED turns red. The OnStar(R) Call Center cannot locate the vehicle. Conditions for Clearing the DTCs The condition responsible for setting the DTC no longer exists. A history DTC will clear once 50 consecutive malfunction-free ignition cycles have occurred. Circuit/System Testing Turn OFF the ignition. 1. Disconnect the navigation antenna coax cable from the VCIM. 2. Ignition ON, test for 4.5-5.5 volts between the VCIM coax cable center conductor terminal at the VCIM and ground. ^ If not within the specified range, replace the VCIM. Refer to the appropriate vehicle in SI. 3. Reconnect the coax cable to the VCIM. 4. Disconnect the coax cable from the navigation antenna. 5. Test for 4.55.5 volts between the coax cable center conductor and the outer shield. ^ If not within the specified range, replace the coax cable. 6. If all circuits test normal, replace the navigation antenna. Refer to the appropriate vehicle in SI. DTC B2470 DTC Descriptor DTC B2470 04: Cellular Phone Antenna Circuit Malfunction Open Circuit Circuit/System Description The cellular antenna is connected to the vehicle communication interface module (VCIM) with an RG-58 coax cable. The VCIM collects the data from the cellular antenna once every second. Page 1464 Turn Signal Multifunction Switch - C2 Page 16182 Power Window Switch: Service and Repair Switch Replacement - Door Lock and Side Window Passenger SWITCH REPLACEMENT - DOOR LOCK AND SIDE WINDOW - PASSENGER REMOVAL PROCEDURE 1. Remove the front door trim panel. 2. Disconnect the electrical connectors. 3. Remove the screw that retains the switch panel bezel (1) from the front door panel. 4. Remove the switch panel bezel from the door panel using a flat-bladed tool. 5. Using a wide plastic flat-bladed tool, release the retaining clips on both sides of the door module. 6. Remove the door module from the switch panel bezel. OnStar(R) - Generation 6 Service Procedures Technical Service Bulletin # 09-08-46-001 Date: 090409 OnStar(R) - Generation 6 Service Procedures INFORMATION Bulletin No.: 09-08-46-001 Date: April 09, 2009 Subject: Servicing Vehicles Upgraded to OnStar(R) Generation 6 Digital‐Capable System (Follow Information Below) Models Attention: This bulletin is being issued to provide dealer personnel with information and the procedures to diagnose an upgraded OnStar(R) Generation 6 Digital-Capable system. Program Overview Since it was launched in 1996, OnStar® has relied on an analog wireless network to provide communication to and from OnStar-equipped vehicles. As part of an industry wide change in the North American wireless telecommunications industry, wireless carriers are transitioning to digital technology and will no longer support the analog wireless network beginning early 2008. Effective January 1, 2008, OnStar(R) service in the United States and Canada will be available only through vehicles that are capable of operating on the digital network. Refer to Corporate Bulletin Number 05-08-46-006H for information about upgrading certain vehicles to digital service. Details were covered in both the November 2006 and December 2007 issues of TechLink, which are available in the Archives of the TechLink website. Vehicles eligible for an OnStar(R) hardware upgrade are listed in this bulletin. Vehicle upgradeability can also be determined by typing the VIN into the field entitled "Determine VIN Hardware Functionality" on the OnStar(R) Online Enrollment website, located in the sales or service workbench tab of GM GlobalConnect. Canadian Dealers can use a similar tool that is available within the OnStar(R) Canada Online Enrollment site that can be accessed from the OnStar(R) Brand Resources in GlobalConnect. Access to the sales and/or service workbench in the GM GlobalConnect website can be granted by the dealership's Partner Security Coordinator (PSC). Page 9842 Junction Block - I/P Wire Entry Part 2 Page 4666 - Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-D in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-D if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Page 4330 Control Module References Part 6 Page 1777 Impact Sensor: Service and Repair Side INFLATABLE RESTRAINT SIDE IMPACT SENSOR REPLACEMENT REMOVAL PROCEDURE CAUTION: - Refer to SIR Inflator Module Handling and Storage Caution in Service Precautions. - When carrying an undeployed inflatable restraint seat belt pretensioner: - Do not carry the seat belt pretensioner by the wires or connector. - Carry the seat belt pretensioner by the piston tube, keeping hands and fingers away from the cable. - Make sure the open end of the seat belt pretensioner piston tube points away from you and other people. - Do not cover the seat belt pretensioner piston tube opening with your hand. Failure to observe these guidelines may result in personal injury. 1. Disable the SIR system. Refer to SIR Disabling and Enabling Zone 6. 2. Remove the front door trim panel. 3. Loosen the 2 inflatable restraint side impact sensor fasteners (2). 4. Remove the inflatable restraint side impact sensor (1) from the door (4). 5. Remove the connector position assurance (CPA) (3), and disconnect the inflatable restraint side impact sensor yellow 2-way harness connector (5). INSTALLATION PROCEDURE 1. Connect the inflatable restraint side impact sensor yellow 2-way harness connector (5) to the inflatable restraint side impact sensor (1). 2. Install the CPA (3) to the inflatable restraint side impact sensor yellow 2-way connector (5). 3. Install the inflatable restraint side impact sensor (1) to the door (4). Page 15904 Vanity Mirror Lamp - Right (With RPO Code Y91) Page 9209 C214 I/P Harness To Headliner Harness (With RPO Code U42) Part 2 Page 14308 WA885K/70 - WA913L/56 Page 9011 Fuse Block - Underhood C1 Part 5 Fuse Block - Underhood C2 Page 2224 10. Grasp firmly while pulling down with a twisting motion in order to remove the filter. 11. Remove and discard the filter seal. The filter seal may be stuck in the pump; if necessary, carefully use pliers or another suitable tool to remove the seal. 12. Inspect the fluid color. 13. Inspect the filter. Pry the metal crimping away from the top of the filter and pull apart. The filter may contain the following evidence for root cause diagnosis: ^ Clutch material ^ Bronze slivers indicating bushing wear ^ Steel particles 14. Clean the transmission case and the oil pan gasket surfaces with solvent, and air dry. You must remove all traces of the old gasket material. Installation Procedure 1. Coat the NEW filter seal with automatic transmission fluid. 2. Install the NEW filter seal into the transmission case. Tap the seal into place using a suitable size socket. 3. Install the NEW filter. Memory Seat Calibration Procedure Memory Positioning Module: Service and Repair Memory Seat Calibration Procedure MEMORY SEAT CALIBRATION PROCEDURE The memory seat module uses position sensor inputs to establish soft stop locations for the adjuster motors several millimeters ahead of the physical limits of the adjuster assembly. After replacing a memory seat module or adjuster components, it may be necessary to reset the adjuster motor soft stop locations. When the repair procedure has been completed, operate the seat adjuster switch in every direction until the seat adjuster reaches its mechanical hard stop by repeatedly pressing and releasing the switch as necessary. Page 6543 Tow/Haul Switch: Testing and Inspection 4L80-E/4L85-E Transmission Tow/Haul Switch/Indicator Always On or Inoperative Circuit Description Tow/haul mode enables the operator to achieve enhanced shift performance when towing or hauling a load. When tow/haul mode is selected, the tow/haul switch input signal to the body control module (BCM) is momentarily toggled to zero volts. This signals the powertrain control module (PCM) to extend the length of time between up shifts and increase transmission line pressure. Cycling the tow/haul switch again disables tow/haul mode and returns the transmission to a normal shift pattern. Diagnostic Aids If the electrical circuit checks are OK and the tow/haul shift pattern is not occurring, there may be a mechanical/hydraulic condition that prevents tow/haul operation. Refer to Symptoms - Automatic Transmission. Page 14561 Disclaimer Interior - Intermittent Seat Heater Operation Seat Heater Control Module: All Technical Service Bulletins Interior - Intermittent Seat Heater Operation Bulletin No.: 05-08-50-008 Date: August 19, 2005 TECHNICAL Subject: Intermittent Heated Seats Inoperative, DTC B3941 Set (Reprogram Driver Seat Module) Models: 2003-2005 Cadillac Escalade, Escalade ESV, Escalade EXT 2003-2005 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2003-2005 GMC Sierra, Yukon, Yukon XL, Yukon Denali All with Seat FRT, Individual (Non BKT) (RPO AN3) 2003-2005 HUMMER H2 with Seat, Front Bucket Deluxe (RPO AR9) Condition Some customers may comment that occasionally the seat heater will not operate when activated. If the ignition key is cycled OFF and back ON again, the heated seat will operate correctly. Also, on some LB7 diesel engine vehicles, the seat heater may turn itself off during the first 10 minutes of operation. This occurs only with the first activation for the day and works correctly with subsequent activations immediately after the event. These conditions are intermiffent and DTC B3941 may be set. Correction Technicians are to reprogram the driver seat module with an updated software calibration. This new service calibration was released with TIS satellite data update version 6.5 available June 13, 2005. As always, make sure your Tech 2(R) is updated with the latest software version. Warranty Information Page 4289 Electrical Symbols Part 6 Page 10231 High Temperature Conditions Tools Required J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency MEASURING FREQUENCY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage MEASURING VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop MEASURING VOLTAGE DROP NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Page 1655 Tighten Tighten the sensor to 42 N.m (31 lb ft). 3. If equipped with a 6.0L engine, connect the HO2S electrical connector (2). 4. If equipped with a 4.8L or 5.3L engine, connect the HO2S electrical connector (2). 5. If equipped with a fuel composition sensor, install the HO2S electrical connector to the fuel line clip. 6. Disconnect the CPA retainer. 7. If equipped, connect the fuel composition sensor electrical connector. 8. Lower the vehicle. Page 5529 7. Remove the throttle body nuts. 8. Remove the throttle body. 9. Remove and discard the throttle body gasket. INSTALLATION PROCEDURE 1. Install the NEW throttle body gasket. 2. Install the throttle body. NOTE: Refer to Fastener Notice in Service Precautions. Page 12812 Page 12220 Important: The optic cable must not be bent with a radius less than 25 mm (1 in). 6.17. Fold back the wiring harness and tape over the connectors (G). Fold back the wiring harness once more and secure with cable ties (H). 6.18. Secure the new optic cable on the parcel shelf along the existing wiring harness by the ordinary securing points and by the speaker (I). 6.19. Thread the optic cable down next to the old cable from the parcel shelf to the left-hand wheel housing, next to REC. The cable is secured in the existing clips. 6.20. Fit the right-hand C-pillar trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.21. Fit the parcel shelf trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.22. Fit the passenger seat in accordance with WIS - 8. Body - Seats - Adjustment/Replacement. 6.23. Fit the right-hand side bolster in accordance with WIS - 8. Body - Seats Adjustment/Replacement. 6.24. Fold up the rear seat backrest. 6.25. Fit the right-hand B-pillar trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.26. Fit the A-pillar's lower side piece. 7. M04-05, 4D: Removing the OnStar® control modules and securing the wiring: Page 13649 1. Repair any damage done to the pillar during the drilling or the removal of the hinge. 2. Position the service hinge within the scribe marks on the pillar. 3. Center punch each stud location on the hinge pillar according to the service hinge. 4. Drill a 3 mm (1/8 in) (1) pilot hole at each center punch location. Important: Drill bit must be exact size. 5. Drill an 11.5 mm (29/64 in) hole at the pilot locations for the studs. 6. Clean and prepare all of the bare metal surfaces. Important: Prior to refinishing, refer to the publication GM 4901M-D-2000 GM Approved Refinish Materials for recommended products. Do not combine paint systems. Refer to paint manufacturer's recommendations. 7. Apply approved anti-corrosion primer. 8. Feed fish wire (1), GM P/N 15017229 or the equivalent, through the hinge, the hinge stud hole and out of the conduit hole in the pillar 9. Install stud (2), GM P/N 15017230, supplied with the service hinge into the wire end. Pull the stud into position. 10. Hold the stud in position with the hinge and remove the fish wire. 11. Draw the stud (4) tight through the pillar. Use the nuts GM P/N 11516746 supplied. 12. Repeat steps 8-11 on the remaining stud locations. 13. Remove each service nut. 14. Apply a full-bodied caulk to the entire hinge mounting surface in order to ensure a proper seal. Notice: Refer to Fastener Notice in Service Precautions. 15. Install the hinge (2) to the pillar (3). Use the supplied nuts (1). Page 484 TOOLS REQUIRED J 34142-B 12 V Unpowered Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. When testing for voltage: 1. Attach 1 lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach 1 lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Using Connector Test Adapters USING CONNECTOR TEST ADAPTERS NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-B Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires USING FUSED JUMPER WIRES TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Connector Position Assurance Locks CONNECTOR POSITION ASSURANCE LOCKS The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Terminal Position Assurance Locks TERMINAL POSITION ASSURANCE LOCKS The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Push to Seat Connectors PUSH TO SEAT CONNECTORS TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Page 8340 Brake Master Cylinder: Service and Repair Master Cylinder Fluid Level Sensor Replacement Master Cylinder Fluid Level Sensor Replacement Removal Procedure 1. Disconnect the electrical connector from the fluid level sensor. 2. Using needle nose pliers, compress the locking tabs at the opposite side of the master cylinder. 3. Remove the fluid level sensor. Installation Procedure Service and Repair Steering Angle Sensor: Service and Repair Rear Position Sensor Replacement Removal Procedure 1. Notice: Refer vehicle Lifting. Raise the vehicle. Refer to Vehicle Lifting. 2. Remove the steering gear protection shield (1) retaining bolts (3). 3. Disconnect the electrical connector (1). 4. Notice: When removing the rear position cover from the steering gear be careful not to damage to the rear position sensor. Remove the rear wheel position sensor cover (4) from the steering gear by prying on the cover using the slot. 5. Remove the rear wheel position sensor retaining bolts (3). 6. Important: Check the inner tie rod boot for wear or damage. If the boots are damaged replace the steering gear actuator. 7. Important: Page 8784 Electrical Symbols Part 14 Page 11722 For vehicles repaired under warranty, use the table. Disclaimer Instruments - DIC Perceived Fuel Economy Settings Driver/Vehicle Information Display: Technical Service Bulletins Instruments - DIC Perceived Fuel Economy Settings Bulletin No.: 03-00-89-021 Date: July 30, 2003 INFORMATION Subject: New Vehicle Pre-Delivery Inspection - Perceived Fuel Economy and Driver Information Center (DIC) Settings Models: 2003-2004 Passenger Cars and Trucks 2003-2004 HUMMER H2 with Driver Information Center (DIC) The customer's initial perception of vehicle fuel economy, based upon the information displayed on the Driver Information Center (DIC), may contribute to poor ratings for fuel economy in various automotive surveys. The way the vehicle is handled during the build and shipping process may leave inaccurate values in the history of the DIC. During the pre-delivery inspection, the dealership must reset the "average fuel economy" setting. Reset the average fuel economy setting according to the information in the appropriate Owner's Manual. Once reset, the average fuel economy will then be calculated starting from that point. The data used to determine fuel range is an average of recent driving conditions. This setting cannot be reset. However, as the customer's driving conditions change, the data will be gradually updated to reflect more accurate readings. If a customer inquires about fuel economy, and the fuel consumption information is not on the price sticker, do not exaggerate the vehicle's capabilities. In either case, stress that fuel economy performance is highly dependent upon driving habits and vehicle usage. Disclaimer Page 9800 Junction Block - Rear Lamps - C3 Page 4516 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Page 9778 C396 Body Harness To Right Rear Door Harness (Crew Cab) Part 2 Page 15838 Tail/Stop Lamp - Right Page 1068 Page 12863 4.2. Release the back end of the connector (C) and remove from the contact rail (D). 4.3. M00-01: Disconnect pin 39, cut off the cable terminal and insulate the end using tape (E). Fold back the cable and secure using tape (F). 4.4. M02-04: Disconnect pin 58, cut off the cable terminal and insulate the end using tape (E). Fold back the cable and secure using tape (F). 4.5. Assemble the contact rail and end. 4.6. Connect connector (A) and secure the cable using a cable tie (B). 5. Assemble the gear shift housing (A). AUT: Connect connector (B). 6. Assemble the center console, see WIS - Body - Interior. 7. Remove the OnStar(R) control module and secure the cable harness: 7.1. 5D: Remove the right-hand cover from the luggage compartment floor. Interior - Front Seat Arm Rest Hinge Broken Arm Rest: Customer Interest Interior - Front Seat Arm Rest Hinge Broken Bulletin No.: 06-08-50-004A Date: July 28, 2006 TECHNICAL Subject: Front Seat Armrest Hinge Breaking (Replace Lid) Models: 2003-2006 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2003-2006 GMC Sierra, Yukon, Yukon XL with Front Split Seat (RPO AE7) Supercede: This bulletin is being revised to include RPO Code and interior trim color code information. Please discard Corporate Bulletin Number 06-08-50-004 (Section 08 - Body and Accessories). Condition Some customers may comment that the lid for the armrest is broken. Correction Replace the armrest lid using the procedure below. 1. Open the armrest lid. 2. Remove the armrest inner panel. Use a flat-bladed screwdriver and place it between the two panels and pull to separate. 3. Fold the seat backs to gain access to the hinge pin. Using a punch, push the hinge pin out. 4. Install the two springs into the new armrest lid. 5. Align the two springs and the lid to the armrest and install the pin. 6. Install the inner lid to the armrest and close the lid. 7. Place the seat back in the upright position. Diagram Information and Instructions Alternator: Diagram Information and Instructions Truck Zoning TRUCK ZONING Truck Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that corresponds to where they are located in the vehicle. The table explains the numbering system. Page 12504 * Dealers using WINs: Add 0.2 hours to the labor time for administrative allowance for the module exchange. Dealers using GWM: Submit 0.2 hours administrative allowance under "Administration Time" for the module exchange. ** The $25 represents the additional net amount allowed for the module exchange. *** Dealers are to claim only administrative allowance of 0.2 hours when the module is replaced by Masscomp's Mobile Unit. Dealers using WINS should submit the 0.2 hours administrative allowance in labor time. Dealer using GWM should submit the 0.2 hours administrative allowance under Administrative Time. Customer Notification OnStar will notify customers of this program on their vehicle. Dealer Program Responsibility All unsold new vehicles in dealers'/retailers' possession and subject to this program must be held and inspected/repaired per the service procedure of this program bulletin before customers take possession of these vehicles. Dealers/retailers are to service all vehicles subject to this program at no charge to customers, regardless of mileage, age of vehicle, or ownership, through April 30, 2011. Customers who have recently purchased vehicles sold from your vehicle inventory, and for which there is no customer information indicated on the dealer/retailer listing, are to be contacted by the dealer/retailer. Arrangements are to be made to make the required correction according to the instructions contained in this bulletin. A copy of the customer letter is provided in this bulletin for your use in contacting customers. Program follow-up cards should not be used for this purpose, since the customer may not as yet have received the notification letter. Page 4957 Extended Cab Short Box Shown Below, Other Configurations Similar 6. Install the new canister vent valve solenoid to the fuel tank clip or mounting bracket as shown above. The valve port closest to the electrical connector must point towards the canister. 7. Cut bulk 5/8" heater hose to a length of approximately 76 mm (3 in). Install the hose between the solenoid and the canister pipe and secure using clamps. 8. Attach bulk 5/8" heater hose to the vent port and secure using a clamp. Run a length as needed along the frame rail routing to the area above the transmission. 9. Cut the hose to determined length and install the supplied filter box. Secure using a clamp. 10. Remove the transmission support and lower the transmission assembly as necessary to allow for access to the new filter box location. 11. Secure the filter box to the transmission vent hose just forward of the hose tee-section using a tie strap. DO NOT pinch or restrict the transmission vent hose. The filter box opening should be pointing downward. 12. Raise the transmission and reinstall the transmission support. 13. Connect the EVAP canister vent valve electrical connector. 14. Tie strap the hose as needed along the frame rail in order to keep the hose away from pinch-points and heat sources. 15. Lower the vehicle. Correction (2007-2010 New Style Models) After following the published SI diagnostics and determining that the EVAP canister vent valve is the cause of the MIL light, replace the EVAP canister vent valve assembly and relocate the remote filter box. To ensure correct installation, follow the procedures below. Important DO NOT replace the EVAP canister assembly for this concern unless it fails the leak test. Use Service Kit P/N 19207763 1. Raise the vehicle. Suitably support the vehicle. 2. Disconnect the EVAP canister vent valve electrical connector. Page 5866 Speed Sensor: Service and Repair Transfer Case - NVG 263-NP1 Transfer Case Speed Sensor Replacement Removal Procedure 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. Disconnect the speed sensor electrical connector. 3. Remove the speed sensor. Installation Procedure 1. Notice: Refer to Fastener Notice in Service Precautions. Install the speed sensor. ^ Tighten the sensor to 15 Nm (11 ft. lbs.). Diagrams Backup Lamp - Switch (Manual Trans) Page 12120 6. See wiring diagram shown above for details. 5. Replace the OnStar(R) Vehicle Communication Interface Module (VCIM) in the vehicle with the provided Digitally-Capable VCIM. Refer to the Communication Interface Module Replacement procedure in the Cellular Communication section of SI. This kit may include a new VCIM bracket. If it does, use this new bracket on the vehicle and discard the original bracket. The kit may also include a small wiring jumper cable. If it does, plug the wiring jumper cable into the connector on the VCIM and the other end to the corresponding vehicle wiring harness connector. ^ For 2001, 2002 and 2003 Chevrolet Impala and Monte Carlo, do not reinstall the black plastic OnStar(R) module cover onto the vehicle after the VCIM and module bracket have been installed. This black plastic cover will no longer fit on the vehicle. ^ The upgrade kit for 2002 Sevilles and DeVilles, and some 2003 Sevilles and DeVilles, will contain a large bracket. To install the new VCIM into this bracket you'll need to carefully line up the notch in the VCIM with the tab in the bracket. Page 9591 Relay Block - I/P C1 Part 2 Page 1114 Power Door Lock Switch: Removal and Replacement Switch Replacement - Door Lock and Side Window - Driver Switch Replacement - Door Lock and Side Window - Driver Removal Procedure 1. Remove the front door trim panel. 2. Disconnect the electrical connectors. 3. Remove the screw that retains the switch panel bezel (1) from the front door panel. 4. Remove the switch panel bezel from the door panel using a flat-bladed tool. 5. Using a wide plastic flat-bladed tool, release the retaining clips on both sides of the door module. 6. Remove the door module from the switch panel bezel. OnStar(R) - Analog/Digital System Information Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Analog/Digital System Information INFORMATION Bulletin No.: 06-08-46-008C Date: September 18, 2008 Subject: Information on OnStar(R) Dual-Mode (Analog/Digital) Systems Models Supercede: This bulletin is being revised to correct the model year range for the Chevrolet Impala and Monte Carlo and update the reference to GM Dealerworld. Please discard Corporate Bulletin Number 06-08-46-008B (Section 08 - Body and Accessories). All 2000-2003 model year vehicles equipped with OnStar® from the list above were built with Analog/Digital-Ready OnStar(R) Hardware. Some of these vehicles may have been upgraded to Dual-Mode (Analog/Digital). Certain 2004-2005 model year vehicles equipped with OnStar(R) from the list above may have been either: ^ Originally built at the factory with Dual-Mode (Analog/Digital) OnStar(R) Hardware with Dual-Mode (Analog/Digital) OnStar(R) Hardware OR ^ Upgraded to Dual-Mode (Analog/Digital) Hardware All 2006 model year and newer vehicles equipped with OnStar(R) were built at the factory with Dual-Mode (Analog/Digital) OnStar(R) Hardware. If a vehicle has Dual-Mode (Analog/Digital) OnStar(R) Hardware, then the system is capable of operating on both the analog and digital cellular Page 8219 6. If the brake rotor assembled LRO measurement exceeds the specification, bring the LRO to within specifications. Refer to Brake Rotor Assembled Lateral Runout (LRO) Correction. 7. Install the rotor by slowly turning the rotor while pushing the rotor towards the axle. 8. Install the caliper and the bracket as an assembly to the vehicle. 9. Perform the following procedure before installing the caliper bracket mounting bolts. 1. Remove all traces of the original adhesive patch. 2. Clean the threads of the bolt with brake parts cleaner or the equivalent and allow to dry. 3. Apply Threadlocker GM P/N 12345493 (Canadian P/N 10953488) to the threads of the bolt. 10. Notice: Refer to Fastener Notice in Service Precautions. Install the caliper bracket mounting bolts. For the 15 series, tighten the brake caliper bracket mounting bolts to 200 Nm (148 ft. lbs.). For the 25/35 series, tighten the brake caliper bracket mounting bolts to 165 Nm (122 ft. lbs.). 11. Install the tire and wheel assembly. 12. Lower the vehicle. 13. With the engine OFF, gradually apply the brake pedal to approximately 2/3 of it's travel distance. 14. Slowly release the brake pedal. 15. Wait 15 seconds, then repeat steps 13-14 until a firm pedal is obtained. This will properly seat the brake caliper pistons and brake pads. 16. Fill the master cylinder reservoir to the proper level with clean brake fluid. Refer to Master Cylinder Reservoir Filling in Hydraulic Brakes. (W/Dual Wheels) Brake Rotor Replacement - Rear (W/Dual Wheels) Caution: Refer to Brake Dust Caution in Service Precautions. Page 365 Important: Secure the wiring harness so that there is no risk of chafing or rattling. 6.1. Remove the passenger seat in accordance with WIS 8. Body - Seats Adjustment/Replacement. 6.2. Remove the right-hand B-pillar trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.3. Remove the right-hand C pillar trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.4. Fold the rear seat backrest forward. 6.5. Remove the right-hand side bolster in accordance with WIS - 8. Body - Seats Adjustment/Replacement. 6.6. Remove the A-pillar's lower side piece. 6.7. Open the cover on the right-hand wiring harness channels. 6.8. Loosen the locking strip (A) on the 2-pin connector (H2-11) for the optic cable, located by the right-hand A-pillar. 6.9. Loosen the catch (B) and remove the optic cable that runs backward in the car. 6.10. Dismantle the end cap from the new optic cable (12 783 577) and connect it to the connector H2-11. Push in the optic cable and make sure the catch (B) locks and refit the locking strip (A). 6.11. Secure the connector and the old optic cable using the cable tie for the existing wiring harness (C). Page 3211 Valve Cover: Service and Repair Valve Rocker Arm Cover Replacement (Right) Valve Rocker Arm Cover Replacement - Right Removal Procedure 1. If equipped with regular production option (RPO) HP2, disconnect the energy storage box (ESB). 2. Remove the engine sight shield, if required. 3. Remove the connector position assurance (CPA) lock (5). 4. Disconnect the main electrical connector (4) to the ignition coil wire harness. 5. Remove the harness clips (1). 6. Reposition the engine harness, if necessary. 7. Remove the spark plug wires from the ignition coils. ^ Twist each plug wire 1/2 turn. ^ Pull only on the boot in order to remove the wire from the ignition coil. 8. Reposition the surge tank/heater hoses from the heater hose bracket. 9. Remove the heater hose bracket nut and bracket. Page 12518 2007 Model Year Vehicles and Newer all have Digital OnStar(R) Modules. Part 1 OnStar(R) Description and Operation This OnStar(R) digital system consists of the following components: ^ Vehicle Communication Interface Module (VCIM) ^ OnStar(R) button assembly ^ Microphone ^ Cellular antenna ^ Navigation antenna Note This system also interfaces with the factory installed vehicle audio system. Vehicle Communication Interface Module (VCIM) The vehicle communication interface module (VCIM) is a cellular device that allows the user to communicate data and voice signals over the national cellular network. Power is provided by a dedicated, fused B+ circuit. Ground is provided through the vehicle wiring harness attached to the module. The ignition state is determined by the VCIM through serial data messaging. Dedicated circuits are used to connect the VCIM to a microphone, the button assembly, and to command the status LED. The VCIM communicates with the rest of the vehicle modules using the serial data bus. The module houses 2 technology systems, one to process GPS data, and another for cellular information. The cellular system connects the OnStar(R) system to the cellular carrier's communication system by interacting with the national cellular infrastructure. The module sends and receives all cellular communications over the cellular antenna and cellular antenna coax. GPS satellites orbiting earth are constantly transmitting signals of their current location. The OnStar(R) system uses the GPS signals to provide location on demand. The module also has the capability of activating the horn, initiating door lock/unlock, or activating the exterior lamps using the serial data circuits. These functions can be commanded by the OnStar(R) Call Center per: a customer request. OnStar(R) Button Assembly The OnStar(R) button assembly may be part of the rearview mirror, or a separate, stand alone unit. The button assembly is comprised of 3 buttons and a status LED. The buttons are defined as follows: ^ The answer/end call button, which is black with a white phone icon, allows the user to answer and end calls or initiate speech recognition. ^ The blue OnStar(R) call center button, which displays the OnStar(R) logo, allows the user to connect to the OnStar(R) call center. ^ The emergency button, which displays a white cross with a red background, sends a high priority emergency call to the OnStar(R) call center when pressed. The VCIM supplies 10 volts to the OnStar(R) button assembly on the keypad supply voltage circuit. When pressed, each button completes a circuit across a resistor allowing a specific voltage to be returned to the VCIM on the keypad signal circuit. Depending upon the voltage range returned the VCIM is able to identify which button has been pressed. The OnStar(R) status LED is located with the button assembly. The LED is green when the system is ON and operating normally. When the status LED is green and flashing, it is an indication that a call is in progress. When the LED is red, this indicates a system malfunction is present. In the event there is a system malfunction and the OnStar(R) system is still able to make a call, the LED will flash red during the call. If the LED does not illuminate, this may indicate that the customers OnStar(R) subscription is not active or has expired. Push the blue OnStar button to connect to an advisor who can then verify the account status. Each LED is controlled by the VCIM over dedicated LED signal circuits. Ground for the LED is provided by the wiring harness attached to the button assembly. Page 14063 Electrical Symbols Part 2 Page 2984 Parts Information Warranty Information For vehicles repaired under warranty use, the table. Disclaimer Power Steering Pulley Power Steering Pump: Service and Repair Power Steering Pulley Power Steering Pulley Replacement ^ Tools Required J 25034-C Power Steering Pump Pulley Remover - J 25033-C Power Steering Pump Pulley Installer Removal Procedure 1. Remove the upper fan shroud. 2. Remove the drive belt. 3. Remove the power steering pump pulley using the J 25034-C. Installation Procedure 1. Place the power steering pump pulley on the end of the power steering pump shaft. 2. Install the power steering pump pulley using J 25033-C. 3. Ensure that the power steering pump pulley (1) is flush against the power steering pump shaft (2), with an allowable variance of 0.25 mm (0.010 inch). 4. Install the drive belt. 5. Install the upper fan shroud. Page 4352 1. Slide the BCM onto the bracket. 2. Connect all the connectors (1) except the brown connector. 3. Connect the brown connector. 4. Install the knee bolster. 5. Connect the negative battery cable(s). 6. Reprogram the BCM. Refer to Body Control Module (BCM) Programming/RPO Configuration. 7. Perform the Passlock Learn Procedure. See: Testing and Inspection/Programming and Relearning Page 15331 5. Connect the fuel pump electrical connector. 6. Install the sending unit. Page 8307 3. Notice: Support the brake caliper with heavy mechanic's wire, or equivalent, whenever it is separated from its mount and the hydraulic flexible brake hose is still connected. Failure to support the caliper in this manner will cause the flexible brake hose to bear the weight of the caliper, which may cause damage to the brake hose and in turn may cause a brake fluid leak. Remove the brake caliper from the brake caliper mounting bracket and support the brake caliper with heavy mechanic's wire or equivalent. DO NOT disconnect the hydraulic brake hose from the caliper. 4. Remove the disc brake pads from the brake caliper mounting bracket. 5. Remove the disc brake pad retainers from the brake caliper mounting bracket. 6. Remove the caliper slide pins (5) from the brake caliper mounting bracket (3). 7. Remove the caliper slide pin boots (4) from the brake caliper mounting bracket. 8. Inspect the disc brake hardware. Installation Procedure 1. Lubricate the brake caliper mounting bracket bushings and the caliper slide pins with high temperature silicone brake lubricant. 2. Install the caliper slide pin boots (4) to the disc brake caliper mounting bracket. 3. Install the caliper slide pins (5) to the brake caliper mounting bracket (3). 4. Install the disc brake pad retainers to the brake caliper mounting bracket. 5. Install the disc brake pads to the brake caliper mounting bracket. 6. Install the disc brake caliper to the brake caliper mounting bracket. 7. With the engine OFF, gradually apply the brake pedal approximately 2/3 of it's travel distance. 8. Slowly release the brake pedal. 9. Wait 15 seconds, then repeat steps 7-8 until a firm brake pedal is obtained. This will properly seat the brake caliper pistons and brake pads. 10. Lower the vehicle. Page 12007 Claim Information - GM, Saturn Canada and Saab Canada Only Claim Information - Saturn US Only Customer Reimbursement Claims - Special Attention Required Customer reimbursement claims must have entered into the "technician comments" field the CSO # (if repair was completed at a Saturn Retail Facility) date, mileage, customer name, and any deductibles and taxes paid by the customer. Claim Information - Saab US Only Page 12439 Models The service procedure in this bulletin has been revised. Step 11 in the procedure for the 2004-2005 Saab 9-3 (9440) Convertible has been revised. Discard all copies of bulletin 08089B, issued September 2008. Condition In November 2002, the U.S. Federal Commissions (FCC) ruled that wireless carriers would no longer be required to support the analog wireless network beginning in 2008. As a result, On Star(R) is unable to continue analog service. OnStar(R) has deactivated most of the systems operating in the analog mode; however, there are some vehicles that OnStar(R) could not deactivate. Although the analog OnStar(R) hardware in these vehicles can no longer communicate with OnStar(R), the hardware in the vehicle is still active. If the OnStar(R) emergency button is pressed, or in the case of an airbag deployment, or near deployment, the customer may hear a recording that OnStar(R) is being contacted. However, since analog service is no longer available, the call will not connect to OnStar(R). To end the call, the customer must press the white phone or white dot button. If the call is not ended, the system will continue to try to connect to OnStar(R) until the vehicle battery is drained. Special Policy Adjustment At the customer's request, dealers/retailers are to deactivate the OnStar(R) system. The service will be made at no charge to the customer. This special coverage covers the condition described above until December 31, 2008 for all non-Saab vehicles; April 30, 2009 for all Saab vehicles. Vehicles Involved Page 12395 Disclaimer Page 7449 Case Adapter: Service and Repair Transfer Case - NVG 261-NP2 Transfer Case Adapter Replacement Removal Procedure 1. Remove the transfer case. 2. Lower the transmission slightly. 3. Remove the transfer case adapter bolts. 4. Remove the transfer case adapter. 5. Remove the transfer case adapter seal. 6. Remove the transfer case gasket, if necessary. Installation Procedure 1. Important: Always use a new gasket and seal for the transfer case and the transfer case adapter. Do not use any type of sealant or adhesive in place of or with the gasket or the seal. Install a NEW transfer case adapter seal. 2. Important: The transfer case adapter must be installed so that the adapter is evenly seated to the transmission before installing the retaining nuts. Position the transfer case adapter. Page 2226 Fluid Filter - A/T: Service and Repair 4L80-E/4L85-E Automatic Transmission Fluid/Filter Replacement Removal Procedure 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. Place a drain pan under the transmission oil pan. 3. Remove the oil pan drain plug, if equipped. 4. Allow the transmission fluid to drain completely. 5. Apply a small amount of sealant GM P/N 12346004 (Canadian P/N 10953480), or equivalent to the treads of the drain plug, if equipped. Notice: Refer to Fastener Notice in Service Precautions. 6. Install the oil pan drain plug. ^ Tighten the oil pan drain plug to 18 Nm (13 ft. lbs.). 7. Remove the drain pan from under the transmission oil pan. 8. Support the transmission with a transmission jack. 9. Remove the transmission mount nuts. 10. Remove the transmission support bolts and nuts. 11. Remove the transmission support side bracket bolts and bracket. 12. Remove the transmission support. 13. Disconnect the range selector cable end (2) from the transmission range selector lever ball stud (1). Page 7932 Page 8091 5. Notice: Refer to Fastener Notice in Service Precautions. Install the WSS mounting bolt. ^ Tighten the WSS mounting bolt to 18 Nm (13 ft. lbs.). 6. Install the WSS cable mounting clip to the knuckle. 7. Install the WSS cable mounting clip to the upper control arm. 8. Install the WSS cable mounting clip to the frame attachment point. 9. Connect the WSS cable electrical connector. Page 753 Control Module HVAC: Diagrams HVAC System - Automatic HVAC Control Module - C1 Part 1 Page 4427 results from the alteration or modification of a vehicle using non-GM approved parts or accessories. Dealers should be especially cautious of accessory companies that claim the installation of their product will not void the factory warranty. Many times these companies have even given direction on how to quickly disassemble the accessory in an attempt to preclude the manufacturer from finding out that is has been installed. Any suspect repairs should be reviewed by the Fixed Operations Manager (FOM), and in Canada by the Warranty Manager (WM) for appropriate repair direction. If it is decided that a goodwill repair is to be made on the vehicle, even with the installation of such non-GM approved components, the customer is to be made aware of General Motors position on this issue and is to sign the appropriate goodwill documentation required by General Motors. It is imperative for dealers to understand that by installing such devices, they are jeopardizing not only the warranty coverage, but also the performance and reliability of the customer's vehicle. Disclaimer Page 12432 THIS PROGRAM IS IN EFFECT UNTIL APRIL 30, 2011. Condition Certain 2002-2009 model year vehicles equipped with OnStar(R) may have a condition in which the vehicle's OnStar(R) system repeatedly makes incomplete calls to OnStar(R) without the vehicle's occupant(s) input or knowledge. Customer initiated Blue Button call, Emergency calls, and Automatic Crash Notification calls will also fail to establish a data connection with the OnStar(R) Call Center. Eventually, the customer's call will connect as a voice only line and the customer will be able to talk with an OnStar(R) advisor; however, the advisor will not get crucial customer data such as vehicle identification and location. Correction Dealers/retailers are to replace the OnStar(R) module (VCIM). Vehicles Involved Involved are certain 2002-2009 model year vehicles equipped with OnStar(R), and built within these VIN breakpoints: Note: Some model years/models have only one vehicle involved. Important Dealers/retailers are to confirm vehicle eligibility prior to beginning repairs by using GMVIS (dealers/retailers using WINS) or the Investigate Vehicle History link (dealers/retailers using GWM). Not all vehicles within the above breakpoints may be involved. For dealers/retailers with involved vehicles, a listing with involved vehicles containing the complete vehicle identification number, customer name, and address information has been prepared and will be provided to dealers/retailers through the GM GlobalConnect Recall Reports. Dealers/retailers will not have a report available if they have no involved vehicles currently assigned. The listing may contain customer names and addresses obtained from Motor Vehicle Registration Records. The use of such motor vehicle registration data for any purpose other than follow-up necessary to complete this program is a violation of law in several states/provinces/countries. Accordingly, you are urged to limit the use of this report to the follow-up necessary to complete this program. Parts Information US: OnStar(R) modules required for this program are to be obtained by contacting Autocraft Electronics via the web at www.autocraft.com, and selecting the catalog item that contains bulletin number 10037 (or PIC 4893B), or by calling 1-800-336-3998. Dealer must provide the VIN, R.O. number, and the current vehicle mileage. Canada: OnStar(R) modules required for this program are to be obtained by contacting MASS Electronics at 1-877-410-6277. Dealer must provide the VIN, R.O. number, and the current vehicle mileage. DO NOT ORDER ONSTAR(R) MODULES FROM GENERAL MOTORS CUSTOMER CARE AND AFTERSALES (GMCC&A;), SATURN SERVICE PARTS OPERATION (SSPO), OR THE TECHNICAL ASSISTANCE CENTER (TAC). Courtesy Transportation The General Motors Courtesy Transportation program is intended to minimize customer inconvenience when a vehicle requires a repair that is covered by the New Vehicle Limited Warranties. The availability of courtesy transportation to customers whose vehicles are within the warranty coverage period and involved in a product program is very important in maintaining customer satisfaction. Dealers/retailers are to ensure that these customers understand that shuttle service or some other form of courtesy transportation is available and will be provided at no charge. Dealers should refer to the General Motors Service Policies and Procedures Manual for Courtesy Transportation guidelines. Claim Information 1. Submit a claim using the table below. 2. Courtesy Transportation - For dealers/retailers using WINS, submit using normal labor code; for dealers/retailers using GWM - submit as Net Item under the repair labor code. Restraints - Passenger Presence System Information Seat Occupant Sensor: All Technical Service Bulletins Restraints - Passenger Presence System Information INFORMATION Bulletin No.: 06-08-50-009F Date: December 23, 2010 Subject: Information on Passenger Presence Sensing System (PPS or PSS) Concerns With Custom Upholstery, Accessory Seat Heaters or Other Comfort Enhancing Devices Models: 2011 and Prior GM Passenger Cars and Trucks Equipped with Passenger Presence Sensing System Supercede: This bulletin is being revised to update the model years. Please discard Corporate Bulletin Number 06-08-50-009E (Section 08 - Body and Accessories). Concerns About Safety and Alterations to the Front Passenger Seat Important ON A GM VEHICLE EQUIPPED WITH A PASSENGER SENSING SYSTEM, USE THE SEAT COVERS AND OTHER SEAT-RELATED EQUIPMENT AS RELEASED BY GM FOR THAT VEHICLE. DO NOT ALTER THE SEAT COVERS OR SEAT-RELATED EQUIPMENT. ANY ALTERATIONS TO SEAT COVERS OR GM ACCESSORIES DEFEATS THE INTENDED DESIGN OF THE SYSTEM. GM WILL NOT BE LIABLE FOR ANY PROBLEMS CAUSED BY USE OF SUCH IMPROPER SEAT ALTERATIONS, INCLUDING ANY WARRANTY REPAIRS INCURRED. The front passenger seat in many GM vehicles is equipped with a passenger sensing system that will turn off the right front passenger's frontal airbag under certain conditions, such as when an infant or child seat is present. In some vehicles, the passenger sensing system will also turn off the right front passenger's seat mounted side impact airbag. For the system to function properly, sensors are used in the seat to detect the presence of a properly-seated occupant. The passenger sensing system may not operate properly if the original seat trim is replaced (1) by non-GM covers, upholstery or trim, or (2) by GM covers, upholstery or trim designed for a different vehicle or (3) by GM covers, upholstery or trim that has been altered by a trim shop, or (4) if any object, such as an aftermarket seat heater or a comfort enhancing pad or device is installed under the seat fabric or between the occupant and the seat fabric. Aftermarket Seat Heaters, Custom Upholstery, and Comfort Enhancing Pads or Devices Important ON A GM VEHICLE EQUIPPED WITH A PASSENGER SENSING SYSTEM, USE ONLY SEAT COVERS AND OTHER SEAT-RELATED EQUIPMENT RELEASED AS GM ACCESSORIES FOR THAT VEHICLE. DO NOT USE ANY OTHER TYPE OF SEAT COVERS OR SEAT-RELATED EQUIPMENT, OR GM ACCESSORIES RELEASED FOR OTHER VEHICLE APPLICATIONS. GM WILL NOT BE LIABLE FOR ANY PROBLEMS CAUSED BY USE OF SUCH IMPROPER SEAT ACCESSORIES, INCLUDING ANY WARRANTY REPAIRS MADE NECESSARY BY SUCH USE. Many types of aftermarket accessories are available to customers, upfitting shops, and dealers. Some of these devices sit on top of, or are Velcro(R) strapped to the seat while others such as seat heaters are installed under the seat fabric. Additionally, seat covers made of leather or other materials may have different padding thickness installed that could prevent the Passenger Sensing System from functioning properly. Never alter the vehicle seats. Never add pads or other devices to the seat cushion, as this may interfere with the operation of the Passenger Sensing System and either prevent proper deployment of the passenger airbag or prevent proper suppression of the passenger air bag. Disclaimer Page 11967 Vehicles Built with Upgradeable OnStar(R) System Analog Modules Note: Junction Block - I/P Relay Box: Application and ID Junction Block - I/P Location View Location View Page 3467 1. Apply sealant GM P/N 12346004, (Canadian P/N 10953480), or equivalent, to the threads of the oil pressure sensor. Notice: Refer to Fastener Notice in Service Precautions. 2. Using J 41712 or equivalent, install the oil pressure sensor. ^ Tighten the oil pressure sensor to 30 Nm (22 ft. lbs.). 3. Connect the oil pressure sensor electrical connector (1). 4. If necessary, install the engine sight shield. Page 12240 10. Disconnect and remove the OnStar(R) jumper harness. Note: You will need to remove the short GPS cable from this jumper harness. 11. Untape the cell antenna coax from the body harness in the trunk. This will be necessary to provide adequate length to connect to the new VCIM. 12. Fasten three retainer clips (1) from the kit to the new bracket that is included in the kit, and position the VCIM to the bracket (2). 13. Install the three bolts from the kit. Tighten the bolts to 10 Nm (89 lb in). 14. Connect the new OnStar(R) jumper harness supplied in the kit to the VCIM (two white connectors on module). 15. Connect small GPS coax cable jumper harness supplied in the kit (end with blue plastic housing) to VCIM GPS connector. 16. Position the VCIM / bracket assembly to the studs. 17. Install the bracket nuts saved from the Removal Procedure above to the VCIM / bracket assembly mounting studs. Tighten the nuts to 4 Nm (35 lb in). 18. Connect the new OnStar(R) jumper harness to the body wiring harness (C410 connector). 19. Connect small coax cable jumper from VCIM to the OnStar(R) Global Positioning Satellite (GPS) antenna coaxial cable at the connector previously left in the vehicle (short jumper removed from old harness in step 5.10). 20. Connect the cellular coaxial cable previously left in vehicle to the OnStar(R) VCIM. 21. Verify that all harnesses are properly secured in vehicle. 6. After replacing the VCIM, it is essential to configure the new OnStar(R) system. Failure to configure the system will result in an additional customer visit for repair. DO NOT press and hold the white dot or phone button on the keypad as it will not reset this version of the OnStar(R) system and may result in a DTC being set. Use of the TIS2WEB and SPS applications, along with the Tech2(R), are required in order to perform the VCIM configuration and setup procedure for this vehicle. The configuration and set-up procedure is now a two-step process which enables an automated activation by the OnStar(R) Center, without a button press by the technician to the OnStar(R) Call Center. 1. Connect the Tech2(R) to the vehicle. Page 12043 Labor Time Information Diagram Information and Instructions Audible Warning Device: Diagram Information and Instructions Truck Zoning TRUCK ZONING Truck Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that corresponds to where they are located in the vehicle. The table explains the numbering system. Page 2726 Location View Page 3733 Lower the vehicle. Parts Information Warranty Information Page 10355 Wheel Alignment. Page 3473 4. Use the J 41665 in order to install the crankshaft sprocket.Install the sprocket onto the crankshaft until fully seated against the crankshaft flange. 5. Rotate the crankshaft sprocket until the alignment mark is in the 12 o'clock position. 6. Important: ^ Properly locate the camshaft sprocket locating pin with the camshaft sprocket alignment hole. ^ The sprocket teeth and timing chain must mesh. ^ The camshaft and the crankshaft sprocket alignment marks MUST be aligned properly.Locate the camshaft sprocket alignment mark in the 6 o'clock position. Install the camshaft sprocket and timing chain. 7. If necessary, rotate the camshaft or crankshaft sprockets in order to align the timing marks. Notice: Refer to Fastener Notice in Service Precautions. 8. Install the camshaft sprocket bolts. ^ Tighten the bolts to 35 Nm (26 ft. lbs.). 9. Install the oil pump. Page 1745 Crankshaft Position Sensor: Service and Repair Crankshaft Position (CKP) Sensor Replacement CRANKSHAFT POSITION (CKP) SENSOR REPLACEMENT REMOVAL PROCEDURE IMPORTANT: Perform the CKP System Variation Learn Procedure whenever the crankshaft position sensor is removed or replaced. 1. Remove the starter. 2. Disconnect the crankshaft position (CKP) sensor electrical connector. 3. Clean the area around the CKP sensor before removal in order to avoid debris from entering the engine. 4. Remove the CKP sensor bolt. 5. Remove the CKP sensor. INSTALLATION PROCEDURE Page 9327 Relay Box: Service and Repair Body Wiring Harness Junction Block Replacement BODY WIRING HARNESS JUNCTION BLOCK REPLACEMENT REMOVAL PROCEDURE 1. Remove the cover retaining nut. 2. Remove the cover by pushing in the tabs. 3. Remove the harness from the front of the junction block. 4. Remove the junction block from the bracket by pressing to release the tabs. 5. Remove the junction block in order to gain access to the rear of the block to remove the retaining bolts. 6. Remove the retaining bolts. 7. Separate the wire harness block from the junction block by inserting a screw driver in between. 8. Remove the junction block from the vehicle. INSTALLATION PROCEDURE 1. Install the wire harness block to the junction block. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the retaining bolts. Tighten Tighten the bolts to 6 N.m (53 lb in). 3. Install the junction block to the bracket. Page 2617 Application Tabel Part 2 Location View Page 15480 Fuel Gauge Sender: Description and Operation Fuel System Description (Cab Chassis) FUEL LEVEL SENSOR The fuel level sensor is a part of the fuel sender assembly. The position of the float arm indicates the fuel level. The fuel level sensor contains a variable resistor which changes resistance in correspondence with the amount of fuel in the fuel tank. On models that are equipped with a single fuel tank, the fuel level sensor is wired directly to the instrument panel (IP) cluster. On models equipped with dual fuel tanks, both fuel level sensors are wired to the PCM. The PCM calculates the total fuel level in both tanks. The instrument panel (IP) fuel gage displays the total fuel level in both fuel tanks. Body - Pick Up Box Reinforcement Installation Truck Bed: All Technical Service Bulletins Body - Pick Up Box Reinforcement Installation Info - Availability of Pickup Box Reinforcement Kits for Toolbox/Rear Window Barrier/Ladder Rack Applications # 01-08-66-005C - (Feb 4, 2005) Models: 1999-2003 Chevrolet Silverado Pickups (New Body Style) 1999-2003 GMC Sierra Pickups (New Body Style) with Steel Fleetside Pickup Box (RPO E63) 2004-2005 Chevrolet Silverado 1500 Series Crew Cab Pickups with 5'8" Pickup Box 2004-2005 GMC Sierra 1500 Series Crew Cab Pickups with 5'8" Pickup Box EXCEPT Dual Rear Wheel (RPO R05), Stepside (RPO E62) and Inner Composite (RPO E37) Pickup Boxes Sales Manager and Service Manager This bulletin is being revised to add 2004-2005 1500 Series Crew Cab with 5'8" Pickup Box model and change equipment weight capacity information. Please discard Corporate Bulletin Number 01-08-66-005B (Section 08--Body and Accessories). Built Prior to the VIN Breakpoints shown. Pickup box reinforcement kits are available as an accessory for customers who may want to install a cross toolbox, side box, or a ladder rack system. Important: The reinforcements must be installed before adding a toolbox or ladder rack system. After the reinforcements have been installed, follow the instructions supplied with the toolbox/ladder rack system for installation onto the pickup box. Pickup Box Reinforcement Installation Use the following service procedure and the applicable kit part number listed below to install the reinforcements. Cross Toolbox and Rear Window Barrier Applications - Front Reinforcement Installation Important: The horizontal surfaces of the reinforcements must be flush to the horizontal surface of the pickup box top rail. Use a clamping tool when positioning the reinforcements onto the top rail to ensure flushness to the outer panel. 1. Place the front L-shaped reinforcements into position on the front top of the pickup box. For vehicles equipped with an over the rail bedliner, the bedliner should be removed with the aid of an assistant prior to installing these reinforcements. 2. Mark the holes necessary for drilling. 3. Remove the front reinforcements. Important: Page 2343 Installation Procedure 1. Install the booster inlet hose to the pump. Notice: Refer to Installing Hoses Without Twists or Bends Notice in Service Precautions. Important: Following this sequence ensures correct routing and orientation. Important: Ensure that the hose contacts the power steering pump as shown. 2. Install the gear inlet hose to the gear (5). Page 5417 Parts Information Parts are currently available from GMSPO. Warranty Information Page 4390 Throttle Actuator Control (TAC) Module Page 3486 Step 3 Page 7366 1. Lubricate the input speed sensor seal with automatic transmission fluid. 2. Install the input speed sensor (1). Notice: Refer to Fastener Notice in Service Precautions. 3. Install the input speed sensor bolt. ^ Tighten the bolt to 11 Nm (96 inch lbs.). 4. Connect the input speed sensor electrical connector (1). 5. Lower the vehicle. Page 14391 Driver Door Module (DDM) - C2 (With RPO Code YE9) Part 2 Page 7763 Speed Sensor: Service and Repair Transfer Case - NVG 261-NP2 Transfer Case Speed Sensor Replacement Removal Procedure 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. Disconnect the speed sensor electrical connector (4). 3. Remove the speed sensor. Installation Procedure 1. Notice: Refer to Fastener Notice in Service Precautions. Install the speed sensor. ^ Tighten the sensor to 15 Nm (11 ft. lbs.). Page 5156 Accelerator Pedal Position Sensor: Diagrams Accelerator Pedal Position (APP) Sensor Part 1 Page 14570 Driver Door Module (DDM) - C5 (Memory/Heated Seat Switch) Part 2 Power Steering Gear Inlet Pipe/Hose Power Steering Line/Hose: Service and Repair Power Steering Gear Inlet Pipe/Hose (Rack and Pinion) Power Steering Gear Inlet Pipe/Hose Replacement (Rack and Pinion) Removal Procedure Notice: Refer to Power Steering Hose Disconnected Notice in Service Precautions. 1. Remove the power steering inlet hose (2) from the power steering pump (1). 2. Remove the power steering inlet hose (2) from the power steering gear (3). Installation Procedure 1. Connect the power steering inlet hose (2) to the power steering gear (3). 2. Notice: Refer to Fastener Notice in Service Precautions. Connect the power steering inlet hose (2) to the power steering pump (1). ^ Tighten the hose connections to 28 Nm (20 ft. lbs.). 3. Bleed the power steering system. Refer to Bleeding the Power Steering System. 4. Inspect all the hose connections for leaks. (With Hydroboost) Power Steering Gear Inlet Pipe/Hose Replacement (With Hydroboost) Removal Procedure Page 8637 Ambient Light Sensor (With RPO Code CJ3) Page 6864 9. Place an alignment mark between the pinion and the pinion yoke. 10. Install the J 8614-01 as shown. 11. Remove the pinion nut while holding the J 8614-01. 12. Remove the washer. 13. Install the J 8614-2 (2) and the J 8614-3 (3) into the J 8614-01 (1) as shown. 14. Remove the pinion yoke by turning the J 8614-3 (3) clockwise while holding the J 8614-01 (1). Use a container in order to retrieve the lubricant. 15. Remove the pinion oil seal. Use a suitable seal removal tool. Do not damage the housing. Installation Procedure 1. Install a new pinion oil seal using the J 22388 (8.6 inch, 9.5 inch axles) or the J 44414 (10.5 inch, 11.5 inch axle). 2. Apply sealant GM P/N 12346004 (Canadian P/N 10953480) or equivalent to the splines of the pinion yoke. Page 1308 Ambient Air Temperature Sensor Page 14300 WA8555/41 - WA8555/41 Page 15935 Electrical Symbols Part 8 Page 11878 In summary, whenever a vehicle subject to this program enters your vehicle inventory, or is in your dealership/facility for service through April 30, 2011, you must take the steps necessary to be sure the program correction has been made before selling or releasing the vehicle. Disclaimer Service Procedure Service Procedure Note Do NOT replace the inside rear view mirror in tandem with this concern. The mirror has no bearing on this specific issue. 1. Remove the OnStar(R) module (referred to as the Communication Interface Module (CIM) or Vehicle Communication Interface Module (VCIM) in SI). Refer to SI for module removal instructions. Note Inform customer that all Bluetooth devices must be paired with the new VCIM. Bluetooth devices that have not been paired to the new VCIM will not function properly. 2. Install the new OnStar(R) module (referred to as the Communication Interface Module (CIM) or Vehicle Communication Interface Module (VCIM) in SI). Refer to SI for module installation instructions. Page 4057 For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to refer to the table above. Disclaimer Page 14603 Front Passenger Seat (1 Of 2) (With RPO Code AN3) Page 10197 until the sensor is seated into the adapter and bearing assembly. If installing a new sensor, it will come with a pin installed in the sensor. Do not remove the pin until the sensor is seated. If the new sensor did not come with a pin installed, you must reorder a new sensor. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install into the adapter and bearing assembly. 16. Install the connector to the sensor. 17. From the technicians point of view, the FRONT of the sensor will have: ^ A pin hole (2) for the centering pin. Note the location of the pin hole. ^ A flush rotor flange cuff (4) ^ An alignment mark (3) for installation 18. From the technicians point of view, the BACK of the sensor will have an alignment tab (1) for installation. This sensor does not have double D flats. 19. Important: If reusing the existing sensor, you must align the marks on the flush rotor flange cuff before installation. The alignment mark must stay aligned until the sensor is seated into the adapter and bearing assembly. If installing a new sensor, it will come with a pin installed in the sensor. Do not remove the pin until the sensor is seated. If the new sensor did not come with a pin installed, you must reorder a new sensor. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install into the adapter and bearing assembly. 20. Install the connector to the sensor. 21. From the technicians point of view, the FRONT of the sensor will have: ^ A pin hole (3) for the centering pin. Note location of the pin hole. ^ A flush rotor flange cuff (5) ^ An alignment mark (4) for installation ^ A foam ring (6) 22. From the technicians point of view, the BACK of the sensor will have: ^ Double D flats (1) ^ An alignment tab (2) for installing into the adapter and bearing assembly 23. Important: If reusing the existing sensor, you must align the marks on the flush rotor flange cuff before installation. The alignment mark must stay aligned until the sensor is seated into the adapter and bearing assembly. If installing a new sensor, it will come with a pin installed in the sensor. Do not remove the pin until the sensor is seated. If the new sensor did not come with a pin installed, you must reorder a new sensor. Page 12801 A current DTC clears when the condition for setting the DTC is no longer present. A history DTC clears after 50 malfunction-free ignition cycles. Circuit/System Testing Without RPO UAV 1. Turn OFF the ignition and all electrical components, including the scan tool. 2. Disconnect the harness connector at the cellular microphone. 3. Test for less than 5 Ohms between the low reference circuit terminal A and ground. ^ If greater than the specified range, test the low reference circuit for an open/high resistance. If the circuit tests normal, replace the VCIM. 4. Ignition ON, test for 9 - 11 volts between the signal circuit terminal B and ground. ^ If greater than the specified range, test the signal circuit for a short to voltage. If the circuit tests normal, replace the VCIM. ^ If less than the specified range, test the signal circuit for a short to ground or an open/high resistance. If the circuit tests normal, replace the VCIM. Refer to the appropriate vehicle in SI. 5. If all circuits test normal, test or replace the cellular microphone. Circuit/System Testing With RPO UAV 1. Turn OFF the ignition and all electrical components, including the scan tool. 2. Disconnect the X4 harness connector at the navigation radio and the harness connector at the cellular microphone. 3. Test for less than 5 Ohms between the low reference circuit terminal A and ground. ^ If greater than the specified range, test the low reference circuit for an open/high resistance. If the circuit tests normal, replace the VCIM. Refer to the appropriate vehicle in SI. 4. Ignition ON, test for 9 - 11 volts between the signal circuit terminal B and ground. ^ If greater than the specified range, test the signal circuit for a short to voltage. If the circuit tests normal, replace the VCIM. ^ If less than the specified range, test the signal circuit for a short to ground or an open/high resistance. If the circuit tests normal, replace the VCIM. 5. If all circuits test normal, test or replace the cellular microphone. 6. Connect the X4 harness connector at the navigation radio. 7. With a scan tool, verify that DTC B2455 is not set as current in the navigation radio. ^ If DTC B2455 is set as current, replace the navigation radio. Refer to the appropriate vehicle in SI. DTC B2462, B2483, or B2484 Circuit/System Description The vehicle communication interface module (VCIM) receives information from a specific navigation antenna located on the outside of the vehicle. The navigation antenna is connected to the VCIM via a shielded coaxial cable. The antenna cable also provides a path for DC current for powering the antenna. DTC Descriptors DTC B2462 02: Global Positioning System (GPS) Antenna Malfunction Short to Ground DTC B2462 04: Global Positioning System (GPS) Antenna Malfunction Open Circuit Page 2470 10. Grasp firmly while pulling down with a twisting motion in order to remove the filter. 11. Remove and discard the filter seal. The filter seal may be stuck in the pump; if necessary, carefully use pliers or another suitable tool to remove the seal. 12. Inspect the fluid color. 13. Inspect the filter. Pry the metal crimping away from the top of the filter and pull apart. The filter may contain the following evidence for root cause diagnosis: ^ Clutch material ^ Bronze slivers indicating bushing wear ^ Steel particles 14. Clean the transmission case and the oil pan gasket surfaces with solvent, and air dry. You must remove all traces of the old gasket material. Installation Procedure 1. Coat the NEW filter seal with automatic transmission fluid. 2. Install the NEW filter seal into the transmission case. Tap the seal into place using a suitable size socket. 3. Install the NEW filter. Locations Page 6976 9. Insert the J 33049 into the axle tube and through the axle shaft seal. 10. While holding the expander assembly nut, turn the driving bar clockwise until the expanding driver is snug against the axle shaft seal. 11. Drive out the seal using the J 33049 and a hammer. Installation Procedure 1. Assemble the drive bar extension onto the drive bar of J 33049. 2. Insert the J 33049 into the opposite side axle shaft tube. 3. Install the J 45177 onto the J 33049. 4. Insert the axle shaft seal into the axle tube. 5. Install the J 45177 (1) and the J 33049 (2) over the axle shaft seal. 6. Drive the axle shaft seal into the axle tube using the J 45177 , the J 33049 and a hammer. 7. Install the differential assembly. 8. Install the axle shafts. 9. Install the tire and wheel assembly. 10. Lower the vehicle. Refer to Vehicle Lifting. Page 12338 Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. 1. Disconnect the connector from the component. 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. Page 5546 Crankshaft Position (CKP) Sensor Page 5361 14. If vehicle is a regular cab, remove the fuel and EVAP bundle nuts. 15. If vehicle is a extended cab, remove the fuel and EVAP bundle nuts. 16. Remove the fuel and EVAP bundle. INSTALLATION PROCEDURE 1. Install the fuel and EVAP bundle. NOTE: Refer to Fastener Notice in Service Precautions. 2. If vehicle is a extended cab, install the fuel and EVAP bundle nuts. Tighten Tighten the nuts to 12 N.m (106 lb in). Page 11555 Inflatable Restraint Sensing and Diagnostic Module (SDM) - Part 3 Page 7895 Park Neutral Position (PNP) Switch C175 Page 10315 Ball Joint: Service and Repair Rear Wheel Steering Upper Ball Joint Replacement Upper Ball Joint Replacement ^ Tools Required J 44664 Upper Ball Joint Nut Remover - J 44663 Upper Ball Joint Remover Removal Procedure 1. Notice: Refer vehicle Lifting. Raise the vehicle. Refer to Vehicle Lifting. 2. Remove the tire and wheel. 3. Remove the bolt (8) and nut (2) retaining the bracket to the axle. 4. Remove the bracket (7) from the vehicle. 5. Remove the bolt (4) retaining the brake hose bracket (3) to the axle. 6. Using the J 44664 (2), remove the nut (1) retaining the upper ball joint to the steering knuckle. 7. Remove the upper ball joint (3) retaining bolts (2) and stud (1). Component Locations Fluid Pressure Sensor/Switch: Component Locations Automatic Transmission - 4L60-E/4L65-E Automatic Transmission Electronic Component Views (M30/M32) Electronic Components Page 9405 Electrical Symbols Part 3 Page 13675 Front Door Weatherstrip: Service and Repair Weatherstrip Replacement - Front Door Weatherstrip Replacement - Front Door Removal Procedure 1. Open the door. 2. Remove the sill plate. 3. Remove the hinge pillar trim panel. 4. Remove the windshield pillar molding. 5. Remove the weatherstrip from the rear side door opening. Pull the unit away from channel, separating the weatherstrip from the pinchweld flange. Installation Procedure 1. Install the weatherstrip from the rear side door opening fully seating the weatherstrip into the channel. 2. Install the windshield pillar molding. 3. Install the hinge pillar trim panel. 4. Install the sill plate. 5. Check door closing effort and seal to door fit. Locations Forward Lamp Harness Front Suspension Suspension Strut / Shock Absorber: Service and Repair Front Suspension Shock Absorber Replacement Shock Absorber Replacement (4WD) Removal Procedure Notice: The front shock absorbers of the vehicle are multifunctional. In addition to contributing to a smooth ride they also provide the only stop to the front suspension when fully extended. Therefore, when servicing the shock absorber, service replacement shock absorbers must be equivalent to original shock absorbers in both extended length and strength. Use of shocks not complying to original equipment or strength could result in suspension over-travel or shock breakage. Suspension over-travel may result in suspension component breakage. 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Support the lower control arm with a jack stand. 3. If equipped with selectable ride, disconnect the electrical connector, with the following procedure: 1. Grasp the connector lock tabs (1,2). Rotate the connector tabs counterclockwise until the connector is unlocked. 2. Disengage the connector from the tension by firmly pulling the connector up. 3. Hold the tension end with a wrench while removing the nut. 4. Remove the nut. Page 5375 9. Connect the brake lines to the BPMV. Tighten Tighten the fittings to 25 N.m (18 lb ft). 10. Connect the chassis electrical harness connectors to the EBCM. 11. Install the EVAP canister. 12. Install the transfer case harness to the clip bracket. 13. Install the clip to the bracket on the frame. 14. If equipped with 4WD, install the fuel hose/pipe clip to the bracket on the transfer case. 15. Install the fuel hose/pipe clip to the bracket on the automatic transmission. 16. Install the HO2S sensor connector to the bracket. 17. Install the fuel pipe bracket to the bellhousing stud. 18. Install the fuel pipe bracket nut (2). Page 14727 1. Install the seat cushion cover to the foam pad. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the center screw retaining the latch cover, if removed. Tighten Tighten the screw to 2 N.m (18 lb in). 3. Engage the hook, and the loop-strips that are retaining the seat cushion cover (3) to the foam pad (4). 4. Install the seat buckles, if removed. 5. Connect the rear heater connector, if equipped. 6. Install the hog rings, and/or the J-clips in order to retain the seat cushion cover to the seat cushion frame (8). 7. Install the rear passenger seat risers. 8. Install the rear seat to the vehicle. Seat Cushion Trim Cover and Pad Replacement SEAT CUSHION TRIM COVER AND PAD REPLACEMENT REMOVAL PROCEDURE Page 12102 The control module ID number list above provides a method for determining which module is not communicating. A module with a class 2 serial data circuit malfunction or which loses power during the current ignition cycle will have a Loss of Communication DTC set by other modules that depend on information from that failed module. The modules that can communicate will set a DTC indicating the module that cannot communicate. Diagnostic Order When more than one Loss of Communication DTC is set in either one module or in several modules, diagnose the DTCs in the following order: 1. Current DTCs before history DTCs unless told otherwise in the diagnostic table. 2. The DTC which is reported the most times. 3. From the lowest number DTC to the highest number DTC. Conditions for Running the DTC The following DTCs do not have a current status: ^ B1327 ^ B1328 ^ U1300 ^ U1301 ^ U1305 AND ^ The vehicle power mode requires serial data communication to occur. Conditions for Setting the DTC A node alive message has not been received from a module with a learned identification number within the last 5 seconds. Action Taken When the DTC Sets Page 15188 Audible Warning Device: Description and Operation AUDIBLE WARNINGS DESCRIPTION AND OPERATION The audible warnings alert the driver of a system concern or a critical vehicle condition. The radio generates the audible warnings through the left front speaker. The radio receives audible warning requests via the class 2 serial data line. If the radio receives multiple audible warning requests, the warning with the highest priority sounds first. On vehicles with an audio amplifier, the amplifier instead of the radio generates the audible warnings and receives audible warnings requests via the class 2 serial data line. Either the radio or the audio amplifier is the chime producer. The following lists the audible warning priority and the pulse rate: 1. Fast rate chime (150 pulses per min) 2. Medium rate chime (100 pulses per min) 3. Slow rate chime (50 pulses per min) 4. Turn signal reminder (will pulse at turn signal flasher rate) DOOR AJAR WARNING The chime producer activates the door ajar audible warning as requested by the instrument panel cluster (IPC). The IPC sends a class 2 message to the chime producer indicating the chime duration, 4 pulses. The door ajar warning sounds and the appropriate DOOR AJAR indicator illuminates in the driver information center (DIC) when the following occurs: The body control module (BCM) determines that a door; driver door, passenger door, left rear door, right rear door, is open, signal is low. The IPC receives a class 2 message from the BCM indicating the door ajar status. - The vehicle is not in PARK. The IPC receives a class 2 message from the powertrain control module (PCM) indicating the gear position. - The vehicle speed is greater than 8.05 km/h (5 mph). The IPC uses the vehicle speed signal circuit , 4000 pulses/mile, from the PCM in order to calculate the vehicle speed. FASTEN SAFETY BELT WARNING The inflatable restraint sensing and diagnostic module (SDM) senses that the drivers seat belt is not buckled and the signal is low. The SDM sends a class 2 message to the instrument panel cluster (IPC) requesting illumination of the seat belt indicator. The SDM sends a class 2 message to the chime producer indicating a chime at the rate of 50 pulses per minute, slow rate chime, for a duration of approximately 6 seconds. The fasten safety belt warning sounds and the seat belt indicator illuminates when the following occurs: Ignition switch transitions to ON. - The seat belt switch signal to the SDM is low. If the seat belt is buckled when the ignition is turned ON, the chime will not sound. If the seat belt is buckled while the chime is sounding, the chime stops. KEY-IN-IGNITION WARNING When the body control module (BCM) detects the key is in the ignition and the signal is low with the driver door open, it activates an audible warning. The key-in-ignition chime sounds at the rate of 100 pulses per minute, medium rate chime, until the driver door is closed or the key removed from the ignition switch. The BCM activates the key-in-ignition warning when all of the following occurs: The ignition switch is OFF. - The key-in-ignition switch signal is low. - The driver door jamb switch signal is low with the driver door open. LIGHTS ON CHIME The body control module (BCM) will activate an audible warning as a reminder that the headlamps are left ON when exiting the vehicle with the ignition switch in the OFF position. The lights ON warning sounds at the rate of 150 pulses per minute, fast rate chime, until the headlamp switch is turned OFF. The BCM receives a signal from the headlamp and panel dimmer switch via the headlamp relay. The BCM activates the lights on warning chime when the following occurs: The ignition is OFF. - The park lamp switch input is active. - The dimming potentiometer input is not in a maximum dimming state. TURN SIGNAL WARNING The body control module (BCM) activates an audible warning as a reminder that the turn signal has been on for a distance of more than 1.20 km (0.75 mi). The BCM receives the vehicle speed and distance via the vehicle speed signal circuit. The turn signal chime will use a tone that is synchronized with the turn signal flasher. The BCM will activate the turn signal chime when the following occurs: The ignition is ON. - Left or right turn signal switch is ON. - The vehicle has traveled further than 1.20 km (0.75 mi). PARK BRAKE CHIME The body control module (BCM) activates the park brake chime when the park brake is engaged and the signal circuit is low and vehicle is driven for at least 3 seconds at a speed above 4.8 km/h (3 mph). The chime will sound at the rate of 150 pulses per minute, fast rate chime. The park brake indicator will flash for any distance the vehicle is driven every half second until the park brake is no longer engaged. Page 9740 C220 I/P Harness To Infotainment Jumper Harness (With RPO Code UQ7 & Without RPO Code Y91) Part 2 Page 7816 Shift Solenoid: Service and Repair Control and Shift Solenoids Replacement Removal Procedure 1. Remove the transmission filter. 2. Important: Removal of the 1-2 accumulator is necessary only if servicing the pressure control solenoid. Remove the 1-2 accumulator, if necessary. 3. Disconnect the internal wiring harness electrical connectors from the following components: ^ Transmission fluid pressure switch (1) ^ 1-2 shift control solenoid (2) ^ 2-3 shift control solenoid (3) ^ Pressure control solenoid (4) ^ torque converter clutch pulse width modulation (TCC PWM) solenoid (5) ^ 3-2 control solenoid (6) 4. Remove the pressure control solenoid retainer bolt (364A) and retainer (378). 5. Remove the pressure control solenoid (377). Page 14683 - Customer induced cuts (knife cuts, cut by customer tools, etc.) - Paint stains (customer should have cleaned paint stains while paint was still wet) - Coffee stains and other removable dirt These should be cleaned as described in the Owner's Manual under Appearance Care. Also, refer to Corporate Bulletin Number 06-00-89-029A or later. - Evidence of chemicals used for cleaning, other than those specified in the Owner's Manual - Other chemical spills - Minor and normal leather wrinkles as a result of use - Other defects to the seat cover not detected during the pre-delivery inspection (PDI). Inform the customer that the above issues were not present when the vehicle was purchased and cannot be replaced under warranty. The covers, however, may be repaired or replaced at the customer's expense. The following conditions are not caused by the customer and should be covered by warranty: - Split seams Page 15115 Rear Door Window Glass Weatherstrip: Service and Repair Door Window Sealing Strip Sealing Strip Replacement - Rear Door Window Belt Outer Removal Procedure Important: The outer belt sealing strip seals between the inner and outer door panels and the window at the belt line. The outer sealing strip is replaceable. Do not remove the inner sealing strip, because the strip is attached to the glass run channel. 1. Lower the window. 2. Remove the outer sealing strip from the door. Installation Procedure 1. Align the sealing strip in place. Lower and press the strip into place. 2. Raise the window. Page 13787 Disclaimer CKP System Variation Learn Procedure Crankshaft Position Sensor: Service and Repair CKP System Variation Learn Procedure CKP SYSTEM VARIATION LEARN PROCEDURE 1. Install a scan tool. 2. Monitor the powertrain control module (PCM) for DTCs with a scan tool. If other DTCs are set, except DTC P0315, refer to Diagnostic Trouble Code (DTC) List for the applicable DTC that set. 3. Select the crankshaft position (CKP) variation learn procedure with a scan tool. 4. The scan tool instructs you to perform the following: 4.1. Accelerate to wide open throttle (WOT). 4.2. Release throttle when fuel cut-off occurs. 4.3. Observe fuel cut-off for applicable engine. 4.4. Engine should not accelerate beyond calibrated RPM value. 4.5. Release throttle immediately if value is exceeded. 4.6. Block drive wheels. 4.7. Set parking brake. 4.8. DO NOT apply brake pedal. 4.9. Cycle ignition from OFF to ON. 4.10. Apply and hold brake pedal. 4.11. Start and idle engine. 4.12. Turn A/C OFF. 4.13. Vehicle must remain in Park or Neutral. 4.14. The scan tool monitors certain component signals to determine if all the conditions are met to continue with the procedure. The scan tool only displays the condition that inhibits the procedure. The scan tool monitors the following components: - CKP sensors activity-If there is a CKP sensor condition, refer to the applicable DTC that set. - Camshaft position (CMP) sensor activity-If there is a CMP sensor condition, refer to the applicable DTC that set. - Engine coolant temperature (ECT)-If the ECT is not warm enough, idle the engine until the engine coolant temperature reaches the correct temperature. 5. Enable the CKP system variation learn procedure with a scan tool. IMPORTANT: While the learn procedure is in progress, release the throttle immediately when the engine starts to decelerate. The engine control is returned to the operator and the engine responds to throttle position after the learn procedure is complete. 6. Accelerate to WOT. 7. Release when the fuel cut-off occurs. 8. Test in progress 9. The scan tool displays Learn Status: Learned this ignition. If the scan tool indicates that DTC P0315 ran and passed, the CKP variation learn procedure is complete. If the scan tool indicates DTC P0315 failed or did not run, refer to DTC P0315. If any other DTCs set, refer to Diagnostic Trouble Code (DTC) List for the applicable DTC that set. 10. Turn OFF the ignition for 30 seconds after the learn procedure is completed successfully. 11. The CKP system variation learn procedure is also required when the following service procedures have been performed, regardless of whether DTC P0315 is set: - A CKP sensor replacement - An engine replacement - A PCM replacement - A harmonic balancer replacement - A crankshaft replacement - Any engine repairs which disturb the CKP sensor relationship Page 7681 9. Disassemble the harness connector (1) from the encoder. 10. Remove the encoder from the output shaft using a flat tip screwdriver. Installation Procedure 1. Assemble the harness to the NEW encoder with the connector legend "TOP" (1) and the encoder part number facing up. 2. Assemble the output shaft into the encoder, being sure to align the encoder tab with the groove on the shaft. 3. Ensure the encoder is seating properly on the output gear. 4. Place the output shaft encoder on the casting. 5. Place the grommet harness on the casting slot, the flat area on the grommet will be facing up. Page 7099 11. If the retainer is difficult to seat, the yoke can be sprung slightly with a firm blow from a dead blow hammer. 12. It may be necessary to lubricate the snap ring with a slight amount of chassis grease so that the snap ring seats in the bearing cup groove. Page 13166 6. See wiring diagram shown above for details. 5. Replace the OnStar(R) Vehicle Communication Interface Module (VCIM) in the vehicle with the provided Digitally-Capable VCIM. Refer to the Communication Interface Module Replacement procedure in the Cellular Communication section of SI. This kit may include a new VCIM bracket. If it does, use this new bracket on the vehicle and discard the original bracket. The kit may also include a small wiring jumper cable. If it does, plug the wiring jumper cable into the connector on the VCIM and the other end to the corresponding vehicle wiring harness connector. ^ For 2001, 2002 and 2003 Chevrolet Impala and Monte Carlo, do not reinstall the black plastic OnStar(R) module cover onto the vehicle after the VCIM and module bracket have been installed. This black plastic cover will no longer fit on the vehicle. ^ The upgrade kit for 2002 Sevilles and DeVilles, and some 2003 Sevilles and DeVilles, will contain a large bracket. To install the new VCIM into this bracket you'll need to carefully line up the notch in the VCIM with the tab in the bracket. A/T - 4L60-E/-4L65E No Shift/Slipping/Fluid Leaks Band Apply Servo: All Technical Service Bulletins A/T - 4L60-E/-4L65E No Shift/Slipping/Fluid Leaks Bulletin No.: 04-07-30-025A Date: July 27, 2004 TECHNICAL Subject: Transmission Fluid Leak, Inoperative 2nd/3rd/4th Gears, No Movement, Case Cracked or Broken at 2-4 Servo (Repair Transmission and Install New Retaining Ring) Models: 2004 Chevrolet Corvette 2004 Pontiac GTO 2004 Light Duty Trucks with 4L60-E and 4L65-E Automatic Transmission (RPOs M30 or M32) Supercede: This bulletin is being revised to add the Corvette and GTO models and to include the 4L65-E transmission. Please discard Corporate Bulletin Number 04-07-30-025 (Section 07 Transmission/Transaxle). Condition Some customers may comment on a transmission leak, inoperative 2nd/4th gear, slipping 3rd/4th gear or no movement due to excess fluid loss. Cause This condition normally occurs at low mileage, usually under 1,600 km (1,000 mi), and investigation may show that the servo cover is loose or that the transmission case is cracked or broken at the servo bore. This condition may be caused by a servo cover retaining ring that did not retain the servo cover. The servo retaining ring design was changed for the 2004 MY from round wire to wire with two flat faces. In mid-April, 2004, the retaining ring design did revert back to a round design in production. It is possible that the transmission case may crack at the servo cover area due to the retaining ring being incorrectly seated. Correction Important: ^ In mid-April, 2004, the retaining ring design did revert back to a round design in production. ^ If the transmission fluid level has lowered due to loss of fluid, it is possible that damaged 3/4 clutches will result. ^ A cracked or broken case may usually be repaired at a significantly lower cost than transmission assembly replacement by replacing the case and any damaged clutches or bands. 1. Raise and suitably support the vehicle. 2. Inspect the transmission case around the servo cover for signs of cracks or damage to the case. ^ If the transmission case is cracked or damaged, replace the transmission case. Refer to the appropriate SI Document for Transmission Case Replacement. ^ If the servo cover is leaking and the case is not damaged, continue with the next step. 3. Remove the front exhaust pipe assembly. Refer to the appropriate SI Document. 4. Remove the heat shield if equipped. Refer to the appropriate SI Document. 5. Clean the servo cover area with Brake Clean and shop air. Page 817 Location View Page 11184 Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 5530 3. Install the throttle body nuts. Tighten Tighten the nuts to 10 N.m (89 lb in). 4. Install the coolant air bleed hose to the throttle body. 5. Position the coolant air bleed hose clamp at the throttle body. IMPORTANT: Verify that the throttle actuator motor harness connector and the connector seal are properly installed and not damaged. 6. Connect the throttle actuator motor electrical connector (2). Page 9217 C223 I/P Harness To Body Harness (Except NYS And HP2) Part 1 Page 5378 16. Remove the bolts (4) attaching the EHCU bracket to the frame (5). 17. Remove the EHCU (1). 18. Remove the torsion bar bracket, if equipped with 4WD. 19. Remove the EVAP canister. 20. Disconnect the fuel line at the tank. 21. Cap the fuel and EVAP lines in order to avoid possible system contamination. 22. Remove the fuel/EVAP bundle clip nuts. 23. Remove the fuel/EVAP bundle. INSTALLATION PROCEDURE 1. Install the fuel/EVAP bundle. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the fuel/EVAP bundle clip nuts. Tighten Tighten the nuts to 12 N.m (106 lb in). 3. Remove the caps from the fuel and EVAP lines. 4. Connect the fuel line at the tank. 5. Install the EVAP canister. 6. Install the torsion bar bracket, if equipped with 4WD. Page 5953 Vehicle Speed Sensor (VSS) Tow/Haul Switch Location Automatic Transmission Electronic Component Views (M33 Only) Automatic Transmission Electronic Component Views (M33 Only) Page 9010 Fuse Block - Underhood C1 Part 4 Page 14734 2. Install the bolts to the hinge assembly, if removed. Tighten Tighten the bolts to 35 N.m (26 lb ft). 3. Install the seat cushion trim cover (8) and the pad (7). Page 8208 (W/NYS) Brake Rotor Replacement - Rear (W/NYS) ^ Tools Required J 41013 Rotor Resurfacing Kit - J 42450-A Wheel Hub Resurfacing Kit Caution: Refer to Brake Dust Caution in Service Precautions. Removal Procedure 1. Release the park brake. 2. Raise and suitably support the vehicle. Refer Vehicle Lifting 3. Remove the tire and wheel assembly. 4. Mark the relationship of the rotor to the hub. 5. Install a C-clamp over the body of the brake caliper, with the C-clamp ends against the rear of the caliper body and the outboard disc brake pad. 6. Slowly tighten the C-clamp until the pistons are pushed into the caliper bores enough to remove the caliper from the pads. 7. Remove the C-clamp from the caliper. 8. Remove the nut and the bolt from the quarter shaft shield. 9. Remove the shield. Page 14187 7. Connect the manual door lock to the door retainer clips. 8. Connect the inside door handle control rod to the lock assembly. 9. Connect the inside door lock rod to the handle retainer clip. 10. Install the water deflector. 11. Install the door trim panel. 12. Inspect the operation of all the related components. Electrical - Instrument Panel & General Wiring Repair Wiring Harness: All Technical Service Bulletins Electrical - Instrument Panel & General Wiring Repair Bulletin No.: 06-08-45-004 Date: May 02, 2006 INFORMATION Subject: Instrument Panel (I/P), Body and General Wiring Harness Repair Models: 2007 and Prior GM Cars and Trucks 2003-2007 HUMMER H2 2006-2007 HUMMER H3 Important: A part restriction has been implemented on all Body and I/P harnesses and is being administered by the PQC. If a body or I/P harness replacement is required, it can take 12-28 weeks for a harness to be built and delivered to a dealer. The dealer technician is expected to repair any harness damage as the first and best choice before replacing a harness. In an effort to standardize repair practices, General Motors is requiring that all wiring harnesses be repaired instead of replaced. If there is a question concerning which connector and/or terminal you are working on, refer to the information in the appropriate Connector End Views in SI. The Instruction Manual J 38125-620, which is sent with each new update of the J 38125 Terminal Repair Kit, also has terminal crimping and terminal remove information. Important: There are some parts in the J 38125 Terminal Repair Kit (i.e. SIR connector CPAs and heat shrink tube (used in high heat area pigtail replacement) and some TPAs that are not available from GMSPO. It is vitally important that each update to the J 38125 Terminal Repair Kit be done as soon as it arrives at the dealer. Utilize the Terminal Repair Kit (J 38125) to achieve an effective wiring repair. The Terminal Repair Kit has been an essential tool for all GM Dealers since 1987. Replacement terminals and tools for this kit are available through SPX/Kent Moore. Refer to Corporate Bulletin Number 06-08-45-001 for more information. The Instruction Manual J 38125-620, which is sent with each new update to the J 38125 Terminal Repair Kit, also has terminal crimping and terminal removal information. U.S. Dealers Only - Training courses (including Tech Assists, Emerging Issues, Web, IDL and Hands-on) are available through the GM Training website. Refer to Resources and then Training Materials for a complete list of available courses. Canadian Dealers Only - Refer to the Training section of GM infoNet for a complete list of available courses and a copy of the J 38125 Terminal Repair Kit Instruction Manual. Wiring repair information is also available in Service Information (SI). The Wiring Repair section contains information for the following types of wiring repairs: - Testing for intermittent conditions and poor conditions - Flat wire repairs - GMLAN wiring repairs - High temperature wiring repairs - Splicing copper wire using splice clips - Splicing copper wire using splice sleeves - Splicing twisted or shielded cable - Splicing inline harness diodes Page 13131 Page 5332 passages. IMPORTANT: Before removal, if necessary, clean the fuel rail assembly with a spray type engine cleaner, use GM X-30A or equivalent. Follow the package instructions. Do not soak fuel rail assembly in any liquid cleaning solvents. 1. Remove the fuel rail. 2. Remove the fuel injector lower O-ring seal (4) from each fuel injector, if necessary. 3. Discard the O-ring seal. INSTALLATION PROCEDURE 1. Lubricate the NEW fuel injector lower O-ring seals (4) with clean engine oil. 2. Install the NEW O-ring seals (4) onto each injector, if necessary. Page 2462 All 2006 and future model transmissions that use DEXRON(R)-VI are to be serviced ONLY with DEXRON(R)-VI fluid. DEXRON(R)-VI is an improvement over DEXRON(R)-III in the following areas: * These ATF change intervals remain the same as DEXRON(R)-III for the time being. 2006-2008 Transmission Fill and Cooler Flushing Some new applications of the 6L80 six speed transmission will require the use of the J 45096 Flushing and Flow Tester to accomplish transmission fluid fill. The clean oil reservoir of the machine should be purged of DEXRON(R)-III and filled with DEXRON(R)-VI. Parts Information Disclaimer Page 4750 1. Install the PCM. Ensure that the mounting tabs are engaged. 2. Secure the spring latch to the PCM. 3. Connect the PCM electrical connectors. NOTE: Refer to Fastener Notice in Service Precautions. 4. Tighten the PCM electrical connector bolts (2). Page 9743 C222 I/P Harness To Body Harness Specifications Harmonic Balancer - Crankshaft Pulley: Specifications Crankshaft Balancer Bolt - Installation Pass - to Ensure the Balancer is Completely Installed; 330 Nm (240 ft. lbs.) Crankshaft Balancer Bolt - First Pass - Install a NEW Bolt After the Installation Pass and Tighten as Described in the First and Final Passes; 50 Nm (37 ft. lbs.) Crankshaft Balancer Bolt - Final Pass ................................................................................................................... .............................................. 140 degrees Page 14149 ^ Reinstall the fuse and fuse panel cover. ^ Press the "Enter" button to perform the "Refresh" function. ^ "Test in Progress" will be displayed and the right front passenger door lock will cycle once. ^ The screen will display "Procedure Completed". ^ Press the "Exit" button as necessary to return to the main menu screen. 3. Using the switches in the right front passenger door, verify that the power window and power door lock located in that door function properly. Important: The calibrations required for performing SPS reprogram in the next step are based on the type of exterior rearview mirror the vehicle has. To determine the correct calibration, check the Service Parts Identification Label on the vehicle for the RPO code for exterior mirrors. 4. Follow normal Service Programming System (SPS) to reprogram the passenger door module with the current calibration available in TIS 2000. 5. After reprogramming is complete, using the switches in the right front passenger door, verify that the power window and power door lock located in that door function properly. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 13708 4. Install the door trim panel. Page 10361 7. Lower the vehicle. 8. Perform a four wheel alignment. Page 6551 3. Lower the transmission. 4. Install the transmission mount to the transmission support retaining nut or nuts. ^ Tighten the nut or nuts to 40 Nm (30 ft. lbs.). 5. Remove the transmission jack. 6. Lower the vehicle. CKP System Variation Learn Procedure Crankshaft Position Sensor: Service and Repair CKP System Variation Learn Procedure CKP SYSTEM VARIATION LEARN PROCEDURE 1. Install a scan tool. 2. Monitor the powertrain control module (PCM) for DTCs with a scan tool. If other DTCs are set, except DTC P0315, refer to Diagnostic Trouble Code (DTC) List for the applicable DTC that set. 3. Select the crankshaft position (CKP) variation learn procedure with a scan tool. 4. The scan tool instructs you to perform the following: 4.1. Accelerate to wide open throttle (WOT). 4.2. Release throttle when fuel cut-off occurs. 4.3. Observe fuel cut-off for applicable engine. 4.4. Engine should not accelerate beyond calibrated RPM value. 4.5. Release throttle immediately if value is exceeded. 4.6. Block drive wheels. 4.7. Set parking brake. 4.8. DO NOT apply brake pedal. 4.9. Cycle ignition from OFF to ON. 4.10. Apply and hold brake pedal. 4.11. Start and idle engine. 4.12. Turn A/C OFF. 4.13. Vehicle must remain in Park or Neutral. 4.14. The scan tool monitors certain component signals to determine if all the conditions are met to continue with the procedure. The scan tool only displays the condition that inhibits the procedure. The scan tool monitors the following components: - CKP sensors activity-If there is a CKP sensor condition, refer to the applicable DTC that set. - Camshaft position (CMP) sensor activity-If there is a CMP sensor condition, refer to the applicable DTC that set. - Engine coolant temperature (ECT)-If the ECT is not warm enough, idle the engine until the engine coolant temperature reaches the correct temperature. 5. Enable the CKP system variation learn procedure with a scan tool. IMPORTANT: While the learn procedure is in progress, release the throttle immediately when the engine starts to decelerate. The engine control is returned to the operator and the engine responds to throttle position after the learn procedure is complete. 6. Accelerate to WOT. 7. Release when the fuel cut-off occurs. 8. Test in progress 9. The scan tool displays Learn Status: Learned this ignition. If the scan tool indicates that DTC P0315 ran and passed, the CKP variation learn procedure is complete. If the scan tool indicates DTC P0315 failed or did not run, refer to DTC P0315. If any other DTCs set, refer to Diagnostic Trouble Code (DTC) List for the applicable DTC that set. 10. Turn OFF the ignition for 30 seconds after the learn procedure is completed successfully. 11. The CKP system variation learn procedure is also required when the following service procedures have been performed, regardless of whether DTC P0315 is set: - A CKP sensor replacement - An engine replacement - A PCM replacement - A harmonic balancer replacement - A crankshaft replacement - Any engine repairs which disturb the CKP sensor relationship Instruments - Service Tire Monitor Message is Displayed Low Tire Pressure Indicator: All Technical Service Bulletins Instruments - Service Tire Monitor Message is Displayed Bulletin No.: 05-08-49-018A Date: May 11, 2006 ADVANCE SERVICE INFORMATION RESOLUTION Subject: EI 05065 - Service Tire Monitor Message Displayed (Pull/Reinstall IPC Fuse or Verify Correct Passenger Door Module (PDM) and Tires) Models: 2004 Chevrolet Silverado 2004 GMC Sierra Supercede: This bulletin is being revised to provide correction action. Please discard Corporate Bulletin Number 05-08-49-018 (Section 08 - Body and Accessories). Condition Some customers may comment that the "SERVICE TIRE MONITOR" message is being displayed on the DIC. Correction DO NOT REPLACE THE INSTRUMENT PANEL CLUSTER. If the DIC is displaying the SERVICE TIRE MONITOR message: 1. Verify if the vehicle has an electronic aftermarket module spliced into the ALDL Class 2 data line (purple wire). 2. If the vehicle HAS an aftermarket module spliced into the Class 2 line, pull the IPC fuse (located underhood) for 25 seconds. Important: Due to the electronic aftermarket module, the SERVICE TIRE MONITOR message may reoccur. 3. Reinstall the IPC fuse. This will clear the SERVICE TIRE MONITOR message from the display. 4. If the vehicle DOES NOT have an aftermarket module spliced into the Class 2 line, verify the vehicle is equipped with the correct PDM (Passenger Door Module) and tires. Warrant Information This repair is not covered under the vehicle warranty due to the installation of an aftermarket module. Disclaimer Page 14409 Door Control Module Diagram 3 Part 1 Page 7220 Electrical Symbols Part 12 Drive Pinion Housing and/or Seal Replacement Pinion Gear: Service and Repair Drive Pinion Housing and/or Seal Replacement Drive Pinion Housing and/or Seal Replacement ^ Tools Required J 44414 Pinion Seal Installer - J 22912-01 Bearing Puller - J 24433 Pinion Cone and Side Bearing Installer - J 37624 Pinion Bearing Installer - J 8092 Driver Handle - J 8608 Rear Pinion Bearing Race Installer - J 8614-01 Flange/Pulley Holding Tool Removal Procedure 1. Raise the vehicle. Refer to Vehicle Lifting. Important: Observe and mark the positions of all the driveline components, relative to the propeller shaft and the axles, prior to disassembly. These components include the propeller shafts, drive axles, pinion flanges, output shafts, etc. Reassemble all the components in the exact places in which you removed the parts. Follow any specifications, torque values, and any measurements made prior to disassembly. 2. Drain the axle lubricant. 3. Remove the axle shafts. 4. Reference mark the rear propeller shaft (3) to the rear axle pinion yoke (4). 5. Disconnect the propeller shaft from the axle. Wrap the bearing caps with tape in order to prevent the loss of bearing rollers. Support the propeller shaft as necessary. 6. Measure the amount of torque required to rotate the pinion and the ring gear. Use an inch-pound torque wrench. Record this measurement for reassembly. This will give the combined preload for the following components: ^ The pinion bearings ^ The pinion pilot bearing ^ The pinion oil seal ^ The differential case bearings Page 11636 Remove all rust from the ground terminal, the cylinder head and the retaining nut or bolt. Position the main engine wiring harness ground terminal and install the nut or bolt. Tighten: Tighten the retaining nut or bolt to 16 N.m (12 lb ft). Apply some type of electrical moisture sealant to protect the harness terminal from further corrosion. Disclaimer Page 9875 of the possible harness chafing/pinching. Also, on any of the above listed vehicles, the PCM wiring harness may be chafing against the precharge pump bracket or the battery tray. Correction On RPO AN3 vehicles, inspect the routing of the seat wiring harness. Reroute the seat wiring harness and attaching harness fastener (1) to the opposite side of the seat module bracket. Repair the harness as necessary. Refer to Wiring Repairs in the Wiring Systems sub-section of SI. The seat may have to be removed for ease of access and proper repair of the wiring harness. Inspect the routing of the PCM wiring harness at the precharge pump bracket and the battery tray. Repair the harness as necessary. Refer to Wiring Repairs in the Wiring Systems sub-section of SI. If any of the above conditions still remain after this repair, refer to SI for further diagnostic information. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 9795 Relay Box: Locations Relay Block - I/P Location View Page 7425 2. Connect the speed sensor electrical connector (4). 3. Lower the vehicle. Transfer Case - NVG 149-NP3 Fluid - Transfer Case: Service and Repair Transfer Case - NVG 149-NP3 Transfer Case Fluid Replacement Removal Procedure Important: When performing the following procedure, use only hand tools to remove and install the drain and fill plugs. 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. Remove the transfer case shield, if equipped. 3. Remove the fill plug. 4. Remove the drain plug. Important: Ensure that an approved drain pan is used when draining the transfer case. 5. Allow the transfer case to drain completely. Installation Procedure 1. Install the drain plug. ^ Tighten the plug to 20 Nm (15 ft. lbs.). Notice: Refer to Fastener Notice in Service Precautions. Important: Use only drain and fill plugs that are made from aluminum. Steel or brass plugs are not compatible with the magnesium case. Page 11158 2. Install the heater core cover. NOTE: Refer to Fastener Notice in Service Precautions. 3. Install heater core cover screws. Tighten Tighten the screws to 1.6 N.m (14 lb in). 4. Install the heater/vent module. Page 13920 Cross-Member: Service and Repair Transmission Support Replacement Transmission Support Replacement Removal Procedure 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Support the transmission with a transmission jack. 3. Remove the nut retaining the transmission mount to the transmission support. 4. Raise the rear of the transmission. 5. Remove the bolts and the nuts retaining the transmission support to the frame. (15 series) 6. Remove the bolts and the nuts retaining the transmission support to the frame. (25/35 series) 7. Remove the transmission support from the frame. Installation Procedure Page 984 1. Install the PCM. Ensure that the mounting tabs are engaged. 2. Secure the spring latch to the PCM. 3. Connect the PCM electrical connectors. NOTE: Refer to Fastener Notice in Service Precautions. 4. Tighten the PCM electrical connector bolts (2). Page 10044 1. Notice: Refer to Power Steering Hose Disconnected Notice in Service Precautions. Install a drain pan under the vehicle. 2. Remove the power steering gear inlet hose (1) from the brake booster. 3. Remove the power steering gear inlet hose from the power steering gear. 4. Remove the power steering gear inlet hose from the vehicle. Installation Procedure 1. Notice: Refer to Installing Hoses Without Twists or Bends Notice in Service Precautions. Route the hose in the same position the hose occupied prior to removal. 2. Install the power steering gear inlet hose (1) to the brake booster (2). Hand tighten only. 3. Notice: Refer to Fastener Notice in Service Precautions. Install the power steering gear inlet hose to the power steering gear. ^ Tighten both power steering gear inlet hose fittings to 28 Nm (20 ft. lbs.). 4. Remove the drain pan from under the vehicle. 5. Bleed the power steering system. Refer to Bleeding the Power Steering System. (Without Hydroboost) Power Steering Gear Inlet Pipe/Hose Replacement (Without Hydroboost) Removal Procedure 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Remove the engine protection shield. Page 13972 Ash Tray: Service and Repair Ashtray Replacement (Non-Console) Ashtray Replacement (Non-Console) Removal Procedure 1. Open the ashtray and press the tab (1). 2. Drill out the head of the rivet (1). 3. Remove the ashtray assembly from the trim panel. Installation Procedure 1. Install the ashtray assembly to the trim panel. 2. Install new rivets (1) to attach the ashtray to the trim panel. 3. Close the ashtray so that the tab (1) goes through the opening. Page 16010 Electrical Symbols Part 5 Component Locations Transmission Temperature Sensor/Switch: Component Locations Automatic Transmission - 4L60-E/4L65-E Automatic Transmission Electronic Component Views (M30/M32) Electronic Components Page 3485 Fuel Pressure: Testing and Inspection Fuel System Diagnosis FUEL SYSTEM DIAGNOSIS SYSTEM DESCRIPTION The control module enables the fuel pump relay when the ignition switch is turned ON. The control module will disable the fuel pump relay within two seconds unless the control module detects ignition reference pulses. The control module continues to enable the fuel pump relay as long as ignition reference pulses are detected. The control module disables the fuel pump relay within two seconds if ignition reference pulses cease to be detected and the ignition remains ON. The Fuel System is a returnless on-demand design. The fuel pressure regulator is a part of the fuel sender assembly, eliminating the need for a return pipe from the engine. A returnless fuel system reduces the internal temperature of the fuel tank by not returning hot fuel from the engine to the fuel tank. Reducing the internal temperature of the fuel tank results in lower evaporative emissions. The fuel tank stores the fuel supply. An electric turbine style fuel pump attaches to the fuel sender assembly inside the fuel tank. The fuel pump supplies high pressure fuel through the fuel filter and the fuel feed pipe to the fuel injection system. The fuel pump provides fuel at a higher rate of flow than is needed by the fuel injection system. The fuel pump also supplies fuel to a venturi pump located on the bottom of the fuel sender assembly. The function of the venturi pump is to fill the fuel sender assembly reservoir. The fuel pressure regulator, a part of the fuel sender assembly, maintains the correct fuel pressure to the fuel injection system. The fuel pump and sender assembly contains a reverse flow check valve. The check valve and the fuel pressure regulator maintain fuel pressure in the fuel feed pipe and the fuel rail in order to prevent long cranking times. TEST Steps 1 - 2 Page 12024 1. Remove the ground cable from the battery's negative cable. 2. Remove the center console, see WIS - Body - Interior. 3. Loosen the gear shift housing (A). AUT: Disconnect the 6-pin connector (B) to improve access to the gear shift housing screws. 4. Disconnect the signal cable from the SRS control module to the OnStar(R) control module and secure the cable. 4.1. Disconnect the connector (A) from the SRS control module and cut the cable tie (B). Page 10104 5. Install the power steering pump return hoses (1, 5) to the power steering pump. 6. Install the clamps retaining the power steering return hoses to the power steering pump. 7. Important: Ensure that the hose contacts the power steering pump as shown. Install the power steering pump pressure hose to the power steering pump. ^ Tighten the power steering pump pressure hose to 32 Nm (24 ft. lbs.). 8. Important: The power steering system on this vehicle does not use standard power steering fluid. Refer to Fluid and Lubricant Recommendations for the correct power steering fluid. Fill and bleed the power steering system. Refer to Bleeding the Power Steering System. 9. Clean up any spilled power steering fluid from the hoses, connectors or pump. 10. Connect the energy storage box after servicing the vehicle. Page 4234 Spark Plug: Testing and Inspection SPARK PLUG INSPECTION - Verify that the correct spark plug is installed. An incorrect spark plug causes driveability conditions. Refer to Ignition System Specifications for the correct spark plug. - Ensure that the spark plug has the correct heat range. An incorrect heat range causes the following conditions: Spark plug fouling - Colder plug - Pre-ignition causing spark plug and/or engine damage - Hotter plug - Inspect the terminal post (1) for damage. Inspect for a bent or broken terminal post (1). - Test for a loose terminal post (1) by twisting and pulling the post. The terminal post (1) should not move. - Inspect the insulator (2) for flashover or carbon tracking, or soot. This is caused by the electrical charge traveling across the insulator (2) between the terminal post (1) and ground. Inspect for the following conditions: Inspect the spark plug boot for damage. - Inspect the spark plug recess area of the cylinder head for moisture, such as oil, coolant, or water. A spark plug boot that is saturated will cause arcing to ground. Page 14241 Driver Door Module (DDM) - C5 (Memory/Heated Seat Switch) Part 2 Page 727 Parts required to complete this special coverage are to be obtained from General Motors Customer Care and Aftersales (GMCC&A;). Service Procedure Note The resistor module connector and blower motor resistor will need to be replaced if one or more of the symptoms below is present. - The HVAC blower may not function on certain or all blower speed settings - A burning plastic smell or smoke may be present in the vehicle - The HVAC blower may run continually with the ignition in the OFF position Determine if one or more of the above symptoms is present. If required refer to HVAC diagnostic information in SI. Refer to Resistor Module Connector and Blower Motor Resistor Replacement in this bulletin if one or more of the symptoms is present. Other HVAC repairs are NOT covered in this product safety special coverage bulletin. Resistor Module Connector and Blower Motor Resistor Replacement 1. Remove the blower fuses (Htr A/C & HVAC 1 fuses). 2. Lower the close-out panel enough to gain access to the resistor module connector. 3. Disconnect the connector from the resistor module. Note Connector replacement is required even if the connector was replaced on a previous service repair. 4. Remove the tape from the wiring harness to expose the wiring. 5. Cut the wires back far enough from the connector to eliminate any melted insulation on the wire. Note Use the old connector as a map for splicing the wires for the new connector. Be sure to use the correct crimping tool from the terminal repair kit J 38125. Use only Duraseal splice sleeves. Other splice sleeves may not protect the splice from moisture or provide a good electrical connection. 6. Install the new connector. Use the yellow splice sleeves provided with the connector. 7. Install the new blower motor resistor. 8. Reinstall the fuses. Test the blower motor to make sure all speeds are functional. 9. Reinstall the hush panel/close-out panel. Customer Reimbursement Customer requests for reimbursement of previously paid repairs to correct the condition described in this bulletin are to be submitted to the dealer prior to or by December 31, 2012. Repairs must have occurred within the 10 years of the date the vehicle was originally placed in service, or 240,000 kilometres, whichever occurs first. When a customer requests reimbursement, they must provide the following: Campaign - Unwanted Repeat Calls to OnStar(R) Technical Service Bulletin # 10037 Date: 100420 Campaign - Unwanted Repeat Calls to OnStar(R) CUSTOMER SATISFACTION Bulletin No.: 10037 Date: April 20, 2010 Subject: 10037 - Unwanted Repeat Calls to OnStar(R) Models: 2003 Buick LeSabre 2004-2006 Buick Rendezvous 2005 Buick LeSabre, Terraza 2005-2006 Buick LaCrosse/Allure 2006-2008 Buick Lucerne 2008 Buick LaCrosse/Allure 2008-2009 Buick Enclave 2003 Cadillac CTS 2004 Cadillac Escalade 2004-2005 Cadillac CTS-V, Deville 2005 Cadillac Escalade ESV, SRX 2005-2006 Cadillac STS 2005-2008 Cadillac CTS 2006-2008 Cadillac DTS 2007 Cadillac Escalade, Escalade EXT 2007-2008 Cadillac Escalade ESV 2008 Cadillac SRX, STS 2002 Chevrolet Impala 2003-2008 Chevrolet Suburban 2003-2009 Chevrolet Silverado 2004-2008 Chevrolet Impala 2005 Chevrolet Colorado, Corvette, Malibu 2005-2006 Chevrolet Uplander 2005-2008 Chevrolet Avalanche, Tahoe, TrailBlazer 2006 Chevrolet HHR, Monte Carlo 2006-2008 Chevrolet Equinox 2007-2008 Chevrolet Corvette 2008 Chevrolet HHR 2008-2009 Chevrolet Cobalt, Colorado, Malibu, Uplander 2003 GMC Envoy XL, Sierra, Yukon XL 2004-2008 GMC Yukon 2005-2009 GMC Sierra 2005-2008 GMC Yukon XL 2006-2008 GMC Envoy 2007 GMC Canyon 2007-2009 GMC Acadia 2006 HUMMER H2 2006-2008 HUMMER H3 2008 HUMMER H2 2003 Oldsmobile Silhouette 2005 Montana SV6 2005-2008 Pontiac Grand Prix 2006 Pontiac G6, Vibe 2007 Pontiac Montana SV6 2007-2008 Pontiac Solstice 2008 Pontiac G6, Torrent 2008-2009 Pontiac G5, G8 2009 Pontiac G3, Montana SV6 2005-2007 Saturn ION 2006-2009Saturn VUE 2007-2008 Saturn AURA, OUTLOOK, SKY Equipped with OnStar(R) (RPO UE1) Page 8898 - Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-D in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-D if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Page 12361 Garage Door Opener Transmitter: Description and Operation GARAGE DOOR OPENER DESCRIPTION AND OPERATION The garage door opener is located in the overhead console. The valet switch provides battery voltage to the garage door opener. If battery voltage is lost due to a condition such as a dead battery, the garage door opener unit relies on the non-serviceable internal power backup supply. The unit is programmed using the customer's hand-held transmitters for the garage doors, electric entrance gates, or lighting and security systems. The garage door opener is rolling code capable. Rolling code is a system that allows the code that the customers receiver receives from the garage door opener to change every time the garage door opener is used within operating range of the receiver. When the receiver and the garage door opener are initially programmed together, a code is established, a new code is created for every new transmission. The software in the receiver recognizes the garage door opener and accepts the new code. The garage door opener is compatible with most, but not all types and brands of transmitters. If a problem should occur with a compatibility conflict with a transmitter, call HomeLink(TM) at 1-800-355-3515. The garage door opener is a transmitter operating between 288-399 MHz. The power and range of the transmitter is limited to comply with laws governing the generation of radio frequency interference (RFI). The transmitter is programmed by the user to accept the signal generated by the user's transmitters, refer to Garage Door Opener Programming - Universal. The garage door opener has 3 buttons that may be programmed for individual transmitter/receiver combinations to control up to 3 garage door openers, security gates, and lighting systems. Each button represents a transmitter code section of the transmitter, which operates separately from any other button, and may be considered a separate transmitter. Operation consists of simply pressing a button to activate the corresponding transmitter. Battery voltage is provided to the garage door opener from the IGN SEN fuse in the IP fuse block. The garage door opener is grounded through G400. Inadvertent power is supplied from the body control module (BCM). Page 12489 Disclaimer Page 5973 Page 10891 Electrical Symbols Part 14 Page 9910 15. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 16. Install the electrical ground wire terminal to the rivet stud. 17. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 18. Install the M6 conductive nut to the rivet stud and: Tighten Tighten to 8 Nm (71 lb in). 19. Verify proper system operation. M6 Weld Nut Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M6 weld nut at the electrical ground location is damaged or stripped, a M7 conductive self-threading bolt may be used to secure the ground wire terminal. 2. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the weld nut and allow to dry. 3. Remove any loose metal particles from the damaged or stripped weld nut with a stiff brush. 4. Select a M7 conductive self-threading bolt. Refer to the Parts Information section of this bulletin 5. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M7 conductive self-threading bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 6. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 7. Install the electrical ground wire terminal to the M7 conductive self-threading bolt. 8. Install the M7 conductive self-threading bolt and: Tighten Tighten to 9 Nm (80 lb in). 9. Verify proper system operation. M6 Weld Nut Alternative Repair Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the electrical ground location is accessible from both sides of the panel, a M6 conductive bolt and a M6 conductive nut may be used to secure the electrical ground wire terminal. Refer to the Parts Information section of this bulletin. 2. Select a location adjacent the damaged M6 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the new electrical ground site. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the ground location and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 8.5 mm (0.33 in) diameter hole through the panel. 5. Remove paint and primer from the area surrounding the 8.5 mm (0.33 in) hole until bare metal is visible. 6. Select a M6 conductive bolt. Refer to the Parts Information section of this bulletin. 7. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 8. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 9. Install the electrical ground wire terminal and the M6 conductive bolt to the ground location. 10. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 11. Install the M6 conductive nut to the bolt and: Page 7755 Page 10194 11. From the technicians point of view, the FRONT of the sensor will have: ^ A raised rotor flange cuff (3) ^ An alignment mark (2) on the rotor flange cuff (3) for installation ^ A pin hole (1) for the centering pin. Note the location of the pin hole. 12. Remove the connector from the sensor. 13. Remove the sensor from the adapter and bearing assembly. 14. To install the sensor, proceed to step 9 in the installation procedure. 15. From the technicians point of view, the FRONT of the sensor will have: ^ A raised rotor flange cuff (3) ^ An alignment mark (2) on the rotor flange cuff (3) for installation ^ A pin hole (1) for the centering pin. Note location of the pin hole. ^ A sensor clip in FRONT of the sensor 16. Remove the connector from the sensor. 17. Remove the sensor clip from the sensor. 18. Remove the sensor from the adapter and bearing assembly. 19. To install the sensor, proceed to step 13 in the installation procedure. 20. From the technicians point of view, the FRONT of the sensor will have: ^ A flush rotor flange cuff (3) ^ A pin hole (1) for the centering pin. Note the location of the pin hole. ^ An alignment mark (2) on the flush rotor flange cuff (3) for installation 21. Remove the connector from the sensor. 22. Remove the sensor from the adapter and bearing assembly. 23. To install the sensor, proceed to step 17 in the installation procedure. Page 11955 Disclaimer Page 2973 Important Other forms of slow air leaks are possible. If the body of the tire, valve stem and wheel flange show no signs of air seepage, refer to Corporate Bulletin Number 05-03-10-003D for additional information on possible wheel porosity issues. 3. Bead seat corrosion is identified by what appears like blistering of the wheel finish, causing a rough or uneven surface that is difficult for the tire to maintain a proper seal on. Below is a close-up photo of bead seat corrosion on an aluminum wheel that was sufficient to cause slow air loss. Close-Up of Bead Seat Corrosion 4. If corrosion is found on the wheel bead seat, measure the affected area as shown below. - For vehicles with 32,186 km (20,000 mi) or less, the total allowable combined linear area of repairable corrosion is 100 mm (4 in) or less. If the total area(s) of corrosion exceed these dimensions, the wheel should be replaced. - For vehicles that have exceeded 32,186 km (20,000 mi), the total allowable combined linear area of repairable corrosion is 200 mm (8 in) or less. If the total area(s) of corrosion exceed these dimensions, the wheel should be replaced. 5. In order to correct the wheel leak, use a clean-up (fine cut) sanding disc or biscuit to remove the corrosion and any flaking paint. You should remove the corrosion back far enough until you reach material that is stable and firmly bonded to the wheel. Try to taper the edge of any flaking paint as best you can in order to avoid sharp edges that may increase the chance of a leak reoccurring. The photo below shows an acceptable repaired surface. Notice Corrosion that extends up the lip of the wheel, where after the clean-up process it would be visible with the tire mounted, is only acceptable on the inboard flange. The inboard flange is not visible with the wheel assembly in the mounted position. If any loose coatings or corrosion extend to the visible surfaces on the FACE of the wheel, that wheel must be replaced. Important Remove ONLY the material required to eliminate the corrosion from the bead seating surface. DO NOT remove excessive amounts of material. ALWAYS keep the sealing surface as smooth and level as possible. Page 10345 Cross-Member: Service and Repair Transmission Support Replacement Transmission Support Replacement Removal Procedure 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Support the transmission with a transmission jack. 3. Remove the nut retaining the transmission mount to the transmission support. 4. Raise the rear of the transmission. 5. Remove the bolts and the nuts retaining the transmission support to the frame. (15 series) 6. Remove the bolts and the nuts retaining the transmission support to the frame. (25/35 series) 7. Remove the transmission support from the frame. Installation Procedure Page 8214 2. Mark the relationship of the front wheel hub extension to the hub. 3. Remove the front wheel hub extension bolts. 4. Remove the front wheel hub extension from the vehicle. It may be necessary to tap around the perimeter of the hub extension with a rubber mallet to loosen it from the hub. 4. Mark the relationship of the rotor to the hub. 5. Install a C-clamp over the body of the brake caliper, with the C-clamp ends against the rear of the caliper body and the outboard disc brake pad. 6. Slowly tighten the C-clamp until the pistons are pushed into the caliper bores enough to remove the caliper from the pads. 7. Remove the C-clamp from the caliper. 8. Notice: Support the brake caliper with heavy mechanic's wire, or equivalent, whenever it is separated from its mount and the hydraulic flexible brake hose is still connected. Failure to support the caliper in this manner will cause the flexible brake hose to bear the weight of the caliper, which may cause damage to the brake hose and in turn may cause a brake fluid leak. Remove the brake caliper and brake caliper bracket as an assembly and support with heavy mechanic's wire or equivalent. DO NOT disconnect the hydraulic brake flexible hose from the caliper. 9. Remove the rotor retaining push nuts from the wheel studs, if applicable. 10. It may be necessary to strike the end of the hub or the rotor with a dead blow hammer to separate the rotor from the hub. Page 4936 Vehicle Speed Sensor: Service and Repair Automatic Transmission - 4L60-E/4L65-E Vehicle Speed Sensor (VSS) Replacement Removal Procedure 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. Disconnect the vehicle speed sensor (VSS) electrical connector (2). 3. Remove the VSS bolt (2). 4. Remove the VSS (1). 5. Remove the O-ring seal (3). Installation Procedure 1. Install the O-ring seal (3) onto the VSS (1). 2. Coat the O-ring seal (3) with a thin film of transmission fluid. 3. Install the VSS (1). 4. Notice: Refer to Fastener Notice in Service Precautions. Install the VSS bolt (2). ^ Tighten the bolt to 11 Nm (97 inch lbs.). Page 1523 Turn Signal Multifunction Switch - C2 Interior - Proper Use of Floor Mats Carpet: Technical Service Bulletins Interior - Proper Use of Floor Mats INFORMATION Bulletin No.: 10-08-110-001 Date: March 30, 2010 Subject: Information on Proper Use of Floor Mats Models: 2011 and Prior GM Passenger Cars and Trucks (Including Saturn) 2003-2009 HUMMER H2 2006-2010 HUMMER H3, H3T 2005-2009 Saab 9-7X GM's carpeted and all-weather (rubber) floor mats are especially designed for use in specific GM vehicles. Using floor mats that were not designed for the specific vehicle or using them incorrectly may cause interference with the accelerator or brake pedal. Please review the following safety guidelines regarding proper driver's side floor mat usage with the customer. Warning If a floor mat is the wrong size or is not properly installed, it can interfere with the accelerator pedal and/or brake pedal. Interference with the pedals can cause unintended acceleration and/or increased stopping distance which can cause a crash and injury. Make sure the floor mat does not interfere with the accelerator or brake pedal. - Do not flip the driver's floor mat over (in an effort to keep the floor mat clean) - Do not place anything on top of the driver's floor mat (e.g. carpet remnant, towel) - Do not place another mat on top of the driver's floor mat (e.g. do not place all-weather rubber mats over carpeted floor mats) - Only use floor mats that are designed specifically for your vehicle - When using replacement mats, make certain the mats do not interfere with the accelerator or brake pedal before driving the vehicle If your vehicle is equipped with a floor mat retaining pin(s) or clip(s), make certain the mat is installed correctly and according to the instructions. Locations Instrument Panel Switches-LH Page 9747 C249 I/P Harness To Bezel Harness (Except Y91) Page 8203 10. Install the front wheel hub extension (dual wheel vehicles only). 0. Insert a drift or large screwdriver through the brake caliper into one of the brake rotor vanes in order to prevent the rotor from turning. 1. Align and install the front wheel hub extension to the original position on the hub. 2. Important: Follow the same tightening sequence for the front wheel hub extension that is used on an eight lug wheel. Install the front wheel hub extension nuts. ^ Tighten the front wheel hub extension nuts to 130 Nm (96 ft. lbs.). 11. Install the tire and wheel assembly. 12. Lower the vehicle. 13. With the engine OFF, gradually apply the brake pedal to approximately 2/3 of its travel distance. 14. Slowly release the brake pedal. 15. Wait 15 seconds, then repeat steps 13-14 until a firm pedal is obtained. This will properly seat the brake caliper pistons and brake pads. 16. Fill the master cylinder reservoir to the proper level with clean brake fluid. Refer to Master Cylinder Reservoir Filling in Hydraulic Brakes. Page 3826 Body Control Module (BCM) - C3 Part 1 Page 5800 1. Lubricate the input speed sensor seal with automatic transmission fluid. 2. Install the input speed sensor (1). Notice: Refer to Fastener Notice in Service Precautions. 3. Install the input speed sensor bolt. ^ Tighten the bolt to 11 Nm (96 inch lbs.). 4. Connect the input speed sensor electrical connector (1). 5. Lower the vehicle. Page 5111 3. If vehicle is a regular cab, install the fuel and EVAP bundle nuts. Tighten Tighten the nuts to 12 N.m (106 lb in). 4. Remove the caps from the fuel and EVAP lines at the fuel tank. 5. Connect the fuel and EVAP quick connect fittings. 6. If equipped with 4WD, install the fuel line clip to the bracket on the transfer case. 7. Install the fuel line clip(s) to the bracket(s) on the transmission. Page 2136 Page 10257 IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. Splicing Twisted or Shielded Cable SPLICING TWISTED OR SHIELDED CABLE Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. - Rewrap the conductors with the mylar tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with mylar tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Control Module References Page 16149 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the cover up until the dress cover releases. Repeat this procedure for the other locking tab. 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. 5. If the connector has a nose piece, use a small flat-blade tool to remove the nose piece by inserting the blade into the slot on the front of the connector and prying up on the nose piece. IMPORTANT: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 6. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. IMPORTANT: Be careful not to angle or rock the J 38125-13A tool when inserting it into the connector or the tool may break. Page 12236 2. Click on the Analog-to-Digital Program link to start the ordering process. 3. To order a kit, you will need the information shown above. 4. After submitting the order, the "Terms and Conditions of Your OnStar(R) Service" page will display. This is your confirmation that the upgrade kit order has been created. U.S. Dealers will also receive an e-mail from Autocraft within several hours of ordering an upgrade kit (Canadian Dealers will receive an e-mail from MASS Electronics). 5. Print the "Terms and Conditions of Your OnStar(R) Service" page, and have the customer sign a copy. 6. A copy of this form should be stapled to the customer's copy of the Repair Order and one copy should be retained in the customer service folder. 7. If the kit you ordered is available, you will receive the upgrade kit within 4 business days of entering your order through the OnStar(R) Online Enrollment webpage. 8. To check on kit availability or the status of your order, U.S. Dealers can log onto the distributor's website at www.autocraft.com. Canadian dealers can call MASS Electronics at 877-410-6277. Upgrade Kit Installation 1. Skip to the next step if the vehicle to be upgraded is not shown above. Page 1282 1. If installing the old sensor, coat the threads with sealant GM P/N 12346004 (Canadian P/N 10953480) or equivalent. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the ECT sensor. Tighten Tighten the sensor to 20 N.m (15 lb ft). 3. Connect the ECT sensor electrical connector (5). 4. Refill the cooling. Refer to Draining and Filling Cooling System in Cooling System. Page 15829 Turn Signal Multifunction Switch - C3 Page 10264 Control Module References Part 7 Page 8991 Location View Page 15034 3. Install the end gate support cable onto cable restraint fastener. 4. Close the end gate. Automatic Transmission - 4L60-E/4L65-E Page 5376 Tighten Tighten the nut to 10 N.m (89 lb in). 19. Lower the vehicle. 20. Remove the caps from the fuel rail and EVAP pipes. 21. Connect the EVAP canister purge tube (3). 22. Connect the fuel feed and return pipes (1) at the fuel rail. 23. Install the fuel fill cap. 24. Connect the negative battery cable. 25. Use the following procedure in order to inspect for leaks: 25.1. Turn the ignition ON, with the engine OFF, for 2 seconds. 25.2. Turn the ignition OFF for 10 seconds. 25.3. Turn the ignition ON, with the engine OFF. 25.4. Inspect for fuel leaks. Fuel Hose/Pipes Replacement - Chassis (1500 Crew Cab) FUEL HOSE/PIPES REPLACEMENT - CHASSIS (1500 CREW CAB) REMOVAL PROCEDURE IMPORTANT: Clean the fuel and evaporative emission (EVAP) connections and surrounding areas prior to disconnecting the fittings in order to avoid possible system contamination. 1. Relieve the fuel system pressure. Refer to Fuel Pressure Relief Procedure. 2. Disconnect the fuel feed line (1) fitting at the engine. 3. Disconnect the EVAP canister purge tube (2) fitting. 4. Cap the fuel rail and EVAP lines in order to avoid possible system contamination. 5. Raise and support the vehicle. Refer to Vehicle Lifting and. Page 15167 9. Use J 38125-12A to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. REPAIR PROCEDURE The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. 1. Cut the wire as close to the terminal as possible. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. Page 2075 Steps 4 - 6 Page 9653 Remove all rust from the ground terminal, the cylinder head and the retaining nut or bolt. Position the main engine wiring harness ground terminal and install the nut or bolt. Tighten: Tighten the retaining nut or bolt to 16 N.m (12 lb ft). Apply some type of electrical moisture sealant to protect the harness terminal from further corrosion. Disclaimer Inlet Radiator Hose: Service and Repair Inlet Radiator Hose Replacement - Inlet (4.8, 5.3, and 6.0L Engines) Removal Procedure 1. Drain the cooling system. 2. Loosen the air cleaner outlet duct clamps at the following locations: ^ Throttle body ^ Mass Airflow/Intake Air Temperature (MAF/IAT) sensor 3. Remove the radiator inlet hose clip from the outlet hose. 4. Remove the air cleaner outlet duct. 5. If necessary, remove the engine sight shield. 6. Remove the radiator vent inlet hose from the radiator inlet hose clips. 7. Reposition the inlet hose clamp at the radiator. 8. Remove the inlet hose clip from the fan shroud. 9. Remove the inlet hose from the radiator. Page 1636 ^ Reinstall the fuse and fuse panel cover. ^ Press the "Enter" button to perform the "Refresh" function. ^ "Test in Progress" will be displayed and the right front passenger door lock will cycle once. ^ The screen will display "Procedure Completed". ^ Press the "Exit" button as necessary to return to the main menu screen. 3. Using the switches in the right front passenger door, verify that the power window and power door lock located in that door function properly. Important: The calibrations required for performing SPS reprogram in the next step are based on the type of exterior rearview mirror the vehicle has. To determine the correct calibration, check the Service Parts Identification Label on the vehicle for the RPO code for exterior mirrors. 4. Follow normal Service Programming System (SPS) to reprogram the passenger door module with the current calibration available in TIS 2000. 5. After reprogramming is complete, using the switches in the right front passenger door, verify that the power window and power door lock located in that door function properly. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 6480 2. Remove the transmission from the vehicle. Refer to the appropriate SI document. Important: ^ Inspect all the transmission components for damage or wear. Replace all damaged or worn components. The parts shown above should be sufficient to correct this concern. ^ This condition does not normally require replacement of the transmission completely. Components such as clutches, valve body, pump and torque converters will NOT require replacement to correct this condition. Disassemble the transmission and replace the appropriate parts listed below. Refer to the Unit Repair Manual - Repair Instructions. 3. Reinstall the transmission in the vehicle. Refer to appropriate service information. When servicing the transmission as a result of this condition, the transmission oil cooler and lines MUST be flushed. Refer to Corporate Bulletin Number 02-07-30-052. Locations Fuel Pump And Sender Assembly Components Page 3711 1. Notice: Refer to Fastener Notice in Service Precautions. Install the heat shield (2), and bolts (3) to the exhaust manifold (1), if necessary. Tighten the bolts to 9 Nm (80 inch lbs.). 2. Important: ^ Tighten the exhaust manifold bolts as specified in the service procedure. Improperly installed and/or leaking exhaust manifold gaskets may affect vehicle emissions and/or On-Board Diagnostics (OBD) II system performance. ^ The cylinder head exhaust manifold bolt hole threads must be clean and free of debris or threadlocking material. Important: Do not apply sealant to the first three threads of the bolt. Apply a 5 mm (0.2 inch) wide band of threadlock GM P/N 12345493 (Canadian P/N 10953488), or equivalent to the threads of the exhaust manifold bolts. 3. Install the exhaust manifold, NEW gasket and bolts. 1. Tighten the bolts a first pass to 15 Nm (11 ft. lbs.). Tighten the bolts beginning with the center two bolts. Alternate from side-to-side, and work toward the outside bolts. 2. Tighten the bolts a final pass to 25 Nm (18 ft. lbs.). Tighten the bolts beginning with the center two bolts. Alternate from side-to-side, and work toward the outside bolts. 4. Using a flat punch, bend over the exposed edge of the exhaust manifold gasket at the rear of the left cylinder head. 5. Install the spark plugs. 6. Raise the vehicle. 7. Install the exhaust manifold pipe nuts. Tighten the nuts to 50 Nm (37 ft. lbs.). 8. Lower the vehicle. Page 12004 Involved are certain vehicles within the VIN breakpoints shown above. PARTS INFORMATION -- Saab US Only Customer Notification General Motors will notify customers of this special coverage on their vehicles (see copy of typical customer letter shown in this bulletin - actual divisional letter may vary slightly). Air Temperature Sensor - Upper Left Air Temperature Sensor - Upper Left Page 9426 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the cover up until the dress cover releases. Repeat this procedure for the other locking tab. 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. 5. If the connector has a nose piece, use a small flat-blade tool to remove the nose piece by inserting the blade into the slot on the front of the connector and prying up on the nose piece. IMPORTANT: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 6. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. IMPORTANT: Be careful not to angle or rock the J 38125-13A tool when inserting it into the connector or the tool may break. Page 15247 Cigar Lighter/Auxiliary Outlets Diagram 4 (1 Of 2) Page 14376 - Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-D in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-D if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Page 11988 DTC B2476 04: Cellular Phone Select Service Switch Open Circuit DTC B2476 59: Cellular Phone Select Service Switch Stuck Button DTC B2482 00: Cellular Phone Select Service Switch Range/Performance Circuit Short to Ground Open / High Resistance Short to Voltage Signal Performance Circuit/System Description The OnStar(R) button assembly consists of 3 buttons, Call/Answer, OnStar(R) Call Center, and OnStar(R) Emergency. The vehicle communication interface module (VCIM) supplies the OnStar(R) button assembly with 10 volts via the keypad supply voltage circuit. Each of the buttons, when pressed, completes the circuit across a resistor allowing a specific voltage to be returned to the VCIM over the keypad signal circuit. Depending upon the voltage range returned, the VCIM is able to identify which button has been activated. Conditions for Running the DTCs The ignition is ON. System voltage is between 9 - 16 volts. Conditions for Setting the DTCs B2476 04: The VCIM detects an open/high resistance on the keypad supply voltage circuit. B2482 and B2476 59: The VCIM detects a valid signal on the keypad signal circuit for more than 15 seconds. If one of the OnStar(R) buttons is held or stuck for 15 seconds or more, the VCIM will set these DTCs. Action Taken When the DTCs Set The OnStar(R) status LED turns red. No calls can be placed. The VCIM will ignore all inputs from the OnStar® button assembly. Conditions for Clearing the DTCs The condition responsible for setting the DTC no longer exists. A history DTC will clear once 100 consecutive malfunction-free ignition cycles have occurred. Tire Monitor System - TPM Sensor Information Tire Pressure Monitor Receiver / Transponder: Technical Service Bulletins Tire Monitor System TPM Sensor Information INFORMATION Bulletin No.: 08-03-16-003 Date: May 12, 2008 Subject: Warranty Reduction - Transfer of Tire Pressure Monitoring (TPM) Sensors to Replacement Wheels and Allowable TPM Sensor Replacements Models: 2000-2009 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2009 HUMMER H2 2006-2009 HUMMER H3 2005-2009 Saab 9-7x with On-Wheel TPM Sensors TPM Sensor / Wheel Warranty Reviews During the last warranty review period it was noted that wheels being returned under the GM New Vehicle Warranty were being shipped back to General Motors with the TPM sensor still attached to the wheel. Return rates ran as high as 60% with the TPM sensors still attached. Operational TPM sensors should not be returned to GM and are to be transferred to replacement wheels if they become necessary. Important: Operational TPM Sensors that are returned under warranty to General Motors will be charged back to the dealer.Sensors have a 10 year /150,000 mile (240,000 km) battery life, and should be transferred if one or more wheels are replaced. TPM Valve Stem / Grommet (0-ring) Replacement When the TPM sensors are transferred to new wheels you should replace the component used to seal the TPM sensor stem to the wheel. On sensors with an aluminum stem and visible nut on the outside of the wheel a replacement grommet (0-ring) should be used to assure a proper seal. The sensor retaining nut (except Aveo) should be tightened to 7 N.m (62 lb in) for all vehicles except Pontiac Vibe (4.0 N.m (35.4 lb in)). Important: ^ DO NOT overtorque the retaining nut. Notice: ^ Factory installed TPM Sensors come with plastic aluminum or nickel-plated brass stem caps. These caps should not be changed. Chrome plated steel caps may cause corrosion of aluminum valve stems due to incompatibility of the metals. On current style sensors the entire rubber stem is replaceable. The service interval on the revised TPM sensor with replaceable stem is the same as for any other traditional valve stem. Replace the stem at the time of tire replacement sensor transfer or whenever air seepage is suspected at the valve stem. When replacing the valve stem tighten the screw to 1.3 N.m (11.5 lb in). For either style of TPM sensor see the service parts guide for the correct GM part numbers to order and use. Disclaimer Page 13268 Important: Secure the wiring harness so that there is no risk of chafing and rattling. 9.4. Fold back the wiring harness and tape over the connectors (C). Fold back the wiring harness once more and secure with cable ties (D). 9.5. Install the right-hand rear luggage compartment in accordance with WIS - 8. Body - Interior equipment - Adjustment/Replacement. 10. Install the ground cable to the battery's negative terminal. 11. Clear the diagnostic trouble codes. 12. Set the date and time, see WIS - 3. Electrical system - Information display (SID_ - Technical description. 2003-2005 Saab 9-3 (9400) 4D/5D; 2004-2005 Saab 9-3 (9400) CV 2003-2005 Saab 9-3 (9440) 4D/5D; 2004-2005 Saab 9-3 (9440) CV Notice: Handle the fiber optic cables with care or the signal may be distorted. ^ It is very important that the two leads in the connector are not confused with one another. ^ Do not splice the cables. ^ Do not bend the cable in a radius smaller than 25 mm (1 in). ^ Do not expose the cable to temperatures exceeding 185°F (85°C). ^ Keep the cable ends free from dirt and grime. ^ Do not expose the cable to impact as this may cause the transparent plastic to whiten, thereby reducing the intensity of the light and causing possible communication interruptions. ^ The cable should not lie against any sharp edges as this may cause increased signal attenuation. 1. Remove the ECU CU with a Tech 2(R) according to the following: Fault diagnosis - Select model year - Select Saab 9-3 Sport (9440) - All - Add/Remove - Control Module - CU/PU - Remove. 2. Remove the ground cable from the battery's negative terminal. 3. Remove the floor console in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 4. Pry out the signal line from the SRS control module to the OnStar(R) control module and secure it: Locations Horn Switch: Locations Upper Steering Column Page 14035 Trim Panel: Service and Repair Garnish Molding Replacement - Center Pillar Garnish Molding Replacement - Center Pillar Removal Procedure 1. Remove the door sill plates. 2. Remove the pillar moldings by holding the moldings firmly while pulling out. Installation Procedure 1. Install the pillar moldings by pushing until the molding locks into place. 2. Install the door sill trim plates. Garnish Molding Replacement - Windshield Pillar Garnish Molding Replacement - Windshield Pillar Removal Procedure 1. Pull the molding straight out in order to release the retainers. 2. Remove the windshield garnish molding. Installation Procedure Page 15937 Electrical Symbols Part 10 Page 3278 9. Install the engine protection shield. 10. Install the tire and wheel. 11. Lower the vehicle. Page 5211 Fuel: Service and Repair FUEL SYSTEM CLEANING 1. Remove the sending unit. 2. Inspect the fuel strainer. Replace a contaminated strainer and inspect the fuel pump. 3. Inspect the fuel pump inlet for dirt and debris. Replace the fuel pump if you find dirt or debris in the fuel pump inlet. IMPORTANT: When flushing the fuel tank, handle the fuel and water mixture as a hazardous material. Handle the fuel and water mixture in accordance with all applicable local, state, and federal laws and regulations. 4. Flush the fuel tank with hot water. 5. Pour the water out of the sending unit opening. Rock the tank to be sure that removal of the water from the tank is complete. 6. Install the sending unit. Door Latch Assembly (Door Jamb Switch) - Driver C2 Door Switch: Diagrams Door Latch Assembly (Door Jamb Switch) - Driver C2 Door Latch Assembly (Door Jamb Switch) - Driver C2 Page 14065 Electrical Symbols Part 4 Page 7192 Shift Boot: Service and Repair NV 4500 Control Lever and/or Boot Replacement Removal Procedure 1. Important: DO NOT move the shift lever assembly adjustment nut if replacing the control lever. Remove the control lever. 2. Remove the control lever boot retainer plastic retainers, if necessary. 3. Remove the control lever boot retainer, if necessary. 4. Remove the control lever boot screws, if necessary. 5. Remove the control lever boot, if necessary. 6. Remove the control lever insulator, if necessary. Installation Procedure Page 15329 5. Remove the fuel level sensor retaining clip. 6. Remove the fuel level sensor. INSTALLATION PROCEDURE 1. Install the fuel level sensor. Page 4078 HO2S Page 5793 Vehicle Speed Sensor (VSS) Tow/Haul Switch Location Page 12549 Page 5092 Canister Vent Valve: Service and Repair EVAP Canister Vent Solenoid Valve Replacement 2 EVAPORATIVE EMISSION (EVAP) CANISTER VENT SOLENOID VALVE REPLACEMENT REMOVAL PROCEDURE IMPORTANT: Clean all evaporative emission (EVAP) pipe connections and surrounding areas before disconnecting the pipe in order to avoid possible EVAP system contamination. 1. Remove the fuel tank. 2. Disconnect the EVAP vent valve electrical connector (1). 3. Open the pipe retaining clips. 4. Remove the EVAP vent valve bracket bolt. 5. Remove the EVAP pipe from the retaining clips. 6. Remove the EVAP vent valve with pipe. INSTALLATION PROCEDURE Page 12706 Recall 04V045000: Possible Hydro-Boost Defect Power Steering Pump: All Technical Service Bulletins Recall 04V045000: Possible Hydro-Boost Defect DEFECT: Certain sport utility vehicles, pickup trucks, and passenger vans fail to comply with the requirements of Federal Motor Vehicle Safety Standard No. 135, "Passenger Car Brake Systems." Some of these vehicles were produced with an out-of-specification brake hydro-boost housing relief valve bore. Consequently, the valve O-ring seal may fracture. Steering efforts may be slightly increased while braking or parking. Under certain driving conditions, a fractured seal may also require an increase in the applied brake pedal effort to achieve the same vehicle deceleration. REMEDY: Dealers are to replace the hydro-boost relief valve. The manufacturer has reported that owner notification is expected to begin during the second quarter of 2004. Owners may contact Cadillac at 1-866-982-2339; Chevrolet at 1-800-630-2438; GMC at 1-866-996-9463; or Hummer at 1-866-486-6376. Page 12853 Important: Secure the wiring harness so that there is no risk of chafing or rattling. 6.1. Remove the passenger seat in accordance with WIS 8. Body - Seats Adjustment/Replacement. 6.2. Remove the right-hand B-pillar trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.3. Remove the right-hand C pillar trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.4. Fold the rear seat backrest forward. 6.5. Remove the right-hand side bolster in accordance with WIS - 8. Body - Seats Adjustment/Replacement. 6.6. Remove the A-pillar's lower side piece. 6.7. Open the cover on the right-hand wiring harness channels. 6.8. Loosen the locking strip (A) on the 2-pin connector (H2-11) for the optic cable, located by the right-hand A-pillar. 6.9. Loosen the catch (B) and remove the optic cable that runs backward in the car. 6.10. Dismantle the end cap from the new optic cable (12 783 577) and connect it to the connector H2-11. Push in the optic cable and make sure the catch (B) locks and refit the locking strip (A). 6.11. Secure the connector and the old optic cable using the cable tie for the existing wiring harness (C). Page 5750 1. If a NEW control module is being installed, program the new module. 2. Install the shift control module to the bracket. 3. Connect the shift control module electrical connectors. 4. Start the engine and test the automatic transfer case system for proper shift operation. Keyless Entry - Inoperative Keyless Entry Module: Customer Interest Keyless Entry - Inoperative Bulletin No.: 04-08-52-005 Date: June 15, 2004 TECHNICAL Subject: Remote Keyless Entry (RKE) System Inoperative (Reprogram Passenger Door Module (PDM)) Models: 2004 Cadillac Escalade, Escalade ESV, Escalade EXT 2004 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2004 GMC Sierra, Yukon, Yukon XL Condition Some customers may comment on any of the following conditions: ^ The RKE key fob does not function. ^ The "Service Tire Pressure Monitoring System" message is displayed, if equipped. ^ The passenger door will not unlock from the passenger's or driver's door switches. ^ The passenger door window is inoperative. Correction Reprogram the PDM with the Tech 2(R). Currently the Tech 2(R) software is not available for the 2004 model year. Engineering is aware of this and are working to release a new service calibration. In the meantime, build the Tech 2(R) as a 2003 model year and perform the reprogram using the procedure listed below. 1. Turn the ignition switch to the ON position. 2. Connect the Tech 2(R) to the vehicle's diagnostic link connector (DLC), power it up and press enter. ^ Select: Diagnostics. ^ Select model year: 2003. ^ Select: Light truck. ^ Select: Body. ^ Select the proper Product line. ^ Select the proper HVAC Type. ^ Select the proper Radio System type. ^ Select: Passenger Door Module. ^ Select: Special Functions. ^ Select: Refresh. Important: You must remove the described fuse in the next step for the "Refresh" program to be performed. If you do not remove the fuse for five seconds, the Tech 2 will continue to display "Test in Progress" and the program will not complete. ^ Remove the PDM fuse for 5 seconds from the fuse center located behind the panel on the left end of the instrument panel. Page 5199 Gasoline Brands That Currently Meet TOP TIER Detergent Gasoline Standards The following gasoline brands meet the TOP TIER Detergent Gasoline Standards in all octane grades : Chevron Canada (markets in British Columbia and western Alberta) - Shell Canada (nationally) - Petro-Canada (nationally) - Sunoco-Canada (Ontario) - Esso-Canada (nationally) What is TOP TIER Detergent Gasoline? TOP TIER Detergent Gasoline is a new class of gasoline with enhanced detergency and no metallic additives. It meets new, voluntary deposit control standards developed by six automotive companies that exceed the detergent recommendations of Canadian standards and does not contain metallic additives, which can damage vehicle emission control components. Where Can TOP TIER Detergent Gasoline Be Purchased? The TOP TIER program began in the U.S. and Canada on May 3, 2004. Some fuel marketers have already joined and introduced TOP TIER Detergent Gasoline. This is a voluntary program and not all fuel marketers will offer this product. Once fuel marketers make public announcements, they will appear on a list of brands that meet the TOP TIER standards. Who developed TOP TIER Detergent Gasoline standards? TOP TIER Detergent Gasoline standards were developed by six automotive companies: BMW, General Motors, Honda, Toyota, Volkswagen and Audi. Why was TOP TIER Detergent Gasoline developed? TOP TIER Detergent Gasoline was developed to increase the level of detergent additive in gasoline. In the U.S., government regulations require that all gasoline sold in the U.S. contain a detergent additive. However, the requirement is minimal and in many cases, is not sufficient to keep engines clean. In Canada, gasoline standards recommend adherence to U.S. detergency requirements but do not require it. In fact, many brands of gasoline in Canada do not contain any detergent additive. In order to meet TOP TIER Detergent Gasoline standards, a higher level of detergent is needed than what is required or recommended, and no metallic additives are allowed. Also, TOP TIER was developed to give fuel marketers the opportunity to differentiate their product. Why did the six automotive companies join together to develop TOP TIER? All six corporations recognized the benefits to both the vehicle and the consumer. Also, joining together emphasized that low detergency and the intentional addition of metallic additives is an issue of concern to several automotive companies. What are the benefits of TOP TIER Detergent Gasoline? TOP TIER Detergent Gasoline will help keep engines cleaner than gasoline containing the "Lowest Additive Concentration" recommended by Canadian standards. Clean engines help provide optimal fuel economy and engine performance, and also provide reduced emissions. Also, the use of TOP TIER Detergent Gasoline will help reduce deposit related concerns. Who should use TOP TIER Detergent Gasoline? All vehicles will benefit from using TOP TIER Detergent Gasoline over gasoline containing the "Lowest Additive Concentration" recommended by Canadian standards. Those vehicles that have experienced deposit related concerns may especially benefit from use of TOP TIER Detergent Gasoline. More information on TOP TIER Detergent Gasoline can be found at this website, http://www.toptiergas.com/. Page 3951 Coolant Temperature Sensor/Switch (For Computer): Service and Repair ENGINE COOLANT TEMPERATURE (ECT) SENSOR REPLACEMENT REMOVAL PROCEDURE NOTE: Use care when handling the coolant sensor. Damage to the coolant sensor will affect the operation of the fuel control system. 1. Drain the cooling system to a level below the engine cooling temperature (ECT) sensor. Refer to Draining and Filling Cooling System in Cooling System. 2. Disconnect the ECT sensor electrical connector (5). 3. Remove the ECT sensor. INSTALLATION PROCEDURE NOTE: Replacement components must be the correct part number for the application. Components requiring the use of the thread locking compound, lubricants, corrosion inhibitors, or sealants are identified in the service procedure. Some replacement components may come with these coatings already applied. Do not use these coatings on components unless specified. These coatings can affect the final torque, which may affect the operation of the component. Use the correct torque specification when installing components in order to avoid damage. - Use care when handling the coolant sensor. Damage to the coolant sensor will affect the operation of the fuel control system. Page 9548 Fuse Block - Underhood C1 Part 2 Page 7994 2. Connect the speed sensor electrical connector (4). 3. Lower the vehicle. Page 11365 Air Temperature Sensor - Upper Right Page 9819 Relay Box: Service and Repair I/P Electrical Center or Junction Block Replacement - Left INSTRUMENT PANEL ELECTRICAL CENTER OR JUNCTION BLOCK REPLACEMENT - LEFT REMOVAL PROCEDURE 1. Remove the left side end panel. 2. Remove the knee bolster. 3. Disconnect all the wiring connectors from the fuse block. 4. Remove all the fuses. 5. Remove the turn signal relay from the back of the fuse block. 6. From behind the fuse block, remove the retaining bolt. 7. Insert a screw driver between the fuse block and the wire harness block to separate. 8. Push on the retainers in order to remove the fuse block. 9. Remove the fuse block from the vehicle. INSTALLATION PROCEDURE 1. Install the fuse block onto the I/P assembly until it clicks in place. 2. Install the wire harness block to the back of the fuse block. NOTE: Refer to Fastener Notice in Service Precautions. 3. Install the bolt. Tighten Tighten the bolt to 6 N.m (53 lb in). 4. Install the turn signal relay to the back of the fuse block. 5. Using the wiring diagram on the cover of the fuse panel, install the fuses. 6. Install the electrical connectors. 7. Install the knee bolster. Page 13169 2. Connect the Techline Information System (TIS) terminal to the Tech2(R). 3. Scroll to the bottom of the Controller List, and select the "ONSA TIS2WEB Pass-Thru OnStar(R) Activation (Replaced/Upgraded Units Only)" option using the Service Programming System (SPS). Important: Do not use the clear DTC function. This will only temporarily turn the LED to green. 4. Upon completion of the OnStar(R) TIS2WEB step, disconnect the TIS terminal from the Tech2(R) and perform the VCIM/OnStar(R) Set-up Procedure using the Tech2(R). The set up procedure is located under the special function menu option. Important: Failure to perform the above steps will result in a red LED, DTC being set and limited or incomplete OnStar(R) services, and will require a customer return visit to the dealership. 5. The default language for the new VCIM will be English. To change to French or Spanish, access the special functions menu on the Tech 2(R), and follow the instructions accordingly. 7. Skip to the next step if the vehicle to be upgraded is not listed below: ^ 2002-2004 Cadillac DeVille ^ 2002-2004 Cadillac Seville ^ 2005 Cadillac STS Set up the Dash Integration Module (DIM) using the following procedure: 1. On the Tech2(R) select the correct Year, Make and Model. 2. Enter Dash Integration Module (DIM) > Special Functions > Set Options > Misc. Options 1 > and turn off phone (if the vehicle does not have the UV8 option). 3. Enter Nav Radio Present and set to "No Nav" (if the vehicle does not have a navigation radio). 4. Turn the ignition off and open the door to turn off the RAP. 5. Turn the ignition on and enter the Vehicle Comm. Interface Module > Special Functions > Set Up OnStar /VCIM. 6. When prompted select "No Phone" (if the vehicle does not have the UV8 phone) and "No Nav" (if the vehicle does not have a navigation radio). 7. Turn the ignition off and open the door to turn off the RAP. Important: OnStar(R) Emergency Services are immediately available after these steps, however, full configuration, including activation of Hands-Free Calling, may take up to 24 hours to complete. Processing the Module Exchange Processing the Module Exchange For this program, submitting a credit request for the removed OnStar(R) VCIM (the core) will be performed through a website. When this process is followed, the removed Analog / Digital-Ready VCIM, in most cases, will not be mailed back to the distributor, but can be scrapped by the dealership. U.S. Dealers 1. Return the removed Analog / Digital-Ready OnStar(R) VCIM to the Parts Manager. 2. The Parts Manager will log onto www.autocraft.com. 3. Select Account Maintenance. 4. Select Outstanding Cores. Page 16291 Avoiding Wiper Damage The following are major contributors to wiper damage. Some of these you can control and others are environmental concerns. - Extremely dusty areas (such as driving on dirt roads) may cause the wipers rubber edge to wear quickly and unevenly. - Sand and salt used on roads for increasing winter traction and ice control will cause the wiper blades to wear quicker. Areas with significant snowfall require more frequent blade replacements. - Heat and time may cause the rubber blades to take a "permanent set" resulting in the rubber not flexing and turning over uniformly. This condition may result in streaking and/or unwiped areas. - Rubber blades are easily cut or torn when using ice scrapers. Likewise pulling blades up off a frozen windshield can tear the rubber. Exercise caution when clearing ice and snow. - Using your wipers to "wear through" frost and ice, instead of allowing the defrosters to melt the ice, can dull, nick or tear the rubber blades. - Banging wipers on the glass to remove ice and snow may cause the blade to bend, dislodging the rubber and causing potential scratching of the windshield. - Ice can form in the pin joints of the wipers, which can cause streaking and unwiped areas. To remove ice from pin joints, compress the blade and rubber edge with your hand to loosen the frozen joints. Consider using Winter Blades that have a rubber cover to avoid this condition. Note GM does not recommend the use of any spray on/wipe on windshield treatments or washer fluid additives. The variation in friction that results on the glass from the use of these products causes wipers to chatter and have premature wear. Disclaimer Page 5290 The fuel injector (1) is stamped with a identification part number (2). A four-digit build date code (3) indicates the month (4), day (5), year (6), and shift (7) that built the injector. 1. Lubricate the NEW injector O-ring seals (2, 4) with clean engine oil. 2. Install the NEW injector O-ring seals onto the fuel injector. 3. Install a NEW retainer clip (1) onto the fuel injector. 4. Push the fuel injector (17) into the fuel rail injector socket with the electrical connector facing outward. The retainer clip (19) locks on to a flange on the fuel rail injector socket. 5. Install the fuel rail. Page 7201 Transmission Mount: Service and Repair NV 4500 Transmission Mount Replacement Removal Procedure Notice: Broken or deteriorated mounts can cause misalignment and destruction of certain drive train components. When a single mount breaks, the remaining mounts are subjected to abnormally high stresses. 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. Remove the transmission mount to crossmember nut. 3. Remove the transmission mount to transmission bolts. 4. Raise the transmission just enough, in order to permit removal of the mount using a suitable transmission jack. 5. Remove the transmission mount. Installation Procedure 1. Position the transmission mount. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the transmission mount to transmission bolts. ^ Tighten the transmission mount bolts to 50 Nm (37 ft. lbs.). 3. Lower the transmission and remove the transmission jack. Page 8694 1. Install the park brake warning lamp switch. 2. Notice: Refer to Fastener Notice in Service Precautions. Install the park brake warning lamp switch mounting bolt. ^ Tighten the bolt to 3 Nm (25 inch lbs.). 3. Connect the park brake warning lamp switch electrical connector. 4. Install the MID-bussed electrical center to the bracket. 5. Connect the negative battery cable. Page 6977 Seals and Gaskets: Service and Repair Rear Axle Shaft Seal and/or Bearing Replacement Rear Axle Shaft Seal and/or Bearing Replacement ^ Tools Required J 8092 Universal Driver Handle-3/4 in - 10 - J 21128 Axle Pinion Oil Seal Installer (8.6 inch Axle) - J 23690 Axle Shaft Bearing Installer (8.6 inch Axle) - J 2619-01 Slide Hammer - J 29709 Wheel Bearing Installer (9.5 inch Axle) - J 29712 Wheel Bearing Remover (9.5 inch Axle) - J 29713 Axle Seal Installer (9.5 inch Axle) - J 44685 Rear Axle Seal and Bearing Remover (8.6 inch Axle) Removal Procedure 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Remove the tire and wheel assembly. 3. Remove the rear axle housing cover. 4. Remove the axle shaft. 5. Remove the axle shaft seal and the bearing from the axle housing using the J 44685 (8.6 inch axle) (1) and the J 2619-01 (2). 6. Remove the axle shaft seal and the bearing from the axle housing using the J 29712 (9.5 inch axle). Installation Procedure 1. Install the axle shaft bearing using the J 23690 (8.6 inch axle) (1) or the J 29709 (9.5 inch axle) (1) and the J 8092 (2). Page 6465 1. Install the transmission range selector cable bracket. 2. Notice: Refer to Fastener Notice in Service Precautions. Install the transmission range selector cable bracket bolts (1). ^ Tighten the bolts to 25 Nm (18 ft. lbs.). 3. Align and install the cable to the bracket. 4. Install the retainer that secures the cable to the bracket. 5. Lower the vehicle. 6. Check the vehicle for proper operation. Instruments - Service Tire Monitor Message is Displayed Fuse: Customer Interest Instruments - Service Tire Monitor Message is Displayed Bulletin No.: 05-08-49-018A Date: May 11, 2006 ADVANCE SERVICE INFORMATION RESOLUTION Subject: EI 05065 - Service Tire Monitor Message Displayed (Pull/Reinstall IPC Fuse or Verify Correct Passenger Door Module (PDM) and Tires) Models: 2004 Chevrolet Silverado 2004 GMC Sierra Supercede: This bulletin is being revised to provide correction action. Please discard Corporate Bulletin Number 05-08-49-018 (Section 08 - Body and Accessories). Condition Some customers may comment that the "SERVICE TIRE MONITOR" message is being displayed on the DIC. Correction DO NOT REPLACE THE INSTRUMENT PANEL CLUSTER. If the DIC is displaying the SERVICE TIRE MONITOR message: 1. Verify if the vehicle has an electronic aftermarket module spliced into the ALDL Class 2 data line (purple wire). 2. If the vehicle HAS an aftermarket module spliced into the Class 2 line, pull the IPC fuse (located underhood) for 25 seconds. Important: Due to the electronic aftermarket module, the SERVICE TIRE MONITOR message may reoccur. 3. Reinstall the IPC fuse. This will clear the SERVICE TIRE MONITOR message from the display. 4. If the vehicle DOES NOT have an aftermarket module spliced into the Class 2 line, verify the vehicle is equipped with the correct PDM (Passenger Door Module) and tires. Warrant Information This repair is not covered under the vehicle warranty due to the installation of an aftermarket module. Disclaimer Page 991 Location View The Fuel Pump Relay is located in the Underhood Fuse Block. The Underhood Fuse Block is located in the left side of the engine compartment to the rear of the battery. Page 5923 For vehicles repaired under the 8 year/80,000 mile (130,000 km) emission controller warranty use the table. Disclaimer Page 4655 7. Insert the J 38125-13A (GM P/N 12031876-1) tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the Terminal Repair Kit to ensure that the correct release tool is used. 8. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. REPAIR PROCEDURE Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. Page 14185 Installation Procedure 1. Install the control rods to the assembly. 2. Connect the electrical connectors to the door lock actuator, if equipped 3. Install the door lock actuator to the door. 4. Connect the outside door handle control rod. 5. Connect the cylinder lock rod. Notice: Refer to Fastener Notice in Service Precautions. 6. Install the bolts which retain the door lock actuator to the door. Tighten the screws to 9 N.m (80 lb in). 7. Connect the manual door lock to the door retainer clips. 8. Connect the inside door handle control rod to the lock assembly. 9. Connect the inside door lock rod to the handle retainer clip. 10. Install the water deflector. 11. Install the door trim panel. 12. Inspect the operation of all the related components. Lock Actuator Replacement - Rear Door Lock Actuator Replacement - Rear Door Removal Procedure 1. Raise the window. 2. Remove the door trim panel. 3. Remove the water deflector. Page 8412 4. Notice: Refer to Fastener Notice in Service Precautions. For the 15 series vehicles, install the nut to the threaded end of the intermediate cable. ^ Tighten the nut to 3.5 Nm (31 inch lbs.). 5. Remove the safety stands and lower the vehicle. 6. Adjust the park brake system. Page 2054 Alignment: Specifications Wheel Alignment Specifications Wheel Alignment Specifications Page 13441 1. Position the steering wheel control switch to the steering wheel. 2. Connect the electrical connector to the steering wheel control switch. 3. Install the steering wheel control switch into the steering wheel, ensuring the retaining tabs are fully seated. 4. Install the shroud to the steering wheel. 5. Notice: Refer to Fastener Notice in Service Precautions. Install the shroud retaining screws to the steering wheel. ^ Tighten the screws to 2 Nm (18 inch lbs.). 6. Install the steering wheel. Page 9228 C305 Body Harness To Drivers Seat Harness (With RPO Code AG1) Part 2 Service and Repair Rear Wheel Steering Switch: Service and Repair Rear Wheel Steering Mode Switch Replacement Removal Procedure 1. Remove the dash trim bezel. 2. Grasp the rear wheel steering mode switch housing (2) and pull outward to remove the switch assembly. 3. Disconnect the electrical connector (3) from the rear wheel steering mode switch. 4. Remove the rear wheel steering mode switch assembly (1) from the vehicle. Installation Procedure 1. Reconnect the rear wheel steering mode switch (3) electrical connectors. 2. Install the rear wheel steering mode switch (1) into the dash. 3. Reinstall the dash trim bezel. Page 3032 Install a new spring bumper assembly for 2WD 1500 Series Only with 20" wheels. Reuse the nut from the original bumper. Install the nut to the spring bumper stud. Tighten Tighten the nut to 30 N.m (22 lb ft). Remove the safety stands. Lower the vehicle. Knee Bolster Deflector This modification is required for the following vehicles and ONLY applies to Extended Cab Long Box (K15953) Pickup models: 1999-2005 Chevrolet Silverado and GMC Sierra (1500 Series Only): 2005 Vehicles Built in Pontiac (VIN Code E) prior to VIN Breakpoint 5E100134 2005 Vehicles Built in Oshawa (VIN Code 1) prior to VIN Breakpoint 51113131 2005 Vehicles Built in Ft. Wayne (VIN Code Z) prior to VIN Breakpoint 5Z126605 The following procedure should be followed: Apply the parking brake to prevent the vehicle from moving. Remove the fuse panel cover. Remove the I/P cluster trim plate bezel. Remove the knee bolster. Remove the 2 mm (0.078 in) thick knee bolster deflector. Install the 1.5 mm (0.059 in) thick knee bolster deflector, P/N 12499966. A detailed instruction sheet will be provided with the service part. Re-Programming Page 1000 Step 6 Page 866 Electrical Symbols Part 2 Page 7021 Please note the following when referring to a specific illustration: ^ When using the illustrations for back to back comparisons of two hubs, the most obvious differences are visible on the back side of the hubs. ^ The most common area of physical difference are in the shape of the four mounting bosses and their surrounds. Disclaimer AWD/4WD - AWD/4WD Lamps/System Inop./DTC C0550 Control Module: All Technical Service Bulletins AWD/4WD - AWD/4WD Lamps/System Inop./DTC C0550 Bulletin No.: 02-04-21-006E Date: July 20, 2006 TECHNICAL Subject: Inoperative 4WD/AWD Lamps, Inoperative 4WD/AWD System, DTC C0550 Set, No Communication with TCCM (Reprogram Transfer Case Control Module) Models: 2004 Buick Rainier 2002-2004 Chevrolet TrailBlazer, TrailBlazer EXT 2003-2004 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2002-2004 GMC Envoy, Envoy XL 2003-2004 GMC Sierra, Yukon, Yukon XL 2004 GMC Envoy XUV 2002-2004 Oldsmobile Bravada with Electronic Shift or Active Transfer Case (RPOs NP1, NP4 or NP8) Supercede: This bulletin is being revised to add Subject information and change the labor operation. This bulletin cancels and supersedes Bulletin Number 03-04-21-006. Please discard Corporate Bulletin Numbers 02-04-21-006D and 03-04-21-006 (Section 04 - Driveline/Axle). Condition Some customers may comment that the 4WD/AWD indicator lights on the selector switch do not work, or the 4WD/AWD system may be inoperative and/or the service 4WD light is illuminated. The condition is typically intermittent and always occurs at key-up. Upon investigation, the technician may find DTC C0550 set. Cause The Transfer Case Control Module (TCCM) has not received the wake-up call during key-up and has remained in the "sleep mode". When the TCCM is in the "sleep mode", it will not communicate with the class II bus or the Tech 2(R). Correction 1. Try to communicate with the TCCM. If no communication, go to step 2. If communication is possible, go to step 5. 2. Remove the underhood (ATCM or TREC) TCCM fuse. 3. Wait 30 seconds. 4. Reinstall the fuse. The module should wake up and communicate with the Tech 2(R). 5. Check for codes in the TCCM. If a C0550 is found current or in history with or without other codes, replace the module and go to step 6. 6. Reprogram the TCCM with the latest TIS software using normal SPS procedures. 7. Verify operation and that no codes are present. Important: For the 2002 model year, the TCCM must be replaced and reprogrammed. Warranty Information Door Sill Plate Replacement - Front Scuff Plate: Service and Repair Door Sill Plate Replacement - Front Door Sill Plate Replacement - Front Removal Procedure 1. Remove the sill plate. Firmly pull the sill plate up and out from the retainers. 2. Remove the sill plate from the vehicle. Start from the front of the door sill. Use a flat-bladed tool in order to pry the door sill plate. Installation Procedure 1. Install the sill plate. 2. Push the sill plate down until the sill plate locks into place. Page 10903 7. Insert the J 38125-13A (GM P/N 12031876-1) tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the Terminal Repair Kit to ensure that the correct release tool is used. 8. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. REPAIR PROCEDURE Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. Page 275 Labor Time Information Page 13137 Page 8209 10. Remove the 2 brake caliper bracket mounting bolts. 11. Mark the relationship of the rotor to the hub. 12. Notice: Support the brake caliper with heavy mechanic's wire, or equivalent, whenever it is separated from its mount and the hydraulic flexible brake hose is still connected. Failure to support the caliper in this manner will cause the flexible brake hose to bear the weight of the caliper, which may cause damage to the brake hose and in turn may cause a brake fluid leak. Remove the brake caliper and brake caliper mounting bracket as an assembly and support with heavy mechanic's wire or equivalent. DO NOT disconnect the hydraulic brake flexible hose from the caliper. 13. Remove the rotor retaining push nuts from the wheel studs, if applicable. 14. It may be necessary to strike the end of the hub or the rotor with a dead blow hammer to separate the rotor from the hub. 15. Remove the rotor by slowly turning the rotor while pulling the rotor away from the axle. Installation Procedure 1. Important: Whenever the brake rotor has been separated from the hub/axle flange, any rust or contaminants should be cleaned from the hub/axle flange and the brake rotor mating surfaces. Failure to do this may result in excessive assembled lateral runout (LRO) of the brake rotor, which could lead to brake pulsation. Use the J 42450-A to clean all rust and contaminants from the mating surface of the hub flange. 2. Use the J 41013 to clean all rust and contaminants from the inside diameter of the hat section of the brake rotor to prevent any foreign material from getting between the brake rotor and the hub flange. 3. Inspect the mating surfaces of the hub/axle flange and the rotor to ensure that there are no foreign particles or debris remaining. 4. Align the rotor to its original position on the hub, if applicable. Page 4092 5. If equipped with a 6.0L engine, disconnect the HO2S electrical connector. 6. Remove the HO2S. INSTALLATION PROCEDURE IMPORTANT: A special anti-seize compound is used on the HO2S threads. The compound consists of liquid graphite and glass beads. The graphite tends to burn away, but the glass beads remain, making the sensor easier to remove. New, or service replacement sensors already have the compound applied to the threads. If the sensor is removed from an exhaust component and if for any reason the sensor is to be reinstalled, the threads must have anti-seize compound applied before the reinstallation. 1. If reinstalling the old sensor, coat the threads with anti-seize compound GM P/N 12377953, or equivalent. NOTE: Refer to Component Fastener Tightening Notice in Service Precautions. Page 5116 3. If vehicle is a regular cab, install the fuel feed, EVAP, and return pipe assembly nuts. Tighten Tighten the nuts to 12 N.m (106 lb in). 4. Remove the caps from the fuel pipes at the fuel tank. 5. Connect the fuel feed and return pipes at the fuel tank. 6. If equipped with 4WD, install the torsion bar bracket. 7. Install the EHCU (1). 8. Install the bolts (4) attaching the EHCU bracket to the frame (5). Tighten Tighten the bolts to 25 N.m (18 lb ft). Page 14175 Door Latch Assembly (Lock Actuator) - LR C1 (Crew Cab Only) Page 702 Disclaimer Page 10318 4. Remove the snap ring (2) from the ball joint stud (1). 5. Remove the bolts (2) retaining the lower ball joint (3) to the steering knuckle. 6. Remove the pinch bolt (1) retaining the lower ball. 7. Remove the lower ball joint (2) from the vehicle. Installation Procedure 1. Install the lower ball joint (2) to the vehicle. Service and Repair Hydraulic Control Assembly - Antilock Brakes: Service and Repair Brake Pressure Modulator Valve (BPMV) Replacement Removal Procedure Caution: Refer to Brake Fluid Irritant Caution in Service Precautions. 1. Caution: Refer to Battery Disconnect Caution in Service Precautions. Notice: Refer to Brake Fluid Effects on Paint and Electrical Components Notice in Service Precautions. Remove the negative battery cable. 2. Important: The area around the EHCU MUST be free from loose dirt to prevent contamination of disassembled ABS components. Thoroughly wash all contaminants from around the EHCU. 3. Disconnect the chassis electrical harness connectors from the EBCM. 4. Important: Make sure that brake lines are tagged and kept in order for proper reassembly. Disconnect 5 brake lines from the BPMV. 5. Remove the bolts (4) securing the EHCU mounting bracket (3) to the frame rail (5). 6. Remove the EHCU assembly (1) from the vehicle. 7. Remove the bolts (4) securing the BPMV mounting bracket (5) to the BPMV (3). Page 4804 Fuel Level Sensor: Service and Repair Fuel Level Sensor Replacement - 2 FUEL LEVEL SENSOR REPLACEMENT REMOVAL PROCEDURE 1. Remove the sending unit. 2. Disconnect the fuel pump electrical connector. 3. Remove the fuel level sensor electrical connector retaining clip. 4. Disconnect the fuel level sensor electrical connector. Locations Fuel Pump And Sender Assembly Components Page 3047 Wheel Bearing: Adjustments Rear Wheel Bearing Adjustment (With Full Floating 10.5" or 11.5" Ring Gear) IMPORTANT: Ensure the brakes are fully released and do not drag. ^ Pull or push the tire at the top back and forth in order to test the wheel bearing play. ^ Use a pry bar under the tire as an alternative. ^ If the wheel bearing adjustment is correct, the movement will be barely noticeable. ^ If the movement is excessive, adjust the bearings. Adjustment Procedure Tools Required J 2222-C Wheel Bearing Nut Wrench 1. Raise the vehicle. 2. Remove the axle shaft. 3. Remove the hub adjuster nut retaining ring. 4. Remove the adjuster nut lock key. Page 6835 Seat the pinion yoke onto the pinion shaft by tapping it with a soft-faced hammer until a few pinion shaft threads show through the yoke. 5. Install the washer. 6. Install the new pinion nut 7. Install the J 8614-01 onto the pinion yoke as shown. 8. Notice: Refer to Fastener Notice in Service Precautions. Tighten the pinion nut while holding the J 8614-01. ^ Tighten the pinion nut to 370 Nm (273 ft. lbs.). 9. Install the propeller shaft to the rear axle pinion yoke. 10. Inspect and add axle lubricant to the axle housing, if necessary. 11. Lower the vehicle. Page 5810 Park Neutral Position (PNP) Switch C175 Page 5661 Shift Interlock Solenoid: Service and Repair Automatic Transmission Shift Lock Actuator Replacement Removal Procedure 1. Caution: Refer to SIR Caution in Service Precautions. Disable the SIR system. 2. Remove the body control module (BCM). 3. Put the shift lever clevis into the neutral position. 4. Disconnect the electrical connector. 5. Using a small screwdriver, pry the automatic transmission shift lock control actuator away from the steering column jacket and the cable shift cam. 6. Remove the shift lock control actuator. Installation Procedure 1. Firmly install the shift lock control actuator onto the steering column jacket and the cable shift cam. 2. Connect the electrical connector. 3. Adjust the shift lock control actuator (with the shift lever clevis in the neutral position) in the following way: 1. Pull out the tab (1) on the adjuster block side (2) of the shift lock control actuator. 2. Press on the adjuster block (2) to compress the internal adjuster spring which disengages the adjuster teeth. Slide the adjuster block (2) as far away from the actuator as possible. 3. Lock the adjuster block (2) in place by pushing in on the tab (1). 4. Inspect the shift lock control actuator for the following items: NV 3500 Backup Lamp Switch: Service and Repair NV 3500 Backup Lamp Switch Replacement Removal Procedure 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. Disconnect the backup lamp switch electrical connector (3). 3. Remove the backup lamp switch. Installation Procedure 1. Notice: Refer to Fastener Notice in Service Precautions. Important: The backup lamp switch has pre-applied thread sealant on the threads. Install the backup lamp switch. ^ Tighten the switch to 37 Nm (27 ft. lbs.). Page 9750 C250 Brake/Clutch Harness To Brake Clutch Jumper Harness (With RPO Codes 5X7, 5G4, 5Y0, And TRW) Instruments - GPS System Performance Degradation Antenna, Navigation: Customer Interest Instruments - GPS System Performance Degradation Info - Global Position Sensor (GPS) Performance Degradation # 00-08-46-003B - (Feb 9, 2005) Models: 1996-2005 Passenger Cars and Trucks 2002-2005 Saturn Vehicles with Navigation Systems and/or OnStar(R) This bulletin is being revised to include additional information. Please discard Corporate Bulletin Number 00-08-46-003A (Section 08 - Body and Accessories). Navigation and OnStar(R) systems require a GPS antenna in order to function properly. This antenna may be located inside the vehicle. If the GPS antenna is located inside the vehicle, performance of the system may be compromised by window tinting film. If the GPS system performance is in question and the vehicle has window tinting, a quick diagnostic check can be made by temporarily moving the GPS antenna to an external vehicle surface, such as the decklid or roof. If the GPS function of the navigation or On Star(R) system operates normally with the antenna relocated the repair would not be considered a warranty repair. The subsequent repair procedure or GPS placement would be up to the customer. Some vehicles have the GPS antenna located on the rear window shelf Objects placed on the rear window shelf such as tissue boxes, books, dolls, etc,, also have the potential to interfere with GPS performance. Warranty Information Repairs made to the vehicle navigation and/or OnStar(R) system, which are the result of window tinting, are not considered warranty repairs. Disclaimer Page 13682 Front Door Window Glass Weatherstrip: Service and Repair Door Window Weatherstrip Weatherstrip Replacement - Front Door Window Removal Procedure 1. Remove the door trim panel. 2. Remove the water deflector. 3. Remove the window. 4. Remove the screws. 5. Pull the weatherstrip from the following locations: * The front of the glass run channel * The top of the window frame flange * The rear of the glass run channel 6. Remove the weatherstrip from the door. Installation Procedure 1. Install the weatherstrip to the following locations: * The front of the glass run channel * The top of the window frame flange * The rear of the glass run channel Notice: Refer to Fastener Notice in Service Precautions. 2. Install the bolts. Tighten to 6 N.m (53 lb in). 3. Install the window. 4. Install the water deflector. 5. Install the door trim panel. 6. Inspect operation of window. Page 10699 1. Install the tire and wheel. Align the locating mark of the tire and wheel to the hub. 2. Install the wheel nuts. ^ Tighten the wheel nuts as shown to 190 Nm (140 ft. lbs.). Notice: Refer to Fastener Notice in Service Precautions. Important: ^ Tighten the nuts evenly and alternately in order to avoid excessive runout. 3. Install the wheel center cap. 4. Remove the safety stands. 5. Lower the vehicle. Page 2002 Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. 1. Disconnect the connector from the component. 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. Page 12878 ^ For U.S. Saturn retailer claim submission, use Net Item code "M" and Case Type VW. Page 9013 Fuse Block - Underhood C2 Part 2 Emissions - MIL ON/DTC P0446 Stored In ECM Canister Purge Control Valve: Customer Interest Emissions - MIL ON/DTC P0446 Stored In ECM TECHNICAL Bulletin No.: 02-06-04-037I Date: September 16, 2010 Subject: Check Engine Light On, Fuel Tank Hard to Fill, DTCs P0442, P0446, P0455 or P0449 Set (Replace Evaporative Emission (EVAP) Vent Valve Solenoid Assembly and Add/Relocate Filter Box Using Service Kit) Models: 1999-2007 Chevrolet Silverado (Classic) Models 1999-2007 GMC Sierra (Classic) Models 2007-2010 Chevrolet Silverado Models (Including Hybrid) 2007-2010 GMC Sierra Models (Including Hybrid) Supercede: This bulletin is being revised to add the 2010 model year and to include the Hybrid models. Please discard Corporate Bulletin Number 02-06-04-037H (Section 06 - Engine/Propulsion System). Condition Some customers may comment about the check engine light being illuminated. They may also comment that their vehicle is difficult to fill with fuel or when filling, the pump continuously shuts off before the tank is full. When checking the vehicle for DTCs, the ECM may report one or more of the following DTCs set as current or in history: P0442, P0446, P0449 or P0455. Cause The EVAP canister vent solenoid (CVS) valve draws fresh air into the system through a vent. Under certain operating conditions, dirt and dust intrusion into the EVAP CVS fresh air intake/venting system, may result in restricted air flow. Under certain operating conditions, water, if ingested into the EVAP CVS fresh air intake/venting system, may reach the CVS valve causing corrosion in the CVS valve, and may cause restrictions in the fresh air intake path, when the valve is in the closed position. Correction (1999-2007 Classic/Old Style Models) After following the published SI diagnostics and determining that the EVAP canister vent valve is the cause of the MIL light, replace the existing EVAP canister vent valve assembly with a new assembly. This new assembly is a sealed unit that is designed to be vented through a remote filter box. To ensure correct installation, follow the procedures below. Important DO NOT replace the EVAP canister assembly for this concern unless it fails the leak test. 1999-2003 Model Year (Use Service Kit P/N 19207762) 1. Raise the vehicle. Suitably support the vehicle. 2. Disconnect the EVAP canister vent valve electrical connector, if equipped. 3. Disengage the two vent valve pipe clips securing the pipe to the underbody. Remove the clips from the underbody and discard. 4. Disconnect the vent valve pipe at the EVAP canister. 5. Remove and retain the EVAP canister vent valve bracket mounting bolt. 6. Remove the complete EVAP canister vent valve assembly with bracket attached and discard. Page 8184 WARRANTY INFORMATION Page 647 4. connect the chassis electrical connectors to the EBCM. 5. Lower the vehicle. 6. Connect the negative battery cable. 7. Revise the tire calibration using the Scan Tool Tire Size Calibration function. 8. Return to Diagnostic Starting Point - Antilock Brake System. A/T - No Movement in Drive or 3rd Gear Clutch: All Technical Service Bulletins A/T - No Movement in Drive or 3rd Gear TECHNICAL Bulletin No.: 08-07-30-027 Date: June 04, 2008 Subject: No Movement When Transmission is Shifted to Drive or Third - Normal Operation When Shifted to Second, First or Reverse (Replace Forward Sprag Assembly) Models: 1982 - 2005 GM Passenger Cars and Light Duty Trucks 2006 - 2007 Buick Rainier 2006 Cadillac Escalade, Escalade ESV, Escalade EXT 2006 Chevrolet SSR 2006 - 2008 Chevrolet Avalanche, Colorado, Express, Silverado Classic, Silverado, Suburban, Tahoe, TrailBlazer 2006 GMC Yukon Denali, Yukon Denali XL 2006 - 2008 GMC Canyon, Envoy, Savana, Sierra Classic, Sierra, Yukon, Yukon XL 2006 Pontiac GTO 2006 - 2007 HUMMER H2 2006 - 2008 HUMMER H3 2006 - 2008 Saab 9-7X with 4L60, 4L60E, 4L65E or 4L70E Automatic Transmission (RPOs MD8, M30, M32, M33 or M70) Condition Some customers may comment that the vehicle has no movement when the transmission is shifted to DRIVE or THIRD position, but there is normal operation when it is shifted to SECOND, FIRST or REVERSE position. Cause This condition may be caused by a damaged forward sprag assembly (642). Correction When inspecting the sprag, it is important to test the sprag for proper operation by holding the outer race (644) with one hand while rotating the input sun gear (640) with the other hand. The sun gear should rotate only in the counterclockwise direction with the input sun gear facing upward. If the sprag rotates in both directions or will not rotate in either direction, the sprag elements should be inspected by removing one of the sprag assembly retaining rings (643). Refer to SI Unit Repair section for forward clutch sprag disassembly procedures. If the sprag is found to be damaged, make repairs to the transmission as necessary. A new forward roller clutch sprag assembly is now available from GMSPO. Page 4756 Accelerator Pedal Position Sensor: Diagrams Accelerator Pedal Position (APP) Sensor Part 1 Page 4121 Locations Oil Pressure Sender: Locations Engine Oil Pressure (EOP) Sensor And CMP Sensor Page 10488 Please note the following when referring to a specific illustration: ^ When using the illustrations for back to back comparisons of two hubs, the most obvious differences are visible on the back side of the hubs. ^ The most common area of physical difference are in the shape of the four mounting bosses and their surrounds. Disclaimer 4L60-E/4L65-E Fluid Filter - A/T: Service and Repair 4L60-E/4L65-E Automatic Transmission Fluid/Filter Replacement Removal Procedure Caution: When the transmission is at operating temperatures, take necessary precautions when removing the drain plug, to avoid being burned by draining fluid. 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. Place a drain pan under the transmission oil pan. 3. Remove the oil pan drain plug, if equipped. 4. If necessary, remove the bolts and position aside the range selector cable bracket for clearance while lowering the pan. It is not necessary to remove the cable from the lever or bracket. 5. Remove the oil pan bolts from the front and sides of the pan only. 6. Loosen the rear oil pan bolts approximately 4 turns. 7. Lightly tap the oil pan with a rubber mallet in order to loosen the pan to allow the fluid to drain. 8. Remove the remaining oil pan bolts. 9. Remove the oil pan and the gasket. Page 15546 Ambient Light Sensor: Diagrams Ambient Light Sensor Page 4558 Knock Sensor: Description and Operation KNOCK SENSOR (KS) SYSTEM DESCRIPTION PURPOSE The knock sensor (KS) system enables the control module to control the ignition timing for the best possible performance while protecting the engine from potentially damaging levels of detonation. The control module uses the KS system to test for abnormal engine noise that may indicate detonation, also known as spark knock. SENSOR DESCRIPTION This KS system uses one or two broadband one-wire sensors. The sensor uses piezo-electric crystal technology that produces an AC voltage signal of varying amplitude and frequency based on the engine vibration, or noise, level. The amplitude and frequency are dependant upon the level of knock that the KS detects. The control module receives the KS signal through a signal circuit. The KS ground is supplied by the engine block through the sensor housing. One way the control module monitors the system is by output of a bias voltage on the KS signal wire. The bias voltage creates a voltage drop that the control module monitors and uses to help diagnose KS faults. The KS noise signal rides along this bias voltage, and due to the constantly fluctuating frequency and amplitude of the signal, will always be outside of the bias voltage parameters. Another way the control module monitors the system is by learning the average normal noise output from the KS. The control module learns a minimum noise level, or background noise, at idle from the KS and uses calibrated values for the rest of the RPM range. The control module uses the minimum noise level to calculate a noise channel. The control module uses this noise channel, and the KS signal that rides along the noise channel, in much the same way as the bias voltage type does. As engine speed and load change, the noise channel upper and lower parameters will change to accommodate the normal KS signal. In order to determine which cylinders are knocking, the control module only uses KS signal information when each cylinder is near top dead center (TDC) of the firing stroke. If the control module has determined that knock is present, it will retard the ignition timing to attempt to eliminate the knock. The control module will always try to work back to a zero compensation level, or no spark retard. An abnormal KS signal will fall within the noise channel or will not be present. KS diagnostics are calibrated to detect faults with the KS circuitry inside the control module, the KS wiring, or the KS voltage output. Page 2108 Ignition Cable: Testing and Inspection SPARK PLUG WIRE INSPECTION Spark plug wire integrity is vital for proper engine operation. A thorough inspection is necessary to accurately identify conditions that may affect engine operation. Inspect for the following conditions: 1. Correct routing of the spark plug wires-Incorrect routing may cause cross-firing. 2. Any signs of cracks or splits in the wires. 3. Inspect each boot for the following conditions: - Tearing - Piercing - Arcing - Carbon tracking - Corroded terminal If corrosion, carbon tracking or arcing are indicated on a spark plug wire boot or terminal, replace the wire and the component connected to the wire. Page 7066 ^ Knock or Clunk Noise ^ Rear Drive Axle Noises (SI Document ID #700580) ^ Launch Shudder/Vibration on Acceleration (Replace Propeller Shaft and Install a New Pinion Flange/Seal), Bulletin # 02-04-17-001 ^ Information on 2-3 Upshift or 3-2 Downshift Clunk Noise, Bulletin # 01-07-30-042 ^ Driveline Clunk When Stopping (Reprogram Powertrain Control Module (PCM), Bulletin # 03-07-30-028 Correction Replace the rear drive shaft slip yoke with a new nickel-plated slip yoke. See the parts table below. Follow the service procedure below. 1. Raise the vehicle on a hoist. 2. Reference mark the propeller shaft to the pinion flange connection. Important: Do not pound on the propeller shaft yoke ears. Never pry or place any tool between a yoke and a universal joint. 3. Remove the bolts and the yoke retainers from the pinion flange. 4. Slide the propeller shaft forward and out of the rear pinion flange. 5. Lower the rear of the propeller shaft and pull the driveshaft out of the transfer case. Note: Never clamp propeller shaft tubing in a vise. Clamping could dent or deform the tube causing an imbalance or unsafe condition. Always clamp on one of the yokes and support the shaft horizontally. Avoid damaging the slip yoke sealing surface. Nicks may damage the bushing or cut the lip seal. 6. Support the propeller shaft in a line horizontal with the table of a press. Important: Remove the front slip yoke and the universal joint together. The new nickel-plated slip yoke comes with a new universal joint. 7. Disassemble the snap rings by pinching the ends together with a pair of pliers. 8. If the ring does not readily snap out of the groove in the yoke, tap the end of the cup lightly in order to relieve the pressure from the ring. 9. Place the universal joint so that the lower ear of the yoke is supported on a 30 mm (1-1/8 in) hex head socket or a 27 mm (1-1/16 in) socket. Page 8342 Brake Master Cylinder: Service and Repair Master Cylinder Replacement (Vacuum Boost) Master Cylinder Replacement (Vacuum Boost) Removal Procedure Caution: Refer to Brake Fluid Irritant Caution in Service Precautions. Notice: Refer to Brake Fluid Effects on Paint and Electrical Components Notice in Service Precautions. 1. Apply the park brake and block the wheels. 2. Disconnect the electrical connector from the brake fluid level sensor. 3. Disconnect the brake pipes from the master cylinder. 4. Important: Install a rubber cap or plug to the exposed brake pipe fitting ends in order to prevent brake fluid loss and contamination. Plug the open brake pipe ends. 5. Remove the master cylinder mounting nuts. 6. Remove the master cylinder from the vehicle. 7. Remove the master cylinder reservoir. Installation Procedure 1. Install the master cylinder reservoir. 2. Bench bleed the master cylinder. Page 4673 Control Module References Part 2 Page 8666 4. Install the ground, then the washer and then the bolt to the frame. Important: It is important to use the bolts, washers and nuts specified in this bulletin. These parts have been identified due to their conductive finish. 5. Install a washer and nut to the back side of the frame. Tighten Tighten the nut to 9 Nm (79 lb in). 6. Cover the front and back side of the repair area using Rubberized Undercoating. An additional check can be made to ensure a good connection for the battery cable to frame ground. It is possible for this ground to cause similar symptoms with the ABS as described above. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Parts Information Warranty Information Disclaimer Page 1072 1. Disconnect the shift control module electrical connectors. 2. Unsnap and remove the shift control module from the bracket. Installation Procedure Page 2407 Page 12813 Diagnostic Tips Review Table Page 7113 8. Install two M11x1.5 mm bolts (1) to the threaded holes of the spacer, if applicable. 9. Rotate the bolts clockwise to remove the spacer. 10. Remove the spacer from the rear of the crankshaft, if applicable. Installation Procedure Important: ^ The flywheel does not use a locating pin for alignment and will not initially seat against the crankshaft flange or spacer (if applicable), but will be pulled onto the crankshaft by the engine flywheel bolts. This procedure requires a three stage tightening process. ^ Certain applications (4.8 L manual transmissions or all 6.0 L) require a spacer and longer bolts for proper flywheel position. Steering Gear Actuator Boot Shield Replacement Rear Wheel Steering Actuator: Service and Repair Steering Gear Actuator Boot Shield Replacement Steering Gear Actuator Boot Shield Replacement Removal Procedure 1. Notice: When lifting the vehicle do not allow the jack to touch the rear steering gear. If the jack touches the rear steering gear you may damage the gear or the rack and pinion boots. If the boots are damaged replace the rack and pinion boot. Raise the vehicle. Refer to Vehicle Lifting. 2. Unsnap the locking tabs on the rack and pinion boot protector (1). 3. Remove the rack and pinion boot protector (1) from the rack and pinion boot (2). Installation Procedure 1. Install the rack and pinion boot protector (1) to the rack and pinion boot (2). Page 16155 9. Use J 38125-12A to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. REPAIR PROCEDURE The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. 1. Cut the wire as close to the terminal as possible. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. Service and Repair Underhood Lamp: Service and Repair UNDERHOOD LAMP REPLACEMENT REMOVAL PROCEDURE 1. Disconnect the electrical connector. 2. Squeeze the lower tab. Remove the underhood lamp from the hood. 3. Remove the lens cover. Use a small flat bladed tool in order to pry the cover off. 4. Remove the bulb from the socket. INSTALLATION PROCEDURE Page 8802 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. REPLACEMENT PROCEDURE After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Insure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the Terminal Removal Procedure. Repairing Connector Terminals REPAIRING CONNECTOR TERMINALS TOOLS REQUIRED J 38125-D Terminal Repair Kit Use the following repair procedures in order to repair the following: - Push to Seat terminals - Pull to Seat terminals - Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-D contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100 World terminals. Soldering Micro-Pack 100 World terminals may damage the terminal. Circuit Protection - Circuit Breakers CIRCUIT PROTECTION - CIRCUIT BREAKERS A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Page 2422 Page 13398 Electrical Symbols Part 11 Page 11480 Impact Sensor: Description and Operation Side Impact Sensor (SIS) (Right) With RPO HP2 INFLATABLE RESTRAINT SIDE IMPACT SENSOR (SIS) (RIGHT) WITH RPO HP2 The right side impact sensor (SIS) contains a sensing device which monitors vehicle acceleration and velocity changes to detect side collisions that are severe enough to warrant disabling the 42-volt system. The SIS is not part of the deployment loop, but instead provides an input to the sensing and diagnostic module (SDM). When the SDM receives a signal from the SIS that a collision has occurred, the SDM communicates this over the vehicles communication bus. The module responsible for the 42-volt system receives this message and disables the 42-volt system. Page 10204 ^ The steering damper for leaks and damage ^ The mounting bolts and the nuts for damage or corrosion Installation Procedure 1. Install the steering damper (4). 2. Install the mounting bolt (5) and a new prevailing torque nut (6). 3. Install the steering damper ball stud (2) to the relay rod (3). 4. Notice: Refer to Fastener Notice in Service Precautions. Install the J 29193. 5. Tighten the steering linkage installer in order to seat the ball stud in the relay rod. ^ Tighten the installer to 54 Nm (40 ft. lbs.). 6. Remove the J 29193. 7. Install the prevailing torque nuts. ^ Tighten the steering damper mounting nut to 40 Nm (30 ft. lbs.). ^ Tighten the ball stud nut to 40 Nm (30 ft. lbs.). 8. Install the engine protection shield, if equipped. 9. Lower the vehicle. Engine - Rough Idle/Misfire/MIL ON/DTC P0300 Intake Manifold Gasket: Customer Interest Engine - Rough Idle/Misfire/MIL ON/DTC P0300 Bulletin No.: 05-06-04-029A Date: June 24, 2005 TECHNICAL Subject: Flexible Fuel (RPO L59) Rough Idle, Misfire, MIL DTC P0300 (Install Intake Manifold Gaskets With Teal Green Gasket Material) Models: 2002-2004 Chevrolet Silverado, Suburban, Tahoe 2002-2004 GMC Sierra, Yukon, Yukon XL with 5.3L Engine and Flexible Fuel (VIN Z - RPO L59) This bulletin may apply to the following engines using regular fuel: 4.8L, 5.3L, 6.0L (VINs V, T, P, U, N - RPOs LR4, LM7, LM4, LQ4, LQ9). Supercede: This bulletin is being revised to add additional diagnostic information. Please discard Corporate Bulletin Number 05-06-04-029 (Section 06 - Engine/Propulsion System). Important: Always begin your diagnosis with the Diagnostic System Check - Engine Controls (SI Document ID # 1289827) for any MIL or driveability concern. The Diagnostic System Check directs you to the next logical step in your diagnosis. Follow the instructions in this bulletin should the rough idle, misfire, or DTC P0300 diagnostic procedure point to an air leak in the intake manifold gasket. Following the published diagnostic procedures will improve diagnostic accuracy and support our fix it right the first time approach. Condition Some customers may comment that the vehicle may have a rough idle, misfires and/or a MIL illuminated with a stored DTC P0300. Cause The L59 engine is calibrated for ethanol fuel (E85). Due to the low volatility of ethanol, the PCM provides higher fuel flow through the injector, which may pool on the upper manifold to head gasket material. Overtime (usually 12 months and longer), the gasket material may degrade resulting in an unmetered air leak. Correction Replace the upper intake manifold gaskets with the teal green gasket material, P/N 89017589. Important: Do not replace the upper intake manifold gaskets with the original orange gasket material, P/N 17113557. Inspect Intake Manifold to Cylinder head Deck for Warpage Electrical - No Module Communication/DTCs/Warning Lamps Wiring Harness: All Technical Service Bulletins Electrical - No Module Communication/DTCs/Warning Lamps Bulletin No.: 03-08-50-014A Date: January 20, 2006 TECHNICAL Subject: No Communication with Any Modules, Memory Seat May Not Recall, Multiple U-DTCs Set or Instrument Panel Cluster (IPC) Warning Indicators, Crank No Start (Inspect/Repair Affected Wiring Harness) Models: 2003-2006 Cadillac Escalade, Escalade ESV, Escalade EXT 2003-2006 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2003-2006 GMC Sierra, Yukon, Yukon XL with Front, Individual (Non-Bkt) Seat (RPO AN3) and/or Active Brake Control (Stabilitrak(R)) (RPO JL4) Supercede: This bulletin is being revised to update the various conditions and add the 2004-2006 model years, additional diagnostic and warranty information. Please discard Corporate Bulletin Number 03-08-50-014 (Section 08 - Body & Accessories). Condition Some customers may comment on any of the following conditions: ^ Various IPC Warning indicators are coming on. ^ Driver Information Center (DIC) displays "Unknown Driver". ^ Memory seat may not recall. ^ RKE fobs may be inoperative. ^ Radio or HVAC may shut off. ^ Engine cranks but will not start. Upon investigation, the Technician may find multiple U-DTCs set. Cause On RPO AN3 equipped vehicles, a chafed or pinched seat wiring harness under the driver seat may be a cause of this condition. Because of the routing, a portion of the seat wiring harness may rest on the inboard edge of the seat track or frame. Over time, the harness may be pinched or chafed because of the seat movement. Refer to the above illustration. The illustration shows the inverted position of the seat bottom. The arrow shows the primary location Page 273 Page 8581 1. Install the gasket. 2. Install the booster assembly. 3. Install the 4 booster to bulkhead nuts. Tighten Tighten the nuts to 36 N.m (26 lb-ft). 4. Snap the stop lamp switch onto the pushrod to the power brake booster. 5. Install the stop lamp switch with the pushrod on the brake pedal pin. 6. Install the brake switch retainer. 7. Connect the electrical connector to the stop lamp switch. 8. Install the master cylinder to the booster. 9. Install the master cylinder mounting nuts. Tighten Tighten the nuts to 36 N.m (27 lb-ft). 10. Connect the power brake booster outlet hose, the steering gear inlet hose, and the power brake booster inlet hose. Tighten ^ Tighten the power brake booster inlet hose to 28 N.m (20 lb-ft). ^ Tighten the steering gear inlet hose to 28 N.m (20 lb-ft). Important: Maintain the fluid level throughout the bleed procedure. 11. Remove the pump reservoir cap. Important: Page 11876 THIS PROGRAM IS IN EFFECT UNTIL APRIL 30, 2011. Condition Certain 2002-2009 model year vehicles equipped with OnStar(R) may have a condition in which the vehicle's OnStar(R) system repeatedly makes incomplete calls to OnStar(R) without the vehicle's occupant(s) input or knowledge. Customer initiated Blue Button call, Emergency calls, and Automatic Crash Notification calls will also fail to establish a data connection with the OnStar(R) Call Center. Eventually, the customer's call will connect as a voice only line and the customer will be able to talk with an OnStar(R) advisor; however, the advisor will not get crucial customer data such as vehicle identification and location. Correction Dealers/retailers are to replace the OnStar(R) module (VCIM). Vehicles Involved Involved are certain 2002-2009 model year vehicles equipped with OnStar(R), and built within these VIN breakpoints: Note: Some model years/models have only one vehicle involved. Important Dealers/retailers are to confirm vehicle eligibility prior to beginning repairs by using GMVIS (dealers/retailers using WINS) or the Investigate Vehicle History link (dealers/retailers using GWM). Not all vehicles within the above breakpoints may be involved. For dealers/retailers with involved vehicles, a listing with involved vehicles containing the complete vehicle identification number, customer name, and address information has been prepared and will be provided to dealers/retailers through the GM GlobalConnect Recall Reports. Dealers/retailers will not have a report available if they have no involved vehicles currently assigned. The listing may contain customer names and addresses obtained from Motor Vehicle Registration Records. The use of such motor vehicle registration data for any purpose other than follow-up necessary to complete this program is a violation of law in several states/provinces/countries. Accordingly, you are urged to limit the use of this report to the follow-up necessary to complete this program. Parts Information US: OnStar(R) modules required for this program are to be obtained by contacting Autocraft Electronics via the web at www.autocraft.com, and selecting the catalog item that contains bulletin number 10037 (or PIC 4893B), or by calling 1-800-336-3998. Dealer must provide the VIN, R.O. number, and the current vehicle mileage. Canada: OnStar(R) modules required for this program are to be obtained by contacting MASS Electronics at 1-877-410-6277. Dealer must provide the VIN, R.O. number, and the current vehicle mileage. DO NOT ORDER ONSTAR(R) MODULES FROM GENERAL MOTORS CUSTOMER CARE AND AFTERSALES (GMCC&A;), SATURN SERVICE PARTS OPERATION (SSPO), OR THE TECHNICAL ASSISTANCE CENTER (TAC). Courtesy Transportation The General Motors Courtesy Transportation program is intended to minimize customer inconvenience when a vehicle requires a repair that is covered by the New Vehicle Limited Warranties. The availability of courtesy transportation to customers whose vehicles are within the warranty coverage period and involved in a product program is very important in maintaining customer satisfaction. Dealers/retailers are to ensure that these customers understand that shuttle service or some other form of courtesy transportation is available and will be provided at no charge. Dealers should refer to the General Motors Service Policies and Procedures Manual for Courtesy Transportation guidelines. Claim Information 1. Submit a claim using the table below. 2. Courtesy Transportation - For dealers/retailers using WINS, submit using normal labor code; for dealers/retailers using GWM - submit as Net Item under the repair labor code. Page 2515 Fluid - Transfer Case: Service and Repair Transfer Case - NVG 246-NP8 Transfer Case Fluid Replacement Removal Procedure Important: When performing the following procedures, use only hand tools to remove and install the drain and fill plugs. 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. Remove the transfer case shield, if equipped. 3. Remove the fill plug. 4. Remove the drain plug. Installation Procedure 1. Notice: Refer to Fastener Notice in Service Precautions. Important: Use only drain and fill plugs that are made from aluminum. Steel or brass plugs are not compatible with the magnesium case. Install the drain plug. ^ Tighten the plug to 20 Nm (15 ft. lbs.). 2. Fill the transfer case to the bottom of the fill plug hole with Auto-Trak II, transfer case fluid, GM P/N 12378508 (Canadian P/N 10953626). Page 10905 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Micro-Pack 100W Connectors MICRO-PACK 100W CONNECTORS TOOLS REQUIRED J 38125-D Terminal Repair Kit REMOVAL PROCEDURE There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2)has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. IMPORTANT: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Page 745 Parts required to complete this special coverage are to be obtained from General Motors Customer Care and Aftersales (GMCC&A;). Service Procedure Note The resistor module connector and blower motor resistor will need to be replaced if one or more of the symptoms below is present. - The HVAC blower may not function on certain or all blower speed settings - A burning plastic smell or smoke may be present in the vehicle - The HVAC blower may run continually with the ignition in the OFF position Determine if one or more of the above symptoms is present. If required refer to HVAC diagnostic information in SI. Refer to Resistor Module Connector and Blower Motor Resistor Replacement in this bulletin if one or more of the symptoms is present. Other HVAC repairs are NOT covered in this product safety special coverage bulletin. Resistor Module Connector and Blower Motor Resistor Replacement 1. Remove the blower fuses (Htr A/C & HVAC 1 fuses). 2. Lower the close-out panel enough to gain access to the resistor module connector. 3. Disconnect the connector from the resistor module. Note Connector replacement is required even if the connector was replaced on a previous service repair. 4. Remove the tape from the wiring harness to expose the wiring. 5. Cut the wires back far enough from the connector to eliminate any melted insulation on the wire. Note Use the old connector as a map for splicing the wires for the new connector. Be sure to use the correct crimping tool from the terminal repair kit J 38125. Use only Duraseal splice sleeves. Other splice sleeves may not protect the splice from moisture or provide a good electrical connection. 6. Install the new connector. Use the yellow splice sleeves provided with the connector. 7. Install the new blower motor resistor. 8. Reinstall the fuses. Test the blower motor to make sure all speeds are functional. 9. Reinstall the hush panel/close-out panel. Customer Reimbursement Customer requests for reimbursement of previously paid repairs to correct the condition described in this bulletin are to be submitted to the dealer prior to or by December 31, 2012. Repairs must have occurred within the 10 years of the date the vehicle was originally placed in service, or 240,000 kilometres, whichever occurs first. When a customer requests reimbursement, they must provide the following: Page 15588 Clearance Lamp - RF (With RPO Code NYS Or E63) Fuse Block - I/P Fuse Block: Application and ID Fuse Block - I/P Location View Page 3231 2. Remove the serpentine belt from the accessory drive system. 3. Install the tool onto the power steering pulley. Position the legs of the tool into the outer grooves of the pulley, farthest from the front of the engine. 4. Install the retaining cord around the pulley and to the legs of the tool. 5. Put on the laser safety glasses provided with the tool. 6. Depress the switch on the rear of the tool to activate the light beam. 7. Rotate the power steering pulley as required to project the light beam onto the crankshaft balancer pulley grooves. 8. Inspect for proper power steering pulley alignment. - If the laser beam projects onto the second rib or raised area (1), the pulleys are aligned properly. - If the laser beam projects more than one-quarter rib 0.9 mm (0.035 in) mis-alignment, adjust the position of the power steering pulley as required. - Refer to SI for Power Steering Pulley Removal and Installation procedures. 9. Install the serpentine belt to the accessory drive system in the original orientation. 10. Operate the vehicle and verify that the belt noise concern is no longer present. Tool Information Please visit the GM service tool website for pricing information or to place your order for this tool. 4L60/4L60-E/4L65-E Transmission Tow/Haul Switch: Testing and Inspection 4L60/4L60-E/4L65-E Transmission Tow/Haul Switch/Indicator Always On or Inoperative Circuit Description Tow/haul mode enables the operator to achieve enhanced shift performance when towing or hauling a load. When tow/haul mode is selected, the tow/haul switch input signal to the body control module (BCM) is momentarily toggled to zero volts. This signals the powertrain control module (PCM) to extend the length of time between upshifts and increase transmission line pressure. Cycling the tow/haul switch again disables tow/haul mode and returns the transmission to a normal shift pattern. Diagnostic Aids If the electrical circuit tests are OK and the tow/haul shift pattern is not occurring, there may be a mechanical/hydraulic condition that prevents tow/haul operation. Refer to Symptoms - Automatic Transmission. Page 9039 Junction Block - I/P - C4 Part 1 Page 5932 Vehicle Speed Sensor (VSS) Tow/Haul Switch Location Page 7905 Tow/Haul Switch: Testing and Inspection 4L80-E/4L85-E Transmission Tow/Haul Switch/Indicator Always On or Inoperative Circuit Description Tow/haul mode enables the operator to achieve enhanced shift performance when towing or hauling a load. When tow/haul mode is selected, the tow/haul switch input signal to the body control module (BCM) is momentarily toggled to zero volts. This signals the powertrain control module (PCM) to extend the length of time between up shifts and increase transmission line pressure. Cycling the tow/haul switch again disables tow/haul mode and returns the transmission to a normal shift pattern. Diagnostic Aids If the electrical circuit checks are OK and the tow/haul shift pattern is not occurring, there may be a mechanical/hydraulic condition that prevents tow/haul operation. Refer to Symptoms - Automatic Transmission. Page 13967 Arm Rest: Service and Repair Armrest Replacement Removal Procedure 1. Remove the door trim panel. 2. Remove the armrest retaining screws. 3. Remove the armrest from the panel. Installation Procedure 1. Install the armrest from the panel. 2. Install the armrest retaining screws. 3. Install the door trim panel. Page 16311 2. Install the drive link onto the wiper motor crank arm with the J 39529. 3. Install the wiper transmission assembly on the vehicle with the 2 bolts. Tighten Tighten the 2 bolts to 9 N.m (80 lb in). 4. Connect the electrical connector to the wiper motor. Page 7776 Transfer Case Clutch: Technical Service Bulletins Drivetrain - Transfer Case Clutch Shimming Bulletin No.: 04-04-21-003 Date: November 10, 2004 INFORMATION Subject: Automatic Transfer Case Clutch Plate Shimming - Parts Availability Change Models: 1999-2000 Cadillac Escalade 1998-2005 Chevrolet Blazer 1999-2005 Chevrolet Astro Van, Silverado, Suburban, Tahoe 2002-2005 Chevrolet Avalanche 1998-2005 GMC Jimmy 1999 GMC Suburban 1999-2005 GMC Safari Van, Sierra, Yukon, Yukon XL 1998-2001 Oldsmobile Bravada with NV 136/236/246 Automatic Transfer Case (RPO NP4 or NP8) While performing the transfer case clutch shimming procedure found in Service Information (SI), you may find it necessary to replace the clutch pack selective fit shim to obtain the correct clutch pack clearance. The selective fit shims for this repair were previously released as a kit, P/N 12474121, which contained all eight selective fit sizes. Effective immediately, the clutch pack shims will be available individually as listed below. The shim kit, P/N 12474121, will be discontinued and no longer available once current stock has been depleted. Parts Information Parts are currently available from GMSPO. Disclaimer Page 12712 Diagnostic Tips Review # 5 - Alpine Silver Box Navigation Radio Disclaimer A/T - 4L60-E/4L65-E New Pump/Seal/Case/Service Fluid Pump: Technical Service Bulletins A/T - 4L60-E/4L65-E New Pump/Seal/Case/Service Bulletin No.: 04-07-30-023 Date: May 12, 2004 INFORMATION Subject: Oil Pump Assembly Seal and Transmission Case Change Models: 2002-2004 Cars and Light Duty Trucks with 4L60-E or 4L65-E Automatic Transmissions (RPOs M30, M32 or M33) An improved oil pump to case seal design has been made to the 4L60-E/4L65-E transmission. The new design affects the oil pump, the oil pump seal, the transmission pan bolts and the transmission case. The complete design was implemented in three phases. The first phase, beginning in September 2002, relocated the machining of the oil pump 0-ring seal groove in the pump body. The 0-ring seal groove moved 1.6 mm (0.62 in) inward on the pump body in order to place the sealing surface deeper into the case bore. The relocated pump body groove can be identified by measuring the groove location. Pump bodies that measure 2.3 mm (0.09 in) from the machined surface to the groove opening have the relocated 0-ring seal groove. Pump bodies that measure 3.9 mm (0.15 in) are prior to September 2002 design. Campaign - Deactivation Of Analog OnStar(R) Technical Service Bulletin # 08089C Date: 081118 Campaign - Deactivation Of Analog OnStar(R) # 08089C: Special Coverage Adjustment - Analog OnStar Deactivation (Nov 18, 2008) Subject: 08089C -- SPECIAL COVERAGE ADJUSTMENT - ANALOG ONSTAR(R) DEACTIVATION Page 7490 For vehicles repaired under warranty, use the table. Disclaimer Page 2974 Acceptably Prepared (Cleaned-Up) Wheel Surface 6. Once the corrosion has been eliminated, you should coat the repaired area with a commercially available tire sealant such as Patch Brand Bead Sealant or equivalent. Commercially available bead sealants are black rubber-like coatings that will permanently fill and seal the resurfaced bead seat. At 21°C (70°F) ambient temperature, this sealant will set-up sufficiently for tire mounting in about 10 minutes.Coated and Sealed Bead Seat 7. Remount the tire and install the repaired wheel and tire assembly. Refer to Tire and Wheel Removal and Installation in SI. Parts Information Patch Brand Bead Sealer is available from Myers Tires at 1-800-998-9897 or on the web at www.myerstiresupply.com. The one-quart size can of sealer will repair about 20 wheels. Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use: Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table above. Instruments - Odometer/Hour Meter Programming Procedure Odometer: All Technical Service Bulletins Instruments - Odometer/Hour Meter Programming Procedure INFORMATION Bulletin No.: 07-08-49-015D Date: May 04, 2010 Subject: Information on Instrument Panel Cluster (IPC) Odometer and Engine Hour Meter Set Up at Dealership After IPC Replacement Models: 2004-2007 Buick Rainier 2003-2006 Cadillac Escalade Models 2002-2009 Chevrolet TrailBlazer 2003-2006 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007 Chevrolet Silverado Classic (12th Digit of VIN 1 or 2) 2002-2009 GMC Envoy 2003-2006 GMC Sierra, Yukon Models 2007 GMC Sierra Classic (12th Digit of VIN 1 or 2) 2002-2004 Oldsmobile Bravada 2003-2007 HUMMER H2 2005-2009 Saab 9-7X Attention: The purpose of this bulletin is to inform dealership personnel that the Instrument Panel Cluster (IPC) odometer and engine hour meter (when applicable) setting will no longer be performed at an Electronic Service Center (ESC). Dealerships will now receive IPCs with the odometer and engine hour meter not programmed. The technician will be required to note the odometer reading and engine hour (when applicable) values of the original IPC, then use the SPS application to program these values into the new IPC. Supercede: This bulletin is being revised to update the text in Steps 1, 2, 3, 4, 5, 6 and 7. Please discard Corporate Bulletin Number 07-08-49-015C (Section 08 - Body and Accessories). Background Information Previous IPC replacement procedures specify that the odometer and engine hour values be communicated to and programmed by the Electronic Service Centers (ESC) into the replacement IPC at the time the replacement is ordered. This required the vehicle to be parked after the replacement IPC is ordered so that no additional mileage can be accumulated on the vehicle while the new IPC is in transit to the dealership. Improvements to the TIS2WEB SPS application will now allow IPC odometer and engine hour programming to be performed as an additional function of the IPC programming event. This new process will allow the vehicle to be returned to the customer, if necessary, and driven while waiting for the replacement IPC to arrive at the dealership. Odometer and engine hour values will no longer be communicated to the ESC for programming purposes but ESCs still need the odometer value for warranty reporting. Dealerships will now receive a replacement IPC with the odometer and engine hour values NOT programmed. The technician will be required to note the odometer and engine hour values of the original IPC, then use the TIS2WEB SPS application to program these values into the replacement IPC. The odometer and engine hour programming will now be included as a normal part of the IPC replacement procedure in SI. Odometer and Engine Hour Programming Procedure Information - If the original IPC odometer value cannot be obtained from the customer's vehicle, follow local and federal regulations regarding unknown odometer mileage situations. - Because the odometer and engine hour values can now be read from the original IPC and programmed into the replacement IPC during the same visit, the customer's vehicle will no longer need to be parked until the replacement IPC is received from an ESC. - Avalanche, Escalade, Sierra, Silverado, H2, Suburban, Tahoe and Yukon vehicles will also require the engine hour data to be recorded for transfer to the replacement IPC. The replacement IPC may already have engine hours showing. This does not affect the IPC Setup procedure. Bravada, Envoy, Rainier and TrailBlazer vehicles do not support the calculation or display of engine hour data. - Ensure that the correct odometer value is entered when prompted. Once programming is complete, the odometer and engine hour values, when applicable cannot be changed. - By default, the application odometer entry will be set to: miles. For metric units, click the button on the left next to: Kilometers. Service Procedure Important The replacement IPC requires IPC Setup procedures and SPS programming to be performed. Legacy Pass-Thru will no longer be Page 15840 Tail Lamp: Service and Repair TAIL/TURN SIGNAL LAMP REPLACEMENT (EXCEPT STEPSIDE) REMOVAL PROCEDURE 1. Ensure that the headlamp switch is in the OFF position. 2. Lower the end gate. 3. Remove the 2 screws retaining the tail/turn signal lamp assembly to the body. 4. Identify the bulb in need of replacement. - The top bulb is a parking lamp and stop lamp - The center bulb is a turn indicator lamp - The lower bulb is a backup lamp 5. Turn the socket assembly. 6. Remove the socket assembly from the housing. INSTALLATION PROCEDURE 1. Turn the socket. 2. Lock the socket in place. 3. Install the tail/turn signal lamp assembly to the vehicle with the 2 screws. Page 8336 3. Install the master cylinder to the vehicle. 4. Notice: Refer to Fastener Notice in Service Precautions. Install the master cylinder mounting nuts. ^ Tighten the nuts to 33 Nm (24 ft. lbs.). 5. Remove the rubber cap or plug from the exposed brake pipe fitting ends. 6. Connect the brake pipes. ^ Tighten the fittings to 25 Nm (18 ft. lbs.). 7. Connect the electrical connector to the brake fluid level sensor. 8. Bleed the hydraulic brake system. 9. Release the park brake and unblock the wheels. Fuel System - SES Lamp ON/Gauge Reads Empty/DTC's Set Fuel Gauge: All Technical Service Bulletins Fuel System - SES Lamp ON/Gauge Reads Empty/DTC's Set Bulletin No.: 05-06-04-008A Date: April 14, 2005 TECHNICAL Subject: Diagnostic Trouble Code (DTC) P1172 or P2636, Fuel Gauge Reads Empty, Service Engine Soon (SES) Light On (Relocate Auxiliary Fuel Tank Vent Hose) Models: 2001-2005 Chevrolet Silverado (Cab Chassis Models Only) 2001-2005 GMC Sierra (Cab Chassis Models Only) with Auxiliary Fuel Tank Supercede: This bulletin is being revised to clarify the difference between the auxiliary fuel tank balance hose and vent hose. Please discard Corporate Bulletin Number 05-06-04-008 (Section 06 Engine/Propulsion System). Condition Some customers may comment that the SES light comes on and the fuel gauge reads empty. when This may occur when the vehicle is parked on an incline with the engine running. Diagnosis with a scan tool may reveal a DTC P1172 and/or P2636. Cause Important: A similar condition may occur if the vehicle is fueled with the engine running AND the rear tank is fueled first. The engine must be shut off (as required by law) during vehicle refueling. The auxiliary fuel tank vent hose is located in the same "T" connection on the main tank vent hose as the auxiliary tank balance hose. During fuel transfer, the fuel is pumped out of the auxiliary tank to the main tank via the balance hose. The fuel is then sucked back into the auxiliary tank via the vent hose rather then dumping the fuel into the main tank. When the Powertrain Control Module (PCM) does not detect a fluid level transfer between the main tank and the auxiliary tank, the PCM shuts off the auxiliary tank pump and the fuel gauge goes to empty. Correction Follow the service procedure below to correct this condition. 1. Depending on the body upfitter, it may be necessary to raise the vehicle in order to gain access to the auxiliary tank balance hose. 2. Depending on the body upfitter, it may be necessary to remove the left rear tire/wheel assemblies in order to gain access to the auxiliary tank balance hose. Page 11293 Parts required to complete this special coverage are to be obtained from General Motors Customer Care and Aftersales (GMCC&A;). Service Procedure Note The resistor module connector and blower motor resistor will need to be replaced if one or more of the symptoms below is present. - The HVAC blower may not function on certain or all blower speed settings - A burning plastic smell or smoke may be present in the vehicle - The HVAC blower may run continually with the ignition in the OFF position Determine if one or more of the above symptoms is present. If required refer to HVAC diagnostic information in SI. Refer to Resistor Module Connector and Blower Motor Resistor Replacement in this bulletin if one or more of the symptoms is present. Other HVAC repairs are NOT covered in this product safety special coverage bulletin. Resistor Module Connector and Blower Motor Resistor Replacement 1. Remove the blower fuses (Htr A/C & HVAC 1 fuses). 2. Lower the close-out panel enough to gain access to the resistor module connector. 3. Disconnect the connector from the resistor module. Note Connector replacement is required even if the connector was replaced on a previous service repair. 4. Remove the tape from the wiring harness to expose the wiring. 5. Cut the wires back far enough from the connector to eliminate any melted insulation on the wire. Note Use the old connector as a map for splicing the wires for the new connector. Be sure to use the correct crimping tool from the terminal repair kit J 38125. Use only Duraseal splice sleeves. Other splice sleeves may not protect the splice from moisture or provide a good electrical connection. 6. Install the new connector. Use the yellow splice sleeves provided with the connector. 7. Install the new blower motor resistor. 8. Reinstall the fuses. Test the blower motor to make sure all speeds are functional. 9. Reinstall the hush panel/close-out panel. Customer Reimbursement Customer requests for reimbursement of previously paid repairs to correct the condition described in this bulletin are to be submitted to the dealer prior to or by December 31, 2012. Repairs must have occurred within the 10 years of the date the vehicle was originally placed in service, or 240,000 kilometres, whichever occurs first. When a customer requests reimbursement, they must provide the following: Page 10245 6. Use fingers to squeeze the 2 locking legs of the cover. 7. Apply pressure and gently rock the cover until one locking leg is unseated. 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. Page 6808 ^ Tighten the rear axle drain plug to 33 Nm (24 ft. lbs.). 2. Fill the rear axle. Use the proper fluid. 3. For the 9.5 inch and the 10.5 inch axles, install the rear axle fill plug. ^ Tighten the rear axle fill plug to 33 Nm (24 ft. lbs.). 4. For the 11.5 inch axle, install the seal and the fill plug. ^ Tighten the rear axle fill plug to 33 Nm (24 ft. lbs.). 5. Lower the vehicle. Page 6706 8. Rotate the clutch master cylinder 45 degrees clockwise to the unlocked position. Important: Complete removal of the clutch master cylinder is not required. 9. Pull the clutch master cylinder out until the pushrod socket is not touching the clutch pedal. 10. Remove the clutch pedal to clutch pedal bracket bolt. 11. Remove the clutch pedal to brake module bolts. 12. Remove the clutch pedal sub-assembly. Installation Procedure 1. Install the clutch pedal sub-assembly. Locations Discharge Air Temperature Sensor / Switch: Locations Air Temperature Sensors - Upper Left And Right OnStar(R) - Generation 6 Service Procedures Technical Service Bulletin # 09-08-46-001 Date: 090409 OnStar(R) - Generation 6 Service Procedures INFORMATION Bulletin No.: 09-08-46-001 Date: April 09, 2009 Subject: Servicing Vehicles Upgraded to OnStar(R) Generation 6 Digital‐Capable System (Follow Information Below) Models Attention: This bulletin is being issued to provide dealer personnel with information and the procedures to diagnose an upgraded OnStar(R) Generation 6 Digital-Capable system. Program Overview Since it was launched in 1996, OnStar® has relied on an analog wireless network to provide communication to and from OnStar-equipped vehicles. As part of an industry wide change in the North American wireless telecommunications industry, wireless carriers are transitioning to digital technology and will no longer support the analog wireless network beginning early 2008. Effective January 1, 2008, OnStar(R) service in the United States and Canada will be available only through vehicles that are capable of operating on the digital network. Refer to Corporate Bulletin Number 05-08-46-006H for information about upgrading certain vehicles to digital service. Details were covered in both the November 2006 and December 2007 issues of TechLink, which are available in the Archives of the TechLink website. Vehicles eligible for an OnStar(R) hardware upgrade are listed in this bulletin. Vehicle upgradeability can also be determined by typing the VIN into the field entitled "Determine VIN Hardware Functionality" on the OnStar(R) Online Enrollment website, located in the sales or service workbench tab of GM GlobalConnect. Canadian Dealers can use a similar tool that is available within the OnStar(R) Canada Online Enrollment site that can be accessed from the OnStar(R) Brand Resources in GlobalConnect. Access to the sales and/or service workbench in the GM GlobalConnect website can be granted by the dealership's Partner Security Coordinator (PSC). Page 14741 13. Install the front seat trim panel. 14. Re-zero the Inflatable Restraint Passenger Presence System. Refer to Passenger Presence System Rezeroing. See: Restraint Systems/Air Bag Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Related Tests and Procedures/Passenger Presence System Rezeroing Procedure Page 8162 1. Raise and support the vehicle. Refer Vehicle Lifting 2. Remove the tire and wheel assembly. 3. Install a C-clamp over the body of the brake caliper, with the C-clamp ends against the rear of the caliper body and the outboard disc brake pad. 4. Slowly tighten the C-clamp until the pistons are pushed into the caliper bores enough to remove the caliper from the pads. 5. Remove the C-clamp from the caliper. 6. Remove the nut and the bolt from the quarter shaft shield. 7. Remove the shield. Page 12419 Seat Memory Switch: Diagrams Driver Door Module (DDM) - C5 (Memory/Heated Seat Switch) Part 1 Page 15053 - On the 2.4 m (8 ft) long pickup box models, this center reinforcement fits over the existing center stake hole. - On the 1.7 m (5 ft. 8 in.) and 2 m (6.5 ft) short box models, these center reinforcements are recommended to be installed. The reinforcements should be centered between the front and rear reinforcements on the pickup box. 12. Mark the holes necessary for drilling and remove the brackets. 13. Drill 7.5 mm (0.30 in) holes into the weld flange of the side outer panel. 14. Touch-up the drilled holes as necessary. Refer to step 6 under the Front Reinforcement Installation procedure. 15. Place the center reinforcements back onto the pickup box. 16. Install the M6 bolts through the reinforcement and side panel with the nuts. Tighten Tighten the bolts to 9 Nm (79 lb-in). 17. Remove any metal shavings from the pickup box after installation. *Maximum Equipment Weight Capacities (Equipment and Cargo) ^ Ladder Rack and Cargo - 340 kg (750 lb) ^ Cross Toolbox and Cargo - 181 kg (400 lb) ^ Side Tool boxes and Cargo - 113 kg (250 lb) (per side) *The combined weight for all rail-mounted equipment should not exceed 454 kg (1,000 lb). Excluded is the 1500 Series Crew Cab models with 5'8" pickup box length. A reinforcement kit for rail-mounted add-on equipment is recommended as described in this bulletin. Ladder racks are not recommended for 1500 Series Crew Cab models with 5'8"pickup box. Maximum recommended cross-mounted tool box and cargo weight is 136 kg (300 lb) for the 1500 Series Crew Cab with 5'8" pickup box. Page 8902 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-8 (12085115) crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-8 (12085115) until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes SPLICING INLINE HARNESS DIODES Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate Service Data wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. 9. Tape the diode to the harness or connector using electrical tape. Page 5515 Flexible Fuel Sensor: Description and Operation FUEL COMPOSITION SENSOR DESCRIPTION The fuel composition sensor (FCS), or flex fuel sensor (service parts term), measures the ethanol-gasoline ratio of the fuel being used in a flexible fuel vehicle. Flexible fuel vehicles can be operated with a blend of ethanol and gasoline, up to 85 percent ethanol. In order to adjust the ignition timing and the fuel quantity to be injected, the engine management system requires information about the percentage of ethanol in the fuel. The FCS uses quick-connect style fuel connections, an incoming fuel connection, and an outgoing fuel connection. The two connections have different diameters, to prevent incorrect attachment of the fuel lines. All fuel passes through the fuel composition sensor before continuing on to the fuel rail. The fuel composition sensor measures two different fuel related parameters, and sends an electrical signal to the powertrain control module (PCM) to indicate ethanol percentage, and fuel temperature. The fuel composition sensor has a three-wire electrical harness connector. The three wires provide a ground circuit, a power source, and a signal output to the PCM. The power source is vehicle system voltage, +12 volts), and the ground circuit connects to chassis ground. The signal circuit carries both the ethanol percentage and fuel temperature within the same signal, on the same wire. The FCS uses a microprocessor inside the sensor to measure the ethanol percentage and fuel temp, and change an output signal accordingly. The electrical characteristic of the FCS signal is a square-wave digital signal. The signal is both variable frequency and variable pulse width. The frequency of the signal indicates the ethanol percentage, and the pulse width indicates the fuel temperature. The PCM provides an internal pull-up to five volts on the signal circuit, and the FCS pulls the 5 volts to ground in pulses. The output frequency is linear to the percentage of ethanol content in the fuel. The normal range of operating frequency is between 50 and 150 Hertz, with 50 Hertz representing 0 percent ethanol, and 150 Hertz representing 100 percent ethanol. The normal pulse width range of the digital pulses is between 1 and 5 milliseconds, with 1 millisecond representing -40°C (-40°F), and 5 milliseconds representing 125°C (257°F). The microprocessor inside the sensor is capable of a certain amount of self-diagnosis. An output frequency of 170 Hertz indicates either that the fuel is contaminated or contains methanol (it should not), or that an internal sensor electrical fault has been detected. Certain substances dissolved in the fuel can cause the fuel to be contaminated, raising the output frequency to be higher than the actual ethanol percentage should indicate. Examples of these substances include water, sodium chloride (salt), and methanol. It should be noted that it is likely that the FCS will indicate a slightly lower ethanol percentage than what is advertised at the fueling station. This is not a fault of the sensor. The reason has to do with government requirements for alcohol-based motor fuels. Government regulations require that alcohol intended for use as motor fuel be DENATURED. This means that 100 percent pure ethanol is first denatured with approximately 41/2 percent gasoline, before being mixed with anything else. When an ethanol gasoline mixture is advertised as E85, the 85 percent ethanol was denatured before being blended with gasoline, meaning an advertised E85 fuel contains only about 81 percent ethanol. The FCS measures the actual percentage of ethanol in the fuel. Page 4232 Spark Plug: Specifications Spark Plug Torque ............................................................................................................................... ........................................................ 15 Nm (11 lb ft) Spark Plug Gap ................................................ ........................................................................................................................................ 1.01 mm (0.040 in) Page 10152 until the sensor is seated into the adapter and bearing assembly. If installing a new sensor, it will come with a pin installed in the sensor. Do not remove the pin until the sensor is seated. If the new sensor did not come with a pin installed, you must reorder a new sensor. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install into the adapter and bearing assembly. 16. Install the connector to the sensor. 17. From the technicians point of view, the FRONT of the sensor will have: ^ A pin hole (2) for the centering pin. Note the location of the pin hole. ^ A flush rotor flange cuff (4) ^ An alignment mark (3) for installation 18. From the technicians point of view, the BACK of the sensor will have an alignment tab (1) for installation. This sensor does not have double D flats. 19. Important: If reusing the existing sensor, you must align the marks on the flush rotor flange cuff before installation. The alignment mark must stay aligned until the sensor is seated into the adapter and bearing assembly. If installing a new sensor, it will come with a pin installed in the sensor. Do not remove the pin until the sensor is seated. If the new sensor did not come with a pin installed, you must reorder a new sensor. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install into the adapter and bearing assembly. 20. Install the connector to the sensor. 21. From the technicians point of view, the FRONT of the sensor will have: ^ A pin hole (3) for the centering pin. Note location of the pin hole. ^ A flush rotor flange cuff (5) ^ An alignment mark (4) for installation ^ A foam ring (6) 22. From the technicians point of view, the BACK of the sensor will have: ^ Double D flats (1) ^ An alignment tab (2) for installing into the adapter and bearing assembly 23. Important: If reusing the existing sensor, you must align the marks on the flush rotor flange cuff before installation. The alignment mark must stay aligned until the sensor is seated into the adapter and bearing assembly. If installing a new sensor, it will come with a pin installed in the sensor. Do not remove the pin until the sensor is seated. If the new sensor did not come with a pin installed, you must reorder a new sensor. Page 6567 Install the parking lock bracket bolts. ^ Tighten the bolts to 24 Nm (18 ft. lbs.). 13. Install the PNP switch. 14. Install the transmission filter. 15. Fill the transmission to the proper level with Dexron® III transmission fluid. Page 9065 Relay Block - I/P C10 Part 1 Page 6661 13. Remove the valve body bolts which retain the transmission fluid pressure switch to the valve body. 14. Remove the transmission fluid pressure switch. 15. Inspect the transmission fluid pressure switch for damage or debris. 16. Remove the manual detent spring bolt. 17. Remove the manual detent spring. 18. Inspect the manual detent spring for cracks or damage. 19. Important: Keep the valve body level when lowering it from the vehicle. This will prevent the loss of checkballs located in the valve body passages. Remove the remaining valve body bolts. 20. Carefully lower the valve body from the transmission case while simultaneously disconnecting the manual valve link. Page 6019 Page 1384 For vehicles repaired under warranty, use the table. Disclaimer Page 12097 ^ Audio amplifier ^ Driver door module (DDM) ^ Driver door switch assembly (DDSA) ^ Front passenger door module (FPDM) ^ Left rear door module (LRDM) ^ Memory seat module (MSM) ^ Radio antenna module (listed as remote function actuation in scan tool display) ^ Rear integration module (RIM) ^ Right rear door module (RRDM) ^ Theft deterrent module (TDM) ^ TV antenna module ^ Vehicle communication interface module (VCIM) The star has 4 splice packs: ^ SP200 located in the left side of the instrument panel, near the steering column , taped to the instrument panel harness ^ SP201 located in the center of the instrument panel, near the radio ^ SP300 located in the left side middle of the passenger compartment, taped to the body harness, near the carpet seam ^ SP303 located in the right rear of the passenger compartment, taped to the body harness, approximately 24 cm (9.5 in) from the fuse block - right rear. Refer to Data Communication Schematics in SI. The following modules, components, and splice packs are connected to the ring portion of the class 2 serial data circuit: ^ Dash integration module (DIM) ^ Electronic brake control module (EBCM) ^ Engine control module (ECM) ^ Inflatable restraint sensing and diagnostic module (SDM) ^ Instrument panel cluster (IPC) ^ HVAC control module ^ Radio ^ Rear integration module (RIM) ^ Vehicle communication interface module (VCIM) OR ^ Communication interface module (CIM) ^ SP200 ^ SP201 ^ SP300 Page 4764 Air Induction Components Page 6434 Electronic Components Page 9759 C306 Infotainment Jumper Harness To Console Harness (With RPO Code Y91) Part 1 Page 11885 Feature Programming Refer to Personalization Description and Operation in Personalization. Driver Warnings For the list of Driver Warnings, refer to Indicator/Warning Message Description and Operation. Page 13029 Diagrams Cellular Microphone Page 12411 Disclaimer Page 11978 Test Description DTC U1001 and U1254 Circuit/System Description Modules connected to the Class 2 serial data circuit monitor for serial data communications during normal vehicle operation. Operating information and commands are exchanged among the modules. When a module receives a message for a critical operating parameter, the module records the identification number of the module which sent the message for State of Health monitoring. A critical operating parameter is one which, when not received, requires that the module use a default value for that parameter. Once an identification number is learned by a module, it will monitor for that module's Node Alive message. Each module on the class 2 serial data circuit which is powered and performing functions that require detection of a communications malfunction is required to send a Node Alive message every 2 seconds. When no message is detected from a learned identification number for 5 seconds, a DTC U1XXX where XXX is equal to the 3-digit identification number is set. Page 13032 Page 9141 For vehicles repaired under warranty, use the table. Disclaimer Page 12328 When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage TESTING FOR A SHORT TO VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity TESTING FOR CONTINUITY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents TESTING FOR ELECTRICAL INTERMITTENTS Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground - Testing for Continuity - Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 msRECORD and emits an audible tone (beep). Page 14985 report with the recall bulletin. For IPC For dealers with involved vehicles, a Campaign Initiation Detail Report containing the complete Vehicle Identification Number, customer name and address data has been prepared and is being furnished to involved dealers. Dealers that have no involved vehicles currently assigned will not receive a report with the recall bulletin. The Campaign Initiation Detail Report may contain customer names and addresses obtained from Motor Vehicle Registration Records. The use of such motor vehicle registration data for any other purpose other than follow-up necessary to complete this recall is a violation of law in several states/provinces/countries. Accordingly, you are urged to limit the use of this report to the follow-up necessary to complete this program. Parts Information Parts required to complete this recall are to be obtained from General Motors Service Parts Operations (GMSPO). Please refer to your "involved vehicles listing" before ordering parts. Normal orders should be placed on a DRO = Daily Replenishment Order. In an emergency situation, parts should be ordered on a CSO = Customer Special Order. Customer Reimbursement - For US All customer requests for reimbursement for previous repairs for the recall condition will be handled by the Customer Assistance Center, not by dealers. Page 2143 Drive Belt: Testing and Inspection Drive Belt Falls Off Drive Belt Falls Off Diagnosis Diagnostic Aids If the drive belt(s) repeatedly falls off the accessory drive pulley(s), this may be caused by a pulley misalignment. An extra load that is quickly applied or released by an accessory drive component may also cause the drive belt(s) to fall off. Verify that the accessory drive component(s) are operating properly. If the drive belt(s) is the incorrect length, the drive belt tensioner may not maintain the proper tension on the drive belt(s). Test Description Steps 1 - 12 The number(s) below refer to the step(s) in the diagnostic table. 2. This inspection is to verify the condition of the drive belt(s). Damage may have occurred to the drive belt(s) when the drive belt(s) fell off the pulley. Inspect the drive belt(s) for cuts, tears, sections of ribs missing, or damaged belt plys. Page 1725 Flexible Fuel Sensor: Service and Repair FUEL COMPOSITION SENSOR REPLACEMENT REMOVAL PROCEDURE 1. Relieve the fuel system pressure. Refer to Fuel Pressure Relief Procedure. 2. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 3. Disconnect the fuel composition sensor electrical connector. 4. Remove the fuel line retainers (1). 5. Disconnect the fuel pipes from the fuel composition sensor. 6. Remove the fuel composition sensor nuts. 7. Remove the fuel composition sensor. 8. If required, remove the fuel composition sensor bolts and remove the sensor from the bracket. Page 10260 Control Module References Part 3 Page 4920 7. Use the modified screw extractor in order to remove the plug. 8. Remove the parking pawl shaft retainer, shaft and pawl. 9. Important: If the manual shaft binds in the case during removal, file or sand the shaft in the area adjacent to the detent lever. Remove the manual shaft. 10. Remove the manual shaft seal. Installation Procedure 1. Install the pawl shaft. 2. Install the parking pawl. 3. Install the plug using a 8 mm or (5/16 inch) rod with Loctite® or equivalent. 4. Install the retainer. 5. Install the pawl return spring. 6. Install the detent lever to the actuator. 7. Install the actuator over the parking pawl. 8. Install the manual shaft seal. 9. Lubricate the manual shaft with transmission oil and install the manual shaft into the case. 10. Install the nut on the shaft. 11. Install the roll pin. 12. Notice: Refer to Fastener Notice in Service Precautions. Page 1235 Parts Information Place unused material on dealer shelf for future use. Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Page 13429 IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. Splicing Twisted or Shielded Cable SPLICING TWISTED OR SHIELDED CABLE Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. - Rewrap the conductors with the mylar tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with mylar tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Control Module References Page 1687 Page 5651 Page 14765 Seat Heater: Description and Operation HEATED SEATS DESCRIPTION AND OPERATION HEATED SEAT COMPONENTS The heated seat system consists of the following components: Driver and passenger heated seat switches - Driver and passenger seat back heater elements - Driver and passenger seat cushion heater elements - Driver and passenger seat back temperature sensors - Driver seat module - Driver door module - Passenger door module HEATED SEAT SYSTEM OPERATION The driver and passenger heated seats have 2 heat zone operating modes with 3 heat level modes and will operate only while the engine is running. The heat zones are determined by which of the 2 heated seat buttons are pressed, while the heat level is determined by the number of times they are pressed. Pressing the seat cushion button 1 time will activate the seat back and cushion heater elements in the high mode. Each time the seat cushion button is pressed the seat back and cushion heat level is reduced from high to medium, low, and off. Pressing the heated seat back button 1 time will activate only the seat back heater element in the high mode. Each time the seat back button is pressed the seat back heat level is reduced from high to medium, low, and off. During heated seat operation the heat zone operating mode may be changed without affecting the current heat level mode. The heated seat switches are momentary contact switches and are inputs to the driver and passenger door modules. Battery voltage is supplied to the switch assembly from the door module, and when a heated seat switch is pressed and released a brief switch signal voltage is supplied to the door module. Whenever the door module receives an active heated seat switch input, the next heated seat operating mode is determined by whatever the current mode may be. The seat heater elements are controlled by the driver seat module using inputs from the door modules through Class 2 serial data circuit messages. The driver seat module controls the voltage supply and the ground circuits to the seat heater elements. When a heated seat function is commanded active, the seat module will switch battery voltage to the heater element supply circuits, and ground is provided through low side drive control circuits. During heated seat operation both the seat back and cushion heater elements are supplied battery voltage. The seat module grounds the appropriate control circuits for back only or back and cushion heating modes, and opens or closes the active control circuits as necessary in order to maintain the desired seat temperature. The seat module relies on inputs from thermistors located in the driver and passenger seat backs to control heated seat temperatures. The thermistors are 2 wire sensors supplied with a 5-voltreferenced signal circuit and a low reference circuit from the seat module. Resistance through the thermistors varies with temperature causing the heated seat sensor signal circuit voltage levels to decrease as the seat back temperatures rise. The seat modules allow heated seat operation only while the engine is running which is determined by a Class 2 serial data circuit message from the powertrain control module. Page 8776 Electrical Symbols Part 5 Page 9194 C153 4-Wheel Drive Harness To Engine Harness Interior - Loose/Unwanted Seat Movement Seat Track: Customer Interest Interior - Loose/Unwanted Seat Movement Bulletin No.: 05-08-50-012A Date: July 24, 2006 TECHNICAL Subject: Unwanted/Loose Seat Movement (Apply Adhesive and Install New Bolts in Seat Mounting Rails) Models: 2002-2006 Cadillac Escalade, Escalade EXT 2003-2006 Cadillac ESV 1999-2007 Chevrolet Silverado Pickup Models (Classic) 2000-2006 Chevrolet Suburban, Tahoe 2002-2006 Chevrolet Avalanche 1999-2007 GMC Sierra Pickup Models (Classic) 2000-2006 GMC Yukon, Yukon XL 2003-2006 HUMMER H2 with Power Driver Front Seat Power Adjuster (RPO AG1) and/or Passenger Seat Power Adjuster (RPO AG2) Supercede: This bulletin is being revised to add model years and additional Warranty Information. Please discard Corporate Bulletin Number 05-08-50-012 (Section 08 - Body and Accessories). Condition Some customers may comment on unwanted seat movement in the front power bucket seat (driver or passenger) during fast acceleration or hard braking. A metal to metal clicking noise is often heard at seat "stops." Cause The threads of the two zinc nut retainers (one on each side of the seat adjuster) may creep over time, causing a loss of self-rolling screw clamp load and ultimately causes relative rail and vehicle seat motion. Correction Apply adhesive and install new bolts in seat mounting rails using the following procedure. 1. Remove the front seat and invert onto a flat surface covered with a clean, non-scratch material (soft cloth or similar). Refer to the applicable Seats sub-section in SI. Adjust so that the seat mounting rails are at 45 degrees. 2. Remove the upper M8 mounting bolt from one rail and discard. Leave the other bolt intact as this will hold the track in place while working. Wipe the bolt hole area with a clean rag. Important: Only use the adhesive provided in the repair kit. Do not substitute with other adhesives. Heater Hose Replacement - Inlet Heater Hose: Service and Repair Heater Hose Replacement - Inlet HEATER HOSE REPLACEMENT - INLET TOOLS REQUIRED J 43181 Quick Connect Connector Removal Tool REMOVAL PROCEDURE 1. Drain the cooling system. Refer to Draining and Filling Cooling System (with HP2)Draining and Filling Cooling System (without HP2) in Cooling System. 2. Remove the air intake tube. 3. Remove the heater and surge tank hose from the mounting clip. 4. Using the J 43181 disconnect the heater hose from the heater core inlet. 4.1. Install the J 43181 to the heater core pipe. 4.2. Close the tool around the heater core pipe. 4.3. Firmly pull the tool into the quick connect end of the heater hose. 4.4. Firmly grasp the heater hose. Pull the heater hose forward in order to disengage the hose from the heater core. 5. Remove the inlet heater hose from the engine. Page 14364 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the cover up until the dress cover releases. Repeat this procedure for the other locking tab. 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. 5. If the connector has a nose piece, use a small flat-blade tool to remove the nose piece by inserting the blade into the slot on the front of the connector and prying up on the nose piece. IMPORTANT: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 6. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. IMPORTANT: Be careful not to angle or rock the J 38125-13A tool when inserting it into the connector or the tool may break. Locations Accelerator Pedal Position (APP) Sensor Connector Page 10768 The 1999 though early 2003 wiring harness jumper that plugs into the relay block will have a reddish/brown 6-way connector and a tag with the last four digits of the wiring harness part number. Second design 2003-05 may have a white plastic connector with part number 5418 as well. ^ The 1999 jumper is/was P/N 12171982 with a pink/purple tag identifier of 1982. This number has been superseded to 15366255, with a pink/purple tag identifier of 6255. ^ The 2000 jumper harness is P/N 15366255. The pink/purple tag identifier is 6255. ^ The 2001-2002 jumper is P/N 15086884. The orange tag identifier is 6884. ^ The 2003-05 jumper is P/N 15085418. The orange tag identifier is 5418. When transferring the brake controller with the wiring jumper attached from a 2001-2002 vehicle to a 2003-05 vehicle, a change to the jumper harness connector must be performed. Page 4319 - Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-D in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-D if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Page 12327 Refer to the table as a guide in selecting the correct test adapter for frontprobing connectors: Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure SCAN TOOL SNAPSHOT PROCEDURE Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: - Snapshot - taken from the Snapshot menu choice - Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information Page 1423 Ambient Air Temperature Sensor - Outside Page 6038 Torque Converter Clutch Solenoid: Service and Repair Torque Converter Clutch Pulse Width Modulation (TCC PWM) Solenoid, TCC Solenoid, and Wiring Harness ^ Tools Required J 28458 Seal Protector Retainer Installer Removal Procedure 1. Remove the transmission filter. 2. Disconnect the transmission harness 20-way connector (1) from the transmission internal harness pass-through connector. Depress both tabs on the connector and pull straight up; do not pry the connector. 3. Important: Removal of the valve body is not necessary for the following procedure. Remove the 1-2 accumulator. Do not remove the spacer plate. 4. Disconnect the internal wiring harness electrical connectors from the following components: ^ Transmission fluid pressure switch (1) ^ 1-2 shift control solenoid (2) ^ 2-3 shift control solenoid (3) ^ Pressure control solenoid (4) ^ Torque converter clutch pulse width modulation (TCC PWM) solenoid (5) ^ 3-2 control solenoid (6) 5. Remove the TCC PWM solenoid retainer. 6. Remove the TCC PWM solenoid in order to access one of the TCC solenoid bolts. Page 13524 Body Control Module: Diagnostic Aids Basic Knowledge Required BASIC KNOWLEDGE REQUIRED Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the Service Data. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories CHECKING AFTERMARKET ACCESSORIES Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: - Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions INDUCING INTERMITTENT FAULT CONDITIONS In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: - Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. Page 1866 Diagrams Cargo Lamp/Center High Mounted Stop Lamp (CHMSL) Page 3472 7. Remove the crankshaft sprocket key, if required. 8. If required, clean and inspect the timing chain and sprockets. Installation Procedure 1. Install the key into the crankshaft keyway, if previously removed. 2. Tap the key (1) into the keyway until both ends of the key bottom onto the crankshaft. 3. Install the crankshaft sprocket onto the front of the crankshaft. Align the crankshaft key with the crankshaft sprocket keyway. Page 9779 C399 Body Harness To Passenger Seat Harness Part 1 Page 971 Engine Control Module: Diagrams Powertrain Control Module (PCM) C2 Procedures Power Seat Switch: Procedures Lumbar Switch Replacement LUMBAR SWITCH REPLACEMENT REMOVAL PROCEDURE 1. Remove the power seat switch bezel containing the lumbar switch (1) from the seat. 2. Remove the lumbar switch screws from the power seat switch bezel. 3. Remove the lumbar switch. INSTALLATION PROCEDURE 1. Install the lumbar switch to the power seat switch bezel. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the lumbar switch screws. Tighten Tighten the screws to 2 N.m (18 lb in). 3. Install the power seat switch bezel (1) to the seat. Seat Switch Bezel Replacement SEAT SWITCH BEZEL REPLACEMENT REMOVAL PROCEDURE Page 14740 6. Install the lumbar actuator (5). 7. Install the seat switch bezel. 8. Place the cushion on the rear plastic holders (1) on the underside of the seat cushion, and push rearward. 9. Connect the lumbar cable to the underside of the seat cushion (6). Connect the lumbar wire harness, if equipped with power lumbar. 10. Install the pressure sensor (2) to the front passenger seat frame, if equipped with the Inflatable Restraint Passenger Presence System. 11. Connect the electrical connectors. Notice: Refer to Fastener Notice in Service Precautions. 12. Install the front nuts (2) onto the studs on the underside of the cushion. Tighten the nuts to 21 N.m (15 lb ft). Page 8689 4. connect the chassis electrical connectors to the EBCM. 5. Lower the vehicle. 6. Connect the negative battery cable. 7. Revise the tire calibration using the Scan Tool Tire Size Calibration function. 8. Return to Diagnostic Starting Point - Antilock Brake System. Page 3786 Electrical Symbols Part 14 Page 10013 6. Install the outer tie rod retaining nut to the steering knuckle. ^ Tighten the nut to 55 Nm (40 ft. lbs.). 7. Install the outer tie rod retaining bracket (2). ^ Tighten the bracket to 65 Nm (48 ft. lbs.). 8. Install the tire and wheel. 9. Lower the vehicle. 10. Perform a four wheel alignment. Page 6017 Park Neutral Position (PNP) Switch C175 Engine - Drive Belt Misalignment Diagnostics Drive Belt: Technical Service Bulletins Engine - Drive Belt Misalignment Diagnostics INFORMATION Bulletin No.: 08-06-01-008A Date: July 27, 2009 Subject: Diagnosing Accessory Drive Belt / Serpentine Belt Noise and Availability and Use of Kent-Moore EN-49228 Laser Alignment Tool - Drive Belt Models: 2010 and Prior GM Passenger Cars and Trucks (Including Saturn) 2010 and Prior HUMMER H2, H3 Vehicles 2009 and Prior Saab 9-7X Supercede: This bulletin is being revised to add a model year and update the Tool Information. Please discard Corporate Bulletin Number 08-06-01-008 (Section 06 - Engine). Background Several aftermarket companies offer laser alignment tools for accessory drive systems that can be very helpful in eliminating drive belt noise as a result of misaligned pulleys. Typically pricing ranges from $160 - $200. EN-49228 Laser Alignment Tool - Drive Belt The GM Tool program has now made available a competitive, simple to use and time-saving laser tool to assist in achieving precise alignment of the drive belt pulleys. This optional tool removes the guesswork from proper pulley alignment and may serve to reduce comebacks from: - Drive Belt Noise - Accelerated Drive Belt Wear - Drive Belt Slippage Instructions The instructions below are specific only to the truck Gen IV V-8 family of engines. These instructions are only for illustrative purposes to show how the tool may be used. Universal instructions are included in the box with the Laser Alignment Tool - Drive Belt. Caution - Do not look directly into the beam projected from the laser. - Use caution when shining the laser on highly polished or reflective surfaces. Laser safety glasses help reduce laser beam glare in many circumstances. - Always use laser safety glasses when using the laser. Laser safety glasses are not designed to protect eyes from direct laser exposure. 1. Observe and mark the serpentine belt orientation. Heated Oxygen Sensor (HO2S) Bank 1 Sensor 1 Heated Oxygen Sensor (HO2S) Bank 1 Sensor 1 Page 323 Diagnostic Trouble Codes DTC U1000 and U1255 Circuit/System Description Modules connected to the Class 2 serial data circuit monitor for serial data communications during normal vehicle operation. Operating information and commands are exchanged among the modules. When a module receives a message for a critical operating parameter, the module records the identification number of the module which sent the message for State of Health monitoring. A critical operating parameter is one which, when not received, requires that the module use a default value for that parameter. When a module does not associate an identification number with at least one critical parameter within 5 seconds of beginning serial data communication, DTC U1000 or U1255 DTC is set. When more than one critical parameter does not have an identification number associated with it, the DTC will only be reported once. The Class 2 serial data communications circuit on this vehicle are in a hybrid ring and star configuration. Each module on the ring has 2 serial data circuits connected to it, except the following modules which have only 1 serial data circuit connected them: Page 6324 Page 3818 Control Module References Part 4 Page 9724 C161 Roof Beacon Harness To Chassis Harness (With RPO Code 5Y0) Page 3245 Drive Belt: Testing and Inspection Drive Belt Chirping Drive Belt Chirping Diagnosis Diagnostic Aids The chirping noise may be intermittent due to moisture on the drive belt(s) or the accessory drive pulley(s). In order to duplicate the customer's concern, it may be necessary to spray a small amount of water onto the drive belt(s). If spraying water onto the drive belt(s) duplicates the symptom, cleaning the accessory drive pulley(s) may be the most probable solution. A loose or improper installation of a body or suspension component, or other item(s) on the vehicle may also cause the chirping noise. Test Description Page 14104 Control Module References Part 2 Heated Oxygen Sensor (HO2S) Replacement Bank 1 Sensor 1 Oxygen Sensor: Service and Repair Heated Oxygen Sensor (HO2S) Replacement Bank 1 Sensor 1 HEATED OXYGEN SENSOR (HO2S) REPLACEMENT BANK 1 SENSOR 1 REMOVAL PROCEDURE 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. If necessary, unbolt the front propeller shaft from the front differential. Refer to Propeller Shaft Replacement - Front in Propeller Shaft. 3. Disconnect the connector position assurance (CPA) retainer. NOTE: Refer to Heated Oxygen and Oxygen Sensor Notice in Service Precautions. 4. Remove the heated oxygen sensor (HO2S) electrical connector from the fuel line clip. 5. If equipped with a 4.8L or 5.3L engine, disconnect the HO2S electrical connector (1). 6. If equipped with a 6.0L engine, disconnect the HO2S electrical connector (1). Lighting - Exterior Lamp Condensation and Replacement Tail Lamp: Technical Service Bulletins Lighting - Exterior Lamp Condensation and Replacement INFORMATION Bulletin No.: 01-08-42-001H Date: January 05, 2011 Subject: Exterior Lamp Condensation and Replacement Guidelines Models: 2011 and Prior GM Passenger Cars and Trucks (including Saturn) Supercede: This bulletin is being revised to add the 2011 model year. Please discard Corporate Bulletin Number 01-08-42-001G (Section 08 - Body and Accessories). The following information is being provided to better define the causes of condensation in exterior lamps and includes guidelines for determining the difference between a lamp with a normal atmospheric condition (condensation) and a lamp with a water leak. Some exterior lamps, such as cornering, turn signal, backup, headlamps or tail lamps may exhibit very small droplets of water, a fine mist or white fog (condensation) on the inside of the lamp lens. This may be more noticeable on lamps with "multi-lens" designs and may be normal during certain weather conditions. Condensation occurs when the air inside the lamp assembly, through atmospheric changes, reaches the "dew point". When this takes place, the moisture in the air within the lamp assembly condenses, creating a fine mist or white fog on the inside surface of the lamp lens. Most exterior lamps on General Motors vehicles use a vented design and feature a replaceable bulb assembly. They are designed to remove any accumulated moisture vapor by expelling it through a vent system. The vent system operates at all times, however, it is most effective when the lamps are ON or when the vehicle is in motion. Depending on the size, shape and location of the lamp on the vehicle, and the atmospheric conditions occurring, the amount of time required to clear the lamp may vary from 2 to 6 hours. Completely sealed headlamp assemblies (sealed beams) are still used on a limited number of models being manufactured today. These lamps require the replacement of the complete lamp assembly if a bulb filament burns out. Condensation 2006 TrailBlazer Shown A Fine Mist or White Fog on the Inside Surface of the Lamp Lens Occurring After a Period of High Humidity - May be located primarily in the lens corners (near the vents) and SHOULD NOT cover more than half the lens surface. - The condition should clear of moisture when the vehicle is parked in a dry environment, or when the vehicle is driven with the lights ON. - A comparison of the equivalent lamp on the opposing side of the vehicle indicates a SIMILAR performance. If the above conditions are noted, the customer should be advised that replacement of a lamp assembly may not correct this condition. Water Leak New Style Pickup Shown Brakes - Low Speed ABS Activation/No DTC's Set Wheel Speed Sensor: All Technical Service Bulletins Brakes - Low Speed ABS Activation/No DTC's Set TECHNICAL Bulletin No.: 03-05-25-007D Date: May 01, 2009 Subject: Antilock Brake (ABS) Activation At Low Speeds (Clean Wheel Speed Sensor Mounting Surface) Models: 2002-2006 Cadillac Escalade, Escalade EXT 2003-2006 Cadillac Escalade ESV 1999-2006 Chevrolet Silverado 2001-2006 Chevrolet Suburban, Tahoe 2002-2006 Chevrolet Avalanche 2003-2006 Chevrolet Express 2007 Chevrolet Silverado Classic 1999-2006 GMC Sierra 2001-2006 GMC Yukon, Yukon Denali, Yukon XL, Yukon Denali XL 2003-2006 GMC Savana 2007 GMC Sierra Classic 2003-2006 HUMMER H2 .............................................................................................................................................................. .................................................................................. Supercede: This bulletin is being revised to add the 2007 Silverado/Sierra Classic models. Please discard Corporate Bulletin Number 03-05-25-007C (Section 05 - Brakes). .............................................................................................................................................................. .................................................................................. Condition Some customers may comment on ABS activation at low speeds, usually below 8 km/h (5 mph). Upon investigation, the technician will find no DTCs set. Cause The cause of this condition may be an increased air gap between the wheel speed sensor and the hub reluctor ring due to rust and debris built up on the sensor mounting surface. Correction Measure AC voltage and clean the wheel speed sensor mounting surfaces. 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in the General Information sub-section of the Service Manual. 2. Disconnect both the front wheel speed sensor connectors at the frame and harness. 3. Place a Digital Volt Meter (DVM) across the terminals of each wheel speed sensor connector. 4. Rotate the wheel clockwise approximately one revolution per second. The minimum reading should be at least 350 ACmV's. If the reading is less than 350 ACmV's, remove the wheel speed sensor. Refer to the applicable Wheel Speed Sensor Replacement procedure in the ABS sub-section of the Service Manual. 5. Plug the wheel speed sensor bore in order to prevent debris from falling into the hub during service. 6. Clean the wheel speed sensor mounting surface using a wire brush, sand paper, emery cloth, scotch brite, or other suitable material. Be sure to thoroughly clean the wheel speed sensor surface. There should be no rust or corrosion. 7. Check the sensor head to determine if it has been warped/distorted due to the corrosion build up or other causes. Check the mounting surface on the sensor head for flatness by placing it on the edge of a metal machinists scale or other suitable straight edge to measure the flatness. Check the sensor for flatness in multiple (minimum 3) positions/directions. If the sensor head is distorted, replace the sensor. 8. Apply (spray) two thin coats of the specified rust penetrating lubricant (corrosion inhibitor) to the complete sensor mounting surface on the bearing hub. Allow to dry for 3-5 minutes between coats. Use ONLY Rust Penetrating Lubricant, P/N 89022217 (in Canada, P/N 89022218). 9. When the corrosion inhibitor is dry to the touch (about 10 minutes), apply a thin layer of bearing grease to the hub surface and sensor O-ring prior to sensor installation. Use ONLY Wheel Bearing Lubricant, P/N 01051344 (in Canada, P/N 993037). 10. Install either the original sensor or a new one in the hub. Ensure that the sensor is seated flush against the hub. Refer to the applicable Wheel Speed Sensor Replacement procedure in the ABS sub-section of the Service Manual. 11. Place the DVM across the sensor terminals and recheck the voltage while rotating the wheel. The voltage should now read at least 350 ACmV's. Locations Crankshaft Position (CKP) Sensor Location Page 1462 Combination Switch: Diagrams Multifunction Accessory Switch Page 8759 6. If equipped with a 4.8L, 5.3L, or 6.0L engine, Install the positive battery cable. 7. Install the positive cable to the clip on the oil pan. 8. Install the positive cable clip to the clip on the oil pan. 9. Install the positive cable to the starter. 10. Install the starter lead nut. Tighten Tighten the nut to 9 N.m (80 lb in). 11. If equipped with a 4.8L, 5.3L, or 6.0L engine, install the battery cable bracket and bolt. Tighten Tighten the bolt to 25 N.m (18 lb ft). Page 12293 analyzed. Therefore, technicians should be checking for loose connections and installing cable connector clamps to ensure a positive and robust connection. Technicians are to install a video cable connector clamp on each cable connector located under each front seat. A total of four cable connector clamps, P/N 19159659, are required for each vehicle. The illustration above shows a pair of display monitor cable connectors without the cable clamps installed. The illustration above shows the display monitor cable connectors with the cable connector clamps. The lower cable connector clamp is installed but not locked together. The upper cable connector clamp is closed and locked. The cable connector clamps have now been added as a permanent component to all GM Accessories Headrest DVD Systems installation kits. Parts Information Warranty Information (excluding Saab U.S. Models) Page 1593 Intake Air Temperature (IAT) Sensor: Service and Repair MASS AIR FLOW (MAF)/INTAKE AIR TEMPERATURE (IAT) SENSOR REPLACEMENT REMOVAL PROCEDURE IMPORTANT: Use care when handling the mass air flow/intake air temperature (MAF/IAT) sensor. Do not dent, puncture, or otherwise damage the honeycell located at the air inlet end of the MAF/IAT. Do not touch the sensing elements or allow anything including cleaning solvents and lubricants to come in contact with them. Use a small amount of a non-silicone based lubricant, on the air duct only, to aid in installation. 1. Remove the air cleaner outlet duct. 2. Pull out the gray connector position assurance (CPA) retainer. 3. Push down on the black clip in order to disconnect the MAF/IAT sensor electrical connector (4). 4. Loosen the MAF/IAT clamp. 5. Remove the MAF/IAT sensor from the air cleaner assembly. INSTALLATION PROCEDURE IMPORTANT: The embossed arrow on the MAF/IAT sensor indicates the proper air flow direction. The arrow must point toward the engine. Page 4317 If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Sir/SRS Wiring Repairs SIR/SRS WIRING REPAIRS TOOLS REQUIRED J 38125-D Terminal Repair Kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-D contains the following items: - Special sealed splices - in order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping tool - A heat torch - An instruction manual The sealed splices have the following 2 critical features: - A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-D also serves as a generic terminal repair kit. The kit contains the following items: - A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors Page 2653 Fuse Block - Underhood C3 Part 3 Page 9584 Junction Block - I/P - C8 Page 7954 Page 5911 Disclaimer Page 831 Location View Page 14138 What if I input the VIN incorrectly? If an incorrect VIN is entered into the system (meaning that the system does not recognize the VIN or that the VIN has been entered incorrectly) the system will return an error message. If I am an authorized user for the KeyCode application, can I access the application from home? Yes. What if I suspect key code misuse? Your dealership should communicate the proper procedures for requesting key codes. Any suspicious activity either within the dealership or externally should be reported to Dealer Systems Support at 1-800-265-0573 or GM of Canada Key Code Inquiry Desk at 1-905-644-4892. Whose key codes can I access through the system? At this time the following Canadian vehicle codes are available through the system: Chevrolet, Cadillac, Buick, Pontiac, GMC, HUMMER (H2 and H3 only), Oldsmobile, Saturn, Saab and Isuzu (up to 2002 model year) for a maximum of 17 model years. What should I do if I enter a valid VIN and the system does not produce any key code information? Occasionally, the KeyCode Look Up application may not produce a key code for a valid VIN. This may be the result of new vehicle information not yet available. In addition, older vehicle information may have been sent to an archive status. If you do not receive a key code returned for valid VIN, you should contact GM of Canada Key Code Inquiry Desk at 1-905-644-4892. How do I access KeyCodes if the KeyCode Look-up system is down? If the KeyCode Look-up system is temporarily unavailable, you can contact the original selling dealer who may have it on file or contact GM of Canada Key Code Inquiry Desk at 1-905-644-4892. If the customer is dealing with an emergency lock-out situation, you need to have the customer contact Roadside assistance, OnStar if subscribed, or 911. What should I do if the KeyCode from the look-up system does not work on the vehicle? On occasion a dealer may encounter a KeyCode that will not work on the vehicle in question. In cases where the KeyCode won't work you will need to verify with the manufacturer of the cutting equipment that the key has been cut correctly. If the key has been cut correctly you may be able to verify the proper KeyCode was given through the original selling dealer. When unable to verify the KeyCode through the original selling dealer contact GM of Canada Key Code Inquiry Desk at 1-905-644-4892. If the key has been cut correctly and the code given does not work, the lock cylinder may have been changed. In these situations following the proper SI document for recoding a key or replacing the lock cylinder may be necessary. How long do I have to keep KeyCode Records? Dealership KeyCode documentation must be retained for two years. Can I get a KeyCode changed in the Look-Up system? Yes, KeyCodes can be changed in the Look-Up system if a lock cylinder has been changed. Contact GM of Canada Key Code Inquiry Desk at 1-905-644-4892. What information do I need before I can provide a driver of a company fleet vehicle Keys or KeyCode information? The dealership should have a copy of the individual's driver's license, proof of employment and registration. If there is any question as to the customer's employment by the fleet company, the dealer should attempt to contact the fleet company for verification. If there is not enough information to determine ownership and employment, this information should not be provided. How do I document a request from an Independent Repair facility for a KeyCode or Key? The independent must provide a copy of their driver's license, proof of employment and signed copy of the repair order for that repair facility. The repair order must include customer's name, address, VIN, city, province and license plate number. Copies of this information must be included in your dealer KeyCode file. Page 7791 Pressure Regulating Solenoid: Service and Repair Automatic Transmission - 4L80-E/4L85-E Pressure Regulator Replacement ^ Tools Required J 36850 Transjel Removal Procedure 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. Remove the transmission filter. 3. Caution: Valve springs can be tightly compressed. Use care when removing retainers and plugs. Personal injury could result. Remove the reverse boost valve bushing retainer ring (2). 4. Remove the following from the reverse boost valve cylinder: ^ The reverse boost valve bushing ^ The reverse boost valve ^ The pressure regulator spring retainer ^ The pressure regulator spring ^ The pressure regulator valve ^ The reverse boost valve bushing Installation Procedure 1. Install the pressure regulator valve using J 36850. 2. Pre-assemble the following parts: Page 16037 Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses CIRCUIT PROTECTION - FUSES The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the Page 13461 The 1999 though early 2003 wiring harness jumper that plugs into the relay block will have a reddish/brown 6-way connector and a tag with the last four digits of the wiring harness part number. Second design 2003-05 may have a white plastic connector with part number 5418 as well. ^ The 1999 jumper is/was P/N 12171982 with a pink/purple tag identifier of 1982. This number has been superseded to 15366255, with a pink/purple tag identifier of 6255. ^ The 2000 jumper harness is P/N 15366255. The pink/purple tag identifier is 6255. ^ The 2001-2002 jumper is P/N 15086884. The orange tag identifier is 6884. ^ The 2003-05 jumper is P/N 15085418. The orange tag identifier is 5418. When transferring the brake controller with the wiring jumper attached from a 2001-2002 vehicle to a 2003-05 vehicle, a change to the jumper harness connector must be performed. Page 3702 Catalytic Converter: Service and Repair Catalytic Converter Replacement (4.3L, 4.8L, and 5.3L Engines) Removal Procedure 1. Raise and suitably support the vehicle. 2. If equipped, unclip the oxygen sensor connection from the floor reinforcement. 3. Disconnect the oxygen sensor electrical connector. 4. Remove the oxygen sensor clips from the frame. 5. Disconnect the connector position assurance (CPA) retainers. 6. Disconnect the oxygen sensor electrical connectors. 7. Unclip the oxygen sensors electrical connectors from the following: ^ Hose clip ^ Transmission crossmember 8. Disconnect the CPA retainers. 9. Disconnect the oxygen sensor electrical connectors (1, 2). Page 10055 2. Remove the brake booster inlet hose (1) from the brake booster (2). 3. Remove the brake booster inlet hose from the power steering pump. 4. Remove the brake booster inlet hose from the vehicle. Installation Procedure 1. Notice: Refer to Installing Hoses Without Twists or Bends Notice in Service Precautions. Route the hose in the same position the hose occupied prior to removal. 2. Install the brake booster inlet hose (1) to the brake booster (2). Hand tighten only. 3. Notice: Refer to Fastener Notice in Service Precautions. Install the brake booster inlet hose to the power steering pump. ^ Tighten the brake booster inlet hose fittings to 28 Nm (20 ft. lbs.). 4. Remove the drain pan from under the vehicle. 5. Bleed the power steering system. Refer to Bleeding the Power Steering System. Power Brake Booster Outlet Hose Replacement Power Brake Booster Outlet Hose Replacement Removal Procedure 1. Notice: Refer to Power Steering Hose Disconnected Notice in Service Precautions. Install a drain pan under the vehicle. 2. Remove the brake booster outlet hose (1) from the brake booster (2). 3. Remove the clamp retaining the brake booster outlet hose to the power steering pump. 4. Remove the brake booster outlet hose from the vehicle. Installation Procedure Page 14347 Electrical Symbols Part 8 Page 12817 Page 7247 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Page 9822 4. Connect the wiring connectors to the fuse block. Refer to Electrical Center Identification Views to ensure the right connections are made. 5. Install the right side end panel. Page 12526 A/T - Fluid Pan Magnet Upgrade Fluid Pan: Technical Service Bulletins A/T - Fluid Pan Magnet Upgrade INFORMATION Bulletin No.: 08-07-30-040B Date: May 05, 2009 Subject: Information on Normal Maintenance or Warranty Service for 4T40, 4T45, 4T65, 4L60 Automatic Transmission Oil Pan Magnet Upgrade Models: 2002-2009 GM Passenger Cars and Light Duty Trucks Equipped With the Following Transmissions: 4T40-E or 4T45 HYDRA-MATIC(R) Automatic Transmission (RPOs MN4, MN5, ME7) 4T65 Transmission (RPO M15 and MN7) 4L60 Transmission and Derivatives (RPO M30 is 4L60, M32 is 4L65, M70 is 4L70) Attention: Do not remove the transmission oil pan unless normal maintenance or diagnosis of a customer concern requires it. .............................................................................................................................................................. .................................................................................. Supercede: This bulletin is being revised to add 4T65 and 4L60 transmissions. Please discard Corporate Bulletin Number 08-07-30-040A (Section 07 - Transmission/Transaxle). .............................................................................................................................................................. .................................................................................. A new transmission oil pan magnet, P/N 29535617, was released for service. The current square transmission oil pan magnet may become saturated with normal ferrous sediment and the Pressure Control Solenoid (PCS) is now collecting ferrous sediment, making it vary from design. For a given current the PCS electromagnet is stronger, causing the line pressure to be less than needed. When checking PCS line pressure (refer to Line Pressure Check in SI) and it shows that the line pressure is lower than required (refer to Current-Amps/Line Pressure Chart in SI), for a given current at the PCS or the transmission oil pan was removed (for either normal maintenance or warranty service), only then should the transmission oil pan magnet be upgraded. 1. Remove and discard the original square transmission oil pan magnet and install a new one in the current location (See graphics below for the correct application). 2. Install the second new transmission oil pan magnet in the following location as shown in the illustration. 4T40 & 4T45 4T65E Page 15172 SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-D. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: - The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair Tools Required J 38125-D Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-D. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Page 12505 In summary, whenever a vehicle subject to this program enters your vehicle inventory, or is in your dealership/facility for service through April 30, 2011, you must take the steps necessary to be sure the program correction has been made before selling or releasing the vehicle. Disclaimer Service Procedure Service Procedure Note Do NOT replace the inside rear view mirror in tandem with this concern. The mirror has no bearing on this specific issue. 1. Remove the OnStar(R) module (referred to as the Communication Interface Module (CIM) or Vehicle Communication Interface Module (VCIM) in SI). Refer to SI for module removal instructions. Note Inform customer that all Bluetooth devices must be paired with the new VCIM. Bluetooth devices that have not been paired to the new VCIM will not function properly. 2. Install the new OnStar(R) module (referred to as the Communication Interface Module (CIM) or Vehicle Communication Interface Module (VCIM) in SI). Refer to SI for module installation instructions. Page 14826 Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 6440 Page 1515 3. Install the horn plunger to the steering column. 4. Install the inflator module. 5. Enable the SIR system. Page 6749 3. Disconnect the vent valve pipe quick connect from the canister. 4. Either cut the existing valve vent pipe and leave the remaining section of pipe in the vehicle or remove along with the valve. 5. Push in the retainer and remove the existing canister vent valve from the fuel tank clip or mounting bracket. 6. Cut back the existing canister pipe approximately 51 mm (2 in) and retain the pipe for use with new valve. 7. Connect the canister pipe quick connect to the canister. 2500 Crew Cab Short Box Shown Below, Other Configurations Similar 1500 Extended Cab Short Box Shown Below, Other Configurations Similar 8. Install the new canister vent valve solenoid to the fuel tank clip or mounting bracket as shown above. The valve port closest to the electrical connector must point towards the canister. 9. Cut bulk 5/8" heater hose to a length of approximately 76 mm (3 in). Install the hose between the solenoid and the canister pipe and secure using clamps. 10. Attach bulk 5/8" heater hose to the vent port and secure using a clamp. Run a length as needed along the frame rail routing to the passenger side area above the transmission. 11. Cut the hose to determined length and install the supplied filter box. Secure using a clamp. 12. Remove the transmission heat shield, if necessary. 13. Remove the transmission support and lower the transmission assembly as necessary to allow for access to the new filter box location. 14. Secure the filter box to the transmission vent hose just forward of the hose tee-section using a tie strap. DO NOT pinch or restrict the transmission vent hose. The filter box opening should be pointing downward. 15. Raise the transmission and reinstall the transmission support. 16. Reinstall the transmission heat shield. 17. Connect the EVAP canister vent valve electrical connector. 18. Tie strap the hose as needed along the frame rail in order to keep the hose away from pinch-points and heat sources. 19. Lower the vehicle. Parts Information Page 9946 average frame angle from the caster reading when making adjustments. 4. The caster and camber adjustments are made by rotating the offset cam bolt and the cam in the slotted frame bracket in order to reposition the control arm. Important: Before adjusting the caster and camber angles, jounce the front bumper three times to allow the vehicle to return to normal height. Measure and adjust the caster and the camber with the vehicle at curb height. The front suspension Z dimension is indicated in Trim Heights. Refer to Trim Height Inspection Procedure in Suspension General Diagnosis. For an accurate reading, do not push or pull on the tires during the alignment process. 5. Determine the caster angle (2). Be sure to compensate for frame angle where required. 6. Determine the positive camber (2) or negative camber (3) angle. 7. Remove the pinned adjusting cam insert. Do not reinstall the cam insert. 8. Loosen the upper control arm cam adjustment bolts. Notice: Refer to Fastener Notice in Service Precautions. 9. Adjust the caster and the camber angle by turning the cam bolts until the specifications have been met.When the adjustments are complete, hold the cam bolt head in order to ensure the cam bolt position does not change while tightening the nut. ^ Tighten the cam nuts to 190 Nm (140 ft. lbs.). 10. Verify that the caster and the camber are still within specifications. Refer to Wheel Alignment Specifications. When the caster and camber are within specifications, adjust the toe. Refer to Front Toe Adjustment. Front Toe Adjustment Front Toe Adjustment Page 2404 Page 13027 Instruments - IPC Odometer Programming Reference Guide Odometer: All Technical Service Bulletins Instruments - IPC Odometer Programming Reference Guide INFORMATION Bulletin No.: 07-08-49-020D Date: December 06, 2010 Subject: IPC Odometer Programming Method Quick Reference Guide Models: 2003-2011 GM Passenger Cars and Trucks (Including Saturn) 2003-2010 HUMMER H2, H3 2005-2009 Saab 9-7X Attention: This bulletin applies to vehicles sold in the U.S. and Canada Only. Supercede: This bulletin is being revised to add information for the 2011 model year and add new 2011 vehicles. Please discard Corporate Bulletin Number 07-08-49-020C (Section 08 - Body and Accessories). The purpose of this bulletin is to provide a reference guide to help identify which season odometer programming method to use after replacing the instrument panel cluster (IPC). The three season odometer programming methods in use today are listed below. In addition, this reference guide lists the component where the season odometer value is stored. The season odometer value may be stored in the IPC, the driver information center (DIC) or the integrated body control module (IBCM), also commonly called a body control module (BCM). Season Odometer Programming Methods in Use Today 1. IPC reprogramming and setup using the service programming system (SPS). 2. Odometer setup at the electronic service center (ESC) when using an exchange IPC/DIC. 3. Tech 2(R) - The Tech 2 is used to set up a replacement BCM, which includes loading the odometer value that is displayed and stored in the IPC. A replacement IPC will display the previously stored vehicle odometer value, communicated from the BCM, after cycling the ignition or driving the vehicle. *The odometer programming is integrated as part of the BCM programming procedure. It is not a stand-alone event. Page 1722 Fuel Composition Sensor Fuel System/Body - Fuel Filler Cap Tether Too Short Fuel Filler Cap: All Technical Service Bulletins Fuel System/Body - Fuel Filler Cap Tether Too Short Bulletin No.: 05-06-04-043A Date: August 02, 2005 TECHNICAL Subject: Fuel Cap Tether Too Short to Hook On Fuel Door While Fueling Vehicle (Install Fuel Filler Housing and Cap) Models: 2004-2005 Cadillac Escalade Models 2004-2005 Chevrolet Silverado, Suburban, Tahoe Models 2004-2005 GMC Sierra, Yukon Models Supercede: This bulletin is being revised to correct the fuel filler cap P/N. P/N 15225006 is released for 2006 and 2007 model year vehicles only. The correct fuel cap for the 2004 and 2005 model year is P/N 15225005. Dealers who currently have P/N 15225006 on order (possibly back-ordered) for this concern should cancel their order and re-order P/N 15225005. Please discard Corporate Bulletin Number 05-06-04-043 (Section 06 - Engine/Propulsion System). Built Prior to the VIN Breakpoints shown. Condition Some customers may comment that the fuel cap tether is too short to hook on the fuel door while fueling the vehicle. Cause The existing fuel cap tether is too short. The existing fuel filler housing elongated hole is too small to accommodate the new fuel cap tether. Correction Page 14842 1. Connect the brake pedal position sensor (2) electrical connector (1). 2. Align the brake pedal position sensor (1) with the actuation arm (2) on the brake pedal and the brake pedal position sensor mounting bracket. Page 8995 Junction Block - I/P Wire Entry Part 2 Page 15603 Daytime Running Lamp (DRL) - Right (Export) Page 4687 Body Control Module (BCM) - C5 Page 4464 Fuel Tank Pressure (FTP) Sensor Page 7115 5. Notice: Refer to Fastener Notice in Service Precautions. Install the engine flywheel bolts. 1. Tighten the bolts a first pass in sequence to 20 Nm (15 ft. lbs.). 2. Tighten the bolts a second pass in sequence to 50 Nm (37 ft. lbs.). 3. Tighten the bolts a final pass in sequence to 100 Nm (74 ft. lbs.). 6. Install the clutch, if equipped with a manual transmission. 7. Install the automatic transmission, if equipped. Page 4322 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves SPLICING COPPER WIRE USING SPLICE SLEEVES TOOLS REQUIRED J 38125-D Terminal Repair Kit IMPORTANT: Use only GM splice sleeves, other splice sleeves may not protect the splice from moisture or a provide good electrical connection. Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. Automatic Transmission - 4L60-E/4L65-E Seals and Gaskets: Service and Repair Automatic Transmission - 4L60-E/4L65-E Filler Tube and Seal Replacement Filler Tube and Seal Replacement Removal Procedure 1. Unlock the transmission oil level indicator. 2. Remove the transmission oil level indicator. 3. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 4. Support the transmission using a suitable jack. 5. Remove the transmission mount nut. Page 13410 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly, Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Pull to Seat Connectors PULL TO SEAT CONNECTORS TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Page 6874 17. Determine the selective shim thickness for the pinion gear bearing retainer. 18. Apply sealant, GM P/N 1052942 (Canadian P/N 10953466) or equivalent, to sealing surface of the pinion gear bearing retainer. 19. Install the selective shim.Align the tab on the shim with the unmachined surface of the pinion gear bearing retainer. 20. Apply sealant, GM P/N 1052942 (Canadian P/N 10953466) or equivalent, to surface of the selective shim. 21. Install the pinion gear bearing retainer. 22. Install the pinion gear bearing retainer bolts. ^ Tighten the pinion gear bearing retainer bolts to 88 Nm (65 ft. lbs.). 23. Measure the rotating torque of the pinion and the ring gear. Compare this measurement with the rotating torque recorded during removal. The rotating torque of the pinion and the ring gear should be between 3.9-6.2 Nm (30-55 inch lbs.) for new bearings or 2.8-5.6 Nm (25-50 inch lbs.) for used bearings. 24. If the rotating torque of the pinion and the ring gear is not within specifications, adjust the preload of the pinion or the differential side bearings as necessary. 25. Install the propeller shaft (3) to the pinion yoke (4).Align the reference marks made during removal. 26. Install the propeller shaft yoke retaining clamps and the bolts. ^ Tighten the propeller shaft yoke retaining clamp bolts to 25 Nm (18 ft. lbs.). 27. Install the axle shafts. 28. Fill the axle with axle lubricant. 29. Lower the vehicle. Page 8406 2. Install the park brake cable to the lever. 3. Notice: Refer to Fastener Notice in Service Precautions. Install the rear park brake cable bracket bolt. ^ Tighten the rear park brake cable bracket bolt to 61 Nm (45 ft. lbs.). 4. Install the park brake cable to the differential clip. 5. Install the park brake cable bolt to the rear axle clip. ^ Tighten the park brake cable bolt to 25 Nm (18 ft. lbs.). 6. Install the park brake cable taking care to correctly route the cable though the guides and the body mounts. 7. Install the park brake cable into the mounting bracket until the locking tabs snap into place. Page 8231 1. Remove the J 45101-100 and the lug nuts that were installed during the assembled LRO measurement procedure. 2. Inspect the mating surface of the hub/axle flange and the brake rotor to ensure that there are no foreign particles or debris remaining. 3. Index the brake rotor in a different orientation to the hub/axle flange. 4. Hold the rotor firmly in place against the hub/axle flange and install one of the J 45101-100 (1) and one lug nut (2) onto the upper-most wheel stud. 5. Continue to hold the rotor secure and tighten the lug nut firmly by hand. 6. Install the remaining J 45101-100 and lug nuts onto the wheel studs and tighten the nuts firmly by hand in a star-pattern. 7. Using the J 39544-KIT , or equivalent, tighten the lug nuts in a star-pattern to specification, in order to properly secure the rotor. 8. Measure the assembled LRO of the brake rotor. Refer to Brake Rotor Assembled Lateral Runout (LRO) Measurement. 9. Compare the amount of change between this measurement and the original measurement. 10. If this measurement is within specifications, proceed to step 14. 11. If this measurement still exceeds specifications, repeat steps 1-9 until the best assembled LRO measurement is obtained. 12. Matchmark the final location of the rotor to the wheel studs if the orientation is different than it was originally. 13. If the brake rotor assembled LRO measurement still exceeds the maximum allowable specification, refer to Brake Rotor Assembled Lateral Runout (LRO) Correction. 14. If the brake rotor assembled LRO is within specification, install the brake caliper and depress the brake pedal several times to secure the rotor in Page 9927 A wheel alignment will generally NOT correct vehicles that follow the road crown since this is within "Normal Operation." Mileage Policy The following mileage policy applies for E2020 and E2000 labor operations: Note Wheel Alignment is NOT covered under the New Vehicle Limited Warranty for Express and Savana Cutaway vehicles as these vehicles require Upfitters to set the wheel alignment after completing the vehicles. - 0-800 km (0-500 mi): E2000/E2020 claims ONLY allowed with Call Center Authorization. Due to the tie down during shipping, the vehicle's suspension requires some time to reach normal operating position. For this reason, new vehicles are generally NOT to be aligned until they have accumulated at least 800 km (500 mi). A field product report should accompany any claim within this mileage range. - 801-12,000 km (501-7,500 mi): - If a vehicle came from the factory with incorrect alignment settings, any resulting off-angle steering wheel, lead/pull characteristics or the rare occurrence of excessive tire wear would be apparent early in the life of the vehicle. The following policy applies: - Vehicles 100% Factory Set/Measured for Caster/Camber/Toe - Escalade/ESV/EXT, Tahoe/Suburban, Yukon/XL/Denali, Silverado/Sierra, Express/Savana, Corvette and Colorado/Canyon: E2000/E2020 Claims: Call Center Authorization Required - All Vehicles NOT 100% Factory Set/Measured for Caster/Camber/Toe as noted above: E2000/E2020 Claims: Dealer Service Manager Authorization Required - 12,001 km and beyond (7,501 miles and beyond): During this period, customers are responsible for the wheel alignment expense or dealers may provide on a case-by case basis a one-time customer enthusiasm claim up to 16,000 km (10,000 mi). In the event that a defective component required the use of the subject labor operations, the identified defective component labor operation will include the appropriate labor time for a wheel alignment as an add condition to the component repair. Important Only one wheel alignment labor operation claim (E2000 or E2020) may be used per VIN. Warranty Documentation Requirements When a wheel alignment service has been deemed necessary, the following items will need to be clearly documented on/with the repair order: - Customer concern in detail - What corrected the customer concern? - If a wheel alignment is performed: - Consult SI for proper specifications. - Document the "Before" AND "After" wheel alignment measurements/settings. - Completed "Wheel Alignment Repair Order Questionnaire" (form attached to this bulletin) 1. Document the customer concern in as much detail as possible on the repair order and in the warranty administration system. Preferred examples: - Steering wheel is off angle in the counterclockwise direction by approximately x degrees or clocking position. - Vehicle lead/pulls to the right at approximately x-y mph. Vehicle will climb the road crown. Severe, Moderate or Slight. - RF and LF tires are wearing on the outside shoulders with severe feathering. Important In the event of a lead/pull or steering wheel angle concern, please note the direction of lead/pull (left or right) or direction of steering wheel angle (clockwise or counterclockwise) on the repair order and within the warranty claim verbatim. Important In the event of a tire wear concern, please note the position on the vehicle and where the wear is occurring on the tire; i.e., the RF tire is wearing on the inside shoulder. 2. Document the technician's findings on cause and correction of the issue. Examples: - Reset LF toe from 0.45 degrees to 0.10 degrees and RF toe from -0.25 degrees to 0.10 degrees to correct the steering wheel angle from 5 degrees counterclockwise to 0 degrees. - Reset LF camber from 0.25 degrees to -0.05 degrees to correct the cross-camber condition of +0.30 degrees to 0.00 degrees on the vehicle. - Front Sum toe was found to be 0.50 degrees, reset to 0.20 degrees. 3. Print-out the "Before" and "After" wheel alignment measurements/settings and attach them to the Repair Order or if print-out capability is not Page 13171 ^ For U.S. Saturn retailer claim submission, use Net Item code "M" and Case Type VW. Engine Controls - MIL ON/Rough Idle/Misfire/DTC's Set PROM - Programmable Read Only Memory: All Technical Service Bulletins Engine Controls - MIL ON/Rough Idle/Misfire/DTC's Set Bulletin No.: 05-06-04-063 Date: October 12, 2005 TECHNICAL Subject: LM7, L59 or L33 Engines with Cold Start Rough or Incorrect Idle, Misfire, Malfunction Indicator Lamp (MIL) or Flashing Requiring 02 Sensor Replacement (Reprogram PCM) Models: 2004-2005 Cadillac Escalade 2004-2005 Chevrolet Avalanche, Silverado 1500, Suburban, Tahoe 2005 Chevrolet Silverado Hybrid (HP2) 2004-2005 GMC Sierra 1500, Yukon, Yukon XL 2005 GMC Sierra Hybrid (PH2) with Vortec 5300 5.3L V-8 Engine (VINs T, Z, B - RPOs LM7, L59, L33) Condition Some customers may comment on a Malfunction Indicator Lamp (MIL) On or that the MIL is flashing. An actual engine misfire may or may not be felt along with an incorrect idle speed. Typically this occurs during cold winter months, on cold engine starts. Some vehicles may have been previously serviced for the same condition. Technicians may also find the following DTCs stored with the Tech 2(R) P0131, P0133, P0134, P0137, P0138, P0140, P0151, P0153, P0154, P0157, P1133, which may be in conjunction with P0171, P0174, P0300 and P1138. Cause Water shock occurs when water droplets are present in the exhaust. The water in the exhaust contacts the sensor element inside the H02 sensor, causing the H02 sensor element to crack. Correction Upon diagnostic investigation, the technician may find that the H02 sensor requires replacement. In addition to replacing the affected H02 sensor, these vehicles should also be reflashed with the latest PCM calibration. An updated PCM calibration will be available to dealerships as part of TIS 2000 incremental satellite update 11.0 (NAO version 25.010) or greater. Always, make sure your Tech 2 is updated with the latest software version. Important: If a DTC P0420 or P0430 is stored along with DTC(s) P0300, the catalytic converter diagnostics in Service Information (SI) must be followed to determine if the catalytic converters are operating properly. Warranty Information For vehicles repaired under warranty, use the table. Page 6424 1. The shift lock control actuator must lock the shift lever clevis when the shift lever clevis is put into the park position. 2. Depress the brake pedal to move the shift lever out of the park position. 3. The actuator will be energized. 4. Readjust the shift lock control actuator if needed. 5. Install the BCM. 6. Enable the SIR system. Page 10648 Install a new spring bumper assembly for 2WD 1500 Series Only with 20" wheels. Reuse the nut from the original bumper. Install the nut to the spring bumper stud. Tighten Tighten the nut to 30 N.m (22 lb ft). Remove the safety stands. Lower the vehicle. Knee Bolster Deflector This modification is required for the following vehicles and ONLY applies to Extended Cab Long Box (K15953) Pickup models: 1999-2005 Chevrolet Silverado and GMC Sierra (1500 Series Only): 2005 Vehicles Built in Pontiac (VIN Code E) prior to VIN Breakpoint 5E100134 2005 Vehicles Built in Oshawa (VIN Code 1) prior to VIN Breakpoint 51113131 2005 Vehicles Built in Ft. Wayne (VIN Code Z) prior to VIN Breakpoint 5Z126605 The following procedure should be followed: Apply the parking brake to prevent the vehicle from moving. Remove the fuse panel cover. Remove the I/P cluster trim plate bezel. Remove the knee bolster. Remove the 2 mm (0.078 in) thick knee bolster deflector. Install the 1.5 mm (0.059 in) thick knee bolster deflector, P/N 12499966. A detailed instruction sheet will be provided with the service part. Re-Programming A/C - Ticking Noise From Instrument Panel/DTC's Set Control Module HVAC: Customer Interest A/C - Ticking Noise From Instrument Panel/DTC's Set Bulletin No.: 06-01-38-003 Date: April 27, 2006 TECHNICAL Subject: Intermittent Ticking Noise from I/P, Poor A/C Performance, HVAC DTCs B0229, B0414, B0424, B3770 (Reprogram HVAC Control Module) Models: 2004-2006 Cadillac Escalade Models 2004-2006 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2004-2006 GMC Sierra Models, Yukon Models with Air Conditioning (RPOs CJ2, CJ3) Condition Some customers may comment on one or more of the following concerns: ^ Intermittent ticking/clicking noise from the instrument panel. ^ Recirculation mode does not work or Air Conditioning (A/C) system performance is poor during high ambient temperatures. ^ Unable to control the driver side temperature. ^ Unable to control the passenger side temperature. ^ Unable to change the front system modes. Cause This condition may be caused by the Heating, Ventilation and Air Conditioning (HVAC) actuators that may hunt for the correct commanded position. This cycling may cause a clicking or ticking noise. An overtravel of the HVAC system control doors may cause one or more of the concerns listed above. If an overtravel occurs, a Diagnostic Trouble Code (DTC) will be set, and the door will go to a preset default position. When a system door defaults, that door will stay at the default position until the DTC is cleared. After the DTC is cleared, the door will operate properly until the overtravel condition re-occurs. The table lists the HVAC system doors and the DTC associated with it. Correction Technicians are to perform the normal diagnostic procedures in SI for these concerns. If diagnostics show that the HVAC system door(s) travel below 5 counts (out of the lower range) or above 250 counts (out of the upper range), then update the software calibrations in the HVAC control module. The new calibrations were made available to dealerships as part of TIS2000 incremental satellite update version 2.5, which was broadcast to dealers in February 2006. Page 2378 Contamination Mixing conventional green coolant with DEX-COOL(R) will degrade the service interval from 5 yrs./150,000 miles (240,000 km) to 2 yrs./30,000 miles (50,000 km) if left in the contaminated condition. If contamination occurs, the cooling system must be flushed twice immediately and re-filled with a 50/50 mixture of DEX-COOL(R) and clean water in order to preserve the enhanced properties and extended service interval of DEX-COOL(R). After 5 years/150,000 miles (240,000 km) After 5 yrs/150,000 miles (240,000 km), the coolant should be changed, preferably using a coolant exchanger. If the vehicle was originally equipped with DEX-COOL(R) and has not had problems with contamination from non-DEX-COOL(R) coolants, then the service interval remains the same, and the coolant does not need to be changed for another 5 yrs/150,000 miles (240,000 km) Equipment (Coolant Exchangers) The preferred method of performing coolant replacement is to use a coolant exchanger. A coolant exchanger can replace virtually all of the old coolant with new coolant. Coolant exchangers can be used to perform coolant replacement without spillage, and facilitate easy waste collection. They can also be used to lower the coolant level in a vehicle to allow for less messy servicing of cooling system components. It is recommended that you use a coolant exchanger with a vacuum feature facilitates removing trapped air from the cooling system. This is a substantial time savings over repeatedly thermo cycling the vehicle and topping-off the radiator. The vacuum feature also allows venting of a hot system to relieve system pressure. Approved coolant exchangers are available through the GMDE (General Motors Dealer Equipment) program. For refilling a cooling system that has been partially or fully drained for repairs other than coolant replacement, the Vac-N-Fill Coolant Refill Tool (GE-47716) is recommended to facilitate removal of trapped air from the cooling system during refill. Disclaimer Page 9517 Location View Page 13116 A current DTC clears when the condition for setting the DTC is no longer present. A history DTC clears after 50 malfunction-free ignition cycles. Circuit/System Testing Without RPO UAV 1. Turn OFF the ignition and all electrical components, including the scan tool. 2. Disconnect the harness connector at the cellular microphone. 3. Test for less than 5 Ohms between the low reference circuit terminal A and ground. ^ If greater than the specified range, test the low reference circuit for an open/high resistance. If the circuit tests normal, replace the VCIM. 4. Ignition ON, test for 9 - 11 volts between the signal circuit terminal B and ground. ^ If greater than the specified range, test the signal circuit for a short to voltage. If the circuit tests normal, replace the VCIM. ^ If less than the specified range, test the signal circuit for a short to ground or an open/high resistance. If the circuit tests normal, replace the VCIM. Refer to the appropriate vehicle in SI. 5. If all circuits test normal, test or replace the cellular microphone. Circuit/System Testing With RPO UAV 1. Turn OFF the ignition and all electrical components, including the scan tool. 2. Disconnect the X4 harness connector at the navigation radio and the harness connector at the cellular microphone. 3. Test for less than 5 Ohms between the low reference circuit terminal A and ground. ^ If greater than the specified range, test the low reference circuit for an open/high resistance. If the circuit tests normal, replace the VCIM. Refer to the appropriate vehicle in SI. 4. Ignition ON, test for 9 - 11 volts between the signal circuit terminal B and ground. ^ If greater than the specified range, test the signal circuit for a short to voltage. If the circuit tests normal, replace the VCIM. ^ If less than the specified range, test the signal circuit for a short to ground or an open/high resistance. If the circuit tests normal, replace the VCIM. 5. If all circuits test normal, test or replace the cellular microphone. 6. Connect the X4 harness connector at the navigation radio. 7. With a scan tool, verify that DTC B2455 is not set as current in the navigation radio. ^ If DTC B2455 is set as current, replace the navigation radio. Refer to the appropriate vehicle in SI. DTC B2462, B2483, or B2484 Circuit/System Description The vehicle communication interface module (VCIM) receives information from a specific navigation antenna located on the outside of the vehicle. The navigation antenna is connected to the VCIM via a shielded coaxial cable. The antenna cable also provides a path for DC current for powering the antenna. DTC Descriptors DTC B2462 02: Global Positioning System (GPS) Antenna Malfunction Short to Ground DTC B2462 04: Global Positioning System (GPS) Antenna Malfunction Open Circuit Page 15957 6. Use fingers to squeeze the 2 locking legs of the cover. 7. Apply pressure and gently rock the cover until one locking leg is unseated. 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. Page 13141 switch lighting connector. 3.3. Undo the floor console's retaining bolts (C). 3.4. Take out the rear ashtray/cover (D). 3.5. Remove the screw (E) for the rear cover. 3.6. Remove the floor console's retaining nuts (E). 3.7. Detach the floor console (G) by pulling it straight back and lifting it slightly. 3.8. If required, detach the switch for the rear seat heater and unplug the connector. 4. Remove the switch and the floor console: 4.1. Detach the window lift module (A) by loosening it in the front edge (snap fastener). Unplug the window lift module's connector. 4.2. Detach the switch for the roof lighting (B) and unplug its connector. Lift away the floor console. 5. Pry out the signal line from the SRS control module to the OnStar(R) control module and secure it: 5.1. Unplug the SRS control module's connector (A). Page 1442 Backup Lamp Switch: Service and Repair NV 4500 Backup Lamp Switch Replacement Removal Procedure 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. Disconnect the backup lamp switch electrical connector (1). 3. Remove the backup lamp switch and seal. Installation Procedure 1. Ensure the seal is installed on the switch. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the backup lamp switch. ^ Tighten the switch to 28 Nm (21 ft. lbs.). Page 9029 Fuse Block- I/P C1 Part 3 Page 15949 TOOLS REQUIRED J 34142-B 12 V Unpowered Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. When testing for voltage: 1. Attach 1 lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach 1 lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Using Connector Test Adapters USING CONNECTOR TEST ADAPTERS NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-B Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires USING FUSED JUMPER WIRES TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Connector Position Assurance Locks CONNECTOR POSITION ASSURANCE LOCKS The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Terminal Position Assurance Locks TERMINAL POSITION ASSURANCE LOCKS The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Push to Seat Connectors PUSH TO SEAT CONNECTORS TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Page 13511 Electrical Symbols ELECTRICAL SYMBOLS Electrical Symbols Part 1 Page 3601 9. Install the surge tank overflow hose. 10. Install the air cleaner assembly. 11. Fill the cooling system. Page 3048 5. Tighten the wheel bearing adjusting nut using the J 2222-C. ^ Rotate the hub in the opposite direction to the way the adjuster nut is turning. ^ Ensure the inner bearing and the seal seats against the spindle shoulder. TIGHTEN ^ Adjusting nut to 70 Nm (52.0 lb ft). 6. Turn the adjusting nut counterclockwise until the nut is loose using the J 2222-C. 7. Turn the adjusting nut clockwise until the nut contacts the bearing cone. Torque on the nut must be zero to finger tight. 8. Insert the adjusting nut lock key into the keyway using one of the following procedures: ^ If the adjusting nut slot is in alignment with the keyway in the axle spindle, insert the adjusting nut lock key into the keyway in the axle spindle. IMPORTANT: Do not turn the adjusting nut more than one slot counterclockwise in order to align the adjusting nut slot with the keyway in the axle spindle. ^ If the adjusting nut slot is not aligned with the keyway in the axle spindle, turn the adjusting nut counterclockwise until the adjusting nut slot is in alignment with the keyway in the axle spindle and insert the adjusting nut lock key. Page 1986 Electrical Symbols Part 13 Engine, A/T - Shift/Driveability Concerns/MIL ON Air Filter Element: All Technical Service Bulletins Engine, A/T - Shift/Driveability Concerns/MIL ON Bulletin No.: 04-07-30-013B Date: February 01, 2007 INFORMATION Subject: Automatic Transmission Shift, Engine Driveability Concerns or Service Engine Soon (SES) Light On as a Result of the Use of an Excessively/Over-Oiled Aftermarket, Reusable Air Filter Models: 2007 and Prior GM Cars and Light Duty Trucks 2007 and Prior Saturn Models 2003-2007 HUMMER H2 2006-2007 HUMMER H3 2005-2007 Saab 9-7X Supercede: This bulletin is being revised to add models and model years. Please discard Corporate Bulletin Number 04-07-30-013A (Section 07 - Transmission/Transaxle). The use of an excessively/over-oiled aftermarket, reusable air filter may result in: Service Engine Soon (SES) light on Transmission shift concerns, slipping and damaged clutch(es) or band(s) Engine driveability concerns, poor acceleration from a stop, limited engine RPM range The oil that is used on these air filter elements may be transferred onto the Mass Air Flow (MAF) sensor causing contamination of the sensor. As a result, the Grams per Second (GPS) signal from the MAF may be low and any or all of the concerns listed above may occur. When servicing a vehicle with any of these concerns, be sure to check for the presence of an aftermarket reusable, excessively/over-oiled air filter. The MAF, GPS reading should be compared to a like vehicle with an OEM air box and filter under the same driving conditions to verify the concern. The use of an aftermarket reusable air filter DOES NOT void the vehicle's warranty. If an aftermarket reusable air filter is used, technicians should inspect the MAF sensor element and the air induction hose for contamination of oil prior to making warranty repairs. Transmission or engine driveability concerns (related to the MAF sensor being contaminated with oil) that are the result of the use of an aftermarket reusable, excessively/over-oiled air filter are not considered to be warrantable repair items. Page 1332 Discharge Air Temperature Sensor / Switch: Service and Repair Air Temperature Sensor Replacement - Lower Right AIR TEMPERATURE SENSOR REPLACEMENT - LOWER RIGHT REMOVAL PROCEDURE 1. Remove the I/P lower closeout panel. 2. Remove the right floor duct. 3. Remove the center console. 4. Disconnect the electrical connector from the lower right air temperature sensor (1). 5. Remove the lower right air temperature sensor (1). INSTALLATION PROCEDURE 1. Install the lower right air temperature sensor (1). 2. Connect the electrical connector to the lower right air temperature sensor (1). 3. Install the center console. 4. Install the right floor duct. 5. Install the I/P lower closeout panel Page 4064 Tighten Tighten to 8 Nm (71 lb in). Note The repair area MUST BE properly refinished to maintain a secure, stable and corrosion-free electrical ground. 12. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 13. Verify proper system operation. M8 Weld Nut Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M8 weld nut electrical ground location is accessible from both sides of the panel, a M8 conductive bolt and a M8 conductive nut may be used to secure the electrical ground wire terminal. Refer to the Parts Information section of this bulletin. 2. Select a location adjacent the M8 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the new electrical ground site. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the ground location and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 10 mm (0.40 in) diameter hole through the panel. 5. Remove paint and primer from the area surrounding the 10 mm (0.40 in) hole until bare metal is visible. 6. Select a M8 conductive bolt. Refer to the Parts Information section of this bulletin. 7. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M8 conductive bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 8. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 9. Install the electrical ground wire terminal and the M8 conductive bolt to the ground location. 10. Select a M8 conductive nut. Refer to the Parts Information section of this bulletin. 11. Install the M8 conductive nut to the bolt and: Tighten Tighten to 22 Nm (16 lb ft). Note The repair area MUST BE properly refinished to maintain a secure, stable and corrosion-free electrical ground. 12. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 13. Verify proper system operation. M8 Weld Nut Alternative Repair Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M8 weld nut electrical ground location is not accessible from both sides of the panel, a M6 conductive rivet stud and a M6 conductive nut may be used to secure the electrical ground wire terminal. 2. Select a location adjacent the damaged M8 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the M6 conductive rivet stud flange. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the repair site and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 10 mm (0.40 in) diameter hole through the panel. Page 8632 Hydraulic Fluid Accumulator: Service and Repair Hydraulic Brake Booster Accumulator Replacement ^ Tools Required J 26889 Accumulator Piston Compressor Removal Procedure Caution: The accumulator contains compressed gas. Always use the proper tools and follow the recommended procedures or personal injury may result. Do not apply heat to accumulator. Do not attempt to repair an inoperative accumulator. Always replace an inoperative accumulator with a new one. Dispose of an inoperative accumulator by drilling a 1.5 mm (1/16 inch) diameter hole through the end of the accumulator can, opposite the O-ring. Caution: Push rod removal is not recommended. Improper staking of the push rod to the Hydroboost reaction piston can result in a loss of brakes. If the rod or seals require service, the entire unit must be replaced. 1. Apply the park brake and block the wheels. 2. Depress brake pedal at least 10 times in order to relieve pressure in the accumulator. 3. Remove the master cylinder from the hydraulic booster. 4. Place the J 26889 over the end of the accumulator. 5. Install the nut on the stud. 6. Depress the accumulator with a C-clamp. If the accumulator does not move with moderate pressure, remove the C-clamp and depress the brake pedal ten times in order to relieve pressure in the accumulator. 7. Rotate the retaining ring (2) until either end of the ring is under the access hole (1). 8. Depress and hold the retaining ring (2) with a small tool inserted into the access hole (1). Page 9582 Junction Block - I/P - C6 Page 3234 Page 834 Location View Location View Page 12444 Specifications Water Pump: Specifications Water Pump Bolts First Pass ............................................................................................................................................. ............................................... 15 Nm (11 ft lb) Final Pass .................................................................. ......................................................................................................................... 30 Nm (22 ft lb) Coolant Heater Cord Replacement Engine Block Heater: Service and Repair Coolant Heater Cord Replacement Coolant Heater Cord Replacement Removal Procedure 1. Raise and suitably support the vehicle. 2. Disconnect the coolant heater electrical connector (2). 3. Remove the coolant heater cord retainer and bolts. 4. Remove the coolant heater cord. Installation Procedure Notice: The heater cord must not touch the engine, hot pipes, manifold, or any moving parts. Route the cord to the left front of the engine compartment securing with tie straps as necessary to prevent damage. 1. Install the coolant heater cord. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the coolant heater cord bolts and retainer. Tighten the bolts to 8 Nm (71 inch lbs.). Page 5096 Canister Vent Valve: Service and Repair EVAP Canister Vent Solenoid Valve Replacement (Cab/Chassis) EVAPORATIVE EMISSION (EVAP) CANISTER VENT SOLENOID VALVE REPLACEMENT (CAB/CHASSIS) REMOVAL PROCEDURE IMPORTANT: Clean all evaporative emission (EVAP) connections and surrounding areas before disconnecting the line in order to avoid possible EVAP system contamination. 1. Disconnect the EVAP canister vent solenoid (CVS) electrical connector (1). 2. Remove the EVAP CVS valve bracket bolt (1). 3. Remove the EVAP CVS line from the clips on the fuel tank. 4. Remove the CVS valve and line. 5. Remove the EVAP CVS valve line from the CVS, if necessary. INSTALLATION PROCEDURE Page 8605 1. Install the gasket. 2. Install the booster assembly. 3. Install the 4 booster to bulkhead nuts. Tighten Tighten the nuts to 36 N.m (26 lb-ft). 4. Snap the stop lamp switch onto the pushrod to the power brake booster. 5. Install the stop lamp switch with the pushrod on the brake pedal pin. 6. Install the brake switch retainer. 7. Connect the electrical connector to the stop lamp switch. 8. Install the master cylinder to the booster. 9. Install the master cylinder mounting nuts. Tighten Tighten the nuts to 36 N.m (27 lb-ft). 10. Connect the power brake booster outlet hose, the steering gear inlet hose, and the power brake booster inlet hose. Tighten ^ Tighten the power brake booster inlet hose to 28 N.m (20 lb-ft). ^ Tighten the steering gear inlet hose to 28 N.m (20 lb-ft). Important: Maintain the fluid level throughout the bleed procedure. 11. Remove the pump reservoir cap. Important: Page 5284 Steps 4 - 5 Page 3999 2. Connect the MAP sensor electrical connector (1). 3. Install the engine sight shield. Page 9083 Location View Page 15399 supported, only J2534. 1. BEFORE the original IPC is disconnected from the vehicle, record the odometer and engine hour values. 2. Replace the IPC with a replacement part obtained from the ESC. Refer to Instrument Cluster Replacement in SI. 3. Using the TIS2WEB SPS application, select either: J2534 Tech 2 or J2534 MDI, when available and build the vehicle. 4. Select: IPC Setup J2534. 5. After selecting IPC Setup J2534, the user will be prompted to: install the new controller. Ignore this prompt if the new IPC was already installed. This prompt is just to remind the user that this application is only for a new IPC. Important FOR 2003 FULLSIZE TRUCKS, UTILITIES AND H2, THE ENGINE MUST BE STARTED AND RUNNING PRIOR TO ENTERING THE MILEAGE AND ENGINE HOURS. After the odometer value is programmed, the engine must remain running for 6 minutes 15 seconds before the ignition can be turned off. Failure to do so will result in engine hours not being programmed and a new IPC will have to be ordered. 6. Enter the odometer and engine hour values, when applicable. By default the application will be set to miles. For metric units, click the button on the left next to: Kilometers. The IPC odometer and engine hour meter setup procedure is now complete. 7. The IPC calibration files can now be programmed into the IPC. Refer to SPS in SI. Disclaimer Emissions - MIL ON/DTC P0446 Stored In ECM Evaporative Canister Filter: Customer Interest Emissions - MIL ON/DTC P0446 Stored In ECM TECHNICAL Bulletin No.: 02-06-04-037I Date: September 16, 2010 Subject: Check Engine Light On, Fuel Tank Hard to Fill, DTCs P0442, P0446, P0455 or P0449 Set (Replace Evaporative Emission (EVAP) Vent Valve Solenoid Assembly and Add/Relocate Filter Box Using Service Kit) Models: 1999-2007 Chevrolet Silverado (Classic) Models 1999-2007 GMC Sierra (Classic) Models 2007-2010 Chevrolet Silverado Models (Including Hybrid) 2007-2010 GMC Sierra Models (Including Hybrid) Supercede: This bulletin is being revised to add the 2010 model year and to include the Hybrid models. Please discard Corporate Bulletin Number 02-06-04-037H (Section 06 - Engine/Propulsion System). Condition Some customers may comment about the check engine light being illuminated. They may also comment that their vehicle is difficult to fill with fuel or when filling, the pump continuously shuts off before the tank is full. When checking the vehicle for DTCs, the ECM may report one or more of the following DTCs set as current or in history: P0442, P0446, P0449 or P0455. Cause The EVAP canister vent solenoid (CVS) valve draws fresh air into the system through a vent. Under certain operating conditions, dirt and dust intrusion into the EVAP CVS fresh air intake/venting system, may result in restricted air flow. Under certain operating conditions, water, if ingested into the EVAP CVS fresh air intake/venting system, may reach the CVS valve causing corrosion in the CVS valve, and may cause restrictions in the fresh air intake path, when the valve is in the closed position. Correction (1999-2007 Classic/Old Style Models) After following the published SI diagnostics and determining that the EVAP canister vent valve is the cause of the MIL light, replace the existing EVAP canister vent valve assembly with a new assembly. This new assembly is a sealed unit that is designed to be vented through a remote filter box. To ensure correct installation, follow the procedures below. Important DO NOT replace the EVAP canister assembly for this concern unless it fails the leak test. 1999-2003 Model Year (Use Service Kit P/N 19207762) 1. Raise the vehicle. Suitably support the vehicle. 2. Disconnect the EVAP canister vent valve electrical connector, if equipped. 3. Disengage the two vent valve pipe clips securing the pipe to the underbody. Remove the clips from the underbody and discard. 4. Disconnect the vent valve pipe at the EVAP canister. 5. Remove and retain the EVAP canister vent valve bracket mounting bolt. 6. Remove the complete EVAP canister vent valve assembly with bracket attached and discard. Driveline - Bump/Clunk/Squawking Noises Output Shaft: All Technical Service Bulletins Driveline - Bump/Clunk/Squawking Noises Bulletin No.: 01-04-17-004B Date: January 05, 2005 TECHNICAL Subject: Clunk, Bump or Squawk when Vehicle Comes to Complete Stop or Accelerating from Complete Stop (Replace Rear Drive Shaft Nickel-Plated Slip Yoke) Models Supercede: This bulletin is being revised to add Cadillac Escalade (Old Style) to the Models section. Please discard Corporate Bulletin Number 01-04-17-004A (Section 04 - Driveline/Axle). Condition Some customers may comment on a clunk, bump or squawk noise when the vehicle comes to a stop or when accelerating from a complete stop. Cause A slip/stick condition between the transfer case output shaft and the driveshaft slip yoke may cause this condition. Diagnostic Tips There are several resources in the electronic Service Information System which can provide the technician with information on diagnosis and repair of clunk conditions, and fix the customer's vehicle right the first time without unnecessary parts replacement. Some of the documents available in SI include: ^ Symptoms - Propeller Shaft Page 13231 Page 13839 5. Remove all adhesive from the pickup box panel surface and the back of the emblem/nameplate using 3M(TM) scotch brite molding adhesive remover disk 3M(TM) P/N 07501 or equivalent. 6. Clean the pickup box surface using varnish makers and painters (VMP) naptha. Installation Procedure 1. If the location of the emblem/nameplate has not been marked apply tape. 2. Warm the pickup box surface with a heat gun J 25070 152 mm (6.0 in) from the surface to a minimum of 21°C (70°F). Important: Do not touch the adhesive backing of the emblem/nameplate. 3. Remove the backing from the front end of the emblem/nameplate. 4. Press the emblem/nameplate to the pickup box panel surface while continuing to remove the backing. 5. Hand roll the emblem/nameplate to the pickup box panel to ensure proper adhesion. 6. Inspect the emblem/nameplate for bonding. 7. Remove the tape from the area around the pickup box emblem. Emblem/Nameplate Replacement - Pickup Cab Emblem/Nameplate Replacement - Pickup Cab Tools Required J 25070 Heat Gun Removal Procedure Important: Use the tape for protection and alignment marks for alignment of the new emblem. 1. Apply tape to the area around the pickup cab emblem. 2. Heat the emblem/nameplate, using a heat gun J 25070 152 mm (6.0 in) from the surface. 3. Apply the heat using a circular motion for about 30 seconds. Notice: Refer to Exterior Trim Emblem Removal Notice in Service Precautions. 4. Remove the emblem/nameplate from the pickup cab surface using a plastic, flat-bladed tool. Page 3422 Important: The intake plenum should also be checked for excessive warpage that may cause an uneven clamping pressure of the seal. If the plenum is found to be warped it will need to be replaced. Service Information states, "An intake manifold with warpage in excess of 3 mm (0.118 in) over a 200 mm (7.87 in) area should be replaced." Intake warpage is measured at the gasket sealing surfaces and should be measured within a 200 mm (7.87 in) area. This measurement is across only two of the intake runner port openings. Measurements taken across the entire distance of all four intake runner ports will lead to unnecessary manifold replacements. Important: Measurements taken across the entire distance of all four intake runner ports will lead to unnecessary intake manifold replacements. 1. Locate a straight edge across the intake manifold cylinder head deck surface. Position the straight edge across two runner port openings. 2. Insert a feeler gauge between the intake manifold and the straight edge. An intake manifold with warpage in excess of 3 mm (0.118 in) over a 200 mm (7.87 in) area is warped and should be replaced. Do not replace intake manifolds with warpage that measures less than 3 mm (0.118 in) over a 200 mm (7.87 in). Parts Information Warranty Information For vehicles repaired under warranty, use the table. Page 15621 Door Switch: Description and Operation DOOR LATCH (DOOR JAMB) SWITCHES The theft deterrent system uses the door key switch as one method in order to activate the alarm. If the BCM detects any door opening before the BCM receives a disarm input, the alarm mode activates. DOOR KEY SWITCH The BCM monitors the door key switches in order to disarm the CTD system. When the lock cylinder turns in order to unlock the door, the switch grounds the disarm input to the BCM. Page 477 Door Module: Diagnostic Aids Basic Knowledge Required BASIC KNOWLEDGE REQUIRED Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the Service Data. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories CHECKING AFTERMARKET ACCESSORIES Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: - Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions INDUCING INTERMITTENT FAULT CONDITIONS In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: - Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. Page 2937 9.1. Push the mud flap to make contact with the front side of the underbody cross sill and mark location of the hole (5) of the mud flap. 9.2. Center punch the marked location and drill a 5.159 mm (13/64 in) hole. 9.3. Install the screw. Tighten Tighten the screw to 4 N.m (35 lb in). 9.4. Repeat the above steps for hole location 6. 10. Repeat the above steps for the opposite side. Parts Information Parts are expected to be available from GMSPO on June 30, 2004. Warranty Information Please advise the customer that the mud flaps can be purchased as an accessory. Installation and/or cost of the mud flaps will not be covered under the vehicle's warranty. Disclaimer Page 13872 Diagram Information and Instructions Information Bus: Diagram Information and Instructions Truck Zoning TRUCK ZONING Truck Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that corresponds to where they are located in the vehicle. The table explains the numbering system. Vehicle Speed Sensor (VSS) Vehicle Speed Sensor: Diagrams Vehicle Speed Sensor (VSS) Page 4381 1. Install the CKP sensor. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the CKP sensor bolt. Tighten Tighten the bolt to 25 N.m (18 lb ft). 3. Connect the CKP sensor electrical connector. 4. Install the starter. 5. Perform the CKP system variation learn procedure. See: Testing and Inspection/Programming and Relearning Page 1018 6. Push down the flex lock button (3) and slide the connector locking cover (4) to the close position. 7. Install the connector position assurance (CPA) (1) to the inflatable restraint sensing and diagnostic module (SDM) wiring harness connector (2). 8. Position the carpet to cover the inflatable restraint sensing and diagnostic module (SDM). 9. Install the door sill plate. 10. Install the driver seat. IMPORTANT: The AIR BAG indicator may remain ON after the SDM has been replaced. DTC B1001 may set requiring the SDM part number to be set in multiple modules. If the indicator remains ON after enabling the SIR system, perform the diagnostic system check and follow the steps thoroughly to ensure that the SDM is set properly. 11. Enable the SIR system. Refer to SIR Disabling and Enabling Zone 7. Page 9859 4. Connect the wiring connectors to the fuse block. Refer to Electrical Center Identification Views to ensure the right connections are made. 5. Install the right side end panel. Page 13683 Front Door Window Glass Weatherstrip: Service and Repair Door Window Sealing Strip Sealing Strip Replacement - Front Door Window Belt Outer - Front Removal Procedure Important: The outer belt sealing strip seals between the inner and outer door panels and the window at the belt line. The outer sealing strip is replaceable. Do not remove the inner sealing strip, because the strip is attached to the glass run channel. 1. Lower the window. 2. Remove the outside mirror. 3. Remove the outer sealing strip from the door, lifting up on the forward end in order to unhook the rear of the strip from the window run channel. Installation Procedure 1. Hook the rear end of the sealing strip into the window run channel. Lower and press the strip into place. 2. Install the outside mirror. 3. Raise the window. Page 7427 2. Connect the front speed sensor electrical connector (5). 3. Install the transfer case shield, if equipped. Transfer Case Speed Sensor Replacement - Left Rear Transfer Case Speed Sensor Replacement - Left Rear Removal Procedure 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. Disconnect the left rear speed sensor electrical connector (4). 3. Remove the left rear speed sensor. Installation Procedure Locations Driver Door Page 13631 1. Install the handle to the vehicle. 2. If the lock cylinder is a replacement, apply a coating of GM P/N 12345120 or Canadian P/N 726548 or a similar lubricant to the inside of the lock case and the cylinder keyway. 3. Install the door lock cylinder to the outside handle housing. In order to code a new lock cylinder. 4. Install the lock cylinder clip to the lock cylinder rod. 5. Install the handle rod to the handle assembly clip. 6. Remove masking tape from door handle. Notice: Refer to Fastener Notice in Service Precautions. 7. Install the outside handle mounting nuts. Tighten the nuts to 9 N.m (80 lb in). 8. Install the rubber cover. 9. Install the water deflector. 10. Install the trim panel. Page 9085 Fuse Block - Underhood - Secondary Wire Entry (With RPO Code HP2) Part 2 Page 5999 5. Compress the reverse boost valve sleeve into the bore of the oil pump to expose the retaining ring slot. 6. Install the reverse boost valve retaining ring, then slowly release tension on the reverse boost valve sleeve. 7. Install the transmission filter. Service and Repair Air Bag(s) Arming and Disarming: Service and Repair SIR Disabling and Enabling The SIR Identification Views shown below illustrate the approximate location of all SIR components available for the vehicle. This will assist in determining the appropriate SIR Disabling and Enabling for a given service procedure. Refer to See: Restraint Systems/Air Bag Systems/Locations/SIR Zone Identification Views There are several reasons for disabling the SIR system, such as repairs to the SIR system or servicing a component near or attached to an SIR component. There are several ways to disable the SIR system depending on what type of service is being performed. The following information covers the proper procedures for disabling/enabling the SIR system. SIR Service Precautions Caution: When performing service on or near the SIR components or the SIR wiring, the SIR system must be disabled. Failure to observe the correct procedure could cause deployment of the SIR components. Serious injury can occur. Failure to observe the correct procedure could also result in unnecessary SIR system repairs. The inflatable restraint sensing and diagnostic module (SDM) maintains a reserved energy supply. The reserved energy supply provides deployment power for the air bags if the SDM loses battery power during a collision. Deployment power is available for as much as 1 minute after disconnecting the vehicle power. Waiting 1 minute before working on the system after disabling the SIR system prevents deployment of the air bags from the reserved energy supply. General Service Instructions The following are general service instructions which must be followed in order to properly repair the vehicle and return it to its original integrity: - Do not expose inflator modules to temperatures above 65°C (150°F). - Verify the correct replacement part number. Do not substitute a component from a different vehicle. - Use only original GM replacement parts available from your authorized GM dealer. Do not use salvaged parts for repairs to the SIR system. Discard any of the following components if it has been dropped from a height of 91 cm (3 feet) or greater: - Inflatable restraint sensing and diagnostic module (SDM) - Any Inflatable restraint air bag module - Inflatable restraint steering wheel module coil - Any Inflatable restraint sensor - Inflatable restraint seat belt pretensioners - Inflatable restraint Passenger Presence System (PPS) module or sensor Disabling Procedure - Air Bag Fuse 1. Turn the steering wheel so that the vehicles wheels are pointing straight ahead. 2. Place the ignition in the OFF position. Important: The SDM may have more than one fused power input. To ensure there is no unwanted SIR deployment, personal injury, or unnecessary SIR system repairs, remove all fuses supplying power to the SDM. With all SDM fuses removed and the ignition switch in the ON position, the AIR BAG warning indicator illuminates. This is normal operation, and does not indicate a SIR system malfunction. 3. Locate and remove the fuse(s) supplying power to the SDM. Page 4858 3. If equipped with a 6.0L engine, connect the HO2S electrical connector (1). 4. If equipped with a 4.8L or 5.3L engine, connect the HO2S electrical connector (1). 5. Install the HO2S electrical connector to the fuel line clip. 6. Disconnect the CPA retainer. 7. If necessary, bolt the front propeller shaft to the front differential. Refer to Propeller Shaft Replacement - Front in Propeller Shaft. 8. Lower the vehicle. Page 15558 Backup Lamp Switch: Service and Repair ZF S6-650 Backup Lamp Switch Replacement Removal Procedure 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. If equipped with a 6.6L engine, disconnect the backup lamp switch electrical connector (3). 2. If equipped with a 8.1L engine, disconnect the backup lamp switch electrical connector (4). 3. Remove the backup lamp switch. Installation Procedure Fuel Level Sensor Replacement - 1 Fuel Gauge Sender: Service and Repair Fuel Level Sensor Replacement - 1 FUEL LEVEL SENSOR REPLACEMENT REMOVAL PROCEDURE 1. Remove the sending unit. 2. Disconnect the fuel pump electrical connector. 3. Remove the fuel lever sensor electrical connector retaining clip. 4. Disconnect the fuel level sensor electrical connector. 5. Remove the fuel level sensor retaining clip. 6. Remove the fuel level sensor (1). INSTALLATION PROCEDURE 1. Install the fuel level sensor (1). 2. Install the fuel level sensor retaining clip. 3. Connect the fuel level sensor electrical connector. 4. Install the fuel lever sensor electrical connector retaining clip. 5. Connect the fuel pump electrical connector. 6. Install the sending unit. Page 4786 1. If installing the old sensor, coat the threads with sealant GM P/N 12346004 (Canadian P/N 10953480) or equivalent. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the ECT sensor. Tighten Tighten the sensor to 20 N.m (15 lb ft). 3. Connect the ECT sensor electrical connector (5). 4. Refill the cooling. Refer to Draining and Filling Cooling System in Cooling System. Page 3586 coolant system integrity and will no longer be considered a 5 yr/150,000 mile (240,000 km) coolant. Coolant Removal Services/Recycling The tables include all coolant recycling processes currently approved by GM. Also included is a primary phone number and demographic information. Used DEX-COOL(R) can be combined with used conventional coolant (green) for recycling. Depending on the recycling service and/or equipment, it is then designated as a conventional 2 yr/30,000 mile (50,000 km) coolant or DEX-COOL(R) 5 yr/150,000 mile (240,000 km) coolant. Recycled coolants as designated in this bulletin may be used during the vehicle(s) warranty period. DEX-COOL(R) Recycling The DEX-COOL(R) recycling service listed in Table 2 has been approved for recycling waste engine coolants (DEX-COOL) or conventional) to DEX-COOL(R) with 5 yr/150,000 mile (240,000 km) usability. Recycling Fluid Technologies is the only licensed provider of Recycled DEX-COOL(R) meeting GM6277M specifications and utilizes GM approved inhibitor packages. This is currently a limited program being monitored by GM Service Operations which will be expanded as demand increases. Conventional (Green) Recycling Drivetrain - Updated Transfer Case Speed Sensor Conn. Speed Sensor: All Technical Service Bulletins Drivetrain - Updated Transfer Case Speed Sensor Conn. Bulletin No.: 06-04-21-001 Date: May 17, 2006 INFORMATION Subject: Updated Transfer Case Connector Service Kit Now Available For Transfer Case Speed Sensor Wire Harness Connector that Comes Loose Or Connector Retainer Clip Breaks Models: 2007 and Prior GM Light Duty Trucks 2007 and Prior HUMMER H2, H3 2005-2007 Saab 9-7X with Four-Wheel Drive or All-Wheel Drive Technicians may find that when the transfer case speed sensor wire harness connector is removed, the connector lock flexes/bends and does not return to the original position. The transfer case speed sensor wire harness connector then has no locking device. On older vehicles, the plastic connector retainer becomes brittle and the clip may break as soon as it is flexed. In the past, the only service fix was to install a wire harness connector service pack, P/N 88987183. This repair procedure involved splicing a new service connector with an integral connector lock. This connector service kit is of the same design and was still prone to failure over time. A new connector service repair kit is now available, P/N 15306187, that is an updated design. This new kit should be used whenever the speed sensor wire harness connector requires replacement. Parts Information Disclaimer Page 9615 Application Table Part 2 Page 2649 Fuse Block - Underhood C2 Part 5 Page 1401 3. Disconnect the vent valve pipe quick connect from the canister. 4. Either cut the existing valve vent pipe and leave the remaining section of pipe in the vehicle or remove along with the valve. 5. Push in the retainer and remove the existing canister vent valve from the fuel tank clip or mounting bracket. 6. Cut back the existing canister pipe approximately 51 mm (2 in) and retain the pipe for use with new valve. 7. Connect the canister pipe quick connect to the canister. 2500 Crew Cab Short Box Shown Below, Other Configurations Similar 1500 Extended Cab Short Box Shown Below, Other Configurations Similar 8. Install the new canister vent valve solenoid to the fuel tank clip or mounting bracket as shown above. The valve port closest to the electrical connector must point towards the canister. 9. Cut bulk 5/8" heater hose to a length of approximately 76 mm (3 in). Install the hose between the solenoid and the canister pipe and secure using clamps. 10. Attach bulk 5/8" heater hose to the vent port and secure using a clamp. Run a length as needed along the frame rail routing to the passenger side area above the transmission. 11. Cut the hose to determined length and install the supplied filter box. Secure using a clamp. 12. Remove the transmission heat shield, if necessary. 13. Remove the transmission support and lower the transmission assembly as necessary to allow for access to the new filter box location. 14. Secure the filter box to the transmission vent hose just forward of the hose tee-section using a tie strap. DO NOT pinch or restrict the transmission vent hose. The filter box opening should be pointing downward. 15. Raise the transmission and reinstall the transmission support. 16. Reinstall the transmission heat shield. 17. Connect the EVAP canister vent valve electrical connector. 18. Tie strap the hose as needed along the frame rail in order to keep the hose away from pinch-points and heat sources. 19. Lower the vehicle. Parts Information Page 10442 2. Install the spring bumper. For 4WD 15-Series and 2WD 25/35-Series. 3. Install the nut to the spring bumper stud. ^ Tighten the nut to 30 Nm (22 ft. lbs.). Notice: Refer to Fastener Notice in Service Precautions. 4. Remove the safety stands. 5. Lower the vehicle. Page 6898 7. Important: When removing the axle shaft do not rotate the shaft. Rotating the shaft will cause the gears to move. Misalignment of the gears will make the assembly difficult. Remove the axle shaft. Installation Procedure 1. Install the axle shaft. 2. Install the spring loaded lock clip to the axle shaft end. 3. Install the steering knuckle assembly. 4. Install the rear steering gear assembly. 5. Install the tire and wheel assembly. 6. Lower the vehicle. Page 1988 Power Window Switch: Diagnostic Aids Basic Knowledge Required BASIC KNOWLEDGE REQUIRED Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the Service Data. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories CHECKING AFTERMARKET ACCESSORIES Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: - Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions INDUCING INTERMITTENT FAULT CONDITIONS In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: - Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. Page 3985 1. Locate the air flow direction arrow (2) on the MAF/IAT sensor. 2. Install the MAF/IAT sensor to the air cleaner assembly. NOTE: Refer to Fastener Notice in Service Precautions. 3. Tighten the MAF/IAT clamp. Tighten Tighten the clamp to 7 N.m (62 lb in). 4. Connect the MAF/IAT sensor electrical connector (4). 5. Push in the gray CPA retainer. 6. Install the air cleaner outlet duct. Page 9830 Junction Block - I/P Wire Entry Part 4 Testing and Inspection Ignition Relay: Testing and Inspection IGNITION RELAY DIAGNOSIS CIRCUIT DESCRIPTION The ignition relay is a normally open relay. The relay armature is held in the open position by spring tension. When the ignition switch is turned to the run or start position, current will flow through the relay coil. A wire connected to the other end of the relay coil completes the path to ground. The electromagnetic field created by the relay coil, overcomes the spring tension and moves the armature allowing the relay contacts to close. The closed relay contacts allow current to flow from the battery to the following fuses: PCM 1 - ETC/ECM - INJ 1 - INJ 2 - SBA, if equipped. When the ignition switch is turned to the OFF position, the electromagnetic field collapses. This action allows the spring tension to move the armature away from the relay contacts, which interrupts current flow to the fuses. If the ignition relay fails to close, the engine will crank, but will not run. The class 2 communications will be available with the use of a scan tool. The ignition relay table assumes that the vehicle battery is fully charged. TEST Page 3384 3. Install the oil filter. ^ Tighten the oil filter to 30 Nm (22 ft. lbs.). 4. Refill the engine oil. Refer to Capacities - Approximate Fluid and/or Fluid and Lubricant Recommendations. Page 14314 WA931L/68 - WA9417/88 Page 13623 4. Align the outboard air inlet grille panel clips and press down in order to install. 5. Install the wiper arms. Page 7479 Case: Service and Repair Transfer Case - NVG 261-NP2 Transfer Case Shield Replacement Removal Procedure 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. If the vehicle is a 1500 series, remove the transfer case shield bolts, if equipped. 3. Remove the transfer case shield, if equipped. 4. If the vehicle is a 2500 series, remove the transfer case shield screws, if equipped. 5. Remove the transfer case shield, if equipped. Installation Procedure 1. If the vehicle is a 2500 series, position the transfer case shield, if equipped. 2. Install the transfer case shield screws. Locations Fuel Pump And Sender Assembly Components Page 9710 C115 Chassis Harness To I/P Harness (With RPO Code NYS) Part 2 Page 8626 3. Remove the master cylinder nuts. Do not remove the pipes from the master cylinder. Position the master cylinder away from the booster head. Secure the master cylinder in an upright position. 4. Disconnect the power brake booster inlet hose, the steering gear inlet hose, and the power brake booster outlet hose from the booster assembly. 5. Remove the booster pump rod retainer from the lever. 6. Remove the stop lamp switch from the lever. 7. Remove the booster pump rod from the lever. 8. Remove the nuts at the booster. 9. Remove the booster assembly. Installation 1. Install the booster assembly to the vehicle. 2. Install the nuts at the booster. Page 10430 Suspension Strut / Shock Absorber: Specifications Shock Absorber Tension Nut (4WD) ....................................................................................................................................................... 20 Nm (15 ft. lbs.) Shock Absorber to Lower Control Arm Bolts (2WD) .............................................................................................................................. 25 Nm (18 ft. lbs.) Shock Absorber to Lower Control Arm Nut (4WD) ................................................................................................................................ 80 Nm (59 ft. lbs.) Page 1903 Transmission Speed Sensor: Service and Repair Output Shaft Speed Sensor Replacement Output Shaft Speed Sensor Replacement Removal Procedure Important: This procedure is for 2-wheel drive (2WD) vehicles only. If the vehicle is equipped with 4-wheel drive (4WD), the output speed sensor is located on the transfer case. 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. Disconnect the output speed sensor (2) electrical connector. 3. Remove the output speed sensor bolt. 4. Remove the output speed sensor (2). 5. Inspect the output speed sensor (2) for any evidence of damage. Installation Procedure Page 14454 Memory Positioning Module: Service and Repair Memory Seat Control Module Replacement MEMORY SEAT CONTROL MODULE REPLACEMENT REMOVAL PROCEDURE 1. Remove the seat cushion. 2. Disconnect the upper electrical harness connectors (3). 3. Remove the module (2) retaining screws (1). 4. Slide the module to the right to disengage the lower retainers. 5. Disconnect the lower electrical harness connectors (2). 6. Remove the module from the vehicle. INSTALLATION PROCEDURE Aluminum Wheel Porosity Repair Wheels: Service and Repair Aluminum Wheel Porosity Repair Aluminum Wheel Porosity Repair 1. Remove the tire and wheel. 2. Inflate the tire to the manufactures specified pressure as stated on the tire. 3. Submerge the tire/wheel into a water bath in order to locate the leak. 4. Inscribe a mark on the wheel in order to indicate the leak areas. 5. Inscribe a mark on the tire at the valve stem in order to Indicate the orientation of the tire to the wheel. 6. Remove the tire from the wheel. 7. Use number 80 grit sandpaper to scuff the inside of the rim surface at the leak area. Important: Do not damage the exterior surface of the wheel. 8. Use general purpose cleaner such as 3M®, P/N 08984 or equivalent, to clean the leak area. 9. Apply 3 mm (0.12 inch) thick layer of adhesive/sealant, GM P/N 12378478 (Canadian P/N 88900041) or equivalent, to the leak area. 10. Allow for the adhesive/sealant to dry. 11. Align the inscribed mark on the tire with the valve stem on the wheel. 12. Install the tire to the wheel. 13. Inflate the tire to the manufactures specified pressure as stated on the tire. 14. Submerge the tire/wheel into a water bath in order ensure the leak is sealed. 15. Balance the tire and wheel. 16. Install the tire and wheel. 17. Lower the vehicle. Page 4805 5. Remove the fuel level sensor retaining clip. 6. Remove the fuel level sensor. INSTALLATION PROCEDURE 1. Install the fuel level sensor. Page 7221 Electrical Symbols Part 13 Page 11307 - Proof of ownership at time of repair. - Original paid receipt confirming the amount of unreimbursed repair expense(s) (including Service Contract deductibles), a description of the repair, and the person or entity performing the repair. If the work was done by someone other than a GM dealership, the amount of reimbursement will be limited to the amount that the repair would have cost GM to have it completed by a GM dealership. Courtesy Transportation The General Motors Courtesy Transportation program is intended to minimize customer inconvenience when a vehicle requires a repair that is covered by the New Vehicle Limited Warranties. The availability of courtesy transportation to customers whose vehicles are within the warranty coverage period and involved in a product program is very important in maintaining customer satisfaction. Dealers are to ensure that these customers understand that shuttle service or some other form of courtesy transportation is available and will be provided at no charge. Dealers should refer to the General Motors Service Policies and Procedures Manual for Courtesy Transportation guidelines. Warranty Transaction Information Submit a transaction using the table below. * The amount identified in "Net Item" should represent the dollar amount reimbursed to the customer. Disclaimer Page 543 ^ Reinstall the fuse and fuse panel cover. ^ Press the "Enter" button to perform the "Refresh" function. ^ "Test in Progress" will be displayed and the right front passenger door lock will cycle once. ^ The screen will display "Procedure Completed". ^ Press the "Exit" button as necessary to return to the main menu screen. 3. Using the switches in the right front passenger door, verify that the power window and power door lock located in that door function properly. Important: The calibrations required for performing SPS reprogram in the next step are based on the type of exterior rearview mirror the vehicle has. To determine the correct calibration, check the Service Parts Identification Label on the vehicle for the RPO code for exterior mirrors. 4. Follow normal Service Programming System (SPS) to reprogram the passenger door module with the current calibration available in TIS 2000. 5. After reprogramming is complete, using the switches in the right front passenger door, verify that the power window and power door lock located in that door function properly. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 11802 Antenna Cable: Service and Repair Coaxial Cable Replacement - Digital Radio (Primary) COAXIAL CABLE REPLACEMENT - DIGITAL RADIO (PRIMARY) REMOVAL PROCEDURE 1. Remove the windshield pillar garnish molding. 2. Disconnect the XM radio antenna cable (1). NOTE: Use care when removing or installing the headliner. Excessive bending will damage the headliner. 3. Lower the front of the headliner. 4. Disconnect the XM antenna cable from the antenna connection above the headliner. 5. Remove the cable clips from the windshield pillar and remove the antenna cable from the vehicle. INSTALLATION PROCEDURE Page 8401 6. Remove the bolt from the rear axle clip. 7. Remove the cable from the differential clip. 8. Remove the cable from the mounting bracket by depressing the locking tabs. 9. Perform the following procedure to remove the cable (2) from the backing plate (4): 1. Compress the spring (3) by pushing towards the lever (1). 2. Depress the locking tabs. 3. Pull the cable housing out of the backing plate (4). 4. Remove the cable (2) through the slot in the backing plate. 10. Remove the park brake cable (2) from the lever (1). 11. Remove the cable from the vehicle. Installation Procedure 1. Install the cable to the vehicle. Page 13041 switch lighting connector. 3.3. Undo the floor console's retaining bolts (C). 3.4. Take out the rear ashtray/cover (D). 3.5. Remove the screw (E) for the rear cover. 3.6. Remove the floor console's retaining nuts (E). 3.7. Detach the floor console (G) by pulling it straight back and lifting it slightly. 3.8. If required, detach the switch for the rear seat heater and unplug the connector. 4. Remove the switch and the floor console: 4.1. Detach the window lift module (A) by loosening it in the front edge (snap fastener). Unplug the window lift module's connector. 4.2. Detach the switch for the roof lighting (B) and unplug its connector. Lift away the floor console. 5. Pry out the signal line from the SRS control module to the OnStar(R) control module and secure it: 5.1. Unplug the SRS control module's connector (A). Page 15989 Steps 1-6 Page 3723 Install the new heat shield (see parts list below) onto the muffler as shown above. Install three straps, P/N 10391259, so that the strap screw head will be located on top of the muffler. Tighten Tighten the strap screw to 4 N.m (35 lb in). Cut off the excess strap material and bend the strap over the strap screw head as indicated above. Remove the exhaust pipe clamp. ONLY 6.0L and 8.1L equipped vehicles require a new exhaust pipe clamp, P/N 15103174. On 6.0L and 8.1L equipped vehicles only, install a new exhaust pipe clamp, P/N 15103174, on the exhaust pipe. Reposition the muffler in the correct position. Slide the muffler forward into position, aligning the studs with the rear of the catalytic converter. Install the nuts securing the muffler to the catalytic converter, but DO NOT tighten at this time. Apply a soapy solution to the following areas in order to ease the installation of the hangers. The inner diameter of the exhaust pipe hanger The exhaust pipe hanger rod Press the exhaust pipe hangers over the exhaust pipe hanger rods. Tighten Tighten the muffler nuts by hand until each contacts the metal flange. Tighten the muffler nuts to 45 N.m (33 lb ft). On 6.0L and 8.1L equipped vehicles only, tighten the exhaust clamp to 50 N.m (36 lb ft). Page 13578 Body Control Module: Removal and Replacement BODY CONTROL MODULE REPLACEMENT REMOVAL PROCEDURE CAUTION: Refer to Battery Disconnect Caution in Service Precautions. 1. Disconnect the negative battery cable(s). 2. Remove the knee bolster. 3. Disconnect the brown connector. 4. Disconnect all other connectors (1). 5. Remove the BCM from the sliding bracket. INSTALLATION PROCEDURE Page 10122 8. Disconnect the differential vent hose (1) from the vent tube (2). 9. Remove the bolts retaining the steering gear actuator and cover (2) to the differential (1). 10. Remove the steering gear actuator and cover from the vehicle. Installation Procedure 1. Important: Clean all of the sealing surfaces prior to installing the gasket. Do not reinstall the old gasket, replace the gasket whenever the actuator is removed from the axle. Install the steering gear actuator (2) and gasket (1) to the differential. 2. Notice: Refer to Fastener Notice in Service Precautions. Page 1735 Camshaft Position (CMP) Sensor Service and Repair Cabin Ventilation Grille: Service and Repair Pressure Relief Valve Replacement Removal Procedure Use a flat-bladed tool to pry the pressure release valve from the cab back panel. Remove the pressure relief valve from the vehicle. Installation Procedure Align the pressure relief valve into the opening of the rear cab. Press the Pressure Relief Valve into the Cab Back Panel until the locking tabs are fully seated. Page 6927 6. Using side cutters, remove the small boot retaining clamp. 7. Remove the following items from the halfshaft bar: 1. The spacer ring (1) 2. The tripot spider assembly (2) 3. The tripot boot (3) 8. Clean the halfshaft bar (4). Use a wire brush in order to remove any rust in the seal mounting area (grooves). 9. Inspect the needle rollers, needle bearings, and trunnion. Inspect the tripot housing for unusual wear, cracks, or other damage. Replace any damaged parts with the appropriate service kit. Assembly Procedure Page 9028 Fuse Block- I/P C1 Part 2 Page 2008 If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Sir/SRS Wiring Repairs SIR/SRS WIRING REPAIRS TOOLS REQUIRED J 38125-D Terminal Repair Kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-D contains the following items: - Special sealed splices - in order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping tool - A heat torch - An instruction manual The sealed splices have the following 2 critical features: - A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-D also serves as a generic terminal repair kit. The kit contains the following items: - A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors Page 5949 Page 15990 Steps 7-10 Steps 1-4 Locations Crankshaft Position (CKP) Sensor Location Drivetrain - Transfer Case Control Module Replacement Control Module: All Technical Service Bulletins Drivetrain - Transfer Case Control Module Replacement Bulletin No.: 05-04-21-002 Date: March 10, 2005 INFORMATION Subject: Guidelines for Replacement of Transfer Case Control Module (TCCM) Models: 2005 and Prior Light Duty Trucks with New Venture Gear (NVG) Transfer Case (RPOs NP1, NP4, NP8) Dealers are replacing the TCCM unnecessarily. Dealers are replacing the TCCM with codes stored in HISTORY only. The TCCM does not have a current fault condition when tested. Parts reviewed at the Warranty Parts Center (WPC) have a 75% No Trouble Found (NTF) rate. The only two legitimate reasons to replace the TCCM are: ^ Diagnostic Trouble Code (DTC) C0550 ^ NO Communication with a scan tool. DTC C0550 This DTC indicates that the module has an internal fault and should be replaced. No Communication ^ The no communication conditions referenced here are also caused by a module internal fault to a point where the module physically will not talk. A technician cannot pull DTCs from the module because it will not communicate. The module is electrically dead. ^ No communication is not to be confused with a U1026 code. This code tells the technician that the module may still be functioning but is temporarily off line. This code may be set by the Instrument Panel (IP) or the Powertrain Control Module (PCM) against the TCCM. The technician needs to figure out why the module went off line. These are typically caused by connection concerns. There is no need to replace a TCCM for a U1026 DTC. Diagnostic Aids ^ When diagnosing a transfer case electrical control system, ALWAYS check power and ground wiring first. ^ Test the connections for intermittent or poor connections, complete plug insertion, bent pins, pushed out terminals and water contamination. Page 11171 5. Install the air cleaner outlet duct. 6. Install the radiator inlet hose clip to the outlet duct. NOTE: Refer to Fastener Notice in Service Precautions. 7. Tighten the air cleaner outlet duct clamps at the following locations: - Throttle body - MAF/IAT sensor Tighten Tighten the screws to 7 N.m (62 lb in). 8. Fill the cooling system. Refer to Draining and Filling Cooling System (with HP2)Draining and Filling Cooling System (without HP2) in Cooling System. Page 882 When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage TESTING FOR A SHORT TO VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity TESTING FOR CONTINUITY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents TESTING FOR ELECTRICAL INTERMITTENTS Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground - Testing for Continuity - Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 msRECORD and emits an audible tone (beep). Page 8698 Traction Control Switch: Diagrams ABS Connector End Views Traction Control Switch (NW7) Page 14356 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors USING CONNECTOR TEST ADAPTERS IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-B Connector Test Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Page 8288 Brake Caliper: Service and Repair Brake Caliper Overhaul - Rear Brake Caliper Overhaul - Rear (15 Series) Caution: Refer to Brake Dust Caution in Service Precautions. Caution: Refer to Brake Fluid Irritant Caution in Service Precautions. Disassembly Procedure Important: ^ Replace all the components included in the repair kits used to service this brake caliper. ^ Lubricate the rubber parts with clean brake fluid to make assembly easier. ^ The torque values specified are for dry, non lubricated fasteners. ^ Perform the service operations on a clean bench free from all mineral oil materials. 1. Remove the brake caliper from the vehicle. 2. Caution: Do not place your fingers in front of the piston in order to catch or protect the piston while applying compressed air. This could result in serious injury. Place a thin piece wood in front of the piston in order to prevent damage. Remove the piston by directing compressed air into the brake hose inlet fitting port of the brake caliper housing. 3. Remove the piston boot. 4. Remove the piston seal. 5. Remove the brake caliper bleed screw cap. 6. Remove the brake caliper bleed screw. 7. Inspect the brake caliper bore and the piston seal groove for scoring and corrosion. If you find excessive scoring or corrosion around the piston seal area, replace the brake caliper housing. Page 886 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly, Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Pull to Seat Connectors PULL TO SEAT CONNECTORS TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Page 6487 2. Remove the transmission from the vehicle. Refer to the appropriate SI document. Important: ^ Inspect all the transmission components for damage or wear. Replace all damaged or worn components. The parts shown above should be sufficient to correct this concern. ^ This condition does not normally require replacement of the transmission completely. Components such as clutches, valve body, pump and torque converters will NOT require replacement to correct this condition. Disassemble the transmission and replace the appropriate parts listed below. Refer to the Unit Repair Manual - Repair Instructions. 3. Reinstall the transmission in the vehicle. Refer to appropriate service information. When servicing the transmission as a result of this condition, the transmission oil cooler and lines MUST be flushed. Refer to Corporate Bulletin Number 02-07-30-052. Page 12684 ^ I/O check Any faults detected during the initialization self-test shall generate a DTC. All nodes also continuously perform a self-test while in an active state. DTCs and their associated telltales will set as a result of unprogrammed or unlearned information. DTCs, which are defined for system configuration (e.g. Vehicle Option Content not programmed) do not support the history status bit (set =0). Warning indicator bit is also set, when applicable, while this DTC is present. Action Taken When the DTCs Sets The module suspends all message transmission. The module uses default values for all parameters received on the serial data circuits. The module inhibits the setting of all other communication DTCs. Conditions for Clearing the DTC A current DTC clears when the malfunction is no longer present. A history DTC clears when the module ignition cycle counter reaches the reset threshold of 50, without a repeat of the malfunction. Circuit/System Verification Refer to Data Link References to determine which serial data system is used for a specific module. The DTCs cannot be retrieved with a current status. Diagnosis is accomplished using the following symptom procedures: Scan Tool Does Not Communicate with High Speed GMLAN Device in SI. OR Scan Tool Does Not Communicate with Low Speed GMLAN Device in SI. DTC U1300, U1301, or U1305 Circuit Description Modules connected to the Class 2 serial data circuit monitor for serial data communications during normal vehicle operation. Operating information and commands are exchanged among the modules. In addition to this, Node Alive messages are transmitted by each module on the Class 2 serial data circuit about once every 2 seconds. When the module detects one of the following conditions on the Class 2 serial data circuit for approximately 3 seconds, the setting of all other Class 2 serial communication DTCs is inhibited and a DTC will set. Conditions for Running the DTCs Voltage supplied to the module is in the normal operating voltage range. The vehicle power mode requires serial data communication to occur. Conditions for Setting the DTCs No valid messages are detected on the Class 2 serial data circuit. The voltage level detected on the Class 2 serial data circuit is in one of the following conditions: Brakes - ABS Lamp ON/DTC's C0265/C0201/U1041 Set Electronic Brake Control Module: Customer Interest Brakes - ABS Lamp ON/DTC's C0265/C0201/U1041 Set TECHNICAL Bulletin No.: 04-05-25-002E Date: March 11, 2009 Subject: ABS Light On, DTCs C0265, C0201, U1041 Set and/or Loss of Communication with Brake Module (Reground EBCM Ground) Models Supercede: This bulletin is being revised to add step 2 to the procedure and update the Parts and Warranty Information. Please discard Corporate Bulletin Number 04-05-25-002D (Section 05 - Brakes). Condition Some customers may comment that the ABS light is on. Upon further inspection, DTCs C0265 and C0201 may be set in the brake module. It is also possible for DTC U1041 to set in other modules. There may also be a loss of communication with the brake module. Cause A poor connection at the EBCM ground is causing unnecessary replacement of brake modules. Important: The EBCM ground is different for each application. Refer to the list below for the proper ground reference: ^ Midsize Utilities = Ground 304 ^ SSR = Ground 400 ^ Fullsize Trucks and Utilities = Ground 110 Correction Important: Do not replace the brake module to correct this condition. Perform the following repair before further diagnosis of the EBCM. Perform the following steps to improve the connection of the EBCM Ground: 1. Remove the EBCM Ground. The EBCM Ground is located on the frame beneath the driver's side door. If multiple grounds are found in this location, the EBCM ground can be identified as the heavy (12-gauge) wire. 2. If the original fastener has a welded on nut, remove the nut from the frame, and if required, enlarge the bolt hole to accommodate the new bolt and nut. 3. Clean the area, front and back, using a tool such as a *3M(TM) Scotch-Brite Roloc disc or equivalent. Page 1164 Power Seat Switch: Diagrams Seat Adjuster Switch - Driver (With RPO Code AN3) Part 1 Page 5050 Put unused material on the shelf for future use. Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Page 12688 Conditions for Running the DTC Ignition is in RUN or ACC position System voltage is between 9.5 - 15.5 volts. The above conditions are met for more than 1 second. Conditions for Setting the DTC The VCIM does not detect the presence of a cellular antenna for more than 1 second. Action Taken When the DTC Sets The vehicle is unable to connect to the OnStar(R) Call Center. The OnStar(R) status LED turns red. Conditions for Clearing the DTC The VCIM detects the presence of a cellular antenna. A history DTC clears after 50 malfunction-free ignition cycles. Circuit/System Testing Perform a visual inspection as shown above in order to verify that the cellular antenna and the cellular antenna coupling assembly are not damaged. If any components are damaged replace the assembly. DTC B2476 or B2482 DTC Descriptors Input Shaft Speed Sensor Replacement Transmission Speed Sensor: Service and Repair Input Shaft Speed Sensor Replacement Input Shaft Speed Sensor Replacement Removal Procedure 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. Disconnect the input speed sensor electrical connector (1). 3. Remove the input speed sensor bolt. 4. Remove the input speed sensor (1). 5. Inspect the input speed sensor (1) for any evidence of damage. Installation Procedure Page 2376 coolant system integrity and will no longer be considered a 5 yr/150,000 mile (240,000 km) coolant. Coolant Removal Services/Recycling The tables include all coolant recycling processes currently approved by GM. Also included is a primary phone number and demographic information. Used DEX-COOL(R) can be combined with used conventional coolant (green) for recycling. Depending on the recycling service and/or equipment, it is then designated as a conventional 2 yr/30,000 mile (50,000 km) coolant or DEX-COOL(R) 5 yr/150,000 mile (240,000 km) coolant. Recycled coolants as designated in this bulletin may be used during the vehicle(s) warranty period. DEX-COOL(R) Recycling The DEX-COOL(R) recycling service listed in Table 2 has been approved for recycling waste engine coolants (DEX-COOL) or conventional) to DEX-COOL(R) with 5 yr/150,000 mile (240,000 km) usability. Recycling Fluid Technologies is the only licensed provider of Recycled DEX-COOL(R) meeting GM6277M specifications and utilizes GM approved inhibitor packages. This is currently a limited program being monitored by GM Service Operations which will be expanded as demand increases. Conventional (Green) Recycling Fender Replacement - Rear (Rear Dual Wheel) Rear Fender: Service and Repair Fender Replacement - Rear (Rear Dual Wheel) Fender Replacement - Rear (Rear Dual Wheel) Removal Procedure 1. Remove the upper molding rear retainer (1) from the fender. 2. Remove the upper molding from the fender. Use a flat-bladed tool in order to release the top molding retainers. 3. Remove the fuel filler neck from the vehicle, if necessary. 4. Remove the bolts from the front of the fender. 5. Remove the rear taillamp assembly from the vehicle. 6. Remove the bolts that retain the fender to the rear pillar. Remove the bolts through the taillamp opening. Page 11118 Discharge Air Temperature Sensor / Switch: Service and Repair Air Temperature Sensor Replacement - Upper Left AIR TEMPERATURE SENSOR REPLACEMENT - UPPER LEFT REMOVAL PROCEDURE 1. Remove the upper left air temperature sensor (2) from the air distributor duct (1). 2. Disconnect the electrical connector (3) from the upper left air temperature sensor (2). INSTALLATION PROCEDURE 1. Install the upper left air temperature sensor (2) to the air distributor duct (1). 2. Connect the electrical connector (3) to the upper left air temperature sensor (2). Page 6865 3. Install the pinion yoke.Align the marks made during removal. 4. Notice: Refer to Pinion Flange/Yoke Installation Notice in Service Precautions. Seat the pinion yoke onto the pinion shaft by tapping it with a soft-faced hammer until a few pinion shaft threads show through the yoke. 5. Install the washer and a new pinion nut. 6. Install the J 8614-01 onto the pinion yoke as shown. 7. Notice: Refer to Fastener Notice in Service Precautions. Important: If the rotating torque is exceeded, the pinion will have to be removed and a new collapsible spacer installed. ^ Tighten the pinion nut while holding the J 8614-01. ^ Tighten the nut until the pinion end play is just taken up. Rotate the pinion while tightening the nut to seat the bearings. 8. Measure the rotating torque of the pinion. Compare this measurement with the rotating torque recorded during removal. ^ Tighten the nut in small increments, as needed, until the rotating torque is 0.40-0.57 Nm (3-5 inch lbs.) greater than the rotating torque recorded during removal. 9. Once the specified torque is obtained, rotate the pinion several times to ensure the bearings have seated. Recheck the rotating torque and adjust if necessary. 10. Install the propeller shaft (3) to the pinion yoke (4). Align the reference marks made during removal. 11. Install the propeller shaft yoke retaining clamps and the bolts. ^ Tighten the propeller shaft yoke retaining clamp bolts to 25 Nm (18 ft. lbs.). Page 15235 Control Module References Part 1 Page 3789 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors USING CONNECTOR TEST ADAPTERS IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-B Connector Test Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Page 824 Junction Block - Rear Lamps - C4 Page 1879 Transmission Position Switch/Sensor: Adjustments Automatic Transmission - 4L80-E/4L85-E Park/Neutral Position Switch Adjustment Important: ^ The following procedure is for vehicles that have not had the park/neutral position (PNP) switch removed or replaced. If the switch has been removed or replaced, refer to Park/Neutral Position Switch Replacement for the proper adjustment procedure. ^ Apply the park brake. ^ The engine must start in the park (P) or neutral (N) positions only. ^ Check the PNP switch for proper operation. If adjustment is required, proceed as follows: 1. Place the shift lever in the neutral (N) position. 2. With an assistant in the drivers seat, raise and suitably support the vehicle. Refer to Vehicle Lifting. 3. Loosen the PNP switch bolts. 4. With the vehicle in neutral (N), rotate the PNP switch while the assistant attempts to start the engine. 5. Following a successful start, turn the engine off. 6. Notice: Refer to Fastener Notice in Service Precautions. Tighten the PNP switch bolts. ^ Tighten the bolts to 25 Nm (18 ft. lbs.). 7. Lower the vehicle. 8. Check the PNP switch for proper operation. The engine must start in the park (P) or neutral (N) positions only. 9. Replace the PNP switch if proper operation can not be achieved. Procedures Head Rest: Procedures Head Restraint Retainer Replacement - Front Seat HEAD RESTRAINT RETAINER REPLACEMENT - FRONT SEAT REMOVAL PROCEDURE 1. Slide up the seat back trim cover in order to gain access to the rear cardboard panel fasteners. Refer to Seat Back Cover and Pad Replacement Front. 2. Remove the panel fasteners. Pull back the panel in order to gain access to the bushings. 3. Remove the head restraint retainers from the seat back frame by squeezing the retaining tabs together at the base of the guide(s) and lifting up. INSTALLATION PROCEDURE Page 11996 Testing and Inspection Seat Belt Retractor: Testing and Inspection EMERGENCY LOCKING RETRACTORS CAUTION: Perform this test in an area clear of other vehicles or obstructions. Do not conduct this test on the open road. A large, empty parking lot is suitable. Failure to observe this precaution may result in damage to the vehicle and possible personal injury. 1. Fasten the seat belts, an assistant is needed when the retractor under test is not part of the driver seat belt. 2. Accelerate the vehicle slowly to 16 km/h (10 mph) and apply the brakes firmly. 3. Verify that the seat belt locks when braking firmly. 4. If the belt does not lock, proceed with the following steps. 4.1. Remove the seat belt retractor assembly. 4.2. Tilt the seat belt retractor slowly. 4.3. Ensure that the seat belt webbing can be pulled from the retractor at an inclination of 15 degrees or less and cannot be pulled from the retractor at an inclination of 60 degrees or more. 4.4. If the seat belt retractor does not operate as described, replace the retractor assembly. Page 10618 of vibration is normally felt more in the "seat of the pants" than the steering wheel. 5. Next, record the Hertz (Hz) reading as displayed by the EVA onto the tire data worksheet found at the end of this bulletin. This should be done after a tire break-in period of at least 16 km (10 mi) at 72 km/h (45 mph) or greater, in order to eliminate any possible tire flat-spotting. This reading confirms what the vehicle vibration frequency is prior to vehicle service and documents the amount of improvement occurring as the result of the various steps taken to repair. Completing the Steering Wheel Shake Worksheet below is required. A copy of the completed worksheet must be saved with the R.O. and a copy included with any parts returned to the Warranty Parts Center for analysis. A reading of 35 to 50 Hz typically indicates a first order propshaft vibration. If this is the situation, refer to Corporate Bulletin Number 08-07-30-044D. Generally, a reading between 10 and 20 Hz indicates a tire/wheel vibration and if this is the reading obtained, continue using this bulletin. If the tire 1st order vibration goes away and stays away during this evaluation, the cause is likely tire flat-spotting. Tire flat-spotting vibration may come and go at any speed over 72 km/h (45 mph) during the first 10 minutes of operation, if vibration continues after 10 minutes of driving at speeds greater than 72 km/h (45 mph), tire flat-spotting can be ruled out as the cause for vibration. 6. If flat-spotting is the cause, provide the explanation that this has occurred due to the vehicle being parked for long periods of time and that the nature of the tire is to take a set. Refer to Corporate Bulletin Number 03-03-10-007E: Information on Tire/Wheel Characteristics (Vibration, Balance, Shake, Flat Spotting) of GM Original Equipment Tires. 7. If the road test indicates a shake/vibration exists, check the imbalance of each tire/wheel assembly on a known, calibrated, off-car dynamic balancer.Make sure the mounting surface of the wheel and the surface of the balancer are absolutely clean and free of debris. Be sure to chose the proper cone/collet for the wheel, and always use the pilot bore for centering. Never center the wheel using the hub-cap bore since it is not a precision machined surface. If any assembly calls for more than 1/4 ounce on either rim flange, remove all balance weights and rebalance to as close to zero as possible. If you can see the vibration (along with feeling it) in the steering wheel (driving straight without your hands on the wheel), it is very likely to be a tire/wheel first order (one pulse per revolution) disturbance. First order disturbances can be caused by imbalance as well as non-uniformities in tires, wheels or hubs. This first order frequency is too low for a human to hear, but if the amplitude is high enough, it can be seen. If a vibration or shake still exists after balancing, any out of round conditions, of the wheel, and force variation conditions of the tire, must be addressed. Equipment such as the Hunter GSP9700 can address both (it is also a wheel balancer). Tire radial force vibration (RFV) can be defined as the amount of stiffness variation the tire will produce in one revolution under a constant load. Radial force variation is what the vehicle feels because the load (weight) of the vehicle is always on the tires. Although free runout of tires (not under load) is not always a good indicator of a smooth ride, it is critical that total tire/wheel assembly runout be within specification. Equipment such as the Hunter GSP9700 loads the tire, similar to on the vehicle, and measures radial force variation of the tire/wheel assembly. Note that the wheel is affecting the tire's RFV measurement at this point. To isolate the wheel, its runout must be measured. This can be easily done on the Hunter, without the need to set up dial indicators. If the wheel meets the runout specification, the tire's RFV can then be addressed. After measuring the tire/wheel assembly under load, and the wheel alone, the machine then calculates (predicts) the radial force variation of the tire. However, because this is a prediction that can include mounting inaccuracies, and the load wheel is much smaller in diameter than used in tire production, this type of service equipment should NOT be used to audit new tires. Rather, it should be used as a service diagnostic tool to minimize radial force variation of the tire/wheel assembly. Equipment such as the Hunter GSP9700 does an excellent job of measuring wheel runout, and of finding the low point of the wheel (for runout) and the high point of the tire (for radial force variation). This allows the tire to be matched mounted to the wheel for lowest tire/wheel assembly force variation. The machine will simplify this process into easy steps. The following assembly radial force variation numbers should be used as a guide: When measuring RFV and match mounting tires perform the following steps. Measuring Wheel Runout and Assembly Radial Force Variation Important The completed worksheet at the end of this bulletin must be attached to the hard copy of the repair order. - Measure radial force variation and radial runout. - If a road force/balancing machine is used, record the radial force variation (RFV) on the worksheet at the end of this bulletin. It may be of benefit to have the lowest RFV assembly to the front left corner. If the machine is not available and the EVA data suggests there is an issue, swap the tire and wheel assemblies from the front to the back. Re-check on the EVA and if the problem still exists, test another vehicle to find tires that do not exhibit the same frequency and swap those tires onto the subject vehicle. - If a runout/balancing machine is used, record the radial runout of the tire/wheel assemblies on the worksheet at the end of this bulletin. If one or more of the tire/wheel assemblies are more than.040 in (1.02 mm), match mount the tire to the wheel to get below.040 in (1.02 mm). For sensitive customers, readings of 0.030 inch (0.76 mm) or less are preferable, it may also be of benefit to have the lowest runout assembly to the front left corner. If the machine is not available and the EVA data suggests there is an issue, swap the tire and wheel assemblies from the front to the back. Re-check on the EVA and if the problem still exists, test another vehicle to find tires that do not exhibit the same frequency and swap those tires Fuel System - Cranks But No Start/Inaccurate Fuel Gauge Fuel Gauge Sender: Customer Interest Fuel System - Cranks But No Start/Inaccurate Fuel Gauge Bulletin No.: 04-08-49-018E Date: January 05, 2005 TECHNICAL Subject: Cranks But No Start, Stall, Inaccurate/Incorrect Fuel Gauge Reading, No Fuel, Vehicle is Out of Fuel and Fuel Gauge Reads Above Empty (Replace Fuel Level Sensor) Models: 2001-2004 Cadillac Trucks 1999-2004 Chevrolet and GMC Trucks with Gasoline Engine (VINs Z, X, V, T, U, N, G, 6, 8 - RPOs LU3, LR4, LM7, LQ4, LQ9, L59, L18,LK5 L52) Attention: Parts are currently available for vehicles with Variable Fuel (VIN Z - RPO L59) vehicles. Please refer to Corporate Bulletin Number 04-06-04-01 2B or newer for Variable Fuel (VIN Z - RPO L59) vehicles. Supercede: This bulletin is being revised to include information on the Chevrolet Colorado and the GMC Canyon. Please discard Corporate Bulletin Number 04-08-49-018D (Section 08 - Body and Accessories). Condition Some customers may comment on the vehicle stalling and will not restart, vehicle ran out of fuel, vehicle appears to be out of fuel but the fuel gauge reads above empty. The fuel gauge may read 1/4 tank. Cause Contamination on the fuel sending card may cause inaccurate/incorrect fuel gauge readings. Correction Follow the service procedure below for diagnosis and repair of this concern. 1. Confirm that the vehicle is actually out of fuel. ^ If the vehicle is not out of fuel but Engine Cranks but Does Not Run, refer to the appropriate Service Information. ^ If the vehicle is out of fuel and the gauge does not read empty, test the fuel gauge. Refer to the following information: - Fuel Gage Inaccurate or Inoperative Single Tank - Fuel Gage Inaccurate or Inoperative Dual Tanks - Fuel Gage Inaccurate or Inoperative Colorado and Canyon 2. If testing reveals that the fuel gauge is operating correctly, replace the fuel sensor assembly and auxiliary tank fuel level sensor if equipped. 3. Replace the fuel level sensor. Refer to the following appropriate service information: ^ Fuel Level Sensor Replacement 4.8L and 5.3L Engines ^ Fuel Level Sensor Replacement 6.0L Engine - Front Tank ^ Fuel Level Sensor Replacement 6.0L Engine - Rear Tank ^ Fuel Level Sensor Replacement 8.1L vehicles with Front Tank ^ Fuel Level Sensor Replacement 8.1 L vehicles with Rear Tank Page 14654 1. Remove the screws retaining the power seat switch bezel. 2. Disconnect the electrical connectors. 3. Remove the lumbar support switch. 4. Remove the power seat adjuster switch assembly. INSTALLATION PROCEDURE 1. Install the power seat adjuster switch assembly to the seat switch bezel. 2. Install the lumbar support switch to the seat switch bezel. 3. Connect the electrical connectors. NOTE: Refer to Fastener Notice in Service Precautions. 4. Install the screws retaining the power seat switch bezel. Tighten Tighten the screws to 2 N.m (18 lb in). Seat Switch Replacement - Power SEAT SWITCH REPLACEMENT - POWER REMOVAL PROCEDURE Page 8785 Alternator: Diagnostic Aids Basic Knowledge Required BASIC KNOWLEDGE REQUIRED Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the Service Data. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories CHECKING AFTERMARKET ACCESSORIES Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: - Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions INDUCING INTERMITTENT FAULT CONDITIONS In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: - Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. Page 3750 6. If equipped with a 4.3L, 4.8L, or 5.3L engine, remove the left exhaust manifold pipe nuts. 7. If equipped with a 4.3L, 4.8L, or 5.3L engine, remove the right exhaust manifold pipe nuts. 8. If equipped with a 6.0L or 8.1L engine, remove the right exhaust manifold pipe nuts. 9. If equipped with a 6.0L or 8.1L engine, perform the following: 1. Remove the left exhaust manifold pipe nuts. 2. Remove the exhaust hanger mounting bracket bolts. 10. Lower the catalytic converter or exhaust manifold pipe using the adjustable jackstands. 11. Remove the exhaust manifold pipe seal(s). Installation Procedure Page 15925 For vehicles repaired under warranty, use the table. Disclaimer Page 8152 Brake Caliper Overhaul - Front Brake Caliper Overhaul - Front ^ Tools Required J 45515 Brake Caliper Piston Boot Seal Installer Caution: Refer to Brake Dust Caution in Service Precautions. Caution: Refer to Brake Fluid Irritant Caution in Service Precautions. Notice: Refer to Brake Fluid Effects on Paint and Electrical Components Notice in Service Precautions. 1. Replace all the components included in the repair kits used to service this brake caliper. 2. Lubricate the rubber parts with new Delco Supreme 11®, GM P/N 12377967 (Canadian P/N 992667) or equivalent DOT-3 brake fluid to make assembly easier. 3. If any hydraulic component is removed or disconnected, it may be necessary to bleed all or part of the brake system. 4. The torque values specified are for dry, non-lubricated fasteners. 5. Perform the service operations on a clean bench, free from all mineral oil materials. 6. Remove the brake caliper from vehicle. Refer to Brake Caliper Replacement - Front. 7. Drain the brake fluid from the brake caliper. 8. Caution: Do not place your fingers in front of the piston in order to catch or protect the piston while applying compressed air. This could result in serious injury. Notice: Use clean cloths to pad interior of caliper housing during piston removal. Use just enough air to ease the pistons out of the bores. If the pistons are blown out, even with the padding provided, it may be damaged. Place a 25 mm (1 inch) block of wood between the caliper and the piston. 9. Install a large C-clamp over the body of the brake caliper with the C-clamp ends against the rear of the caliper body and against the block of wood. 10. Carefully remove the brake caliper piston by directing low pressure compressed air into the brake caliper inlet hole. 11. Remove the C-clamp form the caliper. 12. Remove the block of wood from the caliper. 13. Install clean cloths to pad the interior of the caliper housing between the remaining caliper piston and the caliper body. 14. To cover the open caliper bore place a 25 mm (1 inch) block of wood between the caliper body and the brake caliper dust boot seal. 15. Install a large C-clamp over the body of the brake caliper with the C-clamp ends against the rear of the caliper body and against the block of wood. 16. Carefully remove the brake caliper piston by directing low pressure compressed air into the brake caliper inlet hole. 17. Remove the C-clamp form the caliper. 18. Remove the block of wood from the caliper. Interior - Seat Memory Feature Appears Inoperative Memory Positioning Module: All Technical Service Bulletins Interior - Seat Memory Feature Appears Inoperative Bulletin No.: 04-08-50-003 Date: February 26, 2004 INFORMATION Subject: Enabling Memory Seat Feature via DIC If Feature Appears Inoperative Models: 2003-2004 Cadillac Escalade, Escalade ESV, Escalade EXT 2003-2004 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2003-2004 GMC Sierra, Yukon, Yukon Denali, Yukon Denali XL 2003-2004 HUMMER H2 with Steering Wheel Controls (RPO UK3) (standard on H2) If the memory seat feature appears inoperative, check the Driver Information Center (DIC). Many of the memory seat modules that were returned through the Warranty Parts Center for a condition of inoperative have shown No Trouble Found. The Driver Information Center (DIC), programmed for Seat Entry and Exit, is set to the default "Off" mode at the assembly plant. DO NOT REPLACE THE MEMORY SEAT MODULE. Perform the following procedure. Important: The following procedure will need to be completed for each Remote/Key selection. Using the DIC menu, do the following steps: 1. Set the "Seat Recall" to either "At Key In" or "On Remote" based on the customer's preference. 2. Set the "Exit Seat" to "On". 3. Adjust the following items: Memory Seat: 3.1. Driver's Seat (including the seat back, recliner, lumbar, and side wings) 3.2. Throttle and Brake Pedals (not available on H2 or Silverado and Sierra Trucks) 3.3. Outside Mirrors 3.4. Radio Station Presets 3.5. Last Chosen Climate Control System Settings (not available on Silverado or Sierra Trucks) 3.6. Press and hold the "1" or "2" (for driver 1 or 2) button of the memory control for three seconds. A double chime will sound to let you know that the position has been stored. Easy Exit Seat: 3.1. Press and release the 1 or 2 button or press the unlock button on the desired remote keyless entry transmitter. The seat will move to the stored memory position. 3.2. Adjust the seat to the desired exit position. 3.3. Press and hold the exit button of the memory control (located on the door) for three seconds. A double chime will sound to let you know that the position has been stored for the identified driver (1 or 2). Page 5691 Page 8161 1. Install the brake caliper bracket (1). 2. Perform the following procedure before installing the brake caliper bracket mounting bolts. 1. Remove all traces of the original adhesive patch. 2. Clean the threads of the bolt with denatured alcohol or equivalent and allow to dry. 3. Apply Threadlocker GM P/N 12345493 (Canadian P/N 10953488) to the threads of the bolt. 3. Notice: Refer to Fastener Notice in Service Precautions. Install the caliper bracket mounting bolts (2). For vehicles equipped with JH5 brake systems, tighten the caliper bracket mounting bolts to 200 Nm (148 ft. lbs.). For vehicles equipped with JH6/JH7 brake systems, tighten the caliper bracket mounting bolts to 300 Nm (221 ft. lbs.). 4. Install the anti-rattle clips to the brake caliper mounting bracket. 5. Install the brake pads to the brake caliper mounting bracket. 6. Slide the brake pads in until they contact the rotor. 7. Install the brake caliper. 8. Install the tire and wheel assembly. 9. Lower the vehicle. 10. With the engine OFF, gradually apply the brake pedal to approximately 2/3 of it's travel distance. 11. Slowly release the brake pedal. 12. Wait 15 seconds, then repeat steps 10-11 until a firm pedal is obtained. This will properly seat the brake caliper pistons and brake pads. W/NYS Brake Caliper Bracket Replacement - Rear (15 Series w/NYS) Caution: Refer to Brake Dust Caution in Service Precautions. Removal Procedure Locations Combination Switch: Locations Steering Wheel and Column Sub-System Components Page 11898 Page 8894 Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses CIRCUIT PROTECTION - FUSES The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the Page 12583 5.2 Cut off the cable tie (B), detach the connector's rear end face (C) and pull out the connecting rail (D). 5.3. Remove pin 39, cut off the cable terminal and insulate the end with tape (E). Fold back the cable and secure it with tape (F). 5.4. Fit the connecting rail and end face. 5.5. Plug in the connector (A) and secure the cables with cable ties (B). 6. Install the floor console over the handbrake. Do not press the console down into place, but instead allow it to fit loosely. 7. Install the switch: 7.1. Install the switch for the roof lighting (B) and plug in its connector. 7.2. Guide the connectors for the window lift module and rear seat heater, if equipped, through the hole for each respective unit. Plug in the window lift module's connector and install the module (A). Page 14550 Disclaimer Page 362 7.3. If equipped, connect the rear seat heater's connector and install the switch. 8. Install the floor console: 8.1. Install the floor console's retaining bolts (C) and retaining nuts (F). 8.2. Align the rear cover; make sure that the air duct connects firmly to the air nozzle. Screw in the cover (E). 8.3. Install the ashtray/cover (D). 8.4. Install the ignition switch cover (B). 8.5. Plug in the immobilizer unit (A) connector. Install the unit, bayonet fitting. 9. Remove the OnStar(R) control modules and secure the wiring: 9.1. Remove the right-hand rear luggage compartment trim in accordance with WIS - 8. Body - Interior equipment - Adjustment/Replacement. 9.2. Unplug the connectors (A) from the OnStar(R) control modules. 9.3. Remove the console (B) together with the OnStar(R) control modules. Page 15226 circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links CIRCUIT PROTECTION - FUSIBLE LINKS Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Flat Wire Repairs FLAT WIRE REPAIRS NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Heated Oxygen Sensor (HO2S) Wiring Repairs HEATED OXYGEN SENSOR (HO2S) WIRING REPAIRS TOOLS REQUIRED J 38125-D Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: - Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-D. Repairing Damaged Wire Insulation REPAIRING DAMAGED WIRE INSULATION Page 8886 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the cover up until the dress cover releases. Repeat this procedure for the other locking tab. 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. 5. If the connector has a nose piece, use a small flat-blade tool to remove the nose piece by inserting the blade into the slot on the front of the connector and prying up on the nose piece. IMPORTANT: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 6. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. IMPORTANT: Be careful not to angle or rock the J 38125-13A tool when inserting it into the connector or the tool may break. Page 1594 1. Locate the air flow direction arrow (2) on the MAF/IAT sensor. 2. Install the MAF/IAT sensor to the air cleaner assembly. NOTE: Refer to Fastener Notice in Service Precautions. 3. Tighten the MAF/IAT clamp. Tighten Tighten the clamp to 7 N.m (62 lb in). 4. Connect the MAF/IAT sensor electrical connector (4). 5. Push in the gray CPA retainer. 6. Install the air cleaner outlet duct. Page 2209 3. Disconnect the vent valve pipe quick connect from the canister. 4. Either cut the existing valve vent pipe and leave the remaining section of pipe in the vehicle or remove along with the valve. 5. Push in the retainer and remove the existing canister vent valve from the fuel tank clip or mounting bracket. 6. Cut back the existing canister pipe approximately 51 mm (2 in) and retain the pipe for use with new valve. 7. Connect the canister pipe quick connect to the canister. 2500 Crew Cab Short Box Shown Below, Other Configurations Similar 1500 Extended Cab Short Box Shown Below, Other Configurations Similar 8. Install the new canister vent valve solenoid to the fuel tank clip or mounting bracket as shown above. The valve port closest to the electrical connector must point towards the canister. 9. Cut bulk 5/8" heater hose to a length of approximately 76 mm (3 in). Install the hose between the solenoid and the canister pipe and secure using clamps. 10. Attach bulk 5/8" heater hose to the vent port and secure using a clamp. Run a length as needed along the frame rail routing to the passenger side area above the transmission. 11. Cut the hose to determined length and install the supplied filter box. Secure using a clamp. 12. Remove the transmission heat shield, if necessary. 13. Remove the transmission support and lower the transmission assembly as necessary to allow for access to the new filter box location. 14. Secure the filter box to the transmission vent hose just forward of the hose tee-section using a tie strap. DO NOT pinch or restrict the transmission vent hose. The filter box opening should be pointing downward. 15. Raise the transmission and reinstall the transmission support. 16. Reinstall the transmission heat shield. 17. Connect the EVAP canister vent valve electrical connector. 18. Tie strap the hose as needed along the frame rail in order to keep the hose away from pinch-points and heat sources. 19. Lower the vehicle. Parts Information Page 13119 DTC B2476 04: Cellular Phone Select Service Switch Open Circuit DTC B2476 59: Cellular Phone Select Service Switch Stuck Button DTC B2482 00: Cellular Phone Select Service Switch Range/Performance Circuit Short to Ground Open / High Resistance Short to Voltage Signal Performance Circuit/System Description The OnStar(R) button assembly consists of 3 buttons, Call/Answer, OnStar(R) Call Center, and OnStar(R) Emergency. The vehicle communication interface module (VCIM) supplies the OnStar(R) button assembly with 10 volts via the keypad supply voltage circuit. Each of the buttons, when pressed, completes the circuit across a resistor allowing a specific voltage to be returned to the VCIM over the keypad signal circuit. Depending upon the voltage range returned, the VCIM is able to identify which button has been activated. Conditions for Running the DTCs The ignition is ON. System voltage is between 9 - 16 volts. Conditions for Setting the DTCs B2476 04: The VCIM detects an open/high resistance on the keypad supply voltage circuit. B2482 and B2476 59: The VCIM detects a valid signal on the keypad signal circuit for more than 15 seconds. If one of the OnStar(R) buttons is held or stuck for 15 seconds or more, the VCIM will set these DTCs. Action Taken When the DTCs Set The OnStar(R) status LED turns red. No calls can be placed. The VCIM will ignore all inputs from the OnStar® button assembly. Conditions for Clearing the DTCs The condition responsible for setting the DTC no longer exists. A history DTC will clear once 100 consecutive malfunction-free ignition cycles have occurred. Page 7927 Park Neutral Position (PNP) Switch C175 Page 14284 WA519F/12 - WA5322/33 Page 6025 Shift Solenoid: Service and Repair Control and Shift Solenoids Replacement Removal Procedure 1. Remove the transmission filter. 2. Important: Removal of the 1-2 accumulator is necessary only if servicing the pressure control solenoid. Remove the 1-2 accumulator, if necessary. 3. Disconnect the internal wiring harness electrical connectors from the following components: ^ Transmission fluid pressure switch (1) ^ 1-2 shift control solenoid (2) ^ 2-3 shift control solenoid (3) ^ Pressure control solenoid (4) ^ torque converter clutch pulse width modulation (TCC PWM) solenoid (5) ^ 3-2 control solenoid (6) 4. Remove the pressure control solenoid retainer bolt (364A) and retainer (378). 5. Remove the pressure control solenoid (377). Page 1006 Step 25 - 27 Page 14176 Door Latch Assembly (Lock Actuator) - RR C1 (Crew Cab Only) Front Suspension Ball Joint: Service and Repair Front Suspension (Coil Spring Suspension) Lower Ball Joint Replacement (Coil Spring Suspension) Removal Procedure 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Remove the tire and wheel assembly. 3. Remove the lower control arm. Refer to Lower Control Arm Replacement (RWD) Lower Control Arm Replacement (4WD). 4. Secure the lower control arm in a bench vice or equivalent. 5. Center punch the rivet heads. 6. Drill out the rivets. 7. Remove the lower ball joint. Installation Procedure 1. Install the ball joint to the lower control arm. 2. Install the replacement bolts to the lower control arm. 3. Install the nuts to the bolts. ^ Tighten the nuts to 70 Nm (52 ft. lbs.). Notice: Refer to Fastener Notice in Service Precautions. 4. Remove the lower control arm from the bench vice. 5. Install the lower control arm. Refer to Lower Control Arm Replacement (RWD) Lower Control Arm Replacement (4WD). 6. Install the tire and wheel tire assembly. 7. Remove the safety stands. 8. Lower the vehicle. 9. Verify the wheel alignment. Refer to Measuring Wheel Alignment (w/Rear Wheel Steering) Measuring Wheel Alignment (w/o Rear Wheel Steering) in Wheel Alignment. (Torsion Bar Suspension) Lower Ball Joint Replacement (Torsion Bar Suspension) Removal Procedure 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Remove the tire and wheel assembly. 3. Remove the lower control arm. Refer to Lower Control Arm Replacement (RWD) Lower Control Arm Replacement (4WD). 4. Place the lower control arm in a bench vice. 5. Using a chisel, remove the securing crimps from the ball joint body, if equipped. 6. Using a press, remove the ball joint from the lower control arm. Installation Procedure 1. Install the new ball joint using a press. Important: Use the outer flange of the ball joint in order to press the ball joint into place. 2. Place the lower control arm in a bench vice. 3. Using a punch, install crimps to the ball joint, if necessary. Use the replaced ball joint as a reference. 4. Install the lower control arm. Refer to Lower Control Arm Replacement (RWD) Lower Control Arm Replacement (4WD). 5. Install the tire and wheel assembly. 6. Remove the safety stands. 7. Lower the vehicle. 8. Verify the wheel alignment. Refer to Measuring Wheel Alignment (w/Rear Wheel Steering) Measuring Wheel Alignment (w/o Rear Wheel Steering) in Wheel Alignment. Page 4333 Body Control Module (BCM) - C2 Part 1 Service and Repair Parking Brake Warning Switch: Service and Repair Park Brake Warning Lamp Switch Replacement Removal Procedure 1. Caution: Refer to Battery Disconnect Caution in Service Precautions. Disconnect the negative battery cable. 2. Remove the MID-bussed electrical center from the bracket. 3. Disconnect the park brake warning lamp switch electrical connector. 4. Remove the park brake warning lamp switch mounting bolt. 5. Remove the park brake warning lamp switch. Installation Procedure Page 5298 5. Squeeze where indicated by the arrows on both sides of the plastic ring to disengage the quick connect fitting. 6. Pull the quick connect fitting connection apart. INSTALLATION PROCEDURE CAUTION: In order to reduce the risk of fire and personal injury, before connecting fuel pipe fittings, always apply a few drops of clean engine oil to the male pipe ends. This will ensure proper reconnection and prevent a possible fuel leak. During normal operation, the O-rings located in the female connector will swell and may prevent proper reconnection if not lubricated. 1. Apply a few drops of clean engine oil to the male connection end. 2. Push both sides of the quick-connect fitting together in order to cause the retaining tabs to snap into place. Page 4235 - Inspect the insulator (2) for cracks. All or part of the electrical charge may arc through the crack instead of the electrodes (3, 4). - Inspect for evidence of improper arcing. Measure the gap between the center electrode (4) and the side electrode (3). Refer to Ignition System Specifications. An excessively wide electrode gap can prevent correct spark plug operation. - Inspect for the correct spark plug torque. Refer to Ignition System Specifications. Insufficient torque can prevent correct spark plug operation. An over torqued spark plug, causes the insulator (2) to crack. - Inspect for signs of tracking that occurred near the insulator tip instead of the center electrode (4). - Inspect for a broken or worn side electrode (3). - Inspect for a broken, worn, or loose center electrode (4) by shaking the spark plug. A rattling sound indicates internal damage. - A loose center electrode (4) reduces the spark intensity. - Inspect for bridged electrodes (3, 4). Deposits on the electrodes (3, 4) reduce or eliminates the gap. - Inspect for worn or missing platinum pads on the electrodes (3, 4), if equipped. - Inspect for excessive fouling. - Inspect the spark plug recess area of the cylinder head for debris. Dirty or damaged threads can cause the spark plug not to seat correctly during installation. VISUAL INSPECTION - Normal operation - Brown to grayish-tan with small amounts of white powdery deposits are normal combustion by-products from fuels with additives. - Carbon fouled - Dry, fluffy black carbon, or soot caused by the following conditions: Rich fuel mixtures Leaking fuel injectors - Excessive fuel pressure - Restricted air filter element - Incorrect combustion - Reduced ignition system voltage output Weak ignition coils Page 8434 damage to parts and systems. 5. Install the rear park brake bracket bolt. Tighten Tighten the bolt to 61 Nm (45 lb ft). 6. Install the park brake cable to the equalizer bar. 7. Install the tire and wheel assembly. 8. Lower the vehicle. 9. Adjust the park brake cable. Refer to Park Brake Adjustment See: Adjustments. Page 14195 4. Connect the electrical connectors. 5. Install the front door trim panel. 6. If equipped with camper mirrors program the door module. Refer to Service Programming System (SPS) in Programming. Switch Replacement - Door Lock and Side Window - Passenger SWITCH REPLACEMENT - DOOR LOCK AND SIDE WINDOW - PASSENGER REMOVAL PROCEDURE 1. Remove the front door trim panel. 2. Disconnect the electrical connectors. 3. Remove the screw that retains the switch panel bezel (1) from the front door panel. 4. Remove the switch panel bezel from the door panel using a flat-bladed tool. AWD/4WD - AWD/4WD Lamps/System Inop./DTC C0550 Control Module: Customer Interest AWD/4WD - AWD/4WD Lamps/System Inop./DTC C0550 Bulletin No.: 02-04-21-006E Date: July 20, 2006 TECHNICAL Subject: Inoperative 4WD/AWD Lamps, Inoperative 4WD/AWD System, DTC C0550 Set, No Communication with TCCM (Reprogram Transfer Case Control Module) Models: 2004 Buick Rainier 2002-2004 Chevrolet TrailBlazer, TrailBlazer EXT 2003-2004 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2002-2004 GMC Envoy, Envoy XL 2003-2004 GMC Sierra, Yukon, Yukon XL 2004 GMC Envoy XUV 2002-2004 Oldsmobile Bravada with Electronic Shift or Active Transfer Case (RPOs NP1, NP4 or NP8) Supercede: This bulletin is being revised to add Subject information and change the labor operation. This bulletin cancels and supersedes Bulletin Number 03-04-21-006. Please discard Corporate Bulletin Numbers 02-04-21-006D and 03-04-21-006 (Section 04 - Driveline/Axle). Condition Some customers may comment that the 4WD/AWD indicator lights on the selector switch do not work, or the 4WD/AWD system may be inoperative and/or the service 4WD light is illuminated. The condition is typically intermittent and always occurs at key-up. Upon investigation, the technician may find DTC C0550 set. Cause The Transfer Case Control Module (TCCM) has not received the wake-up call during key-up and has remained in the "sleep mode". When the TCCM is in the "sleep mode", it will not communicate with the class II bus or the Tech 2(R). Correction 1. Try to communicate with the TCCM. If no communication, go to step 2. If communication is possible, go to step 5. 2. Remove the underhood (ATCM or TREC) TCCM fuse. 3. Wait 30 seconds. 4. Reinstall the fuse. The module should wake up and communicate with the Tech 2(R). 5. Check for codes in the TCCM. If a C0550 is found current or in history with or without other codes, replace the module and go to step 6. 6. Reprogram the TCCM with the latest TIS software using normal SPS procedures. 7. Verify operation and that no codes are present. Important: For the 2002 model year, the TCCM must be replaced and reprogrammed. Warranty Information A/C - Defaults To Defrost Mode/Poor Control Wiring Harness HVAC: Customer Interest A/C - Defaults To Defrost Mode/Poor Control Bulletin No.: 04-01-38-008 Date: June 17, 2004 TECHNICAL Subject: HVAC System Cannot be Controlled or Defaults to Defrost Mode (Repair HVAC Actuator Harness) Models: 2003-2005 Cadillac Escalade, Escalade ESV, Escalade EXT 2003-2005 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2003-2005 GMC Sierra, Yukon, Yukon XL Condition ^ Some customers may comment that they cannot control the HVAC (heating, ventilation and air conditioning) system. Others may comment that the HVAC system defaults to the Defrost mode. ^ Technicians may find that the following diagnostic trouble codes have set: ^ B0229 Recirculation Actuator ^ B0414 Left Air Temperature Actuator ^ B0424 Right Air Temperature Actuator ^ B3770 Mode Actuator Cause The HVAC actuator harness may contact a sharp edge on the instrument panel support brace, causing a rub through condition and a ground out of the actuator control and/or feedback circuits. Correction Locate the HVAC actuator harness contact point shown by the arrow in the above illustration. The illustration is of the instrument panel with the instrument panel compartment door opened and folded downward. The actuator harness is located in the left side of the opening in the instrument panel. Interior - Intermittent Seat Heater Operation Seat Heater Control Module: All Technical Service Bulletins Interior - Intermittent Seat Heater Operation Bulletin No.: 05-08-50-008 Date: August 19, 2005 TECHNICAL Subject: Intermittent Heated Seats Inoperative, DTC B3941 Set (Reprogram Driver Seat Module) Models: 2003-2005 Cadillac Escalade, Escalade ESV, Escalade EXT 2003-2005 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2003-2005 GMC Sierra, Yukon, Yukon XL, Yukon Denali All with Seat FRT, Individual (Non BKT) (RPO AN3) 2003-2005 HUMMER H2 with Seat, Front Bucket Deluxe (RPO AR9) Condition Some customers may comment that occasionally the seat heater will not operate when activated. If the ignition key is cycled OFF and back ON again, the heated seat will operate correctly. Also, on some LB7 diesel engine vehicles, the seat heater may turn itself off during the first 10 minutes of operation. This occurs only with the first activation for the day and works correctly with subsequent activations immediately after the event. These conditions are intermiffent and DTC B3941 may be set. Correction Technicians are to reprogram the driver seat module with an updated software calibration. This new service calibration was released with TIS satellite data update version 6.5 available June 13, 2005. As always, make sure your Tech 2(R) is updated with the latest software version. Warranty Information Page 5980 ^ TCC PWM solenoid (5) ^ 3-2 control solenoid (6) 9. Install the 1-2 accumulator. 10. Connect the transmission harness 20-way connector (1) to the transmission pass-through connector. Align the arrows on each half of the connector and insert straight down. 11. Install the transmission filter. Page 10774 Wheel Fastener: Service and Repair Rear Suspension Wheel Stud Replacement ^ Tools Required J 43631 Ball Joint Remover Removal Procedure 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Remove the tire and wheel. 3. Remove the rotor, except dual wheel vehicles. 4. Remove the wheel stud from the axle flange using the J 43631. 5. Remove the axle shaft for vehicles with 9.5 in ring gear. 6. Remove the rear hub assembly for vehicles with 10.5/11.5 in ring gear, with single wheels. 7. Remove the rear axle hub for vehicles with dual wheels. Refer to Rear Axle Hub, Bearing, Cup, and/or Seal Replacement. 8. Remove the wheel stud from the axle flange using the J 43631. 9. Remove the wheel stud from the hub flange using the J 43631. 10. Place the hub and rotor assembly in a press to remove the wheel stud. Installation Procedure Specifications Brake Bleeding: Specifications HYDRAULIC BRAKE SYSTEM Delco Supreme II Brake Fluid or equivalent DOT-3 brake fluid. Page 14420 ^ Reinstall the fuse and fuse panel cover. ^ Press the "Enter" button to perform the "Refresh" function. ^ "Test in Progress" will be displayed and the right front passenger door lock will cycle once. ^ The screen will display "Procedure Completed". ^ Press the "Exit" button as necessary to return to the main menu screen. 3. Using the switches in the right front passenger door, verify that the power window and power door lock located in that door function properly. Important: The calibrations required for performing SPS reprogram in the next step are based on the type of exterior rearview mirror the vehicle has. To determine the correct calibration, check the Service Parts Identification Label on the vehicle for the RPO code for exterior mirrors. 4. Follow normal Service Programming System (SPS) to reprogram the passenger door module with the current calibration available in TIS 2000. 5. After reprogramming is complete, using the switches in the right front passenger door, verify that the power window and power door lock located in that door function properly. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 12515 Page 4332 Body Control Module: Connector Views Body Control Module (BCM) - C1 Page 7085 Page 1703 Accelerator Pedal Position Sensor: Description and Operation ACCELERATOR PEDAL POSITION (APP) SENSOR The accelerator pedal assembly contains 2 individual APP sensors within the assembly. The APP sensors 1 and 2 are potentiometer type sensors, each with the following circuits: - A 5-volt reference circuit - A low reference circuit - A signal circuit The APP sensors are used to determine the pedal angle. The control module provides each APP sensor a 5-volt reference circuit and a low reference circuit. The APP sensors then provide the control module with signal voltage proportional to pedal movement. Both APP sensor signal voltages are low at rest position and increase as the pedal is applied. Page 5877 For vehicles repaired under the 8 year/80,000 mile (130,000 km) emission controller warranty use the table. Disclaimer Page 12871 2. Click on the Analog-to-Digital Program link to start the ordering process. 3. To order a kit, you will need the information shown above. 4. After submitting the order, the "Terms and Conditions of Your OnStar(R) Service" page will display. This is your confirmation that the upgrade kit order has been created. U.S. Dealers will also receive an e-mail from Autocraft within several hours of ordering an upgrade kit (Canadian Dealers will receive an e-mail from MASS Electronics). 5. Print the "Terms and Conditions of Your OnStar(R) Service" page, and have the customer sign a copy. 6. A copy of this form should be stapled to the customer's copy of the Repair Order and one copy should be retained in the customer service folder. 7. If the kit you ordered is available, you will receive the upgrade kit within 4 business days of entering your order through the OnStar(R) Online Enrollment webpage. 8. To check on kit availability or the status of your order, U.S. Dealers can log onto the distributor's website at www.autocraft.com. Canadian dealers can call MASS Electronics at 877-410-6277. Upgrade Kit Installation 1. Skip to the next step if the vehicle to be upgraded is not shown above. Page 6630 Left Side Control Valve Body Assembly Page 15866 Combination Switch: Diagrams Multifunction Accessory Switch Page 10053 1. Notice: Refer to Power Steering Hose Disconnected Notice in Service Precautions. Install a drain pan under the vehicle. 2. Remove the power steering gear outlet hose (3) from the steering gear (2). 3. Remove the clamp retaining the power steering gear outlet hose (3) to the power steering pump (1).Remove the power steering gear outlet hose from the power steering pump. 4. Remove the power steering gear outlet hose from the vehicle. Installation Procedure 1. Notice: Refer to Installing Hoses Without Twists or Bends Notice in Service Precautions. Route the hose in the same position the hose occupied prior to removal. 2. Install the power steering gear outlet hose (3) to the power steering pump (1).Position the clamp at the end of the hose. 3. Notice: Refer to Fastener Notice in Service Precautions. Install the power steering gear outlet hose to the power steering gear. ^ Tighten the outlet hose fitting to 28 Nm (20 ft. lbs.). 4. Remove the drain pan from under the vehicle. 5. Bleed the power steering system. Refer to Bleeding the Power Steering System. (Rack and Pinion) Power Steering Gear Outlet Pipe/Hose Replacement (Rack and Pinion) Removal Procedure Notice: Refer to Power Steering Hose Disconnected Notice in Service Precautions. Page 13880 Page 8150 Brake Caliper: Service and Repair Brake Caliper Replacement - Front Brake Caliper Replacement - Front Caution: Refer to Brake Dust Caution in Service Precautions. Caution: Refer to Brake Fluid Irritant Caution in Service Precautions. Removal Procedure 1. Inspect the fluid level in the brake master cylinder reservoir. 2. If the brake fluid level is midway between the maximum-full point and the minimum allowable level, no brake fluid needs to be removed from the reservoir before proceeding. 3. If the brake fluid level is higher than midway between the maximum-full point and the minimum allowable level, remove brake fluid to the midway point before proceeding. 4. Raise and support the vehicle. Refer Vehicle Lifting 5. Remove the tire and wheel assembly. 6. Compress the brake caliper pistons. ^ Install a large C-clamp over the top of the caliper housing and against the back of the outboard pad. ^ Slowly tighten the C-clamp until the pistons are pushed completely into the caliper bores. ^ Remove the C-clamp from the caliper. 7. Clean all dirt and foreign material from the brake hose end. 8. Important: Install a rubber cap or plug to the exposed brake pipe fitting end to prevent brake fluid loss and contamination. Remove the brake hose to caliper bolt from the brake caliper. 9. Remove and discard the 2 copper brake hose gaskets. These gaskets may be stuck to the brake caliper housing or the brake hose end. 10. Remove the brake hose from the caliper. Page 4392 Throttle Actuator Control (TAC) Module C1 Part 2 Specifications Crankshaft Main Bearing: Specifications Crankshaft Bearing Cap Bolts - Inner Bolts - First Pass in Sequence ....................................................................................................... 20 Nm (15 ft. lbs.) Crankshaft Bearing Cap Bolts - Inner Bolts - Final Pass in Sequence .................................................................................................................. 80 degrees Crankshaft Bearing Cap Bolts - Outer Bolts - First Pass in Sequence ...................................................................................................... 20 Nm (15 ft. lbs.) Crankshaft Bearing Cap Bolts - Outer Bolts - Final Pass in Sequence ................................................................................................................. 51 degrees Crankshaft Bearing Cap Side Bolts .......................................................................................................................................................... 25 Nm (18 ft. lbs.) Crankshaft Main Bearing Clearance - Production ....................................................................................................... 0.02-0.052 mm (0.0008-0.0021 inch) Crankshaft Main Bearing Clearance - Service ............................................................................................................ 0.02-0.065 mm (0.0008-0.0025 inch) Crankshaft Main Bearing Bore Diameter .................................................................................................................... 69.871-69.889 mm (2.75-2.751 inch) Crankshaft Main Bearing Bore Out-of-Round ................................................................................................................................. 0.006 mm (0.0002 inch) Page 9986 Steering Column Position Sensor: Service and Repair Inflatable Restraint Steering Wheel Module Coil Centering Inflatable Restraint Steering Wheel Module Coil Centering 1. Notice: The new SIR coil assembly will be centered. Improper alignment of the SIR coil assembly may damage the unit, causing an inflatable restraint malfunction. Important: If double wire harness strap is installed onto the wire harness assembly and column, you must reuse the holder for the wire straps during installation. Remove the wire harness strap(s) where necessary. Verify the following conditions before centering the SIR coil: ^ The wheels on the vehicle are straight ahead. ^ The block tooth (1) of the steering shaft assembly is in the 12 o'clock position. ^ The ignition switch is in the LOCK position. 2. If the front (5) of the SIR coil has a centering window (4), and the back side (2) includes a spring service lock (1), perform the following steps: 1. Hold the SIR coil with the face up. 2. While depressing the spring service lock, rotate the coil hub clockwise until the coil ribbon stops. 3. Rotate the coil hub slowly, counterclockwise, until the centering window appears yellow and both arrows (3) line up. 4. Release spring service lock between the locking tab. The SIR coil is now centered. 5. Align the centered SIR coil with the horn tower and slide onto the steering shaft assembly. 3. If the front (4) of the SIR coil has a centering window (3), and the back side (1) includes NO spring service lock, perform the following steps: 0. Hold the SIR coil with the face up. 1. Rotate the coil hub clockwise until the coil ribbon stops. Page 6471 Refer to Fastener Notice in Service Precautions. Install the transmission range selector cable bracket bolts (1). ^ Tighten the bolts to 25 Nm (18 ft. lbs.). 3. Install the transmission range selector cable to the bracket (2) and the lever. 4. Lower the vehicle. 5. Check the vehicle for proper operation. Exhaust System - Catalytic Converter Precautions Catalytic Converter: Technical Service Bulletins Exhaust System - Catalytic Converter Precautions Bulletin No.: 06-06-01-010A Date: February 04, 2008 INFORMATION Subject: Information on Close-Coupled Converter and Engine Breakdown or Non-Function Due to Severe Overheat or Lack of Oil Causing Piston(s) Connecting Rod(s) Crankshaft Cylinder(s) and/or Head(s) Camshaft(s) Intake and/or Exhaust Valve(s) Main and/or Rod Bearing(s) Damage Models: 2004-2008 GM Passenger Cars and Trucks with Close-Coupled Catalytic Converters Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 06-06-01-010 (Section 06 - Engine/Propulsion System). Certain 2004-2008 General Motors products may be equipped with a new style of catalytic converter technically known as the close-coupled catalytic converter providing quick catalyst warm-up resulting in lower tail pipe emissions earlier in the vehicle operating cycle. If an engine breakdown or non-function were to occur (such as broken intake/exhaust valve or piston) debris may be deposited in the converter through engine exhaust ports. If the engine is non-functioning due to a severe overheat event damage to the ceramic "brick" internal to the catalytic converter may occur. This may result in ceramic debris being drawn into the engine through the cylinder head exhaust ports. If a replacement engine is installed in either of these instances the replacement engine may fail due to the debris being introduced into the combustion chambers when started. When replacing an engine for a breakdown or non-function an inspection of the catalytic converters and ALL transferred components (such as exhaust/ intake manifolds) should be performed. Any debris found should be removed. In cases of engine failure due to severe overheat dealers should also inspect each catalytic converter for signs of melting or cracking of the ceramic "brick". If damage is observed the converter should be replaced. Disclaimer Page 1046 For vehicles repaired under warranty, use the table. Disclaimer Page 13652 3. Position the service hinge within the scribe marks on the door. 4. Center punch each hole location on the door according to the service hinge. 5. Drill a 3 mm (1/8 in) pilot hole at each center punch location. Important: Drill bit must be exact size. 6. Drill an 11.5 mm (29/64 in) hole at the pilot locations. 7. Clean and prepare all of the bare metal surfaces. Important: Prior to refinishing, refer to the publication GM 4901M-D-2000 GM Approved Refinish Materials for recommended products. Do not combine paint systems. Refer to paint manufacturer's recommendations. 8. Apply approved anti-corrosion primer. 9. Apply a full-bodied caulk to the entire hinge mounting surface in order to ensure a proper seal. Notice: Refer to Fastener Notice in Service Precautions. 10. Align the hinge (1) and the backing plate (4) with the holes in the door (2) and install the bolts (3) Tighten the bolts to 25 N.m (18 lb ft). 11. Apply the sealers. 12. Refinish the metal surfaces as necessary. 13. Install and align all of the related panels and the components. Page 7376 Park Neutral Position (PNP) Switch C175 Page 2545 Refrigerant: Fluid Type Specifications Air Conditioning Refrigerant ....................................................................................................................... R134a P/N 12356150 U.S. (10953485 Canada) Page 9702 C100 I/P Harness To Engine Harness Part 2 Page 10485 Locations Ambient Light Sensor Page 638 4. Install the ground, then the washer and then the bolt to the frame. Important: It is important to use the bolts, washers and nuts specified in this bulletin. These parts have been identified due to their conductive finish. 5. Install a washer and nut to the back side of the frame. Tighten Tighten the nut to 9 Nm (79 lb in). 6. Cover the front and back side of the repair area using Rubberized Undercoating. An additional check can be made to ensure a good connection for the battery cable to frame ground. It is possible for this ground to cause similar symptoms with the ABS as described above. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Parts Information Warranty Information Disclaimer AWD/4WD - AWD/4WD Lamps/System Inop./DTC C0550 Control Module: Customer Interest AWD/4WD - AWD/4WD Lamps/System Inop./DTC C0550 Bulletin No.: 02-04-21-006E Date: July 20, 2006 TECHNICAL Subject: Inoperative 4WD/AWD Lamps, Inoperative 4WD/AWD System, DTC C0550 Set, No Communication with TCCM (Reprogram Transfer Case Control Module) Models: 2004 Buick Rainier 2002-2004 Chevrolet TrailBlazer, TrailBlazer EXT 2003-2004 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2002-2004 GMC Envoy, Envoy XL 2003-2004 GMC Sierra, Yukon, Yukon XL 2004 GMC Envoy XUV 2002-2004 Oldsmobile Bravada with Electronic Shift or Active Transfer Case (RPOs NP1, NP4 or NP8) Supercede: This bulletin is being revised to add Subject information and change the labor operation. This bulletin cancels and supersedes Bulletin Number 03-04-21-006. Please discard Corporate Bulletin Numbers 02-04-21-006D and 03-04-21-006 (Section 04 - Driveline/Axle). Condition Some customers may comment that the 4WD/AWD indicator lights on the selector switch do not work, or the 4WD/AWD system may be inoperative and/or the service 4WD light is illuminated. The condition is typically intermittent and always occurs at key-up. Upon investigation, the technician may find DTC C0550 set. Cause The Transfer Case Control Module (TCCM) has not received the wake-up call during key-up and has remained in the "sleep mode". When the TCCM is in the "sleep mode", it will not communicate with the class II bus or the Tech 2(R). Correction 1. Try to communicate with the TCCM. If no communication, go to step 2. If communication is possible, go to step 5. 2. Remove the underhood (ATCM or TREC) TCCM fuse. 3. Wait 30 seconds. 4. Reinstall the fuse. The module should wake up and communicate with the Tech 2(R). 5. Check for codes in the TCCM. If a C0550 is found current or in history with or without other codes, replace the module and go to step 6. 6. Reprogram the TCCM with the latest TIS software using normal SPS procedures. 7. Verify operation and that no codes are present. Important: For the 2002 model year, the TCCM must be replaced and reprogrammed. Warranty Information Page 4432 Page 8872 Electrical Symbols Part 11 Interior - Erratic Memory Seat Operation Memory Positioning Module: Customer Interest Interior - Erratic Memory Seat Operation Bulletin No.: 04-08-50-016C Date: August 12, 2005 TECHNICAL Subject: Memory Seat May Not Return to Requested Position (Reprogram Driver Seat Module) Models: 2003-2005 Cadillac Escalade, Escalade ESV, Escalade EXT 2003-2005 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2003-2005 GMC Sierra, Yukon, Yukon XL, Yukon Denali All with Seat FRT, Individual (Non BKT) (RPO AN3) 2003-2005 HUMMER H2 with Seat, Front Bucket Deluxe (RPO AR9) Supercede: This bulletin is being revised to update the correction information. Please discard Corporate Bulletin Number 04-08-50-016B (Section 08 - Body and Accessories). Condition Some customers may comment that with repeated cycling of the memory seat between the "exit" and one of the "presets", the position of the seat may "creep" forward or rearward out of expected adjustment. Cause There is a coding deficiency in the software for the memory seat module. Correction Technicians are to reprogram the driver seat module with an updated software calibration. The previous bulletin stated to use a service calibration that was released with TIS satellite data update version 4.5. Feedback has proved that calibration to be ineffective in eliminating the memory seat creep condition. An updated service calibration was released with TIS satellite data update version 6.5 available June 13, 2005. This new calibration has additional memory seat creep protection. As always, make sure your Tech 2(R) is updated with the latest software version. Important: After programming is complete, move the seat all the way rearward and down, then bump the seat slightly forward and up. This position will be just off the end of travel hard stops. Reset both memory seat exit positions at this position. Having the seat set at just off the hard stops will aid in reducing the creep condition. Warranty Information Page 8580 2. Remove the master cylinder from the booster. Do not remove the pipes from the master cylinder. Set the master cylinder aside in the engine compartment. 3. Disconnect the power brake booster inlet hose, the steering gear inlet hose, and the power brake booster outlet hose from the booster assembly. 4. Disconnect the electrical connector from the stop lamp switch. 5. Remove the retainer from the brake pedal pin. 6. Remove the stop lamp switch and the pushrod to the power brake booster from the brake pedal pin. 7. Unsnap the stop lamp switch from the power brake booster pushrod. 8. Remove the 4 booster to bulkhead nuts. 9. Remove the booster assembly. 10. Remove the gasket. Installation Page 12856 7.1. Remove the console (A) together with the OnStar(R) control modules. 7.2. Remove the connectors (B). Important: The optic cable must not be bent with a radius less than 25 mm (1 in). Important: Secure the wiring harness so that there is no risk of chafing and rattling. 7.3. Fold back the wiring harness and tape over the connectors (C). Fold back the wiring harness once more and secure with cable ties (D). 7.4. Fit the parcel shelf trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 8. CV: Removing the OnStar(R) control modules and securing the wiring: Adjustment/Replacement. 8.1. Open the luggage compartment floor. Page 385 6. See wiring diagram shown above for details. 5. Replace the OnStar(R) Vehicle Communication Interface Module (VCIM) in the vehicle with the provided Digitally-Capable VCIM. Refer to the Communication Interface Module Replacement procedure in the Cellular Communication section of SI. This kit may include a new VCIM bracket. If it does, use this new bracket on the vehicle and discard the original bracket. The kit may also include a small wiring jumper cable. If it does, plug the wiring jumper cable into the connector on the VCIM and the other end to the corresponding vehicle wiring harness connector. ^ For 2001, 2002 and 2003 Chevrolet Impala and Monte Carlo, do not reinstall the black plastic OnStar(R) module cover onto the vehicle after the VCIM and module bracket have been installed. This black plastic cover will no longer fit on the vehicle. ^ The upgrade kit for 2002 Sevilles and DeVilles, and some 2003 Sevilles and DeVilles, will contain a large bracket. To install the new VCIM into this bracket you'll need to carefully line up the notch in the VCIM with the tab in the bracket. Page 7592 10. Place the J 9522-3 on the open horizontal bearing cups. Press the lower bearing cup out of the yoke ear. 11. If you do not completely remove the bearing cup, lift the cross and insert the J 9522-5 between the seal and the bearing cup you are removing. Continue pressing the bearing cup out of the yoke. 12. Rotate the propeller shaft. Press the opposite bearing cup out of the drive shaft yoke. 13. Remove the old slip yoke and universal joint. 14. Inspect the retaining ring grooves for dirt, corrosion, or pieces of the old ring. 15. Inspect the bearing cup bores for burrs or imperfections. 16. Clean the retaining ring grooves. Corrosion, dirt, rust, or pieces of the old retaining ring may prevent the bearing cups from pressing into place or prevent the bearing retainers from properly seating. 17. Install the new nickel-plated slip yoke and universal joint. See parts table below for parts information. 18. Remove the bearing cups from the universal joint. 19. Assemble one bearing cup part way into one side of the yoke. Turn the yoke ear toward the bottom. 20. Assemble the cross into the yoke so that the trunnion seats freely into the bearing cup. Page 15975 Control Module References Part 6 Page 14853 5. Install the front door trim panel. 6. If equipped with camper mirrors program the door module. Refer to Service Programming System (SPS) in Programming. Page 6515 4. Important: When installing the pressure control solenoid, the electrical connector (2) must be in the position shown. Install the pressure control solenoid (377). 5. Install the pressure control solenoid retainer (378) and retainer bolt (364A). ^ Tighten the bolt to 11 Nm (97 inch lbs.). 6. Install the TCC PWM solenoid to the control valve body. 7. Install the TCC PWM solenoid retainer. 8. Connect the internal wiring harness electrical connectors to the following components: ^ Transmission fluid pressure switch (1) ^ 1-2 shift control solenoid (2) ^ 2-3 shift control solenoid (3) ^ Pressure control solenoid (4) Page 10888 Electrical Symbols Part 11 Page 13861 Page 11159 Heater Core: Service and Repair Heater Core Replacement - Delphi HEATER CORE REPLACEMENT (DELPHI) REMOVAL PROCEDURE 1. Remove the HVAC module assembly. See: Housing Assembly HVAC/Service and Repair/HVAC Module Assembly Replacement 2. Remove the screws from the heater core cover. 3. Remove the heater core cover (1) from the HVAC module assembly (2). 4. Remove the heater core cowl gasket (1) from the heater core (2). 5. Remove the heater core (2) from the HVAC module assembly (3). INSTALLATION PROCEDURE Page 465 Electrical Symbols Part 2 Page 6582 1. Lubricate the output speed sensor seal with automatic transmission fluid. 2. Install the output speed sensor (2). Notice: Refer to Fastener Notice in Service Precautions. 3. Install the output speed sensor bolt. ^ Tighten the bolt to 11 Nm (96 inch lbs.). 4. Connect the output speed sensor (2) electrical connector. 5. Lower the vehicle. Page 12420 Driver Door Module (DDM) - C5 (Memory/Heated Seat Switch) Part 2 Page 13423 SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-D. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: - The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair Tools Required J 38125-D Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-D. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Page 8963 For vehicles repaired under warranty, use the table. Disclaimer Page 2025 Window Switch - RR (Crew Cab Only) Part 2 Page 823 Junction Block - Rear Lamps - C3 Page 6849 5. Important: The ring gear bolts have left-hand threads. Remove the ring gear bolts. Discard the bolts. 6. Notice: Refer to Ring Gear Removal Notice in Service Precautions. Remove the ring gear from the differential. Drive the gear off with a brass drift if necessary. Installation Procedure 1. If the differential case has become separated, assemble the differential case by aligning the two arrows inside the differential case as shown. 2. Important: The mating surface of the ring gear and the differential case must be clean and free of burrs before installing the ring gear. Install the ring gear to the differential case. 3. Important: The ring gear bolts have left-hand threads. Install the new ring gear bolts. Hand start each bolt to ensure that the ring gear is properly installed to the differential case. 4. Notice: Refer to Fastener Notice in Service Precautions. ^ Tighten the new ring gear bolts. Tighten the ring gear bolts alternately and in stages, gradually pulling the ring gear onto the differential case. ^ Tighten the ring gear bolts in sequence to 165 Nm (122 ft. lbs.). 5. Install the pinion and the pinion bearings. 6. Install the pinion gear bearing retainer. Page 2645 Fuse Block - Underhood C2 Part 1 Page 7250 IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. Splicing Twisted or Shielded Cable SPLICING TWISTED OR SHIELDED CABLE Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. - Rewrap the conductors with the mylar tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with mylar tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Control Module References Page 16115 Power Window Switch: Service and Repair Switch Replacement - Door Lock and Side Window Passenger SWITCH REPLACEMENT - DOOR LOCK AND SIDE WINDOW - PASSENGER REMOVAL PROCEDURE 1. Remove the front door trim panel. 2. Disconnect the electrical connectors. 3. Remove the screw that retains the switch panel bezel (1) from the front door panel. 4. Remove the switch panel bezel from the door panel using a flat-bladed tool. 5. Using a wide plastic flat-bladed tool, release the retaining clips on both sides of the door module. 6. Remove the door module from the switch panel bezel. Propshaft Speed Sensor - Front Page 8374 6. Remove the cable from the mounting bracket by depressing the locking tabs. 7. Remove the cable at the shock absorber bracket by removing the bolt. 8. Perform the following procedure to remove the cable (2) from the backing plate (4): 1. Compress the spring (3) by pushing towards the lever (1). 2. Depress the locking tabs. 3. Pull the cable housing out of the backing plate (4). 4. Remove the cable (2) through the slot in the backing plate. 9. Remove the park brake cable (2) from the lever (1). 10. Remove the cable from the vehicle. Installation Procedure 1. Install the cable to the vehicle. Page 12675 ^ Audio amplifier ^ Driver door module (DDM) ^ Driver door switch assembly (DDSA) ^ Front passenger door module (FPDM) ^ Left rear door module (LRDM) ^ Memory seat module (MSM) ^ Radio antenna module (listed as remote function actuation in scan tool display) ^ Rear integration module (RIM) ^ Right rear door module (RRDM) ^ Theft deterrent module (TDM) ^ TV antenna module ^ Vehicle communication interface module (VCIM) The star has 4 splice packs: ^ SP200 located in the left side of the instrument panel, near the steering column , taped to the instrument panel harness ^ SP201 located in the center of the instrument panel, near the radio ^ SP300 located in the left side middle of the passenger compartment, taped to the body harness, near the carpet seam ^ SP303 located in the right rear of the passenger compartment, taped to the body harness, approximately 24 cm (9.5 in) from the fuse block - right rear. Refer to Data Communication Schematics in SI. The following modules, components, and splice packs are connected to the ring portion of the class 2 serial data circuit: ^ Dash integration module (DIM) ^ Electronic brake control module (EBCM) ^ Engine control module (ECM) ^ Inflatable restraint sensing and diagnostic module (SDM) ^ Instrument panel cluster (IPC) ^ HVAC control module ^ Radio ^ Rear integration module (RIM) ^ Vehicle communication interface module (VCIM) OR ^ Communication interface module (CIM) ^ SP200 ^ SP201 ^ SP300 Page 2228 1. Install the filter neck seal. 2. Install the oil filter. 3. Install the oil pan gasket to the pan. 4. Install the magnet into the bottom of the pan, if necessary. 5. Install the oil pan and bolts. ^ Tighten the oil pan bolts to 24 Nm (18 ft. lbs.). 6. Position the bracket with cable. Install the transmission range selector cable bracket (2) and bolts to the transmission. ^ Tighten the selector bracket bolts to 25 Nm (18 ft. lbs.). 7. Connect the range selector cable end (2) to the transmission range selector lever ball stud (1). Page 9578 Junction Block - I/P - C2 Part 2 Page 12457 7.3. If equipped, connect the rear seat heater's connector and install the switch. 8. Install the floor console: 8.1. Install the floor console's retaining bolts (C) and retaining nuts (F). 8.2. Align the rear cover; make sure that the air duct connects firmly to the air nozzle. Screw in the cover (E). 8.3. Install the ashtray/cover (D). 8.4. Install the ignition switch cover (B). 8.5. Plug in the immobilizer unit (A) connector. Install the unit, bayonet fitting. 9. Remove the OnStar(R) control modules and secure the wiring: 9.1. Remove the right-hand rear luggage compartment trim in accordance with WIS - 8. Body - Interior equipment - Adjustment/Replacement. 9.2. Unplug the connectors (A) from the OnStar(R) control modules. 9.3. Remove the console (B) together with the OnStar(R) control modules. Page 5087 Canister Vent Valve: Description and Operation EVAP VENT SOLENOID VALVE The EVAP vent solenoid valve controls fresh airflow into the EVAP canister. The valve is normally open. The control module commands the valve ON, closing the valve during some EVAP tests, allowing the system to be tested for leaks. Page 16046 IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. Splicing Twisted or Shielded Cable SPLICING TWISTED OR SHIELDED CABLE Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. - Rewrap the conductors with the mylar tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with mylar tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Control Module References Page 15381 supported, only J2534. 1. BEFORE the original IPC is disconnected from the vehicle, record the odometer and engine hour values. 2. Replace the IPC with a replacement part obtained from the ESC. Refer to Instrument Cluster Replacement in SI. 3. Using the TIS2WEB SPS application, select either: J2534 Tech 2 or J2534 MDI, when available and build the vehicle. 4. Select: IPC Setup J2534. 5. After selecting IPC Setup J2534, the user will be prompted to: install the new controller. Ignore this prompt if the new IPC was already installed. This prompt is just to remind the user that this application is only for a new IPC. Important FOR 2003 FULLSIZE TRUCKS, UTILITIES AND H2, THE ENGINE MUST BE STARTED AND RUNNING PRIOR TO ENTERING THE MILEAGE AND ENGINE HOURS. After the odometer value is programmed, the engine must remain running for 6 minutes 15 seconds before the ignition can be turned off. Failure to do so will result in engine hours not being programmed and a new IPC will have to be ordered. 6. Enter the odometer and engine hour values, when applicable. By default the application will be set to miles. For metric units, click the button on the left next to: Kilometers. The IPC odometer and engine hour meter setup procedure is now complete. 7. The IPC calibration files can now be programmed into the IPC. Refer to SPS in SI. Disclaimer Page 8142 11. Remove the 2 brake caliper mounting bolts. 12. Caution: Do not depress the brake pedal with the brake rotors/calipers and/or the brake drums removed. Damage to the brake system may result. If brake system damage occurs and is not repaired, vehicle damage and/or personal injury or death may result. Remove the brake caliper from the brake caliper mounting bracket. Installation Procedure 1. Notice: Refer to Fastener Notice in Service Precautions. Install the brake caliper to the brake caliper mounting bracket. 2. Install the 2 brake caliper mounting bolts. ^ Tighten the 2 brake caliper mounting bolts to 108 Nm (80 ft. lbs.). 3. Remove the rubber cap or plug from the exposed brake hose fitting end. 4. Important: Install 2 New copper brake hose gaskets. Assemble the 2 New copper brake hose gaskets and the brake hose to caliper bolt to the brake hose. 5. Install the brake hose to caliper bolt to the brake caliper. ^ Tighten the brake hose to caliper bolt to 40 Nm (30 ft. lbs.). 6. Bleed the hydraulic brake system. 7. Install the tire and wheel assembly. 8. Lower the vehicle. 9. Fill the master cylinder reservoir to the proper level with clean brake fluid. Refer to Master Cylinder Reservoir Filling in Hydraulic Brakes. Page 10842 INSTALLATION PROCEDURE 1. Install the air temperature actuator. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the air temperature actuator retaining screws. Tighten Tighten the screws to 1.6 N.m (14 lb in). 3. Connect the electrical connector (8) to the air temperature actuator (9). 4. Install the IP insulator. Air Temperature Actuator Replacement - Left Page 3909 Step 6 Page 2924 Important Other forms of slow air leaks are possible. If the body of the tire, valve stem and wheel flange show no signs of air seepage, refer to Corporate Bulletin Number 05-03-10-003D for additional information on possible wheel porosity issues. 3. Bead seat corrosion is identified by what appears like blistering of the wheel finish, causing a rough or uneven surface that is difficult for the tire to maintain a proper seal on. Below is a close-up photo of bead seat corrosion on an aluminum wheel that was sufficient to cause slow air loss. Close-Up of Bead Seat Corrosion 4. If corrosion is found on the wheel bead seat, measure the affected area as shown below. - For vehicles with 32,186 km (20,000 mi) or less, the total allowable combined linear area of repairable corrosion is 100 mm (4 in) or less. If the total area(s) of corrosion exceed these dimensions, the wheel should be replaced. - For vehicles that have exceeded 32,186 km (20,000 mi), the total allowable combined linear area of repairable corrosion is 200 mm (8 in) or less. If the total area(s) of corrosion exceed these dimensions, the wheel should be replaced. 5. In order to correct the wheel leak, use a clean-up (fine cut) sanding disc or biscuit to remove the corrosion and any flaking paint. You should remove the corrosion back far enough until you reach material that is stable and firmly bonded to the wheel. Try to taper the edge of any flaking paint as best you can in order to avoid sharp edges that may increase the chance of a leak reoccurring. The photo below shows an acceptable repaired surface. Notice Corrosion that extends up the lip of the wheel, where after the clean-up process it would be visible with the tire mounted, is only acceptable on the inboard flange. The inboard flange is not visible with the wheel assembly in the mounted position. If any loose coatings or corrosion extend to the visible surfaces on the FACE of the wheel, that wheel must be replaced. Important Remove ONLY the material required to eliminate the corrosion from the bead seating surface. DO NOT remove excessive amounts of material. ALWAYS keep the sealing surface as smooth and level as possible. Page 1579 Fuel Level Sensor: Service and Repair Fuel Level Sensor Replacement - 2 FUEL LEVEL SENSOR REPLACEMENT REMOVAL PROCEDURE 1. Remove the sending unit. 2. Disconnect the fuel pump electrical connector. 3. Remove the fuel level sensor electrical connector retaining clip. 4. Disconnect the fuel level sensor electrical connector. Page 4637 Electrical Symbols Part 8 Page 9211 C216 Brake/Clutch Harness To Fuse Block Jumper Harness (With RPO Code 9L4) Page 15484 5. Remove the fuel level sensor retaining clip. 6. Remove the fuel level sensor. INSTALLATION PROCEDURE 1. Install the fuel level sensor. Page 14090 6. Use fingers to squeeze the 2 locking legs of the cover. 7. Apply pressure and gently rock the cover until one locking leg is unseated. 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. Page 1701 Accelerator Pedal Position Sensor: Diagrams Accelerator Pedal Position (APP) Sensor Part 1 Page 9450 Control Module References Part 7 Page 6758 3. Disconnect the vent valve pipe quick connect from the canister. 4. Either cut the existing valve vent pipe and leave the remaining section of pipe in the vehicle or remove along with the valve. 5. Push in the retainer and remove the existing canister vent valve from the fuel tank clip or mounting bracket. 6. Cut back the existing canister pipe approximately 51 mm (2 in) and retain the pipe for use with new valve. 7. Connect the canister pipe quick connect to the canister. 2500 Crew Cab Short Box Shown Below, Other Configurations Similar 1500 Extended Cab Short Box Shown Below, Other Configurations Similar 8. Install the new canister vent valve solenoid to the fuel tank clip or mounting bracket as shown above. The valve port closest to the electrical connector must point towards the canister. 9. Cut bulk 5/8" heater hose to a length of approximately 76 mm (3 in). Install the hose between the solenoid and the canister pipe and secure using clamps. 10. Attach bulk 5/8" heater hose to the vent port and secure using a clamp. Run a length as needed along the frame rail routing to the passenger side area above the transmission. 11. Cut the hose to determined length and install the supplied filter box. Secure using a clamp. 12. Remove the transmission heat shield, if necessary. 13. Remove the transmission support and lower the transmission assembly as necessary to allow for access to the new filter box location. 14. Secure the filter box to the transmission vent hose just forward of the hose tee-section using a tie strap. DO NOT pinch or restrict the transmission vent hose. The filter box opening should be pointing downward. 15. Raise the transmission and reinstall the transmission support. 16. Reinstall the transmission heat shield. 17. Connect the EVAP canister vent valve electrical connector. 18. Tie strap the hose as needed along the frame rail in order to keep the hose away from pinch-points and heat sources. 19. Lower the vehicle. Parts Information Page 4677 Control Module References Part 6 Page 12311 Electrical Symbols ELECTRICAL SYMBOLS Electrical Symbols Part 1 Page 3803 9. Use J 38125-12A to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. REPAIR PROCEDURE The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. 1. Cut the wire as close to the terminal as possible. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. Page 9522 Fuse: Application and ID Fuse Block - I/P Location View Electrical - MIL ON/DTC's Set By Various Control Modules Relay Module: All Technical Service Bulletins Electrical - MIL ON/DTC's Set By Various Control Modules TECHNICAL Bulletin No.: 09-06-03-004D Date: December 08, 2010 Subject: Intermittent No Crank/No Start, No Module Communication, MIL, Warning Lights, Vehicle Messages or DTCs Set by Various Control Modules - Diagnosing and Repairing Fretting Corrosion (Disconnect Affected Connector and Apply Dielectric Lubricant) Models: 2011 and Prior GM Passenger Cars and Trucks Attention: This repair can be applied to ANY electrical connection including, but not limited to: lighting, body electrical, in-line connections, powertrain control sensors, etc. DO NOT over apply lubricant to the point where it prevents the full engagement of sealed connectors. A light coating on the terminal surfaces is sufficient to correct the condition. Supercede: This bulletin is being revised to update the Attention statement and add the 2011 model year. Please discard Corporate Bulletin Number 09-06-03-004C (Section 06 Engine/Propulsion System). Condition Some customers may comment on any of the following conditions: - An intermittent no crank/no start - Intermittent malfunction indicator lamp (MIL) illumination - Intermittent service lamp illumination - Intermittent service message(s) being displayed The technician may determine that he is unable to duplicate the intermittent condition. Cause This condition may be caused by a buildup of nonconductive insulating oxidized debris known as fretting corrosion, occurring between two electrical contact surfaces of the connection or connector. This may be caused by any of the following conditions: - Vibration - Thermal cycling - Poor connection/terminal retention - Micro motion - A connector, component or wiring harness not properly secured resulting in movement On low current signal circuits this condition may cause high resistance, resulting in intermittent connections. On high current power circuits this condition may cause permanent increases in the resistance and may cause a device to become inoperative. Representative List of Control Modules and Components The following is only a representative list of control modules and components that may be affected by this connection or connector condition and DOES NOT include every possible module or component for every vehicle. - Blower Control Module - Body Control Module (BCM) - Communication Interface Module (CIM) - Cooling Fan Control Module - Electronic Brake Control Module (EBCM) - Electronic Brake and Traction Control Module (EBTCM) - Electronic Suspension Control (ESC) Module - Engine Control Module (ECM) - Heating, Ventilation and Air Conditioning (HVAC) Control Module Page 13288 2. Click on the Analog-to-Digital Program link to start the ordering process. 3. To order a kit, you will need the information shown above. 4. After submitting the order, the "Terms and Conditions of Your OnStar(R) Service" page will display. This is your confirmation that the upgrade kit order has been created. U.S. Dealers will also receive an e-mail from Autocraft within several hours of ordering an upgrade kit (Canadian Dealers will receive an e-mail from MASS Electronics). 5. Print the "Terms and Conditions of Your OnStar(R) Service" page, and have the customer sign a copy. 6. A copy of this form should be stapled to the customer's copy of the Repair Order and one copy should be retained in the customer service folder. 7. If the kit you ordered is available, you will receive the upgrade kit within 4 business days of entering your order through the OnStar(R) Online Enrollment webpage. 8. To check on kit availability or the status of your order, U.S. Dealers can log onto the distributor's website at www.autocraft.com. Canadian dealers can call MASS Electronics at 877-410-6277. Upgrade Kit Installation 1. Skip to the next step if the vehicle to be upgraded is not shown above. Service and Repair Hydraulic Control Assembly - Antilock Brakes: Service and Repair Brake Pressure Modulator Valve (BPMV) Replacement Removal Procedure Caution: Refer to Brake Fluid Irritant Caution in Service Precautions. 1. Caution: Refer to Battery Disconnect Caution in Service Precautions. Notice: Refer to Brake Fluid Effects on Paint and Electrical Components Notice in Service Precautions. Remove the negative battery cable. 2. Important: The area around the EHCU MUST be free from loose dirt to prevent contamination of disassembled ABS components. Thoroughly wash all contaminants from around the EHCU. 3. Disconnect the chassis electrical harness connectors from the EBCM. 4. Important: Make sure that brake lines are tagged and kept in order for proper reassembly. Disconnect 5 brake lines from the BPMV. 5. Remove the bolts (4) securing the EHCU mounting bracket (3) to the frame rail (5). 6. Remove the EHCU assembly (1) from the vehicle. 7. Remove the bolts (4) securing the BPMV mounting bracket (5) to the BPMV (3). Page 12034 2. Skip to the next step if the vehicle to be upgraded is not shown above. 3. Skip to the next step if the vehicle to be upgraded is not a 2005 Cadillac STS. The 2005 Cadillac STS kit may include a new inside rearview (ISRV) mirror assembly and a new ISRV mirror wiring cover. If the kit you receive includes these parts, please remove the existing ISRV mirror and wire cover from the vehicle and install the ones provided in the kit per the instructions in SI. 4. Skip this step if the vehicle to be upgraded is not listed below. ^ 2003-2004 Saturn L-Series ^ 2003 Saturn ION ^ 2002-2003 Saturn VUE 1. Locate and remove the Right Audio output signal terminal 7 from Connector C2 at the Vehicle Communication Interface Module (VCIM). 2. Remove the terminal end and strip the wire. 3. Locate the Left Audio output signal wire from terminal 1 in Connector C2. 4. Splice the Right Audio output signal wire from terminal 7 with the Left Audio output signal wire from terminal 1. 5. See Wiring Repairs in SI for approved splicing methods. Page 14528 1. Install the head restraint retainers by pressing into the seat back frame until the retaining tabs snap into place at the bottom of the frame opening. 2. Position the cardboard panel to the seat back frame and install the panel fasteners. 3. Install the seat back trim cover. Head Restraint Replacement HEAD RESTRAINT REPLACEMENT REMOVAL PROCEDURE Page 8646 2. Connect the vacuum brake booster hose at the engine (4.3L). 3. Install the manifold sight shield (4.8L, 5.3L, 6.0L). 4. Install the vacuum brake booster check valve to the hose. 5. Install the vacuum brake booster hose clamp to the check valve. 6. Install the vacuum brake booster check valve to the vacuum brake booster. Page 398 networks, and will not require an upgrade in connection with the cellular industry's transition to the digital network. In order to verify the type of OnStar(R) Hardware in a vehicle, type the VIN into the VIN look-up tool, which is available at the OnStar(R) Online Enrollment website within GM GlobalConnect (for U.S. dealers) or InfoNet (for Canadian dealers). Disclaimer Page 1173 1. Remove the screws retaining the power seat switch bezel. 2. Disconnect the electrical connectors. 3. Remove the lumbar support switch. 4. Remove the power seat adjuster switch assembly. INSTALLATION PROCEDURE 1. Install the power seat adjuster switch assembly to the seat switch bezel. 2. Install the lumbar support switch to the seat switch bezel. 3. Connect the electrical connectors. NOTE: Refer to Fastener Notice in Service Precautions. 4. Install the screws retaining the power seat switch bezel. Tighten Tighten the screws to 2 N.m (18 lb in). Seat Switch Replacement - Power SEAT SWITCH REPLACEMENT - POWER REMOVAL PROCEDURE Interior - Seat Cover Wrinkle/Crease/Burn Info Seat Cover: All Technical Service Bulletins Interior - Seat Cover Wrinkle/Crease/Burn Info INFORMATION Bulletin No.: 04-08-50-006D Date: September 09, 2010 Subject: Minor Wrinkles/Creases, Discoloration, Cigarette Burns and Customer Induced Cuts and Stains on Front and Rear Driver and Passenger Seats with Leather, Vinyl or Cloth Seat Covers Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks 2009 and Prior HUMMER H2 2010 and Prior HUMMER H3 2009 and Prior Saab 9-7X 2010 and Prior Saturn Supercede: This bulletin is being revised to add a model year. Please discard Corporate Bulletin Number 04-08-50-006C (Section 08 - Body and Accessories). If a customer comes in to your dealership due to certain conditions of the seat covers (splits, wrinkles, loose stitching, etc.), you must examine the seat cover in order to determine the validity of the customer claim. Some components from the above listed vehicles have been returned to the Warranty Parts Center (WPC) and analysis of these parts showed "customer induced damage" or No Trouble Found (NTF). The dealer should pay particular attention to the following conditions: - Cigarette burns Service and Repair Trailer Hitch: Service and Repair Trailer Hitch Replacement Removal Procedure 1. Disconnect the trailer wiring harness. 2. Remove the hitch platform bolts from the frame rails and the rear bumper. 3. Remove the hitch platform from the vehicle. Installation Procedure 1. Position the hitch platform to the vehicle. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the platform hitch bolts to the frame rails and the rear bumper. Tighten the bolts to 125 N.m (92 lb ft). Page 7235 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Weather Pack Connectors WEATHER PACK CONNECTORS The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. Interior - Seat Memory Feature Appears Inoperative Memory Positioning Module: All Technical Service Bulletins Interior - Seat Memory Feature Appears Inoperative Bulletin No.: 04-08-50-003 Date: February 26, 2004 INFORMATION Subject: Enabling Memory Seat Feature via DIC If Feature Appears Inoperative Models: 2003-2004 Cadillac Escalade, Escalade ESV, Escalade EXT 2003-2004 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2003-2004 GMC Sierra, Yukon, Yukon Denali, Yukon Denali XL 2003-2004 HUMMER H2 with Steering Wheel Controls (RPO UK3) (standard on H2) If the memory seat feature appears inoperative, check the Driver Information Center (DIC). Many of the memory seat modules that were returned through the Warranty Parts Center for a condition of inoperative have shown No Trouble Found. The Driver Information Center (DIC), programmed for Seat Entry and Exit, is set to the default "Off" mode at the assembly plant. DO NOT REPLACE THE MEMORY SEAT MODULE. Perform the following procedure. Important: The following procedure will need to be completed for each Remote/Key selection. Using the DIC menu, do the following steps: 1. Set the "Seat Recall" to either "At Key In" or "On Remote" based on the customer's preference. 2. Set the "Exit Seat" to "On". 3. Adjust the following items: Memory Seat: 3.1. Driver's Seat (including the seat back, recliner, lumbar, and side wings) 3.2. Throttle and Brake Pedals (not available on H2 or Silverado and Sierra Trucks) 3.3. Outside Mirrors 3.4. Radio Station Presets 3.5. Last Chosen Climate Control System Settings (not available on Silverado or Sierra Trucks) 3.6. Press and hold the "1" or "2" (for driver 1 or 2) button of the memory control for three seconds. A double chime will sound to let you know that the position has been stored. Easy Exit Seat: 3.1. Press and release the 1 or 2 button or press the unlock button on the desired remote keyless entry transmitter. The seat will move to the stored memory position. 3.2. Adjust the seat to the desired exit position. 3.3. Press and hold the exit button of the memory control (located on the door) for three seconds. A double chime will sound to let you know that the position has been stored for the identified driver (1 or 2). Page 8795 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the cover up until the dress cover releases. Repeat this procedure for the other locking tab. 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. 5. If the connector has a nose piece, use a small flat-blade tool to remove the nose piece by inserting the blade into the slot on the front of the connector and prying up on the nose piece. IMPORTANT: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 6. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. IMPORTANT: Be careful not to angle or rock the J 38125-13A tool when inserting it into the connector or the tool may break. Page 2290 Heater Hose: Service and Repair Heater Hose Replacement - Inlet (With RPO Code HP2 Rear) HEATER HOSE REPLACEMENT - INLET (W/ HP2 REAR) TOOLS REQUIRED J 43181 Quick Connect Connector Removal Tool REMOVAL PROCEDURE 1. Drain the cooling system. Refer to Draining and Filling Cooling System (with HP2)Draining and Filling Cooling System (without HP2) in Cooling System. 2. Using the J 43181 disconnect the heater hose from the heater core inlet. 2.1. Install the J 43181 to the heater core pipe. 2.2. Close the tool around the heater core pipe. 2.3. Firmly pull the tool into the quick connect end of the heater hose. 2.4. Firmly grasp the heater hose. Pull the heater hose forward in order to disengage the hose from the heater core. 3. Reposition the inlet heater hose clamp (2) from the auxiliary water pump (1). 4. Remove the inlet heater hose (3) from the auxiliary water pump (1). INSTALLATION PROCEDURE Page 4147 1. Locate the air flow direction arrow (2) on the MAF/IAT sensor. 2. Install the MAF/IAT sensor to the air cleaner assembly. NOTE: Refer to Fastener Notice in Service Precautions. 3. Tighten the MAF/IAT clamp. Tighten Tighten the clamp to 7 N.m (62 lb in). 4. Connect the MAF/IAT sensor electrical connector (4). 5. Push in the gray CPA retainer. 6. Install the air cleaner outlet duct. Page 12931 Tighten Tighten the retaining screws to 2 N.m (18 lb in). 10. Reposition the inboard seat track trim (1). 11. Connect the audio amplifier electrical connectors. 12. Connect the floor console electrical connector. 13. Install the center console end panel. 14. Install the console storage bin. 15. Install the cupholder to the console. 16. Install the upper console bezel. 17. Install the radio amp fuse. 18. If the amplifier has been replaced, perform the audio amplifier set up procedure for the BOSE. amplifier with UQ7 and Y91. Refer to Audio Amplifier Setup. Page 9070 Application Tabel Part 1 Page 16171 Control Module References Part 5 Page 4296 Electrical Symbols Part 14 Locations Knock Sensors Page 14626 Seat Rear Vertical Position Sensor - Driver (With RPO Code AN3) Page 9624 Fuse Block - Underhood - Secondary Wire Entry (With RPO Code HP2) Part 1 Page 9404 Electrical Symbols Part 2 Automatic Transmission - 4L60-E/4L65-E Transmission Speed Sensor: Locations Automatic Transmission - 4L60-E/4L65-E Automatic Transmission Electronic Component Views (M30/M32) Electronic Components Page 12609 10. Disconnect and remove the OnStar(R) jumper harness. Note: You will need to remove the short GPS cable from this jumper harness. 11. Untape the cell antenna coax from the body harness in the trunk. This will be necessary to provide adequate length to connect to the new VCIM. 12. Fasten three retainer clips (1) from the kit to the new bracket that is included in the kit, and position the VCIM to the bracket (2). 13. Install the three bolts from the kit. Tighten the bolts to 10 Nm (89 lb in). 14. Connect the new OnStar(R) jumper harness supplied in the kit to the VCIM (two white connectors on module). 15. Connect small GPS coax cable jumper harness supplied in the kit (end with blue plastic housing) to VCIM GPS connector. 16. Position the VCIM / bracket assembly to the studs. 17. Install the bracket nuts saved from the Removal Procedure above to the VCIM / bracket assembly mounting studs. Tighten the nuts to 4 Nm (35 lb in). 18. Connect the new OnStar(R) jumper harness to the body wiring harness (C410 connector). 19. Connect small coax cable jumper from VCIM to the OnStar(R) Global Positioning Satellite (GPS) antenna coaxial cable at the connector previously left in the vehicle (short jumper removed from old harness in step 5.10). 20. Connect the cellular coaxial cable previously left in vehicle to the OnStar(R) VCIM. 21. Verify that all harnesses are properly secured in vehicle. 6. After replacing the VCIM, it is essential to configure the new OnStar(R) system. Failure to configure the system will result in an additional customer visit for repair. DO NOT press and hold the white dot or phone button on the keypad as it will not reset this version of the OnStar(R) system and may result in a DTC being set. Use of the TIS2WEB and SPS applications, along with the Tech2(R), are required in order to perform the VCIM configuration and setup procedure for this vehicle. The configuration and set-up procedure is now a two-step process which enables an automated activation by the OnStar(R) Center, without a button press by the technician to the OnStar(R) Call Center. 1. Connect the Tech2(R) to the vehicle. Page 10248 Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses CIRCUIT PROTECTION - FUSES The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the Page 9177 C102 I/P Harness To Chassis Harness Part 2 Page 10448 7. Remove the adjustment arm by sliding the torsion bar forward until the torsion bar clears the adjustment arm. Use your hand to support the adjustment arm as the adjustment arm releases from the torsion bar. 8. Remove the torsion bar crossmember bolts (4) from the weld nuts (1). 9. Remove the upper link mounting nuts (1) and the bolts (2). 10. Remove the torsion bar crossmember. Page 3075 Axle Nut: Specifications Axle Shaft Nut ...................................................................................................................................... ................................................ 240 Nm (177 ft. lbs.) Page 16008 Electrical Symbols Part 3 Automatic Transmission - 4L60-E/4L65-E Transmission Speed Sensor: Locations Automatic Transmission - 4L60-E/4L65-E Automatic Transmission Electronic Component Views (M30/M32) Electronic Components Emissions - MIL ON/DTC P0446 Stored In ECM Evaporative Canister Filter: All Technical Service Bulletins Emissions - MIL ON/DTC P0446 Stored In ECM TECHNICAL Bulletin No.: 02-06-04-037I Date: September 16, 2010 Subject: Check Engine Light On, Fuel Tank Hard to Fill, DTCs P0442, P0446, P0455 or P0449 Set (Replace Evaporative Emission (EVAP) Vent Valve Solenoid Assembly and Add/Relocate Filter Box Using Service Kit) Models: 1999-2007 Chevrolet Silverado (Classic) Models 1999-2007 GMC Sierra (Classic) Models 2007-2010 Chevrolet Silverado Models (Including Hybrid) 2007-2010 GMC Sierra Models (Including Hybrid) Supercede: This bulletin is being revised to add the 2010 model year and to include the Hybrid models. Please discard Corporate Bulletin Number 02-06-04-037H (Section 06 - Engine/Propulsion System). Condition Some customers may comment about the check engine light being illuminated. They may also comment that their vehicle is difficult to fill with fuel or when filling, the pump continuously shuts off before the tank is full. When checking the vehicle for DTCs, the ECM may report one or more of the following DTCs set as current or in history: P0442, P0446, P0449 or P0455. Cause The EVAP canister vent solenoid (CVS) valve draws fresh air into the system through a vent. Under certain operating conditions, dirt and dust intrusion into the EVAP CVS fresh air intake/venting system, may result in restricted air flow. Under certain operating conditions, water, if ingested into the EVAP CVS fresh air intake/venting system, may reach the CVS valve causing corrosion in the CVS valve, and may cause restrictions in the fresh air intake path, when the valve is in the closed position. Correction (1999-2007 Classic/Old Style Models) After following the published SI diagnostics and determining that the EVAP canister vent valve is the cause of the MIL light, replace the existing EVAP canister vent valve assembly with a new assembly. This new assembly is a sealed unit that is designed to be vented through a remote filter box. To ensure correct installation, follow the procedures below. Important DO NOT replace the EVAP canister assembly for this concern unless it fails the leak test. 1999-2003 Model Year (Use Service Kit P/N 19207762) 1. Raise the vehicle. Suitably support the vehicle. 2. Disconnect the EVAP canister vent valve electrical connector, if equipped. 3. Disengage the two vent valve pipe clips securing the pipe to the underbody. Remove the clips from the underbody and discard. 4. Disconnect the vent valve pipe at the EVAP canister. 5. Remove and retain the EVAP canister vent valve bracket mounting bolt. 6. Remove the complete EVAP canister vent valve assembly with bracket attached and discard. Locations Engine Oil Pressure (EOP) Sensor And CMP Sensor Page 9252 C399 Body Harness To Passenger Seat Harness Part 1 Page 9771 C324 Lumbar Bolster Harness To Seat Harness (With RPO Code AN3) Page 15827 Turn Signal Switch: Diagrams Turn Signal Multifunction Switch - C1 Page 16144 IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections TESTING FOR INTERMITTENT AND POOR CONNECTIONS TOOLS REQUIRED - J 35616-C GM-Approved Terminal Test Kit - J 38125-D Terminal Repair Kit - J 42675 Flat-Wire Probe Adapter Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector. - Poor terminal to wire connection - Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. - Wire insulation which is rubbed through - This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. - Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. Testing For Proper Terminal Contact It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-D or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-D, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. Page 9191 C151 I/P Harness To ATC Harness (With RPO Codes NP1/NP8) Page 328 Test Description DTC U1001 and U1254 Circuit/System Description Modules connected to the Class 2 serial data circuit monitor for serial data communications during normal vehicle operation. Operating information and commands are exchanged among the modules. When a module receives a message for a critical operating parameter, the module records the identification number of the module which sent the message for State of Health monitoring. A critical operating parameter is one which, when not received, requires that the module use a default value for that parameter. Once an identification number is learned by a module, it will monitor for that module's Node Alive message. Each module on the class 2 serial data circuit which is powered and performing functions that require detection of a communications malfunction is required to send a Node Alive message every 2 seconds. When no message is detected from a learned identification number for 5 seconds, a DTC U1XXX where XXX is equal to the 3-digit identification number is set. Page 6593 AWD/4WD - AWD/4WD Lamps/System Inop./DTC C0550 Control Module: Customer Interest AWD/4WD - AWD/4WD Lamps/System Inop./DTC C0550 Bulletin No.: 02-04-21-006E Date: July 20, 2006 TECHNICAL Subject: Inoperative 4WD/AWD Lamps, Inoperative 4WD/AWD System, DTC C0550 Set, No Communication with TCCM (Reprogram Transfer Case Control Module) Models: 2004 Buick Rainier 2002-2004 Chevrolet TrailBlazer, TrailBlazer EXT 2003-2004 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2002-2004 GMC Envoy, Envoy XL 2003-2004 GMC Sierra, Yukon, Yukon XL 2004 GMC Envoy XUV 2002-2004 Oldsmobile Bravada with Electronic Shift or Active Transfer Case (RPOs NP1, NP4 or NP8) Supercede: This bulletin is being revised to add Subject information and change the labor operation. This bulletin cancels and supersedes Bulletin Number 03-04-21-006. Please discard Corporate Bulletin Numbers 02-04-21-006D and 03-04-21-006 (Section 04 - Driveline/Axle). Condition Some customers may comment that the 4WD/AWD indicator lights on the selector switch do not work, or the 4WD/AWD system may be inoperative and/or the service 4WD light is illuminated. The condition is typically intermittent and always occurs at key-up. Upon investigation, the technician may find DTC C0550 set. Cause The Transfer Case Control Module (TCCM) has not received the wake-up call during key-up and has remained in the "sleep mode". When the TCCM is in the "sleep mode", it will not communicate with the class II bus or the Tech 2(R). Correction 1. Try to communicate with the TCCM. If no communication, go to step 2. If communication is possible, go to step 5. 2. Remove the underhood (ATCM or TREC) TCCM fuse. 3. Wait 30 seconds. 4. Reinstall the fuse. The module should wake up and communicate with the Tech 2(R). 5. Check for codes in the TCCM. If a C0550 is found current or in history with or without other codes, replace the module and go to step 6. 6. Reprogram the TCCM with the latest TIS software using normal SPS procedures. 7. Verify operation and that no codes are present. Important: For the 2002 model year, the TCCM must be replaced and reprogrammed. Warranty Information Page 4664 If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Sir/SRS Wiring Repairs SIR/SRS WIRING REPAIRS TOOLS REQUIRED J 38125-D Terminal Repair Kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-D contains the following items: - Special sealed splices - in order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping tool - A heat torch - An instruction manual The sealed splices have the following 2 critical features: - A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-D also serves as a generic terminal repair kit. The kit contains the following items: - A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors Page 10470 18. Inspect and add axle lubricant to the axle housing, if necessary. 19. Lower the vehicle. Page 13144 Important: Secure the wiring harness so that there is no risk of chafing and rattling. 9.4. Fold back the wiring harness and tape over the connectors (C). Fold back the wiring harness once more and secure with cable ties (D). 9.5. Install the right-hand rear luggage compartment in accordance with WIS - 8. Body - Interior equipment - Adjustment/Replacement. 10. Install the ground cable to the battery's negative terminal. 11. Clear the diagnostic trouble codes. 12. Set the date and time, see WIS - 3. Electrical system - Information display (SID_ - Technical description. 2003-2005 Saab 9-3 (9400) 4D/5D; 2004-2005 Saab 9-3 (9400) CV 2003-2005 Saab 9-3 (9440) 4D/5D; 2004-2005 Saab 9-3 (9440) CV Notice: Handle the fiber optic cables with care or the signal may be distorted. ^ It is very important that the two leads in the connector are not confused with one another. ^ Do not splice the cables. ^ Do not bend the cable in a radius smaller than 25 mm (1 in). ^ Do not expose the cable to temperatures exceeding 185°F (85°C). ^ Keep the cable ends free from dirt and grime. ^ Do not expose the cable to impact as this may cause the transparent plastic to whiten, thereby reducing the intensity of the light and causing possible communication interruptions. ^ The cable should not lie against any sharp edges as this may cause increased signal attenuation. 1. Remove the ECU CU with a Tech 2(R) according to the following: Fault diagnosis - Select model year - Select Saab 9-3 Sport (9440) - All - Add/Remove - Control Module - CU/PU - Remove. 2. Remove the ground cable from the battery's negative terminal. 3. Remove the floor console in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 4. Pry out the signal line from the SRS control module to the OnStar(R) control module and secure it: Page 6303 The second design oil pump rotor (212) and slide (203) are identified with dimples (circular depression) as shown above. The rotor (212) has two dimples adjacent to the rotor drive tangs (1). The slide (203) has one dimple located on the spring tab (2). Disclaimer Underhood Electrical Center or Junction Block Replacement Relay Box: Service and Repair Underhood Electrical Center or Junction Block Replacement UNDERHOOD ELECTRICAL CENTER OR JUNCTION BLOCK REPLACEMENT REMOVAL PROCEDURE 1. Disconnect the negative battery cable. 2. Remove the left fender upper brace. 3. Remove the electrical center brace cover assemble by lifting the cover (3) outwards to clear the tabs. 4. Remove all fuses and relays. Page 2618 Location View Page 9843 Junction Block - I/P Wire Entry Part 3 Page 5178 1. Install a NEW air filter element. 2. Install the air cleaner housing cover. 3. Tighten the air cleaner housing top screws until snug. 4. Connect the MAF/IAT sensor electrical connector (4). 5. Install the air cleaner outlet duct. Page 9273 Junction Block - Rear Lamps - C3 Page 2525 - Support the GM Oil Life System, thereby minimizing the replacement of engine oil, before its life has been depleted. - Reduce the duplication of requirements for a large number of internal GM engine oil specifications. International Lubricants Standardization and Approval Committee (ILSAC) GF-5 Standard In addition to GM dexos 1(TM), a new International Lubricants Standardization and Approval Committee (ILSAC) standard called GF-5, was introduced in October 2010. - There will be a corresponding API category, called: SN Resource Conserving. The current GF-4 standard was put in place in 2004 and will become obsolete in October 2011. Similar to dexos 1(TM), the GF-5 standard will use a new fuel economy test, Sequence VID, which demands a statistically significant increase in fuel economy versus the Sequence VIB test that was used for GF-4. - It is expected that all dexos 1(TM) approved oils will be capable of meeting the GF-5 standard. However, not all GF-5 engine oils will be capable of meeting the dexos 1(TM) specification. - Like dexos(TM), the new ILSAC GF-5 standard will call for more sophisticated additives. The API will begin licensing marketers during October 2010, to produce and distribute GF-5 certified products, which are expected to include SAE 0W-20, 0W-30, 5W-20, 5W-30 and 10W-30 oils. Corporate Average Fuel Economy (CAFE) Requirements Effect on Fuel Economy Since CAFE standards were first introduced in 1974, the fuel economy of cars has more than doubled, while the fuel economy of light trucks has increased by more than 50 percent. Proposed CAFE standards call for a continuation of increased fuel economy in new cars and trucks. To meet these future requirements, all aspects of vehicle operation are being looked at more critically than ever before. New technology being introduced in GM vehicles designed to increase vehicle efficiency and fuel economy include direct injection, cam phasing, turbocharging and active fuel management (AFM). The demands of these new technologies on engine oil also are taken into consideration when determining new oil specifications. AFM for example can help to achieve improved fuel economy. However alternately deactivating and activating the cylinders by not allowing the intake and exhaust valves to open contributes to additional stress on the engine oil. Another industry trend for meeting tough fuel economy mandates has been a shift toward lower viscosity oils. dexos 1(TM) will eventually be offered in several viscosity grades in accordance with engine needs: SAE 0W-20, 5W-20, 0W-30 and 5W-30. Using the right viscosity grade oil is critical for proper engine performance. Always refer to the Maintenance section of a vehicle Owner Manual for the proper viscosity grade for the engine being serviced. GM Oil Life System in Conjunction With dexos (TM) Supports Extended Oil Change Intervals To help conserve oil while maintaining engine protection, many GM vehicles are equipped with the GM Oil Life System. This system can provide oil change intervals that exceed the traditional 3,000 mile (4,830 km) recommendation. The dexos (TM) specification, with its requirements for improved oil robustness, compliments the GM Oil Life System by supporting extended oil change intervals over the lifetime of a vehicle. If all GM customers with GM Oil Life System equipped vehicles would use the system as intended, GM estimates that more than 100 million gallons of oil could be saved annually. GM dexos 2(TM) Information Center Website Refer to the following General Motors website for dexos 2(TM) information about the different licensed brands that are currently available: http://www.gmdexos.com GM dexos 2(TM) Engine Oil Trademark and Icons Page 643 Electronic Brake Control Module: Service and Repair Electronic Brake Control Module (EBCM) Replacement Removal Procedure Important: After installation, calibrate the new EBCM to the tire size that is appropriate to the vehicle. 1. Caution: Refer to Battery Disconnect Caution in Service Precautions. Disconnect the negative battery cable. 2. Raise and suitably support the vehicle. 3. Important: The area around the EHCU MUST be free from loose dirt to prevent contamination of disassembled ABS components. Thoroughly wash all contaminants from around the EHCU. 4. Disconnect the chassis electrical connectors from the EBCM. Page 12170 Vehicles Built with Upgradeable OnStar(R) System Analog Modules Note: Page 1428 1. Install the park brake warning lamp switch. 2. Notice: Refer to Fastener Notice in Service Precautions. Install the park brake warning lamp switch mounting bolt. ^ Tighten the bolt to 3 Nm (25 inch lbs.). 3. Connect the park brake warning lamp switch electrical connector. 4. Install the MID-bussed electrical center to the bracket. 5. Connect the negative battery cable. Page 15269 Door Switch: Diagrams Door Latch Assembly (Door Jamb Switch) - Front Passenger C2 Door Latch Assembly (Door Jamb Switch) - Front Passenger C2 Page 13434 Control Module References Part 5 Page 15818 Upper Steering Column Page 875 Electrical Symbols Part 12 Service and Repair Engine Oil Dip Stick - Dip Stick Tube: Service and Repair Oil Level Indicator and Tube Replacement Removal Procedure 1. Remove the oil level indicator. 2. Remove the oil level indicator tube bolt. 3. Remove the oil level indicator tube from the engine block. 4. Important: The O-ring seal may be reused if not cut or damaged. Inspect the O-ring seal for cuts or damage. 5. Remove the O-ring seal from the tube, if required. Page 9417 High Temperature Conditions Tools Required J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency MEASURING FREQUENCY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage MEASURING VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop MEASURING VOLTAGE DROP NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Description and Operation Seat Belt Reminder Lamp: Description and Operation FASTEN SAFETY BELT INDICATOR The fasten safety belt indicator may only be illuminated during RUN. The instrument panel cluster (IPC) illuminates the fasten safety belt indicator under the following conditions: - During bulb check. - The inflatable restraint sensing and diagnostic module (SDM) sends the status of the driver's seat belt switch to the IPC via a class 2 message. If the driver's seat belt is unfastened, the IPC will illuminate the fasten safety belt indicator for 72 seconds or until the driver's seat belt is fastened. If the driver's seat belt is unfastened within 8 seconds following the bulb check, the IPC will send a class 2 serial message requesting 5 chimes to sound. Page 8019 4. Install the ground, then the washer and then the bolt to the frame. Important: It is important to use the bolts, washers and nuts specified in this bulletin. These parts have been identified due to their conductive finish. 5. Install a washer and nut to the back side of the frame. Tighten Tighten the nut to 9 Nm (79 lb in). 6. Cover the front and back side of the repair area using Rubberized Undercoating. An additional check can be made to ensure a good connection for the battery cable to frame ground. It is possible for this ground to cause similar symptoms with the ABS as described above. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Parts Information Warranty Information Disclaimer Page 5584 Steps 19 - 23 Front Suspension Stabilizer Link: Service and Repair Front Suspension The content of this article reflects the changes identified in TSB 05-03-08-006. Stabilizer Shaft Link Replacement Removal Procedure 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Remove the stabilizer shaft nut (1) from the link bolt. 3. Remove the stabilizer shaft link bolt (3). 4. Remove the stabilizer shaft link insulators and spacers (2). 5. Inspect all of the parts for wear and damage. Installation Procedure 1. Install the stabilizer shaft link insulators and spacers (2). 2. Perform the following procedure before installing the stabilizer link bolts. ^ Remove all traces of the original adhesive patch. ^ Apply Threadlocker GM P/N 12345382 (Canadian P/N 10953489) BLUE LOCTITE # 242 on the threads of the bolts. 3. Install the stabilizer shaft link bolts (3). 4. Notice: Refer to Fastener Notice in Service Precautions. Install the stabilizer shaft nut (1) to the link bolt. ^ Tighten the nut to 10 Nm (89 inch lbs.). Continue tightening the nut until 2-4 threads protrude above the nut. 5. Remove the safety stands. 6. Lower the vehicle. Page 7073 Page 9469 Hybrid Control Module (HCM) - Part 2 Page 2506 ^ Tighten the rear axle drain plug to 33 Nm (24 ft. lbs.). 2. Fill the rear axle. Use the proper fluid. 3. For the 9.5 inch and the 10.5 inch axles, install the rear axle fill plug. ^ Tighten the rear axle fill plug to 33 Nm (24 ft. lbs.). 4. For the 11.5 inch axle, install the seal and the fill plug. ^ Tighten the rear axle fill plug to 33 Nm (24 ft. lbs.). 5. Lower the vehicle. Navigation Radio - Diagnostic Tips Navigation System: All Technical Service Bulletins Navigation Radio - Diagnostic Tips INFORMATION Bulletin No.: 08-08-44-010F Date: March 09, 2009 Subject: Navigation Radio Diagnostic Tips Models: 2008 and Prior GM Passenger Cars and Trucks (Including Saturn) 2008 and Prior HUMMER H2, H3 2008 and Prior Saab 9-7X All Equipped with Navigation Radio Supercede: This bulletin is being revised to update the model years involved, the radio part number list, remove the PQC parts restriction and revise the diagnostic information. Please discard Corporate Bulletin Number 08-08-44-010E (Section 08 - Body and Accessories). Recent part reviews indicate that the majority of Navigation Radios returned for analysis do not test as defective. In many cases, published SI documents were available to correct the condition without the need for an exchange unit. The following Diagnostic Tips may assist with the proper diagnosis and repair of Navigation Radio Concerns. Note For U.S. dealers the 2009 and 2010 Model Year Navigation Radios are currently on restriction through the Technical Assistance Center (TAC). Refer to PI PIC5102. To order Radios and Instrument Panel Clusters (IPC) for 2008 and prior model year vehicles, please continue to follow the normal process and contact an authorized Electronic Service Center (ESC) for assistance. For any Navigation Radio replaced, a copy of the Repair Order (RO) must be included with the returned radio. Be sure to document the customer's concern in detail, including unusual noises and what functions are affected. List any Diagnostic Trouble Codes (DTCs) on the RO. Ensure the radio is sufficiently protected during shipping to prevent damage to the radio assembly. Note Navigation Radios with physical damage (for example: shattered displays, impact damage to the radio face and fluid damage) must be reviewed with the District Service Manager for appropriate coverage prior to replacing the radio. The dealership must note the District Service Manager's approval on the Repair Order, along with the reason for the goodwill assistance. Do NOT disassemble the radio to try and retrieve stuck CDs/DVDs as this may result in a debit to the dealership. Refer to Corporate Bulletin Number 08-08-44-015, Information on Inappropriate Warranty Claims submitted for Damaged Radios and Instrument Panel Clusters. Getting Started Retrieve the Navigation Radio part number using the Tech 2(R). Refer to Corporate Bulletin Number 04-08-44-005C - Utilizing Tech 2 to Retrieve Part Numbers for Radios, Compact Disc (CD) Changers and Instrument Panel Clusters (IPC). Use the table below to determine the appropriate Diagnostic Tips Review to follow based on the radio part number. Scroll down the bulletin to find the corresponding Diagnostic Tips Review. Printing This Document To print the applicable Diagnostic Tips Review pages, select File then Print Preview. Use the arrows at the top of the screen to scroll left and right through the bulletin to identify the correct pages containing the questions. With the pages identified, click on the Print button at the top left. In the pop-up box, select "Pages" in the "Print Range" and type in the pages. For example, to print pages 19 through 22, type in the box provided "19-22". Once the page range has been filled in, click the Print box at the bottom of the pop-up box. Capacity Specifications Refrigerant: Capacity Specifications Refrigerant Charge .............................................................................................................................. ........................................................... 0.7 kg (1.6 lbs) Refrigerant Charge with Front and Rear A/C ................................................................................................................................................ 1.13 kg (2.5 lb) Page 3881 Page 10887 Electrical Symbols Part 10 Page 8383 1. Install the cable to the vehicle. 2. Install the park brake cable (2) to the lever (1). 3. Perform the following procedure to install the cable (2) to the backing plate (4): 1. Compress the spring (3) by pushing towards the lever (1). 2. Route the cable (2) through the slot in the backing plate. 3. Push the cable housing into the backing plate (4) until the locking tabs snap into place. 4. Install the cable to the mounting bracket until the locking tabs snap into place. 5. Notice: Refer to Fastener Notice in Service Precautions. Bolt the cable to the differential (clips). ^ Tighten the bolt to 25 Nm (18 ft. lbs.). Transfer Case - NVG 149-NP3 Speed Sensor: Service and Repair Transfer Case - NVG 149-NP3 Transfer Case Speed Sensor Replacement Removal Procedure 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. Disconnect the speed sensor electrical connector (4). 3. Remove the speed sensor. Installation Procedure 1. Install the speed sensor. ^ Tighten the sensor to 15 Nm (11 ft. lbs.). Notice: Refer to Fastener Notice in Service Precautions. Page 2695 Relay Block - I/P C8 (With RPO Codes 5G4/5X7/5Y0/TRW) Page 1654 7. Remove the HO2S. INSTALLATION PROCEDURE IMPORTANT: A special anti-seize compound is used on the HO2S threads. The compound consists of liquid graphite and glass beads. The graphite tends to burn away, but the glass beads remain, making the sensor easier to remove. New, or service replacement sensors already have the compound applied to the threads. If the sensor is removed from an exhaust component and if for any reason the sensor is to be reinstalled, the threads must have anti-seize compound applied before the reinstallation. 1. If reinstalling the old sensor, coat the threads with anti-seize compound GM P/N 12377953, or equivalent. NOTE: Refer to Component Fastener Tightening Notice in Service Precautions. 2. Install the HO2S. Page 12452 Claim Information - GM, Saturn Canada and Saab Canada Only Claim Information - Saturn US Only Customer Reimbursement Claims - Special Attention Required Customer reimbursement claims must have entered into the "technician comments" field the CSO # (if repair was completed at a Saturn Retail Facility) date, mileage, customer name, and any deductibles and taxes paid by the customer. Claim Information - Saab US Only Page 345 Automatic Transmission - 4L60-E/4L65-E Shift Cable: Adjustments Automatic Transmission - 4L60-E/4L65-E Automatic Transmission Range Selector Cable Adjustment 1. Ensure that the steering column shift lever is in the park (P) position. 2. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 3. Ensure that the transmission manual shaft lever is in the park (P) position. 4. Grasp the shift cable shifter end (1) in the left hand and the shift cable transmission end (2) in the right hand. 5. Align the outside diameter of the transmission end (2) with the inside diameter of the shifter end (1). 6. Push the end of the transmission cable (3) inside the shifter end until the blue spring (2) on the transmission end (3) is fully compressed, this will engage the inner wire and lock both wires together. Page 2621 Application Table Part 2 Electrical - MIL ON/DTC's Set By Various Control Modules Relay Module: Customer Interest Electrical - MIL ON/DTC's Set By Various Control Modules TECHNICAL Bulletin No.: 09-06-03-004D Date: December 08, 2010 Subject: Intermittent No Crank/No Start, No Module Communication, MIL, Warning Lights, Vehicle Messages or DTCs Set by Various Control Modules - Diagnosing and Repairing Fretting Corrosion (Disconnect Affected Connector and Apply Dielectric Lubricant) Models: 2011 and Prior GM Passenger Cars and Trucks Attention: This repair can be applied to ANY electrical connection including, but not limited to: lighting, body electrical, in-line connections, powertrain control sensors, etc. DO NOT over apply lubricant to the point where it prevents the full engagement of sealed connectors. A light coating on the terminal surfaces is sufficient to correct the condition. Supercede: This bulletin is being revised to update the Attention statement and add the 2011 model year. Please discard Corporate Bulletin Number 09-06-03-004C (Section 06 Engine/Propulsion System). Condition Some customers may comment on any of the following conditions: - An intermittent no crank/no start - Intermittent malfunction indicator lamp (MIL) illumination - Intermittent service lamp illumination - Intermittent service message(s) being displayed The technician may determine that he is unable to duplicate the intermittent condition. Cause This condition may be caused by a buildup of nonconductive insulating oxidized debris known as fretting corrosion, occurring between two electrical contact surfaces of the connection or connector. This may be caused by any of the following conditions: - Vibration - Thermal cycling - Poor connection/terminal retention - Micro motion - A connector, component or wiring harness not properly secured resulting in movement On low current signal circuits this condition may cause high resistance, resulting in intermittent connections. On high current power circuits this condition may cause permanent increases in the resistance and may cause a device to become inoperative. Representative List of Control Modules and Components The following is only a representative list of control modules and components that may be affected by this connection or connector condition and DOES NOT include every possible module or component for every vehicle. - Blower Control Module - Body Control Module (BCM) - Communication Interface Module (CIM) - Cooling Fan Control Module - Electronic Brake Control Module (EBCM) - Electronic Brake and Traction Control Module (EBTCM) - Electronic Suspension Control (ESC) Module - Engine Control Module (ECM) - Heating, Ventilation and Air Conditioning (HVAC) Control Module Page 7808 Park Neutral Position (PNP) Switch C175 Page 9409 Electrical Symbols Part 8 Page 15021 2. With the tailgate (1) completely open as shown in the upper part of the illustration, pull the RIGHT SIDE of the tailgate rearward as shown in the lower illustration. Do not pull on the left side of the tailgate. - If the tailgate hinge (2) will NOT disengage from the pickup box on the right side, no repair is needed to the hinge. Proceed to the section titled "Support Cable Replacement" and replace any support cable that HAD sealant in the earlier inspection. If neither of the support cables requires replacement, no further action is required. - If the tailgate hinge (3) will disengage from the pickup box on the right side, proceed to the next step. 3. With the right side of the tailgate disengaged from the pickup box, inspect the hinge on the right side of the tailgate for damage. The illustration above shows an undamaged hinge (1) and a damaged or bent hinge (2). - If the hinge is NOT damaged, no repair is needed to the hinge. Proceed to the section titled, "Support Cable Replacement" and replace any support cables that HAD sealant in the earlier inspection. If neither of the support cables require replacement, no further action is required. - If the hinge IS damaged or bent, the hinge needs to be replaced. Proceed to the section titled, "Hinge Replacement". Hinge Replacement - Escalade EXT, Avalanche, New Style Silverado and Sierra, Kodiak, TopKick The following procedure should only be performed if the right side of the tailgate could be disengaged from the pickup box. 1. Release (unhook) the left side tailgate support cable from the pickup box. Front Drive Axle Pinion Flange: Service and Repair Front Drive Axle Differential Drive Pinion Flange/Yoke, Seal, and Dust Deflector Replacement - Front ^ Tools Required J 8614-01 Flange and Pulley Holding Tool - J 36366 Pinion Oil Seal Installer Removal Procedure 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Remove the tire and wheel assemblies. 3. Remove the brake calipers. 4. Remove the differential carrier assembly shield, if equipped. 5. Reference mark the relationship of the propeller shaft to the front axle pinion yoke. 6. Remove the yoke retainer bolts (6) and the yoke retainers (7) from the front axle pinion yoke (1). 7. Disconnect the propeller shaft universal joint (2) from the front axle pinion yoke (1). Wrap the bearing caps with tape in order to prevent the loss of bearing rollers. Notice: When removing the propeller shaft, do not attempt to remove the shaft by pounding on the yoke ears or using a tool between the yoke and the universal joint. If the propeller shaft is removed by using such means, the injection joints may fracture and lead to premature failure of the joint. 8. Support the propeller shaft and move out of the way as necessary. 9. Measure the torque required in order to rotate the pinion. Use an inch-pound torque wrench. Record the torque value for reassembly. This will give the combined preload for the following components: ^ The pinion bearings ^ The pinion seal ^ The carrier bearings Page 11094 1. Remove the instrument panel accessory trim plate. 2. Remove the screws from the HVAC control module. 3. Depress the control assembly retaining tabs and remove the HVAC control module from the instrument panel. 4. Disconnect the electrical connectors from the HVAC control module. INSTALLATION PROCEDURE IMPORTANT: The Key should be in the off position when connecting the electrical connectors to ensure proper calibration. 1. Connect the electrical connectors to the HVAC control module. 2. Install the HVAC control module into the instrument panel, ensuring that the HVAC control module retaining tabs lock into place. NOTE: Refer to Fastener Notice in Service Precautions. 3. Install the screws from the HVAC control module. Tighten Tighten the screws to 1.9 N.m (17 lb in). 4. Install the instrument panel accessory trim plate IMPORTANT: Do not adjust any controls on the HVAC control module while the HVAC control module is calibrating. If interrupted improper HVAC performance will result. 5. Start the vehicle and let run for one minute. OnStar(R) - Analog/Digital Ready System Digital Upgrade Technical Service Bulletin # 05-08-46-006Q Date: 081028 OnStar(R) - Analog/Digital Ready System Digital Upgrade INFORMATION Bulletin No.: 05-08-46-006Q Date: October 28, 2008 Subject: Information on Upgrading Certain OnStar(R) Analog/Digital-Ready Systems to OnStar(R) Generation 6 Digital-Capable System Models Supercede: This bulletin is being revised to update the upgrade kit installation information for the 2001 Chevrolet Impala and Monte Carlo. Please discard Corporate Bulletin Number 05-08-46-006P (Section 08 - Body and Accessories). This bulletin is being issued to provide dealer personnel with information and procedures to follow should an owner wish to upgrade their OnStar(R) Analog/Digital-Ready system to an OnStar(R) Generation 6 Digital-Capable system. Disclaimer Program Overview Program Overview To upgrade their vehicle to an OnStar(R) Generation 6 Digital-Capable system, all that a customer must do is: ^ Take their vehicle to their dealer for the system upgrade. Interior - Seat Memory Feature Appears Inoperative Memory Positioning Module: All Technical Service Bulletins Interior - Seat Memory Feature Appears Inoperative Bulletin No.: 04-08-50-003 Date: February 26, 2004 INFORMATION Subject: Enabling Memory Seat Feature via DIC If Feature Appears Inoperative Models: 2003-2004 Cadillac Escalade, Escalade ESV, Escalade EXT 2003-2004 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2003-2004 GMC Sierra, Yukon, Yukon Denali, Yukon Denali XL 2003-2004 HUMMER H2 with Steering Wheel Controls (RPO UK3) (standard on H2) If the memory seat feature appears inoperative, check the Driver Information Center (DIC). Many of the memory seat modules that were returned through the Warranty Parts Center for a condition of inoperative have shown No Trouble Found. The Driver Information Center (DIC), programmed for Seat Entry and Exit, is set to the default "Off" mode at the assembly plant. DO NOT REPLACE THE MEMORY SEAT MODULE. Perform the following procedure. Important: The following procedure will need to be completed for each Remote/Key selection. Using the DIC menu, do the following steps: 1. Set the "Seat Recall" to either "At Key In" or "On Remote" based on the customer's preference. 2. Set the "Exit Seat" to "On". 3. Adjust the following items: Memory Seat: 3.1. Driver's Seat (including the seat back, recliner, lumbar, and side wings) 3.2. Throttle and Brake Pedals (not available on H2 or Silverado and Sierra Trucks) 3.3. Outside Mirrors 3.4. Radio Station Presets 3.5. Last Chosen Climate Control System Settings (not available on Silverado or Sierra Trucks) 3.6. Press and hold the "1" or "2" (for driver 1 or 2) button of the memory control for three seconds. A double chime will sound to let you know that the position has been stored. Easy Exit Seat: 3.1. Press and release the 1 or 2 button or press the unlock button on the desired remote keyless entry transmitter. The seat will move to the stored memory position. 3.2. Adjust the seat to the desired exit position. 3.3. Press and hold the exit button of the memory control (located on the door) for three seconds. A double chime will sound to let you know that the position has been stored for the identified driver (1 or 2). Page 9931 What corrected the customer concern and was the repair verified? Please Explain: ............. Disclaimer Page 9092 Junction Block - I/P Wire Entry Part 4 Page 13706 4. Install the door trim panel. Component Locations Transmission Temperature Sensor/Switch: Component Locations Automatic Transmission - 4L60-E/4L65-E Automatic Transmission Electronic Component Views (M30/M32) Electronic Components Page 16154 6. Use fingers to squeeze the 2 locking legs of the cover. 7. Apply pressure and gently rock the cover until one locking leg is unseated. 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. Page 12803 Conditions for Running the DTC Ignition is in RUN or ACC position System voltage is between 9.5 - 15.5 volts. The above conditions are met for more than 1 second. Conditions for Setting the DTC The VCIM does not detect the presence of a cellular antenna for more than 1 second. Action Taken When the DTC Sets The vehicle is unable to connect to the OnStar(R) Call Center. The OnStar(R) status LED turns red. Conditions for Clearing the DTC The VCIM detects the presence of a cellular antenna. A history DTC clears after 50 malfunction-free ignition cycles. Circuit/System Testing Perform a visual inspection as shown above in order to verify that the cellular antenna and the cellular antenna coupling assembly are not damaged. If any components are damaged replace the assembly. DTC B2476 or B2482 DTC Descriptors Electrical - Information For Electrical Ground Repair Wiring Harness: All Technical Service Bulletins Electrical - Information For Electrical Ground Repair INFORMATION Bulletin No.: 10-08-45-001B Date: October 25, 2010 Subject: Information for Electrical Ground Repair - Use New Replacement Fasteners with Conductive Finish Models: 2011 and Prior GM Passenger Cars and Trucks (including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X Supercede: This bulletin is being revised to add the 2011 model year and update the Warranty Information. Please discard Corporate Bulletin Number 10-08-45-001A (Section 08 - Body and Accessories). Electrical Ground Repair Overview Proper electrical system function relies on secure, stable and corrosion-free electrical ground connections. Loose, stripped, or corroded connections increase the possibility of improper system function and loss of module communication. These conditions may also lead to unnecessary repairs and component replacement. In general, electrical ground connections are accomplished using one, or a combination of the following attachment methods: - Welded M6 stud and nut - Welded M6 nut and bolt - Welded M8 nut and bolt Determine which attachment method is used and perform the appropriate or alternative repair as described in this bulletin. M6 Weld Stud Replacement Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. Select a location adjacent the damaged or missing M6 ground stud having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the M6 conductive rivet stud flange. 2. Using GM approved residue-free solvent or equivalent, remove any grease from the repair site and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 3. Drill a 10 mm (0.40 in) diameter hole through the panel. 4. Remove paint and primer from the area surrounding the 10 mm (0.40 in) hole until bare metal is visible. Specifications Ignition Cable: Specifications Spark Plug Wire Resistance ................................................................................................................ .................................................... 1000 ohms per foot Page 9471 Starter/Generator Control Module (SGCM) Page 9738 C216 Brake/Clutch Harness To Fuse Block Jumper Harness (With RPO Code 9L4) Page 5933 Steering - Underhood Clunk Heard/Felt in Steering Wheel Steering Shaft: All Technical Service Bulletins Steering - Underhood Clunk Heard/Felt in Steering Wheel TECHNICAL Bulletin No.: 00-02-35-003N Date: March 26 2008 Subject: Clunking Noise Under Hood and Can Be Felt in Steering Wheel and/or Steering Column (Replace Upper Intermediate Steering Shaft [I-Shaft] Assembly) Models: 2002-2006 Cadillac Escalade Models 1999-2007 Chevrolet Silverado Models (Classic) 2000-2006 Chevrolet Suburban, Tahoe Models 2002-2006 Chevrolet Avalanche 1999-2007 GMC Sierra Models (Classic) 2000-2006 GMC Yukon, Yukon XL Models 2003-2006 HUMMER H2 Attention: This Service Bulletin DOES NOT include Mid-Size Utilities such as Buick Rainier, Chevrolet TrailBlazer Models, GMC Envoy Models or Oldsmobile Bravada. Refer to Service Bulletin 02-02-35-006A or newer for Mid-Size Utilities. Supercede: This bulletin is being revised to add diagnostic information (refer to Diagnostic Tips) to check the lower steering column bearing as a potential source of the noise. Please discard Corporate Bulletin Number 00-02-35-003M (Section 02-Steering). Condition Some customers may comment on a clunk-type noise coming from under the hood that also can be felt in the steering wheel. These conditions may be more noticeable when turning at low speeds on rough road surfaces. Diagnostic Tips Use the information below to help diagnose the source of the noise. ^ The lower steering column bearing may create the same noise as the intermediate shaft. Before replacing the I-shaft, verify the noise isn't being caused by movement from the lower steering column bearing. Check the bearing for movement by pushing up and down on the I-shaft where it attaches to the steering column. ^ Frame Snap and/or Popping Type Noise - A frame snap or popping type noise can be duplicated on rough or smooth road surfaces with steering wheel input to the left or the right. This type of noise can be HEARD and is typically louder with the windows rolled down. For additional information refer to Corporate Bulletin Number 03-08-61-002F or newer - Snap/Popping Type Noise Coming from Front of Vehicle (Remove Front Crossmember Change Fastener Orientation). ^ Intermediate Shaft Clunk - Intermediate shaft clunk is heard and FELT in the steering wheel and/or steering column area typically while driving on rough road surfaces with steering wheel input. Correction Important: ^ I-shaft P/N 19153614 has been designed to replace previous designed dampened and non-dampened I-shafts. The physical difference in the yoke size will accommodate all vehicles listed in this bulletin. ^ Due to the design of the new I-shaft, it is not possible to lubricate/grease the I-shaft. Replace the steering column upper intermediate shaft with an improved design shaft that will eliminate the clunk noise using the procedure listed below. Page 3202 1. Lubricate the valve rocker arms and pushrods with clean engine oil. 2. Lubricate the flange of the valve rocker arm bolts with clean engine oil.Lubricate the flange or washer surface of the bolt that will contact the valve rocker arm. 3. Install the valve rocker arm pivot support. 4. Important: Make sure that the pushrods seat properly to the valve lifter sockets. Install the pushrods. 5. Important: Make sure that the pushrods seat properly to the ends of the rocker arms. DO NOT tighten the rocker arm bolts at this time. Install the rocker arms and bolts. Page 2146 the description. Remove only one drive belt at a time if the vehicle has multiple drive belts. Operate the engine for a few seconds, this will verify if the rumbling noise is related to the drive belt(s) or not. With the drive belt(s) removed the water pump will not operate and the engine may overheat. Also diagnostic trouble codes (DTCs) may set when the engine is operated with the drive belt(s) removed. 4. Inspect the drive belt(s) to ensure that the drive belt(s) is not the cause of the noise. Small cracks across the ribs of the drive belt(s) will not cause the noise. Belt separation is identified by the plys of the belt separating, this may be seen at the edge of the belt or felt as a lump in the belt. 5. Small amounts of pilling is a normal condition and acceptable. When the pilling is severe the drive belt(s) does not have a smooth surface for proper operation. Page 9533 Fuse: Application and ID Junction Block - I/P Location View Location View Page 11410 Technicians are to inspect the HVAC actuator harness for contact with the instrument panel support brace. Repair any damage to the actuator harness wiring and install protective plastic conduit over the harness. Install friction tape over the sharp edge of the instrument panel brace. Clear the diagnostic trouble codes and verify proper HVAC system operation. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 14351 Electrical Symbols Part 12 Page 9308 Relay Box: Diagrams Junction Block - Rear Lamps - C1 Page 11368 Discharge Air Temperature Sensor / Switch: Description and Operation AIR TEMPERATURE SENSORS The air temperature sensors are a 2-wire negative temperature co-efficient thermistor. The vehicle uses the following air temperature sensors: Ambient Air Temperature Sensor - Inside Air Temperature Sensor Assembly - Upper Left Air Temperature Sensor - Upper Right Air Temperature Sensor - Lower Left Air Temperature Sensor - Lower Right Air Temperature Sensor A signal and a low-reference circuit enables the sensor to operate. As the air temperature surrounding the sensor increases, the sensor resistance decreases. The sensor signal voltage decreases as the resistance decreases. The sensor operates within a temperature range between -40°C (-40°F) to 101°C (215°F). The sensor signal varies between 0.5 volts. The input of the duct air temperature sensors are different from the ambient and inside sensors. The HVAC control module converts the signal to a range between 0-255 counts. As the air temperature increases the count value will decrease. If the HVAC control module detects a malfunctioning sensor, then the control module software will use a defaulted air temperature value. The default value for the ambient and inside air temperature sensors will be displayed on the scan tool. The default value for the duct air temperature sensors will not be displayed on the scan tool. The scan tool parameter for the duct air temperature sensors are the actual state of the signal circuit. The default action ensures that the HVAC system can adjust the inside air temperature near the desired temperature until the condition is corrected. The ambient air temperature sensor mounts underhood and can be affected by city traffic, by idling, and by restarting a hot engine. Therefore, the HVAC control module filters the value of the ambient air temperature sensor for temperature display. The ambient air temperature value is updated under the above conditions. The scan tool has the ability to update the displayed ambient air temperature. To update the ambient air temperature display on the HVAC control module, perform the following procedure: Simultaneously press the MODE, FRONT DEFROST and REAR DEFROST switches. 1. Turn ON the ignition. 2. Simultaneously press the MODE, FRONT DEFROST and REAR DEFROST switches. Page 4063 15. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 16. Install the electrical ground wire terminal to the rivet stud. 17. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 18. Install the M6 conductive nut to the rivet stud and: Tighten Tighten to 8 Nm (71 lb in). 19. Verify proper system operation. M6 Weld Nut Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M6 weld nut at the electrical ground location is damaged or stripped, a M7 conductive self-threading bolt may be used to secure the ground wire terminal. 2. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the weld nut and allow to dry. 3. Remove any loose metal particles from the damaged or stripped weld nut with a stiff brush. 4. Select a M7 conductive self-threading bolt. Refer to the Parts Information section of this bulletin 5. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M7 conductive self-threading bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 6. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 7. Install the electrical ground wire terminal to the M7 conductive self-threading bolt. 8. Install the M7 conductive self-threading bolt and: Tighten Tighten to 9 Nm (80 lb in). 9. Verify proper system operation. M6 Weld Nut Alternative Repair Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the electrical ground location is accessible from both sides of the panel, a M6 conductive bolt and a M6 conductive nut may be used to secure the electrical ground wire terminal. Refer to the Parts Information section of this bulletin. 2. Select a location adjacent the damaged M6 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the new electrical ground site. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the ground location and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 8.5 mm (0.33 in) diameter hole through the panel. 5. Remove paint and primer from the area surrounding the 8.5 mm (0.33 in) hole until bare metal is visible. 6. Select a M6 conductive bolt. Refer to the Parts Information section of this bulletin. 7. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 8. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 9. Install the electrical ground wire terminal and the M6 conductive bolt to the ground location. 10. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 11. Install the M6 conductive nut to the bolt and: Steering - 'Service Rear Wheel Steering' Message Body Control Module: Customer Interest Steering - 'Service Rear Wheel Steering' Message Bulletin No.: 05-02-118-002 Date: February 03, 2005 TECHNICAL Subject: DTC C0455, "Service Rear Wheel Steering", System Jumps from 4-Wheel Steer to 2-Wheel Steer (Reprogram BCM) Models: 2003-2005 Chevrolet Silverado, Suburban 2003-2005 GMC Sierra, Yukon XL with 4-Wheel Steer (RPO NYS) Condition Some customers may comment that the system will jump from 4-wheel steer to 2-wheel steer and the DIC displays the message "Service Rear Wheel Steering". Diagnosis will show DTC C0455-Front Steering Position Sensor malfunction. Cause This condition may be caused by a Class2 communication issue. Correction Reprogram the BCM. 2005 Model Year Vehicles: New software calibration, P/N 15248410, was released on TIS version 12 - broadcast to dealers on December 4, 2004. 2003-2004 Model Year Vehicles: New software calibration, P/N 15259330 ('03 Model Year) and P/N 15259331 ('04 04 Model Year), was released on TIS version 1.75 - broadcast to dealers on January 24, 2005. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Assist Handle Replacement - Front Passenger Assist Handle: Service and Repair Assist Handle Replacement - Front Assist Handle Replacement - Front Removal Procedure 1. Lower the right side of the headliner. Refer to Headliner Replacement. 2. Turn the retainers in the directions as shown in the graphic and then remove the retainers. 3. Remove the assist handle from the headliner. Installation Procedure 1. Install the assist handle through the opening in the headliner. 2. While holding the assist handle to the head liner install the retainer in the direction as shown in the graphic. 3. Install the headliner. Page 12334 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the cover up until the dress cover releases. Repeat this procedure for the other locking tab. 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. 5. If the connector has a nose piece, use a small flat-blade tool to remove the nose piece by inserting the blade into the slot on the front of the connector and prying up on the nose piece. IMPORTANT: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 6. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. IMPORTANT: Be careful not to angle or rock the J 38125-13A tool when inserting it into the connector or the tool may break. Locations Impact Sensor: Locations Front End Sensors Page 9438 - Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-D in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-D if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Page 11648 Seat Belt Switch - Front Passenger (With RPO Code AL0) Page 6170 4. Install the ground, then the washer and then the bolt to the frame. Important: It is important to use the bolts, washers and nuts specified in this bulletin. These parts have been identified due to their conductive finish. 5. Install a washer and nut to the back side of the frame. Tighten Tighten the nut to 9 Nm (79 lb in). 6. Cover the front and back side of the repair area using Rubberized Undercoating. An additional check can be made to ensure a good connection for the battery cable to frame ground. It is possible for this ground to cause similar symptoms with the ABS as described above. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Parts Information Warranty Information Disclaimer Page 15770 Turn Signal Multifunction Switch - C3 Page 10826 Air Temperature Actuator - Right Page 13834 Body Emblem: Service and Repair Emblem Replacement - Grille (Cadillac) Emblem Replacement - Grille (Cadillac) Removal Procedure 1. Mask grille in the area surrounding the emblem to prevent damage to the painted surface. 2. Remove the emblem (1) from the grille (2) using a small plastic flat-bladed tool. 3. Remove all traces of adhesive from the grille surface using an oil-free naphtha or alcohol. Installation Procedure 1. Remove the protective tape from the adhesive strip on the grille emblem (1). 2. Install the emblem (1) onto the grille (2) centering the emblem on the mating surface. Page 13585 8. Remove the following components from the front assist step brackets, and from the rear assist step brackets: 1. The bolts (1) 2. The lock washers (2) 3. The washers (3) 9. Remove the front brackets, and the rear brackets (4) from the assist step. 10. Remove the front gaskets, and the rear gaskets (5) from the assist step. Installation Procedure Important: Apply thread locker GM P/N 12345382 to all bolt threads prior to assembly. 1. Install the front gaskets, and the rear gaskets (5) to the assist step. 2. Install the front brackets, and the rear brackets (4) to the assist step. Notice: Refer to Fastener Notice in Service Precautions. 3. Install the following components to the front assist step bracket, and the rear assist step bracket: 1. The washers (3) 2. The lock washers (2) 3. The bolts (1) Torque the bolts to 90 N.m (66 lb ft). 4. Install the lower body-mount cushion assemblies (4), front and rear, to the vehicle. Page 6091 Band Apply Servo: Service and Repair Automatic Transmission - 4L80-E/4L85-E Reverse Servo Replacement Reverse Servo Replacement Removal Procedure 1. Remove the transmission filter. 2. Remove the rear servo from the transmission case in the following order: 1. Cover bolts (6) 2. Cover (5) 3. Cover gasket (4) 4. Bottom retaining clip (3) 5. Servo piston (2) 6. Outer ring oil seal (1) 7. Inner ring oil seal (7) 8. Accumulator piston (8) 9. Piston seal (9) 10. Washer (10) 11. Servo spring (11) 12. Servo spring retainer (12) 13. Selective pin (13) 14. Accumulator spring (14) Installation Procedure 1. Install the rear servo to the transmission in the following order: 1. Accumulator spring (14) 2. Selective pin (13) 3. Servo spring retainer (12) 4. Servo spring (11) 5. Washer (10) 6. Piston seal (9) 7. Accumulator piston (8) 8. Inner ring oil seal (7) 9. Outer ring oil seal (1) 10. Servo piston (2) Page 7513 Page 7081 ^ Knock or Clunk Noise ^ Rear Drive Axle Noises (SI Document ID #700580) ^ Launch Shudder/Vibration on Acceleration (Replace Propeller Shaft and Install a New Pinion Flange/Seal), Bulletin # 02-04-17-001 ^ Information on 2-3 Upshift or 3-2 Downshift Clunk Noise, Bulletin # 01-07-30-042 ^ Driveline Clunk When Stopping (Reprogram Powertrain Control Module (PCM), Bulletin # 03-07-30-028 Correction Replace the rear drive shaft slip yoke with a new nickel-plated slip yoke. See the parts table below. Follow the service procedure below. 1. Raise the vehicle on a hoist. 2. Reference mark the propeller shaft to the pinion flange connection. Important: Do not pound on the propeller shaft yoke ears. Never pry or place any tool between a yoke and a universal joint. 3. Remove the bolts and the yoke retainers from the pinion flange. 4. Slide the propeller shaft forward and out of the rear pinion flange. 5. Lower the rear of the propeller shaft and pull the driveshaft out of the transfer case. Note: Never clamp propeller shaft tubing in a vise. Clamping could dent or deform the tube causing an imbalance or unsafe condition. Always clamp on one of the yokes and support the shaft horizontally. Avoid damaging the slip yoke sealing surface. Nicks may damage the bushing or cut the lip seal. 6. Support the propeller shaft in a line horizontal with the table of a press. Important: Remove the front slip yoke and the universal joint together. The new nickel-plated slip yoke comes with a new universal joint. 7. Disassemble the snap rings by pinching the ends together with a pair of pliers. 8. If the ring does not readily snap out of the groove in the yoke, tap the end of the cup lightly in order to relieve the pressure from the ring. 9. Place the universal joint so that the lower ear of the yoke is supported on a 30 mm (1-1/8 in) hex head socket or a 27 mm (1-1/16 in) socket. Page 10435 12. The connector is locked into place when you hear an audible snap and the tabs (1, 2) are aligned. 13. Dispose of the shock absorber. Refer to Shock Absorber Disposal. Shock Absorber Disposal Shock Absorber Disposal Caution: Gas charged shock absorbers contain high pressure gas. Do not remove the snap ring from inside the top of the tube. If the snap ring is removed, the contents of the shock absorber will come out with extreme force which may result in personal injury. Caution: To prevent personal injury, wear safety glasses when centerpunching and drilling the shock absorber. Use care not to puncture the shock absorber tube with the centerpunch. 1. Make an indentation 10 mm (0.4 inch) from the bottom (4) of the tube (3) using a centerpunch. 2. Clamp the shock absorber in a vise horizontally with the shock absorber rod (1) completely extended. 3. Drill a hole in the shock absorber at the centerpunch (4) using a 5 mm (3/16 inch) drill bit. Gas or a gas/oil mixture will exhaust when the drill bit penetrates the shock absorber. Use shop towels in order to contain the escaping oil. 4. Make an indentation in the middle (2) of the tube (3) with a centerpunch. 5. Drill a second hole in the shock absorber at the centerpunch (2) using a 5 mm (3/16 inch) drill bit. Oil will exhaust when the drill bit penetrates the shock absorber. Use shop towels in order to contain the escaping oil. 6. Remove the shock absorber from the vise. Hold the shock absorber over a drain pan horizontally with the holes down. Move the rod (1) in and out of the tube (3) to completely drain the oil from the shock absorber. Page 2752 Junction Block - Rear Lamps - C3 Page 16072 Power Window Switch: Diagnostic Aids Basic Knowledge Required BASIC KNOWLEDGE REQUIRED Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the Service Data. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories CHECKING AFTERMARKET ACCESSORIES Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: - Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions INDUCING INTERMITTENT FAULT CONDITIONS In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: - Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. Page 7237 Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. 1. Disconnect the connector from the component. 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. Page 8879 Refer to the table as a guide in selecting the correct test adapter for frontprobing connectors: Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure SCAN TOOL SNAPSHOT PROCEDURE Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: - Snapshot - taken from the Snapshot menu choice - Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information Page 12002 Page 10154 Steering Column Position Sensor: Service and Repair Inflatable Restraint Steering Wheel Module Coil Centering Inflatable Restraint Steering Wheel Module Coil Centering 1. Notice: The new SIR coil assembly will be centered. Improper alignment of the SIR coil assembly may damage the unit, causing an inflatable restraint malfunction. Important: If double wire harness strap is installed onto the wire harness assembly and column, you must reuse the holder for the wire straps during installation. Remove the wire harness strap(s) where necessary. Verify the following conditions before centering the SIR coil: ^ The wheels on the vehicle are straight ahead. ^ The block tooth (1) of the steering shaft assembly is in the 12 o'clock position. ^ The ignition switch is in the LOCK position. 2. If the front (5) of the SIR coil has a centering window (4), and the back side (2) includes a spring service lock (1), perform the following steps: 1. Hold the SIR coil with the face up. 2. While depressing the spring service lock, rotate the coil hub clockwise until the coil ribbon stops. 3. Rotate the coil hub slowly, counterclockwise, until the centering window appears yellow and both arrows (3) line up. 4. Release spring service lock between the locking tab. The SIR coil is now centered. 5. Align the centered SIR coil with the horn tower and slide onto the steering shaft assembly. 3. If the front (4) of the SIR coil has a centering window (3), and the back side (1) includes NO spring service lock, perform the following steps: 0. Hold the SIR coil with the face up. 1. Rotate the coil hub clockwise until the coil ribbon stops. Diagrams Seat Belt Buckle Switch: Diagrams Seat Belt Switch - Driver Page 2010 - Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-D in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-D if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Page 7347 8. Connect the PNP switch electrical connector (2). 9. If equipped with 4WD, install the front propeller shaft. 10. Lower the vehicle. 11. Check the switch for proper operation. The engine must start in the park (P) or neutral (N) positions only. If proper operation of the switch can not be obtained, replace the switch. Page 15204 Electrical Symbols Part 12 Page 12523 Diagnostic Trouble Codes DTC U1000 and U1255 Circuit/System Description Modules connected to the Class 2 serial data circuit monitor for serial data communications during normal vehicle operation. Operating information and commands are exchanged among the modules. When a module receives a message for a critical operating parameter, the module records the identification number of the module which sent the message for State of Health monitoring. A critical operating parameter is one which, when not received, requires that the module use a default value for that parameter. When a module does not associate an identification number with at least one critical parameter within 5 seconds of beginning serial data communication, DTC U1000 or U1255 DTC is set. When more than one critical parameter does not have an identification number associated with it, the DTC will only be reported once. The Class 2 serial data communications circuit on this vehicle are in a hybrid ring and star configuration. Each module on the ring has 2 serial data circuits connected to it, except the following modules which have only 1 serial data circuit connected them: Page 2135 Drive Belt: Technical Service Bulletins Engine - Serpentine Drive Belt Wear Information Bulletin No.: 04-06-01-013 Date: April 29, 2004 INFORMATION Subject: Information on Serpentine Belt Wear Models: 2004 and Prior Passenger Cars and Trucks 2003-2004 and Prior HUMMER H2 All current GM vehicles designed and manufactured in North America were assembled with serpentine belts that are made with an EPDM material and should last the life of the vehicle. It is extremely rare to observe any cracks in EPDM belts and it is not expected that they will require maintenance before 10 years or 240,000 km (150,000 mi) of use. Older style belts, which were manufactured with a chloroprene compound, may exhibit cracks depending on age. However, the onset of cracking typically signals that the belt is only about halfway through its usable life. A good rule of thumb for chloroprene-based belts is that if cracks are observed 3 mm (1/8 in) apart, ALL AROUND THE BELT, the belt may be reaching the end of its serviceable life and should be considered a candidate for changing. Small cracks spaced at greater intervals should not be considered as indicative that the belt needs changing. Any belt that exhibits chunking should be replaced. Disclaimer Page 4259 Mass Air Flow (MAF) Sensor: Service and Repair MASS AIR FLOW (MAF)/INTAKE AIR TEMPERATURE (IAT) SENSOR REPLACEMENT REMOVAL PROCEDURE IMPORTANT: Use care when handling the mass air flow/intake air temperature (MAF/IAT) sensor. Do not dent, puncture, or otherwise damage the honeycell located at the air inlet end of the MAF/IAT. Do not touch the sensing elements or allow anything including cleaning solvents and lubricants to come in contact with them. Use a small amount of a non-silicone based lubricant, on the air duct only, to aid in installation. 1. Remove the air cleaner outlet duct. 2. Pull out the gray connector position assurance (CPA) retainer. 3. Push down on the black clip in order to disconnect the MAF/IAT sensor electrical connector (4). 4. Loosen the MAF/IAT clamp. 5. Remove the MAF/IAT sensor from the air cleaner assembly. INSTALLATION PROCEDURE IMPORTANT: The embossed arrow on the MAF/IAT sensor indicates the proper air flow direction. The arrow must point toward the engine. Page 2006 Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses CIRCUIT PROTECTION - FUSES The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the Locations Coolant Temperature Sensor/Switch (For Computer): Locations Full Engine View Left Side Page 5602 Steps 7 - 9 Page 16093 SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-D. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: - The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair Tools Required J 38125-D Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-D. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Page 8563 Electrical - No Module Communication/DTCs/Warning Lamps Wiring Harness: Customer Interest Electrical - No Module Communication/DTCs/Warning Lamps Bulletin No.: 03-08-50-014A Date: January 20, 2006 TECHNICAL Subject: No Communication with Any Modules, Memory Seat May Not Recall, Multiple U-DTCs Set or Instrument Panel Cluster (IPC) Warning Indicators, Crank No Start (Inspect/Repair Affected Wiring Harness) Models: 2003-2006 Cadillac Escalade, Escalade ESV, Escalade EXT 2003-2006 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2003-2006 GMC Sierra, Yukon, Yukon XL with Front, Individual (Non-Bkt) Seat (RPO AN3) and/or Active Brake Control (Stabilitrak(R)) (RPO JL4) Supercede: This bulletin is being revised to update the various conditions and add the 2004-2006 model years, additional diagnostic and warranty information. Please discard Corporate Bulletin Number 03-08-50-014 (Section 08 - Body & Accessories). Condition Some customers may comment on any of the following conditions: ^ Various IPC Warning indicators are coming on. ^ Driver Information Center (DIC) displays "Unknown Driver". ^ Memory seat may not recall. ^ RKE fobs may be inoperative. ^ Radio or HVAC may shut off. ^ Engine cranks but will not start. Upon investigation, the Technician may find multiple U-DTCs set. Cause On RPO AN3 equipped vehicles, a chafed or pinched seat wiring harness under the driver seat may be a cause of this condition. Because of the routing, a portion of the seat wiring harness may rest on the inboard edge of the seat track or frame. Over time, the harness may be pinched or chafed because of the seat movement. Refer to the above illustration. The illustration shows the inverted position of the seat bottom. The arrow shows the primary location Page 9526 Fuse: Application and ID Fuse Block - Underhood Location View Service and Repair Gear Sensor/Switch: Service and Repair Encoder Motor Sensor Replacement Removal Procedure Important: For ease of reassembly, shift the transfer case to 2HI prior to removing any components. 1. Remove the encoder motor. 2. Place the encoder motor on a clean work bench, 3. Remove the 2 screws (2) from the motor cover. 4. Remove the 2 screws (1) from the casting. 5. Remove the cover. 6. Remove and save the shim on the output gear. 7. Remove and discard the orange rubber seal from the cover. 8. Remove the output gear (1). Page 12110 Conditions for Running the DTC Ignition is in RUN or ACC position System voltage is between 9.5 - 15.5 volts. The above conditions are met for more than 1 second. Conditions for Setting the DTC The VCIM does not detect the presence of a cellular antenna for more than 1 second. Action Taken When the DTC Sets The vehicle is unable to connect to the OnStar(R) Call Center. The OnStar(R) status LED turns red. Conditions for Clearing the DTC The VCIM detects the presence of a cellular antenna. A history DTC clears after 50 malfunction-free ignition cycles. Circuit/System Testing Perform a visual inspection as shown above in order to verify that the cellular antenna and the cellular antenna coupling assembly are not damaged. If any components are damaged replace the assembly. DTC B2476 or B2482 DTC Descriptors Page 6145 Remove all rust from the ground terminal, the cylinder head and the retaining nut or bolt. Position the main engine wiring harness ground terminal and install the nut or bolt. Tighten: Tighten the retaining nut or bolt to 16 N.m (12 lb ft). Apply some type of electrical moisture sealant to protect the harness terminal from further corrosion. Disclaimer Page 11668 9. Remove the upper anchor bolt. 10. Remove the retractor from the seat. INSTALLATION PROCEDURE 1. Position the seat belt retractor onto the seat. Line up the tab on the retractor to the tab on the seat frame. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the upper anchor bolt. Tighten Tighten the bolt to 53 N.m (39 lb ft). Heated Oxygen Sensor (HO2S) Replacement Bank 1 Sensor 1 Oxygen Sensor: Service and Repair Heated Oxygen Sensor (HO2S) Replacement Bank 1 Sensor 1 HEATED OXYGEN SENSOR (HO2S) REPLACEMENT BANK 1 SENSOR 1 REMOVAL PROCEDURE 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. If necessary, unbolt the front propeller shaft from the front differential. Refer to Propeller Shaft Replacement - Front in Propeller Shaft. 3. Disconnect the connector position assurance (CPA) retainer. NOTE: Refer to Heated Oxygen and Oxygen Sensor Notice in Service Precautions. 4. Remove the heated oxygen sensor (HO2S) electrical connector from the fuel line clip. 5. If equipped with a 4.8L or 5.3L engine, disconnect the HO2S electrical connector (1). 6. If equipped with a 6.0L engine, disconnect the HO2S electrical connector (1). Brakes - ABS Lamp ON/DTC's C0265/C0201/U1041 Set Grounding Point: All Technical Service Bulletins Brakes - ABS Lamp ON/DTC's C0265/C0201/U1041 Set TECHNICAL Bulletin No.: 04-05-25-002E Date: March 11, 2009 Subject: ABS Light On, DTCs C0265, C0201, U1041 Set and/or Loss of Communication with Brake Module (Reground EBCM Ground) Models Supercede: This bulletin is being revised to add step 2 to the procedure and update the Parts and Warranty Information. Please discard Corporate Bulletin Number 04-05-25-002D (Section 05 - Brakes). Condition Some customers may comment that the ABS light is on. Upon further inspection, DTCs C0265 and C0201 may be set in the brake module. It is also possible for DTC U1041 to set in other modules. There may also be a loss of communication with the brake module. Cause A poor connection at the EBCM ground is causing unnecessary replacement of brake modules. Important: The EBCM ground is different for each application. Refer to the list below for the proper ground reference: ^ Midsize Utilities = Ground 304 ^ SSR = Ground 400 ^ Fullsize Trucks and Utilities = Ground 110 Correction Important: Do not replace the brake module to correct this condition. Perform the following repair before further diagnosis of the EBCM. Perform the following steps to improve the connection of the EBCM Ground: 1. Remove the EBCM Ground. The EBCM Ground is located on the frame beneath the driver's side door. If multiple grounds are found in this location, the EBCM ground can be identified as the heavy (12-gauge) wire. 2. If the original fastener has a welded on nut, remove the nut from the frame, and if required, enlarge the bolt hole to accommodate the new bolt and nut. 3. Clean the area, front and back, using a tool such as a *3M(TM) Scotch-Brite Roloc disc or equivalent. Page 4688 Body Control Module (BCM) - C6 Part 1 Page 9695 5. Remove paint and primer from the area surrounding the 10 mm (0.40 in) until bare metal is visible. Important The M6 conductive rivet stud as shown, can accommodate a panel thickness range of 0.7-4.2 mm (0.03-0.17 in). If there are layers of sheet metal, they should be touching without any air gaps to ensure a good ground. 6. Select a M6 conductive rivet stud. Refer to the Parts Information section of this bulletin. Note Use the GE-50317 rivet stud tool kit. 7. Place the M6 conductive rivet stud (1) in the 10 mm (0.40 in) hole. Assemble the rivet stud tool (2) with the groove and flare side facing the rivet stud, then the washer and the M6 nut (3). 8. Using a wrench on the rivet stud tool, and a socket on the M6 nut, secure the M6 conductive rivet stud. 9. Ensure the new rivet stud is securely fastened, WITHOUT ANY detectable movement. 10. Completely wrap the threads of the rivet stud with painters tape or equivalent. Page 16026 TOOLS REQUIRED J 34142-B 12 V Unpowered Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. When testing for voltage: 1. Attach 1 lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach 1 lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Using Connector Test Adapters USING CONNECTOR TEST ADAPTERS NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-B Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires USING FUSED JUMPER WIRES TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Connector Position Assurance Locks CONNECTOR POSITION ASSURANCE LOCKS The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Terminal Position Assurance Locks TERMINAL POSITION ASSURANCE LOCKS The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Push to Seat Connectors PUSH TO SEAT CONNECTORS TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Page 12348 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Page 4943 Catalytic Converter: Service and Repair Catalytic Converter Replacement (4.3L, 4.8L, and 5.3L Engines) Removal Procedure 1. Raise and suitably support the vehicle. 2. If equipped, unclip the oxygen sensor connection from the floor reinforcement. 3. Disconnect the oxygen sensor electrical connector. 4. Remove the oxygen sensor clips from the frame. 5. Disconnect the connector position assurance (CPA) retainers. 6. Disconnect the oxygen sensor electrical connectors. 7. Unclip the oxygen sensors electrical connectors from the following: ^ Hose clip ^ Transmission crossmember 8. Disconnect the CPA retainers. 9. Disconnect the oxygen sensor electrical connectors (1, 2). Page 3833 Body Control Module: Electrical Diagrams Door Control Module Diagram 1 Page 6537 1. Install the auxiliary oil cooler to the vehicle. 2. Notice: Refer to Fastener Notice in Service Precautions. Install the bolts (1) to the radiator brace. ^ Tighten the bolts to 12 Nm (106 inch lbs.). 3. Install the push pins (2) to the radiator brace. 4. Connect the transmission oil cooler lines to the auxiliary cooler. 5. Install the grille assembly. Page 1316 2. Install the inside air temperature sensor to the headliner and sensor grille. 3. Connect the electrical connector to the inside air temperature sensor. 4. Install the left sunshade. 5. Install the left center pillar garnish molding. 6. Install the left center assist handle. 7. Install the left windshield garnish molding. Page 4911 Transmission Position Switch/Sensor: Adjustments Automatic Transmission - 4L80-E/4L85-E Park/Neutral Position Switch Adjustment Important: ^ The following procedure is for vehicles that have not had the park/neutral position (PNP) switch removed or replaced. If the switch has been removed or replaced, refer to Park/Neutral Position Switch Replacement for the proper adjustment procedure. ^ Apply the park brake. ^ The engine must start in the park (P) or neutral (N) positions only. ^ Check the PNP switch for proper operation. If adjustment is required, proceed as follows: 1. Place the shift lever in the neutral (N) position. 2. With an assistant in the drivers seat, raise and suitably support the vehicle. Refer to Vehicle Lifting. 3. Loosen the PNP switch bolts. 4. With the vehicle in neutral (N), rotate the PNP switch while the assistant attempts to start the engine. 5. Following a successful start, turn the engine off. 6. Notice: Refer to Fastener Notice in Service Precautions. Tighten the PNP switch bolts. ^ Tighten the bolts to 25 Nm (18 ft. lbs.). 7. Lower the vehicle. 8. Check the PNP switch for proper operation. The engine must start in the park (P) or neutral (N) positions only. 9. Replace the PNP switch if proper operation can not be achieved. Page 9535 Junction Block - I/P Wire Entry Part 2 Electrical - A/T Stuck in 2nd/3rd Gear/MIL ON/DTC's Wiring Harness: All Technical Service Bulletins Electrical - A/T Stuck in 2nd/3rd Gear/MIL ON/DTC's Bulletin No.: 01-07-30-002E Date: September 23, 2005 TECHNICAL Subject: Malfunction Indicator Lamp (MIL) On, Transmission Stuck in Second or Third Gear, Instrument Cluster Inoperative (Verify and Repair Source of Voltage Loss In Transmission Solenoid Power Supply Circuit) Models: 2006 and Prior GM Passenger Cars and Light Duty Trucks 2005-2006 HUMMER H2 2006 HUMMER H3 2005-2006 Saab 9-7X with 4L60-E, 4L65-E, 4L80-E or 4L85-E Automatic Transmission (RPOs M30, M32, M33, MT1, MN8) Supercede: This bulletin is being revised to update model years, add additional models and add additional diagnostic information. Please discard Corporate Bulletin Number 01-07-30-002D (Section 07 Transmission/Transaxle). Condition Some customers may comment on one or more of the following conditions: ^ The Malfunction Indicator Lamp (MIL) is ON. ^ The transmission is defaulted to second gear (4L80/85-E). ^ The transmission is defaulted to third gear (4L60/65-E). ^ The instrument cluster is inoperative. Upon investigation, one or all of the diagnostic trouble codes (DTCs) P0740, P0753, P0758, P0785, P0787, P0973, P0976, P1860, P2761, P2764 and P2769 may be set depending on the vehicle. Cause The most likely cause of this condition may be a loss of voltage to the transmission solenoid power supply circuit. This condition may also be the result of an incorrect installation of an aftermarket electronic device such as a remote starter or alarm system. Correction Important: If the vehicle is equipped with an aftermarket electronic device and the DTCs are being set when the device is being used, verify that the appropriate fuse is being supplied battery voltage during operation. If voltage is not present at this fuse, these DTCs will be set due to lack of voltage at the solenoids. This condition is most likely to occur with an incorrectly installed remote starting system. If this is the case, refer the customer to the installer of the system for corrections. ANY REPAIRS DUE TO AFTERMARKET INSTALLATION OF ACCESSORIES IS A NON-WARRANTABLE ITEM. 1. With the ignition switch in the RUN position, test for battery voltage at the circuit fuse in the transmission solenoid power supply circuit. Refer to the appropriate SI Document for the transmission solenoid power supply circuit information. 2. If battery voltage is present at the fuse, inspect the ignition voltage circuit between the fuse and the transmission for possible opens. 3. If battery voltage is not present at the fuse, test for continuity between the fuse and the ignition switch. If NO continuity is between the fuse and the ignition switch, repair the open in that circuit. 4. If you have continuity between the fuse and the ignition switch, the most likely cause is the ignition switch. Replace the ignition switch using the appropriate Ignition Switch Replacement procedure in SI. Refer to group number 2.188 of the parts catalog for part description and usage of the ignition switch. Page 16159 If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Sir/SRS Wiring Repairs SIR/SRS WIRING REPAIRS TOOLS REQUIRED J 38125-D Terminal Repair Kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-D contains the following items: - Special sealed splices - in order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping tool - A heat torch - An instruction manual The sealed splices have the following 2 critical features: - A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-D also serves as a generic terminal repair kit. The kit contains the following items: - A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors Page 747 Control Module HVAC: Locations HVAC Control Module Page 13412 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the cover up until the dress cover releases. Repeat this procedure for the other locking tab. 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. 5. If the connector has a nose piece, use a small flat-blade tool to remove the nose piece by inserting the blade into the slot on the front of the connector and prying up on the nose piece. IMPORTANT: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 6. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. IMPORTANT: Be careful not to angle or rock the J 38125-13A tool when inserting it into the connector or the tool may break. Page 15706 Numerous & Various Size Drops of Water Collecting on the Inside Surface of the Lamp Lens After the Vehicle Has Been Exposed to Rain or a Car Washing Environment - A condition that covers more than half the surface of the lamp lens. - An accumulation of water in the bottom of the lamp assembly. - A condition that WON'T clear when the vehicle is parked in a dry environment, or when the vehicle is driven with the lights ON. - A comparison of the equivalent lamp on the opposing side of the vehicle indicates a different performance. Any of the above conditions would indicate the need to service the lens or lamp assembly. Disclaimer Page 9720 C152 Chassis Harness To Engine Harness Part 2 Page 1826 Maintain the sensor position. Do not turn the sensor. Remove the rear wheel position sensor (2) from the steering gear. Installation Procedure 1. Important: Make sure the O-ring (1) is installed. Install the rear wheel position sensor (2) to the steering gear. 2. Important: Be careful to maintain the position of the replacement sensor. Remove the pin retaining the position of the new sensor and immediately install the sensor to the steering gear. 3. Notice: Refer to Fastener Notice in Service Precautions. Install the rear wheel position sensor retaining bolts. Apply LOCTITE 242 blue. ^ Tighten the bolts to 4 Nm (35 inch lbs.). 4. Install the rear wheel position sensor cover (4). 5. Connect the electrical connector (1). 6. Install the steering gear protection shield (1) and retaining bolts (3). ^ Tighten the steering gear protection shield retaining bolts to 180 Nm (132 ft. lbs.). Drive Belt Chirping Drive Belt: Testing and Inspection Drive Belt Chirping Drive Belt Chirping Diagnosis Diagnostic Aids The chirping noise may be intermittent due to moisture on the drive belt(s) or the accessory drive pulley(s). In order to duplicate the customer's concern, it may be necessary to spray a small amount of water onto the drive belt(s). If spraying water onto the drive belt(s) duplicates the symptom, cleaning the accessory drive pulley(s) may be the most probable solution. A loose or improper installation of a body or suspension component, or other item(s) on the vehicle may also cause the chirping noise. Test Description Page 10077 Power Steering Pressure Control Valve: Service and Repair On Vehicle Power Steering Pump Flow Control Valve Actuator Replacement - On Vehicle Disassembly Procedure 1. Remove the electrical connector from the variable assist steering actuator (1). 2. Remove pump assembly from the vehicle, if the variable assist steering actuator (1) is not accessible. 3. Remove the retaining ring (2) from the variable assist steering actuator (1). 4. Important: Note the orientation of the variable assist steering actuator discharge fitting. Remove the variable assist steering actuator (1). 5. Remove the O-ring seal from the variable assist steering actuator. Assembly Procedure 1. Important: Note the orientation of the variable assist steering actuator discharge fitting. Lubricate and install the new O-ring seal with power steering fluid. 2. Notice: Refer to Fastener Notice in Service Precautions. Install the variable assist steering actuator (1) to the pump assembly. ^ Tighten the actuator to 62 Nm (46 ft. lbs.). 3. Install the negative battery cable. 4. Important: If a new variable assist steering actuator (1) is being installed, position the electrical connector before installing the retaining ring (2). Install the electrical connector to the variable assist steering actuator (1). 5. Install the retaining ring (2) to the variable assist steering actuator (1). Page 16025 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground TESTING FOR SHORT TO GROUND NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting With A Digital Multimeter TROUBLESHOOTING WITH A DIGITAL MULTIMETER NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TROUBLESHOOTING WITH A TEST LAMP Page 6664 10. Notice: Refer to Fastener Notice in Service Precautions. Notice: Torque valve body bolts in a spiral pattern starting from the center. If the bolts are torqued at random, valve bores may be distorted and inhibit valve operation. ^ Tighten the valve body bolts in a spiral pattern starting from the center, as indicated by the arrows. ^ Tighten the bolts in the sequence shown to 11 Nm (97 inch lbs.). 11. Ensure that the manual detent spring is aligned properly with the detent lever. ^ Tighten the bolt to 11 Nm (97 inch lbs.). 12. Install the TCC solenoid with a NEW O-ring seal to the valve body. Page 5569 Ignition Coil: Description and Operation IGNITION COILS Each ignition coil has an ignition 1 feed and a ground. The PCM supplies a low reference and an ignition control (IC) circuit. Each ignition coil contains a solid state driver module as the primary element. The PCM signals the coil driver to initiate a firing event by applying the IC circuit voltage for the appropriate time, or dwell. When the voltage is removed the coil fires the spark plug. The coils are current limited to prevent overloading if the IC current is held high too long. The spark plugs are connected to their respective coils by a short secondary wire. The spark plugs are tipped with platinum for long life and efficiency. Page 8915 Auxiliary Power Outlet 120-Volt AC - Exterior (With RPO Code HP2) Locations Full Engine View Left Side Instruments - Oil Life Monitoring System Oil Change Reminder Lamp: All Technical Service Bulletins Instruments - Oil Life Monitoring System Bulletin No.: 04-06-04-045 Date: June 22, 2004 INFORMATION Subject: Oil Life Monitoring System - PCM Reset Models: 2004 All GM Passenger Cars and Trucks Important: The Oil Life Monitoring System can be found on many General Motor's vehicles prior to 2004. Refer to SI and/or the Owner's Manual for detailed information. The purpose of this bulletin is to help technicians identify which vehicles are equipped with the oil life monitoring system. Although many General Motors vehicles prior to 2004 have been equipped with the oil life monitoring system, the 2004 model year vehicles were used as a starting point to validate the system/scan tool functionality. Customers have come to depend on the Oil Life Monitoring System found on most General Motor's vehicles to inform them when it's time for an oil change. If for any reason the PCM is replaced, it is important to access the "Percent of Oil Life Remaining" from the vehicle's current PCM PRIOR to removing the PCM. This value must be programmed into the new PCM (after it is installed in the vehicle) by using the scan tool. Note: Failure to reprogram the value to the new PCM will result in missed maintenance, which may cause damage to the engine. Important: If the replacement module is not programmed with the remaining engine oil life, the engine oil will need to changed at 5,000 km (3,000 mi) from the last engine oil change. Disclaimer Page 2697 Relay Block - I/P C9 Part 2 Page 15012 A General Motors Product Recall Customer Reimbursement Procedure Form is shown. Important: Refer to the GM Service Policies and Procedures Manual, section 6.1.12 for specific procedures regarding customer reimbursement and the form. Customer Reimbursement - For Canada Customer requests for reimbursement of previously paid repairs to correct the condition addressed in this bulletin are to be submitted by January 31, 2006. All reasonable customer paid receipts should be considered for reimbursement. The amount to be reimbursed will be limited to the amount the repair would have cost if completed by an authorized General Motors dealer. When a customer requests reimbursement, they must provide the following: ^ Proof of ownership at time of repair. ^ Original paid receipt confirming the amount of repair expense(s) that were not reimbursed, a description of the repair, and the person or entity performing the repair. Claims for customer reimbursement on previously paid repairs are to be submitted as required by WINS. Important: Refer to the GM Service Policies and Procedures Manual, section 1.6.2, for specific procedures regarding customer reimbursement verification. Courtesy Transportation The General Motors Courtesy Transportation program is intended to minimize customer inconvenience when a vehicle requires a repair that is covered by the New Vehicle Limited Warranty. The availability of courtesy transportation to customers whose vehicles are within the warranty coverage period Page 9423 TOOLS REQUIRED J 34142-B 12 V Unpowered Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. When testing for voltage: 1. Attach 1 lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach 1 lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Using Connector Test Adapters USING CONNECTOR TEST ADAPTERS NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-B Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires USING FUSED JUMPER WIRES TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Connector Position Assurance Locks CONNECTOR POSITION ASSURANCE LOCKS The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Terminal Position Assurance Locks TERMINAL POSITION ASSURANCE LOCKS The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Push to Seat Connectors PUSH TO SEAT CONNECTORS TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Page 10286 1. Set the front wheels in the straight ahead position. Notice: On the 2002 and later model year vehicles the steering column LOCK was removed from the steering column. It is critical that the J 42640 - Steering column Anti-Rotation Pin is used when servicing steering columns on 2002 and later model year vehicles. Failure to use the J 42640 may result in damage to the SIR coil. 2. Set the steering wheel in the LOCK position on 2001 and prior model year vehicles. 3. For 2002 and later vehicles install the J 42640 in the steering column lower access hole. 4. From under the hood remove the lower bolt that connects the upper intermediate shaft to the steering gear coupling shaft. 5. Slide the shaft towards the dash in order to disengage the shaft from the steering gear coupling shaft. 6. For vehicles equipped with adjustable foot pedals perform the following steps: 1. Reposition the carpet away from the accelerator pedal position (APP) sensor. 2. Remove the two nuts retaining the accelerator pedal to the bulkhead. 3. Reposition the accelerator pedal out of the way so the intermediate shaft can be removed. Off Vehicle Power Steering Pressure Control Valve: Service and Repair Off Vehicle Power Steering Pump Flow Control Valve Replacement - Off Vehicle (Regular) Disassembly Procedure 1. Drain the oil from the reservoir (1). 2. Remove the control valve assembly (3) from the pump housing (1). Make sure the flow control spring (4) does not fall out of the pump housing (1). 3. Remove the rectangular section seal (2) from the control valve assembly (3). Assembly Procedure 1. Install the flow control spring (4) if removed from the pump housing (1). 2. Lubricate the new rectangular section seal (2) with power steering fluid. 3. Install the rectangular section seal (2) onto the control valve assembly (3). 4. Install the control valve assembly (3). Page 4689 Body Control Module (BCM) - C6 Part 2 Page 8786 High Temperature Conditions Tools Required J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency MEASURING FREQUENCY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage MEASURING VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop MEASURING VOLTAGE DROP NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Page 9356 For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to refer to the table above. Disclaimer Page 9846 Relay Box: Application and ID Relay Block - I/P Location View Page 4594 HO2S Page 10850 3. Remove the recirculation actuator retaining screws. 4. Remove the recirculation actuator. INSTALLATION PROCEDURE 1. Install the recirculation actuator. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the recirculation actuator retaining screws. Tighten Tighten the screws to 1.6 N.m (14 lb in). Page 13339 - HVAC Actuator - Inflatable Restraint Sensing and Diagnostic Module (SDM) - Any AIR BAG module - Seatbelt Lap Anchor Pretensioner - Seatbelt Retractor Pretensioner - An SIR system connection or connector condition resulting in the following DTCs being set: B0015, B0016, B0019, B0020, B0022, or B0023 - Powertrain Control Module (PCM) - Remote Control Door Lock Receiver (RCDLR) - Transmission Control Module (TCM) Correction Important DO NOT replace the control module, wiring or component for the following conditions: - The condition is intermittent and cannot be duplicated. - The condition is present and by disconnecting and reconnecting the connector the condition can no longer be duplicated. Use the following procedure to correct the conditions listed above. 1. Install a scan tool and perform the Diagnostic System Check - Vehicle. Retrieve and record any existing history or current DTCs from all of the control modules (refer to SI). ‹› If any DTC(s) are set, refer to Diagnostic Trouble Code (DTC) List - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). ‹› If DTCs are not set, refer to Symptoms - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). 2. When identified, use the appropriate DTC Diagnostics, Symptoms, Schematics, Component Connector End Views and Component Locator documents to locate and disconnect the affected harness connector(s) which are causing the condition. Note Fretting corrosion looks like little dark smudges on electrical terminals and appear where the actual electrical contact is being made. In less severe cases it may be unable to be seen or identified without the use of a magnifying glass. Important DO NOT apply an excessive amount of dielectric lubricant to the connectors as shown, as hydrolock may result when attempting to mate the connectors. Use ONLY a clean nylon brush that is dedicated to the repair of the conditions in this bulletin. 3. With a one-inch nylon bristle brush, apply dielectric lubricant to both the module/component side and the harness side of the affected connector(s). 4. Reconnect the affected connector(s) and wipe away any excess lubricant that may be present. 5. Attempt to duplicate the condition by using the following information: - DTC Diagnostic Procedure - Circuit/System Description - Conditions for Running the DTC - Conditions for Setting the DTC - Diagnostic Aids - Circuit/System Verification ‹› If the condition cannot be duplicated, the repair is complete. ‹› If the condition can be duplicated, then follow the appropriate DTC, Symptom or Circuit/System Testing procedure (refer to SI). Repair Order Documentation Page 4713 results from the alteration or modification of a vehicle using non-GM approved parts or accessories. Dealers should be especially cautious of accessory companies that claim the installation of their product will not void the factory warranty. Many times these companies have even given direction on how to quickly disassemble the accessory in an attempt to preclude the manufacturer from finding out that is has been installed. Any suspect repairs should be reviewed by the Fixed Operations Manager (FOM), and in Canada by the Warranty Manager (WM) for appropriate repair direction. If it is decided that a goodwill repair is to be made on the vehicle, even with the installation of such non-GM approved components, the customer is to be made aware of General Motors position on this issue and is to sign the appropriate goodwill documentation required by General Motors. It is imperative for dealers to understand that by installing such devices, they are jeopardizing not only the warranty coverage, but also the performance and reliability of the customer's vehicle. Disclaimer Page 14918 Seat Heater Switch: Diagrams Driver Door Module (DDM) - C5 (Memory/Heated Seat Switch) Part 1 Locations Hazard Warning Switch: Locations Upper Steering Column Page 8233 Whenever the brake rotor has been separated from the hub/axle flange, clean any rust or contaminants from the hub/axle flange and the brake rotor mating surfaces. Failure to do this may result in increased assembled lateral runout (LRO) of the brake rotor, which could lead to brake pulsation. Using the J 42450-A , thoroughly clean any rust or corrosion from the mating surface of the hub/axle flange. 2. Using the J 41013 , thoroughly clean any rust or corrosion from the mating surface and mounting surface of the brake rotor. 3. Inspect the mating surfaces of the hub/axle flange and the rotor to ensure that there are no foreign particles or debris remaining. 4. Mount the brake rotor to the brake lathe according to the lathe manufacturer's instructions, ensuring that all mounting attachments and adapters are clean and free of debris. 5. Ensure that any vibration dampening attachments are securely in place. 6. With the brake lathe running, slowly bring in the cutting tools until they just contact the brake rotor friction surfaces. 7. Observe the witness mark on the brake rotor. If the witness mark extends approximately three-quarters or more of the way around the brake rotor friction surface on each side, the brake rotor is properly mounted to the lathe. 8. If the witness mark does not extend three-quarters or more of the way around the brake rotor, re-mount the rotor to the lathe. 9. Following the brake lathe manufacturer's instructions, refinish the brake rotor. 10. After each successive cut, inspect the brake rotor thickness. Refer to Brake Rotor Thickness Measurement. 11. If at any time the brake rotor exceeds the minimum allowable thickness after refinish specification, the brake rotor must be replaced. 12. After refinishing the brake rotor, use the following procedure in order to obtain the desired non-directional finish: 1. Follow the brake lathe manufacturer's recommended speed setting for applying a non-directional finish 2. Using moderate pressure, apply the non-directional finish: ^ If the lathe is equipped with a non-directional finishing tool, apply the finish with 120 grit aluminum oxide sandpaper ^ If the lathe is not equipped with a non-directional finishing tool, apply the finish with a sanding block and 150 grit aluminum oxide sandpaper 3. After applying a non-directional finish, clean each friction surface of the brake rotor with denatured alcohol, or an equivalent approved brake cleaner 13. Remove the brake rotor from the brake lathe. 14. Measure the assembled lateral runout (LRO) of the brake rotor to ensure optimum performance of the disc brakes. Refer to Brake Rotor Assembled Lateral Runout (LRO) Measurement. 15. If the brake rotor assembled LRO measurement exceeds the specification, bring the LRO to within specifications. Refer to Brake Rotor Assembled Lateral Runout (LRO) Correction. Page 6996 8. Remove the wheel hub and the 15-series bearing mounting bolts (4). 9. Remove the wheel hub and bearing (4) mounting bolts, 25/35 series. 10. Remove the wheel hub and bearing and splash shield from the vehicle. 11. Remove the O-ring seal from the steering knuckle bore, 25/35 series. 12. Remove the wheel speed sensor mounting bolt (5). 13. Clean and inspect the O-ring seal, 25/35 series. 14. Replace the seal if the following conditions exist: ^ Nicks ^ Cuts ^ Dry or brittle ^ Compression set Installation Procedure 1. Clean all corrosion or contaminates from the steering knuckle bore and the hub and bearing assembly. 2. Lubricate the steering knuckle bore with wheel bearing grease or the equivalent. 3. Install the O-ring (7) to the steering knuckle, the 25/35 series. 4. Notice: Refer to Fastener Notice in Service Precautions. Install the wheel speed sensor mounting bolt to the wheel hub and bearing. ^ Tighten the sensor mounting bolt to 18 Nm (13 ft. lbs.). 5. Install the wheel hub and bearing and splash shield to the vehicle, 25/35 series. Page 10646 Refer to the Model Application Chart shown to verify usage. Supercede: This bulletin is being revised to include 2007 model year and calibration information. Please discard Corporate Bulletin Number 03-03-10-006E (Section 03 - Suspension). Tires GM has designed 20" wheels based on the Goodyear Eagle LS and LS2 P275/55R20 tire. The Goodyear Eagle LS tire has a Tire Performance Criteria spec # 1235 and the LS2 has a Tire Performance Criteria spec # 1245. These tires have been designed to GM's specific Tire Performance Criteria. GM's Tire Performance Criteria specifications meet or exceed all Federal safety guidelines. When mounting the tires, rubber lubricant, P/N 12345884 (in Canada, P/N 5728223), MUST be used. The vehicle should not be driven aggressively (hard acceleration or braking) for at least 6-8 hours after tire mounting to allow the lube to dry. Failure to do so may cause the tire to slip on the rim. This condition will affect wheel balance which could result in a vibration. Spare Tire A P265/75R16 or P265/70R17 tire should be used as a spare. Re-use the vehicle's original spare wheel to mount the spare tire. The spare tire should be used to drive the vehicle to a tire repair/replacement facility and is not intended for extended driving conditions. Tire Changers Dealers must have the correct level of tire changing equipment to perform tire changing services. GM requirements and recommendations for servicing glamour wheels are as follows: ^ Rim Clamp design ^ Runflat capable (preferred) ^ Side mounted bead breaking to reduce stress on the wheel and tire ^ No metal contact to the wheel at the clamping jaws Protective devices to prevent damage during mounting and dismounting operations Regulated air pressure to protect user and wheel assembly. Approved lubricant (P/N 12345884 [in Canada, P/N 5728223]) to avoid wheel slip and damage to the wheel For further information regarding equipment meeting the requirements for this program, call 1-800-GM-TOOLS. Balancing MC style coated weights are recommended and will provide the best balancing of the tire-wheel assembly. If stick-on weights are used, be sure to follow the manufacturers recommended installation procedure (SI Document ID # 664222) making sure the surface is clean and dry. Using the incorrect type of weights will result in improper fit, and such weights may fall off the wheel. Page 7262 Power Take-Off: Description and Operation POWER TAKE-OFF (PTO) DESCRIPTION AND OPERATION The PTO is an Upfitter integrated system that allows the user to create an auxiliary power source that will drive either a hydraulic pump or a generator. When the operator requests PTO the PTO switch will be turned ON and the engine RPM will go to a default standby speed. The operator will then press and release the PTO switch to SET and the PTO solenoid will engage. Turning the PTO switch to OFF or pressing the brake pedal will turn the PTO off. The PTO system is integrated with the Cruise Control system and Computers and Control Systems. The PTO system utilizes the following parts: - PTO Switch - Cruise Control Multi-Function Switch - PTO Relay - PTO Solenoid - PCM with 8.1L gasoline only - ECM with 6.6L diesel only - TAC Module with 8.1L gasoline only - TAC Motor with 8.1L gasoline only Voltage will be supplied at all times through the Fog Lamp fuse to the secondary side of the PTO Relay. When the operator turns the ignition switch to RUN, voltage will be supplied through the Cruise fuse to the open PTO switch. When the PTO switch is turned ON voltage will be present through the primary side of the PTO Relay and at the PCM. If the PCM sees all of the requirements for PTO engagement the PCM will send a Class 2 signal to the TAC Module. The TAC Module will use the TAC Motor to increase the engine RPM to the standby speed. When the PTO switch is turned to the SET position and released the PCM will ground the primary side of the PTO Relay. Current will flow through the coil in the PTO Relay and close the normally open contacts. This will allow current to flow to the PTO Solenoid and eventually to ground. In the event that any of the PTO requirements are no longer met then the PCM or TAC will return the engine RPM to idle and turn the PTO Solenoid off. MODES OF OPERATION PTO - Preset Mode (Factory Default Setting) The PTO preset mode is used for stationary applications. PTO will remain engaged while mobile in the preset mode however PTO Preset 1 and PTO Preset 2 speed controls will be inoperative. The engine RPM will also return to normal. This mode provides a default standby speed of 800 or 850 RPM depending on the engine and transmission combination. This mode also provides 2 default PTO control speeds: PTO Preset 1 of 1250 RPM and PTO Preset 2 of 1700 RPM. Please note that the standby speed is not to be used as a PTO control speed. Vehicles not equipped with cruise control will not have the resume speed capability. Page 4514 - Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-D in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-D if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Page 5207 Fuel: Specifications GASOLINE OCTANE Use regular unleaded gasoline with a posted octane of 87 or higher. If the octane is less than 87, you may get a heavy knocking noise when you drive. If this occurs, use a gasoline rated at 87 octane or higher as soon as possible. Otherwise, you might damage your engine. A little pinging noise when you accelerate or drive uphill is considered normal. This does not indicate a problem exists or that a higher-octane fuel is necessary. If you are using 87 octane or higher-octane fuel and hear heavy knocking, your engine needs service. GASOLINE SPECIFICATIONS It is recommended that gasoline meet specifications which were developed by automobile manufacturers around the world and contained in the World-Wide Fuel Charter which is available from the Alliance of Automobile Manufacturers at www.autoalliance.org/fuel_charter.htm. Gasoline meeting these specifications could provide improved driveability and emission control system performance compared to other gasoline. In Canada, look for the "Auto Makers' Choice" label on the pump. CALIFORNIA FUEL If your vehicle is certified to meet California Emission Standards (see the underhood emission control label), it is designed to operate on fuels that meet California specifications. If this fuel is not available in states adopting California emissions standards, your vehicle will operate satisfactorily on fuels meeting federal specifications, but emission control system performance may be affected. The malfunction indicator lamp may turn on (see Malfunction Indicator Lamp ) and your vehicle may fail a smog-check test. If this occurs, return to your authorized GM dealer for diagnosis. If it is determined that the condition is caused by the type of fuel used, repairs may not be covered by your warranty. ADDITIVES To provide cleaner air, all gasoline in the United States are now required to contain additives that will help prevent engine and fuel system deposits from forming, allowing your emission control system to work properly. You should not have to add anything to your fuel. However, some gasoline contain only the minimum amount of additive required to meet U.S. Environmental Protection Agency regulations. General Motors recommends that you buy gasoline that are advertised to help keep fuel injectors and intake valves clean. If your vehicle experiences problems due to dirty injectors or valves, try a different brand of gasoline. Gasoline containing oxygenates, such as ethers and ethanol, and reformulated gasoline may be available in your area to contribute to clean air. General Motors recommends that you use these gasoline, particularly if they comply with the specifications described earlier. NOTICE: Your vehicle was not designed for fuel that contains methanol. Do not use fuel containing methanol. It can corrode metal parts in your fuel system and also damage the plastic and rubber parts. That damage would not be covered under your warranty. Some gasoline that are not reformulated for low emissions may contain an octane-enhancing additive called methylcyclopentadienyl manganese tricarbonyl (MMT); ask the attendant where you buy gasoline whether the fuel contains MMT. General Motors does not recommend the use of such gasoline Fuels containing MMT can reduce the life of spark plugs and the performance of the emission control system may be affected. The malfunction indicator lamp may turn on. If this occurs, return to your authorized GM dealer for service. FUELS IN FOREIGN COUNTRIES If you plan on driving in another country outside the United States or Canada, the proper fuel may be hard to find. Never use leaded gasoline or any other fuel not recommended in the previous text on fuel. Costly repairs caused by use of improper fuel would not be covered by your warranty. To check the fuel availability, ask an auto club, or contact a major oil company that does business in the country where you will be driving. Page 5895 For vehicles repaired under the 8 year/80,000 mile (130,000 km) emission controller warranty use the table. Disclaimer Page 10893 High Temperature Conditions Tools Required J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency MEASURING FREQUENCY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage MEASURING VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop MEASURING VOLTAGE DROP NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Page 7546 3. Install the fill plug. ^ Tighten the plug to 20 Nm (15 ft. lbs.). 4. Install the transfer case shield, if equipped. Page 6645 This diagnostic table should be used when addressing a harsh 1-2 shift concern. Disclaimer Page 14856 Switch Replacement - Door Lock and Side Window - Passenger Removal Procedure 1. Remove the front door trim panel. 2. Disconnect the electrical connectors. 3. Remove the screw that retains the switch panel bezel (1) from the front door panel. 4. Remove the switch panel bezel from the door panel using a flat-bladed tool. 5. Using a wide plastic flat-bladed tool, release the retaining clips on both sides of the door module. 6. Remove the door module from the switch panel bezel. Installation Procedure Page 12516 Page 2962 onto the subject vehicle. - After match mounting, the tire/wheel assembly must be rebalanced. If match mounting tires to in-spec wheels produces assembly values higher than these, tire replacement may be necessary. Replacing tires at lower values will probably mean good tires are being condemned. Because tires can sometimes become temporarily flat-spotted, which will affect force variation, it is important that the vehicle be driven at least 16 km (10 mi) prior to measuring. Tire pressure must also be adjusted to the usage pressure on the vehicle's tire placard prior to measuring. Most GM vehicles will tolerate radial force variation up to these levels. However, some vehicles are more sensitive, and may require lower levels. Also, there are other tire parameters that equipment such as the Hunter GSP9700 cannot measure that may be a factor. In such cases, TAC should be contacted for further instructions. Important - When mounting a GM wheel to a wheel balancer/force variation machine, always use the wheel's center pilot hole. This is the primary centering mechanism on all GM wheels; the bolt holes are secondary. Usually a back cone method to the machine should be used. For added accuracy and repeatability, a flange plate should be used to clamp the wheel onto the cone and machine. This system is offered by all balancer manufacturers in GM's dealer program. - Any type of service equipment that removes tread rubber by grinding, buffing or truing is NOT recommended, and may void the tire warranty. However, tires may have been ground by the tire company as part of their tire manufacturing process. This is a legitimate procedure. Steering Wheel Shake Worksheet When diagnosing vibration concerns, use the following worksheet in conjunction with the appropriate Vibration Analysis-Road testing procedure in the Vibration Correction sub-section in SI. Page 9364 5. Remove paint and primer from the area surrounding the 10 mm (0.40 in) until bare metal is visible. Important The M6 conductive rivet stud as shown, can accommodate a panel thickness range of 0.7-4.2 mm (0.03-0.17 in). If there are layers of sheet metal, they should be touching without any air gaps to ensure a good ground. 6. Select a M6 conductive rivet stud. Refer to the Parts Information section of this bulletin. Note Use the GE-50317 rivet stud tool kit. 7. Place the M6 conductive rivet stud (1) in the 10 mm (0.40 in) hole. Assemble the rivet stud tool (2) with the groove and flare side facing the rivet stud, then the washer and the M6 nut (3). 8. Using a wrench on the rivet stud tool, and a socket on the M6 nut, secure the M6 conductive rivet stud. 9. Ensure the new rivet stud is securely fastened, WITHOUT ANY detectable movement. 10. Completely wrap the threads of the rivet stud with painters tape or equivalent. Page 6750 Put unused material on the shelf for future use. Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Page 12996 Steps 4-5 Steps 1-5 Page 1007 Steps 28 - 31 Page 14973 Tailgate Release Handle: Service and Repair Handle Rod Retainer Replacement - Endgate Handle Rod Retainer Replacement - Endgate Removal Procedure 1. Open the endgate. 2. Remove the fasteners (1) retaining the endgate handle bezel. 3. Remove the endgate handle bezel 4. Release the endgate latch rod from the handle rod retainer. 5. Release the retaining clip (2) and remove the handle rod retainer from the handle. Installation Procedure 1. Install the handle rod retainer to the handle, ensuring the retaining clip (2) is fully seated. 2. Attach the endgate latch rod to the handle rod retainer. Page 9703 C102 I/P Harness To Chassis Harness Part 1 Page 759 Control Module HVAC: Description and Operation HVAC System - Automatic HVAC CONTROL MODULE The HVAC control module is a class 2 device that interfaces between the operator and the HVAC system to maintain air temperature and distribution settings. The battery positive voltage circuit provides power that the control module uses for keep alive memory (KAM). If the battery positive voltage circuit loses power, all HVAC DTCs and settings will be erased from KAM. The body control module (BCM), which is the vehicle mode master, provides a device on signal. The control module supports the above features. HVAC CONTROL MODULE The HVAC control module is a class 2 device that interfaces between the operator and the HVAC system to maintain air temperature and distribution settings. The battery positive voltage circuit provides power that the control module uses for keep alive memory (KAM). If the battery positive voltage circuit loses power, all HVAC DTCs and settings will be erased from KAM. The body control module (BCM), which is the vehicle mode master, provides a device on signal. The control module supports the above features. Service and Repair Rocker Arm Assembly: Service and Repair Valve Rocker Arm and Push Rod Replacement Removal Procedure 1. Remove the valve rocker arm cover. Important: Place the valve rocker arms, pushrods, and pivot support, in a rack so that they can be installed in the same location from which they were removed. 2. Remove the valve rocker arm bolts. 3. Remove the valve rocker arms. 4. Remove the valve rocker arm pivot support. 5. Remove the pushrods. 6. Clean and inspect the valve rocker arms and pushrods. Installation Procedure Important: When reusing the valve train components, always install the components to the original location and position. Valve lash is net build, no valve adjustment is required. Page 6802 Fluid - Differential: Service and Repair Rear Drive Axle 8.6 Inch Axle Lubricant Level Inspection - Rear Drive Axle (8.6 Inch Axle) 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Make sure the vehicle is level. 3. Inspect the rear axle for leaks. Repair as necessary. 4. Clean the area around the rear axle fill plug. 5. Remove the rear axle fill plug. 6. Fabricate a dipstick from a pipe cleaner or similar item. Form the pipe cleaner into an "L". 7. Insert the pipe cleaner into the fill plug opening with the stem facing down. 8. Remove the pipe cleaner and measure the distance from the bend in the pipe cleaner to the lubricant level. The distance between the bend and the lubricant level should be 15-40 mm (0.6-1.6 inch). 9. If the measurement is greater than 40 mm (1.6 inch), add lubricant until the level is between 15-40 mm (0.6-1.6 inch) from the bottom edge of the fill plug hole. Use the proper fluid. 10. Notice: Refer to Fastener Notice in Service Precautions. Install the rear axle fill plug. ^ Tighten the rear axle fill plug to 33 Nm (24 ft. lbs.). 11. Lower the vehicle. 9.5, 10.5 Inch Axle Lubricant Level Inspection - Rear Drive Axle (9.5, 10.5 Inch Axle) 1. Raise the vehicle. Refer to Vehicle Lifting in General Information. 2. Make sure the vehicle is level. 3. Inspect the rear axle for leaks. Repair as necessary. 4. Clean the area around the rear axle fill plug. 5. Remove the rear axle fill plug. 6. Inspect the lubricant level. The lubricant level should be between 0-10 mm (0-0.4 inch) below the fill plug opening. Page 9434 Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses CIRCUIT PROTECTION - FUSES The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the Page 13855 The moldings are available in factory colors; however, quantities are limited. When these quantities are exhausted, the moldings will only be available in paint to match only. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Engine Controls - MIL ON/Misfire/Misfire DTC's Set Engine Control Module: Customer Interest Engine Controls - MIL ON/Misfire/Misfire DTC's Set Bulletin No.: 06-06-04-046 Date: September 12, 2006 INFORMATION Subject: Information on Engine Misfire MIL/SES Light Illuminated or Flashing DTC P0300, P0301, P0302, P0303, P0304, P0305, P0306, P0307, P0308, P0420 or P0430 Models: 1999-2007 Cadillac, Chevrolet, GMC Full-Size Pickup and/or Utility Trucks with 4.8L, 5.3L, 5.7L, 6.0L or 6.2L VORTEC GEN III, GEN IV, V-8 Engine (VINs V, C, T, Z, B, 3, M, 0, J, R, U, N, Y, K, 8 - RPOs LR4, LY2, LM7, L59, L33, LC9, LH6, LMG, LY5, L31, LQ4, LQ9, L76, LY6, L92) with Active Fuel Management(TM) and E85 Flex Fuel If you encounter vehicles that exhibit the above conditions, refer to SI for the appropriate DTC(s) set. If no trouble is found, the cause may be due to an ECM ground terminal that has corroded with rust over time. Inspect the main engine wiring harness ground terminal (G103) for this condition. The wire terminal (G103) attaches either to the front or to the rear of the right side cylinder head, depending on the model year of the Full Size Pickup and/or Utility Trucks. If the ECM ground terminal has been found to be corroded, then follow the service procedure outlined in this bulletin to correct the corrosion issue. Remove either the nut or bolt securing the main engine wiring harness ground terminal (G103) to the right cylinder head. Refer to the above illustration to determine where the ground is located on the vehicle (1). Page 2730 1. Install the engine electrical center bracket assembly to the front fender. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the 4 retaining bolts (1). Tighten Tighten the 4 retaining bolts (1) to 9 N.m (80 lb in). 3. Align the electrical center block (1) stubs in the slots so that the tabs (2) retains it in place. Engine - Drive Belt Misalignment Diagnostics Drive Belt: Technical Service Bulletins Engine - Drive Belt Misalignment Diagnostics INFORMATION Bulletin No.: 08-06-01-008A Date: July 27, 2009 Subject: Diagnosing Accessory Drive Belt / Serpentine Belt Noise and Availability and Use of Kent-Moore EN-49228 Laser Alignment Tool - Drive Belt Models: 2010 and Prior GM Passenger Cars and Trucks (Including Saturn) 2010 and Prior HUMMER H2, H3 Vehicles 2009 and Prior Saab 9-7X Supercede: This bulletin is being revised to add a model year and update the Tool Information. Please discard Corporate Bulletin Number 08-06-01-008 (Section 06 - Engine). Background Several aftermarket companies offer laser alignment tools for accessory drive systems that can be very helpful in eliminating drive belt noise as a result of misaligned pulleys. Typically pricing ranges from $160 - $200. EN-49228 Laser Alignment Tool - Drive Belt The GM Tool program has now made available a competitive, simple to use and time-saving laser tool to assist in achieving precise alignment of the drive belt pulleys. This optional tool removes the guesswork from proper pulley alignment and may serve to reduce comebacks from: - Drive Belt Noise - Accelerated Drive Belt Wear - Drive Belt Slippage Instructions The instructions below are specific only to the truck Gen IV V-8 family of engines. These instructions are only for illustrative purposes to show how the tool may be used. Universal instructions are included in the box with the Laser Alignment Tool - Drive Belt. Caution - Do not look directly into the beam projected from the laser. - Use caution when shining the laser on highly polished or reflective surfaces. Laser safety glasses help reduce laser beam glare in many circumstances. - Always use laser safety glasses when using the laser. Laser safety glasses are not designed to protect eyes from direct laser exposure. 1. Observe and mark the serpentine belt orientation. Locations Page 1657 5. If equipped with a 6.0L engine, disconnect the HO2S electrical connector. 6. Remove the HO2S. INSTALLATION PROCEDURE IMPORTANT: A special anti-seize compound is used on the HO2S threads. The compound consists of liquid graphite and glass beads. The graphite tends to burn away, but the glass beads remain, making the sensor easier to remove. New, or service replacement sensors already have the compound applied to the threads. If the sensor is removed from an exhaust component and if for any reason the sensor is to be reinstalled, the threads must have anti-seize compound applied before the reinstallation. 1. If reinstalling the old sensor, coat the threads with anti-seize compound GM P/N 12377953, or equivalent. NOTE: Refer to Component Fastener Tightening Notice in Service Precautions. Page 5963 Shift Solenoid: Service and Repair Control and Shift Solenoids Replacement Removal Procedure 1. Remove the transmission filter. 2. Important: Removal of the 1-2 accumulator is necessary only if servicing the pressure control solenoid. Remove the 1-2 accumulator, if necessary. 3. Disconnect the internal wiring harness electrical connectors from the following components: ^ Transmission fluid pressure switch (1) ^ 1-2 shift control solenoid (2) ^ 2-3 shift control solenoid (3) ^ Pressure control solenoid (4) ^ torque converter clutch pulse width modulation (TCC PWM) solenoid (5) ^ 3-2 control solenoid (6) 4. Remove the pressure control solenoid retainer bolt (364A) and retainer (378). 5. Remove the pressure control solenoid (377). Page 3092 Disclaimer Page 1845 Maintain the sensor position. Do not turn the sensor. Remove the rear wheel position sensor (2) from the steering gear. Installation Procedure 1. Important: Make sure the O-ring (1) is installed. Install the rear wheel position sensor (2) to the steering gear. 2. Important: Be careful to maintain the position of the replacement sensor. Remove the pin retaining the position of the new sensor and immediately install the sensor to the steering gear. 3. Notice: Refer to Fastener Notice in Service Precautions. Install the rear wheel position sensor retaining bolts. Apply LOCTITE 242 blue. ^ Tighten the bolts to 4 Nm (35 inch lbs.). 4. Install the rear wheel position sensor cover (4). 5. Connect the electrical connector (1). 6. Install the steering gear protection shield (1) and retaining bolts (3). ^ Tighten the steering gear protection shield retaining bolts to 180 Nm (132 ft. lbs.). Tires/Wheels - Low Tire/Leaking Cast Aluminum Wheels Wheels: Customer Interest Tires/Wheels - Low Tire/Leaking Cast Aluminum Wheels TECHNICAL Bulletin No.: 05-03-10-003F Date: April 27, 2010 Subject: Low Tire Pressure, Leaking Cast Aluminum Wheels (Repair with Adhesive Sealant) Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks (Including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X with Cast Aluminum Wheels Supercede: This bulletin is being revised to update the model years and the bulletin reference information. Please discard Corporate Bulletin Number 05-03-10-003E (Section 03 - Suspension). Condition Some customers may comment on a low tire pressure condition. Diagnosis of the low tire pressure condition indicates an air leak through the cast aluminum wheel. Cause Porosity in the cast aluminum wheel may be the cause. Notice This bulletin specifically addresses issues related to the wheel casting that may result in an air leak. For issues related to corrosion of the wheel in service, please refer to Corporate Bulletin Number 08-03-10-006C - Tire Slowly Goes Flat, Tire Air Loss, Low Tire Pressure Warning Light Illuminated, Aluminum Wheel Bead Seat Corrosion (Clean and Resurface Wheel Bead Seat). Correction 1. Remove the tire and wheel assembly from the vehicle. Refer to the appropriate service procedure in SI. 2. Locate the leaking area by inflating the tire to 276 kPa (40 psi) and dipping the tire/wheel assembly in a water bath, or use a spray bottle with soap and water to locate the specific leak location. Important - If the porosity leak is located in the bead area of the aluminum rim (where the tire meets the rim), the wheel should be replaced. - If two or more leaks are located on one wheel, the wheel should be replaced. 3. If air bubbles are observed, mark the location. - If the leak location is on the tire/rubber area, refer to Corporate Bulletin Number 04-03-10-001F Tire Puncture Repair Procedures for All Cars and Light Duty Trucks. - If the leak is located on the aluminum wheel area, continue with the next step. 4. Inscribe a mark on the tire at the valve stem in order to indicate the orientation of the tire to the wheel. 5. Dismount the tire from the wheel. Refer to Tire Mounting and Dismounting. 6. Remove the tire pressure sensor. Refer to Tire Pressure Sensor removal procedure in SI. 7. Scuff the INSIDE rim surface at the leak area with #80 grit paper and clean the area with general purpose cleaner, such as 3M(R) General Purpose Adhesive Cleaner, P/N 08984, or equivalent. 8. Apply a 3 mm (0.12 in) thick layer of Silicone - Adhesive/Sealant, P/N 12378478 (in Canada, use 88900041), or equivalent, to the leak area. 9. Allow for the adhesive/sealant to dry. Notice Caution must be used when mounting the tire so as not to damage the sealer. Damaging the repair area may result in an air leak. Page 4652 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly, Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Pull to Seat Connectors PULL TO SEAT CONNECTORS TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Page 5580 Step 6 Page 13905 10. Install the upper molding to the pickup box side. Align the locator pins (2) and press down in order to secure. 11. Install the upper molding rear retainer to the pickup box side. Page 10819 HVAC Module Assembly - Top Page 5729 For vehicles repaired under warranty, use the table. Disclaimer Page 900 - Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-D in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-D if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Locations Full Engine View Left Side Page 10958 Cut the wires back far enough from the connector to eliminate any melted insulation on the wire. Tip Use the old connector as a map for splicing the wires for the new connector. Be sure to use the correct crimping tool from the terminal repair kit J 38125. Use only Duraseal splice sleeves. Other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Install the new connector. Use the yellow splice sleeves provided with the connector. Install new blower motor resistor. Reinstall the fuse or connector block. Test the blower motor to make sure all speeds are functional. Reinstall the hush panel/close-out panel. Parts Information Warranty Information Page 14270 Paint: By Symptom Technical Service Bulletin # 05-08-51-008C Date: 090622 Body - Bumps or Rust Colored Spots in Paint TECHNICAL Bulletin No.: 05-08-51-008C Date: June 22, 2009 Subject: Bumps or Rust Colored Spots in Paint Due to Rail or Iron Dust (Remove Rail Dust) Models: 1994-2010 GM Passenger Cars and Trucks (Including Saturn) 2003-2010 HUMMER H2 2006-2010 HUMMER H3 2005-2009 Saab 9-7X Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 05-08-51-008B (Section 08 - Body and Accessories). Condition Visible rust colored spots or bumps on a vehicle's paint surface from rail or iron dust. Cause Rail dust comes from tiny iron particles produced from the friction between train wheels and the tracks and gets deposited on the vehicle surfaces. Iron dust can get deposited on the surface if the vehicle is stored near any operation producing iron dust such as an iron ore yard. Either material can lay on top of, or become embedded in, the paint surface. Correction Because the severity of the condition varies, proper diagnosis of the damage is critical to the success of repairs. Diagnosis should be performed on horizontal surfaces (hood, roof, deck lid, pick up box, etc.) after the vehicle has been properly cleaned. There are two types of repair materials recommended to repair rail dust or iron dust: 1. GEL TYPE OXALIC ACID: - Has the characteristics of the liquid type oxalic acid but stays where you put it because of its gel consistency. 2. CLAY TYPE NON-ACID BASED: - Requires surface lubricant during use. - Has different grades available. Caution Rail dust remover (Oxalic Acid) is an acidic substance containing chemicals that will break down the iron particles embedded in the finish. When working with rail dust remover, use the necessary safety equipment, including gloves and goggles. Follow the chemical manufacturer's directions closely because it may require special handling and disposal. If, upon inspection, some particles are still present, the various chemical manufacturer's processes can be repeated. After the removal process, small pits may remain in the clearcoat and can be corrected, in most cases, with a finesse/polish operation. Procedure 1. Move the vehicle to a cool shaded area and make sure that the vehicle surfaces are cool during the removal process. DO NOT PERFORM THE REMOVAL PROCESS IN DIRECT SUNLIGHT OR ON A VEHICLE WITH HOT OR WARM BODY PANELS. 2. Wash the vehicle with soap and water. Dry it immediately and clean the affected areas with a wax and grease remover. 3. Perform the removal process according to the chemical manufacturer's directions. Once the damage has been repaired, the final step involves a polishing process. Rail Dust Remover Manufacturers Page 8220 Removal Procedure 1. Release the park brake. 2. Raise and support the vehicle. Refer Vehicle Lifting 3. Remove the tire and wheel assembly. 4. Remove the hub and rotor assembly. 5. Mark the relationship of the hub to the rotor. 6. Place the hub and rotor assembly on a hydraulic press. 7. Press the wheel studs out of the hub and rotor assembly. Installation Procedure 1. Align the hub and the rotor (if applicable). 2. Install each of the new wheel studs into the hub and rotor assembly by performing the following steps: 1. Install the stud. 2. Install 4 washers to the stud. 3. Install a lug nut to the stud with the flat side of the nut towards the washers. 4. Tighten the lug nut to draw the stud into the hub and rotor assembly. 5. Inspect the hub and rotor assembly to ensure that the hub is tight against the rotor and the stud is seated completely. 6. Remove the lug nut and the washers. 3. Install the hub and rotor assembly to the vehicle. 4. Install the tire and wheel assembly. 5. Lower the vehicle. 6. With the engine OFF, gradually apply the brake pedal to approximately 2/3 of it's travel distance. 7. Slowly release the brake pedal. 8. Wait 15 seconds, then repeat steps 6-7 until a firm pedal is obtained. This will properly seat the brake caliper pistons and brake pads. 9. Fill the master cylinder reservoir to the proper level with clean brake fluid. Refer to Master Cylinder Reservoir Filling in Hydraulic Brakes. Page 1600 Knock Sensor: Service and Repair KNOCK SENSOR (KS) REPLACEMENT REMOVAL PROCEDURE 1. Remove the intake manifold. 2. Gently pry up the rubber covers. 3. Disconnect the knock sensor electrical connectors. 4. Remove the knock sensors. INSTALLATION PROCEDURE NOTE: Refer to Fastener Notice in Service Precautions. Page 10230 Steering Mounted Controls Transmitter: Diagnostic Aids Basic Knowledge Required BASIC KNOWLEDGE REQUIRED Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the Service Data. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories CHECKING AFTERMARKET ACCESSORIES Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: - Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions INDUCING INTERMITTENT FAULT CONDITIONS In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: - Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. Page 4443 Engine Control Module: Description and Operation Electronic Ignition (EI) System POWERTRAIN CONTROL MODULE (PCM) The PCM controls all ignition system functions, and constantly corrects the basic spark timing. The PCM monitors information from various sensor inputs that include the following: - The throttle position (TP) sensor - The engine coolant temperature (ECT) sensor - The mass air flow (MAF) sensor - The intake air temperature (IAT) sensor - The vehicle speed sensor (VSS) - The transmission gear position or range information sensors - The engine knock sensors (KS) Page 8796 7. Insert the J 38125-13A (GM P/N 12031876-1) tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the Terminal Repair Kit to ensure that the correct release tool is used. 8. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. REPAIR PROCEDURE Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. Page 4958 3. Disconnect the vent valve pipe quick connect from the canister. 4. Either cut the existing valve vent pipe and leave the remaining section of pipe in the vehicle or remove along with the valve. 5. Push in the retainer and remove the existing canister vent valve from the fuel tank clip or mounting bracket. 6. Cut back the existing canister pipe approximately 51 mm (2 in) and retain the pipe for use with new valve. 7. Connect the canister pipe quick connect to the canister. 2500 Crew Cab Short Box Shown Below, Other Configurations Similar 1500 Extended Cab Short Box Shown Below, Other Configurations Similar 8. Install the new canister vent valve solenoid to the fuel tank clip or mounting bracket as shown above. The valve port closest to the electrical connector must point towards the canister. 9. Cut bulk 5/8" heater hose to a length of approximately 76 mm (3 in). Install the hose between the solenoid and the canister pipe and secure using clamps. 10. Attach bulk 5/8" heater hose to the vent port and secure using a clamp. Run a length as needed along the frame rail routing to the passenger side area above the transmission. 11. Cut the hose to determined length and install the supplied filter box. Secure using a clamp. 12. Remove the transmission heat shield, if necessary. 13. Remove the transmission support and lower the transmission assembly as necessary to allow for access to the new filter box location. 14. Secure the filter box to the transmission vent hose just forward of the hose tee-section using a tie strap. DO NOT pinch or restrict the transmission vent hose. The filter box opening should be pointing downward. 15. Raise the transmission and reinstall the transmission support. 16. Reinstall the transmission heat shield. 17. Connect the EVAP canister vent valve electrical connector. 18. Tie strap the hose as needed along the frame rail in order to keep the hose away from pinch-points and heat sources. 19. Lower the vehicle. Parts Information Page 15691 License Plate Lamp: Service and Repair LICENSE LAMP REPLACEMENT (PICKUP W/O BUMPER) REMOVAL PROCEDURE 1. Ensure the headlamp switch is in the OFF position. 2. Remove the lens from the lamp assembly (2). 3. Remove the bulb. INSTALLATION PROCEDURE 1. Install the bulb. 2. Install the lens to the lamp assembly (2). 3. Install the wiring (3) to the back of the lens assembly. Page 2495 Fluid - Differential: Fluid Type Specifications Differential Fluid Type Differential Fluid Type Front 4WD Grade ................................................................................................................................ ............................................................................................. GL-5 Viscosity ....................................... .............................................................................................................................................................. .............. 80W-90 Front AWD Grade ................................................................................................... .................................................................................................................... Synthetic Viscosity .......... .............................................................................................................................................................. ........................................... 75W-90 Rear Grade ................................................................................ ....................................................................................................................................... Synthetic Viscosity .............................................................................................................................................. ..................................................................... 75W-90 Rear (Steerable) Grade ................................... .............................................................................................................................................................. ...................... Synthetic Viscosity ........................................................................................................ ........................................................................................................... 75W-90 Front Differential Differential Fluid Type The content of this article reflects the changes identified in TSB number 05-00-90-010 dated December 07, 2005. 1999-2004 7.25 Inch (Blazer, Jimmy, S-10, Sonoma, Astro, Safari) Grade ........................................ .............................................................................................................................................................. ....................... GL-5 Viscosity ............................................................................................................. ...................................................................................................... 80W-90 2002-2005 7.25 Inch (Trailblazer, Envoy, Bravada, Rainier Grade ....................................................................................... ................................................................................................................................ Synthetic Viscosity .............................................................................................................................................. ..................................................................... 75W-90 8.25 Inch With Selectable 4WD Grade ............ .............................................................................................................................................................. ................................................... GL-5 Viscosity ................................................................................. .................................................................................................................................. 80W-90 8.25 Inch With AWD Grade ......................................................................................................................... .............................................................................................. Synthetic Viscosity ................................ .............................................................................................................................................................. ..................... 75W-90 1999-2001 9.25 Inch Grade ............................................................................. ................................................................................................................................................ GL-5 Viscosity .............................................................................................................................................. ..................................................................... 80W-90 2002-2005 9.25 Inch Grade ............................. .............................................................................................................................................................. ............................ Synthetic Viscosity .................................................................................................. ................................................................................................................. 75W-90 Front Drive Axle Differential Fluid Type The content of this article reflects the changes identified in TSB number 05-00-90-010 dated December 07, 2005. 1999-2004 7.25 Inch (Blazer, Jimmy, S-10, Sonoma, Astro, Safari) Grade ........................................ .............................................................................................................................................................. ....................... GL-5 Viscosity ............................................................................................................. ...................................................................................................... 80W-90 2002-2005 7.25 Inch (Trailblazer, Envoy, Bravada, Rainier Grade ....................................................................................... ................................................................................................................................ Synthetic Viscosity .............................................................................................................................................. ..................................................................... 75W-90 8.25 Inch With Selectable 4WD Grade ............ .............................................................................................................................................................. ................................................... GL-5 Viscosity ................................................................................. .................................................................................................................................. 80W-90 8.25 Inch With AWD Grade ......................................................................................................................... .............................................................................................. Synthetic Viscosity ................................ .............................................................................................................................................................. ..................... 75W-90 1999-2001 9.25 Inch Grade ............................................................................. ................................................................................................................................................ GL-5 Viscosity .............................................................................................................................................. ..................................................................... 80W-90 2002-2005 9.25 Inch Instruments - Trip Odometer Apparently Inoperative Odometer: All Technical Service Bulletins Instruments - Trip Odometer Apparently Inoperative Bulletin No.: 04-08-49-007 Date: February 26, 2004 INFORMATION Subject: Personal Trip/Business Trip Feature - Must be On for Trip Odometer to Accumulate Models: 2003-2004 Cadillac Escalade, Escalade ESV, Escalade EXT 2003-2004 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2003-2004 GMC Sierra, Sierra Denali, Yukon, Yukon XL, Yukon Denali The purpose of this bulletin is to prevent the inadvertent replacement of the instrument cluster if a customer comes in to your dealership stating that the trip odometer is inoperative or does not accumulate. For vehicles with steering wheel controls, the Personal Trip (or Business Trip) feature must be turned On in order for the trip odometer to accumulate. When the display reads Personal Trip: On (or Business Trip: On), the trip odometer shall accumulate. The Personal Trip and Business Trip features can be turned on or off by pressing the select button. Refer to Driver Information Center (DIC) in the Owner's Manual for additional information. Page 5734 Pay particular attention to the terminal connections at the module. Spread or open terminal connections may create an intermittent contact. Do a pin drag test. Refer to the terminal testing information in the table shown. ^ After repairs are complete, ALWAYS clear DTCs from the module prior to a system function test. If codes are not cleared first, the system will not function after repair. The technician may erroneously think that the system is still down and that further repairs are needed. Warranty Dealers who unnecessarily replace the TCCM that are found to have No Trouble Found (NTF) at the WPC will be returned to the AVM (Area Service Manager), or the DSM (District Service Manager) in Canada, through the Regional Feedback Process and may be charged back for the repair through the WINS system. Disclaimer Page 14324 Paint: Application and ID Parts ID Label Location The vehicle service parts identification label is located inside the instrument panel I/P compartment. The label is used to help identify the vehicle original parts and options. Initial Inspection and Diagnostic Overview Auxiliary Power Outlet: Initial Inspection and Diagnostic Overview Diagnostic Starting Point DIAGNOSTIC STARTING POINT - POWER OUTLETS Begin the system diagnosis with the Diagnostic System Check - Power Outlets. The Diagnostic System Check will provide the following information: - The identification of the control module(s) which command the system. - The ability of the control modules to communicate through the serial data circuit. - The identification of any stored diagnostic trouble codes (DTCs) and their status. The use of the Diagnostic System Check will identify the correct procedure for diagnosing the system and where the procedure is located. Diagnostic System Check - Power Outlets DIAGNOSTIC SYSTEM CHECK - POWER OUTLETS TEST DESCRIPTION Steps 1-2 Page 2032 INSTALLATION PROCEDURE 1. Install the door module into the switch panel bezel until it snaps into place. 2. Install the switch panel bezel and module to the door panel. NOTE: Refer to Fastener Notice in Service Precautions. 3. Install the screw that retains the switch panel bezel (1) to the front door panel. Tighten Tighten the screw to 2 N.m (18 lb in). 4. Connect the electrical connectors. 5. Install the front door trim panel. 6. If equipped with camper mirrors program the door module. Refer to Service Programming System (SPS) in Programming. Page 15811 Headlamp Switch: Service and Repair HEADLAMP SWITCH REPLACEMENT REMOVAL PROCEDURE 1. Remove the instrument cluster bezel. 2. Unsnap the switch from the housing. 3. Disconnect the electrical connectors. 4. Remove the switch. INSTALLATION PROCEDURE Page 15166 6. Use fingers to squeeze the 2 locking legs of the cover. 7. Apply pressure and gently rock the cover until one locking leg is unseated. 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. Page 9250 C396 Body Harness To Right Rear Door Harness (Crew Cab) Part 1 Page 4498 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground TESTING FOR SHORT TO GROUND NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting With A Digital Multimeter TROUBLESHOOTING WITH A DIGITAL MULTIMETER NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TROUBLESHOOTING WITH A TEST LAMP Page 8436 9. Remove the park brake shoe return spring (6). 10. Remove the park brake shoe anchor springs and pins. 11. Separate the tips of the shoes from the park brake actuator and remove the park brake shoes and adjuster assembly from the vehicle. Installation Procedure 1. Clean the debris and the dust from the park brake components using a clean shop cloth. 2. Install the adjuster assembly to the park brake shoes. 3. Separate the tips of the shoes and install the park brake shoes to the park brake actuator. 4. Install the park brake shoe anchor springs and pins. Page 13662 Snap the handle bezel into place in the door trim panel. Page 13147 Important: The optic cable must not be bent with a radius less than 25 mm (1 in). 6.12. Place the optic cable in the wiring harness channels on the right-hand side. Thread through the existing cable ties (C) if possible, otherwise, secure with a cable tie to the existing one. Close the cover on the channels. Ensure the catches lock. 6.13. Secure the optic cable along the right-hand rear wheel housing, next to the ordinary wiring harness securing points and by the SRS unit (D). 6.14. Thread the optic cable up next to the safety belt by the old optic cable and place on the parcel shelf. 6.15. Unplug the connectors (E) from the OnStar(R) control modules. 6.16. Remove the console (F) together with the OnStar(R) control modules. Page 3258 Drive Belt: Service and Repair Air Conditioning Drive Belt Replacement - Air Conditioning Removal Procedure 1. Remove the accessory drive belt. 2. Raise and suitably support the vehicle. 3. Remove the engine shield bolts. 4. Remove the engine shield. 5. Install a ratchet into the air conditioning (A/C) belt tensioner adapter opening. 6. Rotate the A/C belt tensioner clockwise in order to relieve tension on the belt. 7. Remove the A/C belt from the pulleys. 8. Slowly release the tension on the A/C belt tensioner. 9. Remove the ratchet from the A/C belt tensioner. 10. Clean and inspect the belt surfaces of all the pulleys. Installation Procedure 1. Install the A/C belt around the crankshaft balancer. 2. Install a ratchet into the A/C drive belt tensioner adapter opening 3. Rotate the A/C belt tensioner clockwise in order to relieve tension on the tensioner. 4. Install the A/C belt over the idler pulley. 5. Install the A/C belt around the A/C compressor pulley. Page 8519 CLAIM INFORMATION CUSTOMER NOTIFICATION - For US and CANADA General Motors will notify customers of this recall on their vehicle (see copy of customer letter shown in this bulletin). CUSTOMER NOTIFICATION - For IPC Letters will be sent to known owners of record located within areas covered by the US National Traffic and Motor Vehicle Safety Act. For owners outside these areas, dealers should notify customers using the sample letter. DEALER RECALL RESPONSIBILITY - For US and IPC (US States, Territories, and Possessions) The US National Traffic and Motor Vehicle Safety Act provides that each vehicle that is subject to a recall of this type must be adequately repaired within a reasonable time after the customer has tendered it for repair. A failure to repair within sixty days after tender of a vehicle is prima facie evidence of failure to repair within a reasonable time. If the condition is not adequately repaired within a reasonable time, the customer may be entitled to an identical or reasonably equivalent vehicle at no charge or to a refund of the purchase price less a reasonable allowance for depreciation. To avoid having to provide these burdensome remedies, every effort must be made to promptly schedule an appointment with each customer and to repair their vehicle as soon as possible. In the recall notification letters, customers are told how to contact the US National Highway Traffic Safety Administration if the recall is not completed within a reasonable time. This bulletin is notice to you that the new motor vehicles included in this recall may not comply with the standard identified above. Under Title 49, Section 30112 of the United States Code, it is illegal for a dealer to sell a new motor vehicle which the dealer knows does not comply with an applicable Federal Motor Vehicle Safety Standard. As a consequence, if you sell any of these motor vehicles without first performing the recall correction, your dealership may be subject to a civil penalty for each such sale. DEALER RECALL RESPONSIBILITY - ALL All unsold new vehicles in dealers' possession and subject to this recall must be held and inspected/repaired per the service procedure of this recall bulletin before customers take possession of these vehicles. Dealers are to service all vehicles subject to this recall at no charge to customers, regardless of mileage, age of vehicle, or ownership, from this time forward. Customers who have recently purchased vehicles sold from your vehicle inventory, and for which there is no customer information indicated on the dealer listing, are to be contacted by the dealer. Arrangements are to be made to make the required correction according to the instructions contained in this bulletin. A copy of the customer letter is shown in this bulletin for your use in contacting customers. Recall follow-up cards should not be used for this purpose, since the customer may not as yet have received the notification letter. In summary, whenever a vehicle subject to this recall enters your vehicle inventory, or is in your dealership for service in the future, you must take the steps necessary to be sure the recall correction has been made before selling or releasing the vehicle. Disclaimer Service Procedure The following procedure provides instructions for inspecting, and if necessary, replacing the hydraulic brake booster relief valve. 1. Open the hood. Important You may notice that there is a blue epoxy-type material in the center of the relief valve described in the next step. This material will be found in both the original arid replacement relief valves. 2. Locate the relief valve (2) on the hydraulic brake booster. The valve is located in the front of the brake booster directly behind the master cylinder reservoir (1). ^ If the color of the relief valve is metallic yellow or has a brass appearance, then further action is required. Page 14360 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground TESTING FOR SHORT TO GROUND NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting With A Digital Multimeter TROUBLESHOOTING WITH A DIGITAL MULTIMETER NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TROUBLESHOOTING WITH A TEST LAMP Page 4485 Electrical Symbols Part 8 Page 4015 Disclaimer Page 8499 visible in the clear adapter tube). If fluid is seen coming out of the inlet port adapter up to 65 Nm (48 lb-ft) maximum torque, the hydro-boost booster assembly is "OK", Proceed to Step 19. A. If NO fluid is seen exiting from the inlet port adapter, complete Steps 19-27 and then repeat Steps 1-18. B. If no fluid is visible from the second evaluation, replace the hydro-boost unit. Proceed to the appropriate procedure found in this bulletin. 19. Loosen the clamp bolt, remove the clamp containment bolt, and remove the accumulator pressure clamp. Remove the inlet port adapter from the supply port of the booster. Wipe the excess power steering fluid off of the adapter with a clean, lint-free shop cloth. Store the adapter in a clean location, such as a plastic bag. 20. Reinstall the supply hose/tube to the booster. Tighten Tighten to 28 N.m (21 lb-ft). 21. Clean any spilled fluid from the outside of the booster. 22. For Express/Savana only: ^ Connect the reservoir outlet hose to the booster unit. Keeping the hose end higher than reservoir, reposition the reservoir onto the mounting studs. A. Install the remote power steering reservoir mounting nuts. Tighten Tighten to 7 Nm (58 lb in). 23. Start the engine and run at idle. Depress the brake pedal 5 times. Turn the steering wheel to the "steering lock" position. Hold for 1-2 seconds. Check to see if there is any leakage from the ports/fittings. 24. Turn the engine off. 25. If leaks were observed, re-check that the fittings are at the recommended torque values. Repeat Steps 17 and 18. 26. Check the power steering reservoir fluid level, add fluid if necessary. 27. Close the hood. Hydro-Boost(R) Replacement - Avalanche, Express, Savana, Silverado, Sierra, Suburban, Yukon XL Tools Required ^ J 35555 Metal Mityvac ^ J 43485 Power Steering Bleeder Adapter Removal 1. Apply the park brake and block the wheels. Page 12722 10. Disconnect and remove the OnStar(R) jumper harness. Note: You will need to remove the short GPS cable from this jumper harness. 11. Untape the cell antenna coax from the body harness in the trunk. This will be necessary to provide adequate length to connect to the new VCIM. 12. Fasten three retainer clips (1) from the kit to the new bracket that is included in the kit, and position the VCIM to the bracket (2). 13. Install the three bolts from the kit. Tighten the bolts to 10 Nm (89 lb in). 14. Connect the new OnStar(R) jumper harness supplied in the kit to the VCIM (two white connectors on module). 15. Connect small GPS coax cable jumper harness supplied in the kit (end with blue plastic housing) to VCIM GPS connector. 16. Position the VCIM / bracket assembly to the studs. 17. Install the bracket nuts saved from the Removal Procedure above to the VCIM / bracket assembly mounting studs. Tighten the nuts to 4 Nm (35 lb in). 18. Connect the new OnStar(R) jumper harness to the body wiring harness (C410 connector). 19. Connect small coax cable jumper from VCIM to the OnStar(R) Global Positioning Satellite (GPS) antenna coaxial cable at the connector previously left in the vehicle (short jumper removed from old harness in step 5.10). 20. Connect the cellular coaxial cable previously left in vehicle to the OnStar(R) VCIM. 21. Verify that all harnesses are properly secured in vehicle. 6. After replacing the VCIM, it is essential to configure the new OnStar(R) system. Failure to configure the system will result in an additional customer visit for repair. DO NOT press and hold the white dot or phone button on the keypad as it will not reset this version of the OnStar(R) system and may result in a DTC being set. Use of the TIS2WEB and SPS applications, along with the Tech2(R), are required in order to perform the VCIM configuration and setup procedure for this vehicle. The configuration and set-up procedure is now a two-step process which enables an automated activation by the OnStar(R) Center, without a button press by the technician to the OnStar(R) Call Center. 1. Connect the Tech2(R) to the vehicle. Page 6296 Phase three will eliminate the oil pump body 0-ring seal groove and the 0-ring seal. Beginning March 2004, a new stamped carrier molded rubber seal (2) will be used to seal the pump assembly to the transmission case. The pump sealing surface is now the outer diameter of the pump and the inner diameter (1) of the transmission case bore. Unlike the current 0-ring seal, which is installed on the oil pump body, the new seal is installed after the pump assembly is properly positioned and torqued in place. Seating the seal is accomplished when the torque converter housing is installed, which presses the seal (3) into position between the pump and the case bore (1). As a result of the modified casting and the deeper pump bore machining, the area between the oil pan mounting surface and the pump bore has decreased. Because of the reduced material in this area (1) it is necessary to use the shorter oil pan attaching bolts (2). Early pan bolts (3), before November 2002, should not be used with the modified case design, since they are 1.0 mm (0.39 in) longer and could deform the chamfer surface (4). Service Information Page 501 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Page 9046 Junction Block - Rear Lamps - C1 Part 2 Page 2318 7. Remove the push pin from the right side radiator air baffle. 8. Remove the bolts (2) from the starter/generator control module (SGCM) coolant pump (1). 9. Reposition the SGCM coolant pump. 10. Remove the right park/turn signal lamp. 11. Remove the grille from the vehicle. 12. Remove the evaporator tube nut from the condenser. 13. Remove the evaporator tube from the condenser. 14. Remove the front evaporator tube from the vehicle. Page 8375 2. Install the park brake cable (2) to the lever (1). 3. Perform the following procedure to install the cable (2) to the backing plate (4): 1. Compress the spring (3) by pushing towards the lever (1). 2. Route the cable (2) through the slot in the backing plate. 3. Push the cable housing into the backing plate (4) until the locking tabs snap into place. 4. Notice: Refer to Fastener Notice in Service Precautions. Install the cable at the shock absorber bracket and install the bolt. ^ Tighten the bolt to 25 Nm (18 ft. lbs.). 5. Install the cable to the mounting bracket until the locking tabs snap into place. 6. For 25/35 series vehicles, connect the cable at the equalizer. Page 1341 and close between 275-317 kPa (40-46 psi). 11. Remove special tool GE-47742 after diagnosis is complete. 12. Install a new O-ring on the A/C low pressure switch port on the accumulator. Lightly coat the new O-ring seal with mineral base 525 viscosity refrigerant oil. 13. Install the A/C low pressure switch onto the accumulator. Tighten Tighten the A/C low pressure switch to 6 Nm (44 lb in). Important Remember to install the seal back onto the A/C low pressure switch wire harness connector. Failure to replace the seal could result in terminal corrosion. 14. Reconnect the wire harness to the A/C low pressure switch. Disclaimer Page 13874 The moldings are available in factory colors; however, quantities are limited. When these quantities are exhausted, the moldings will only be available in paint to match only. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 11522 43. Install the right inner axle shaft housing assembly to the differential carrier assembly. 44. Install the inner axle shaft housing bolts. Tighten Tighten the inner axle shaft housing bolts to 40 N.m (30 lb ft). 45. Install the inner axle shaft housing washers and nuts to the bracket. Tighten Tighten the inner axle shaft housing nuts to 100 N.m (75 lb ft). 46. Connect the wheel drive shaft inboard flange to the inner axle shaft. 47. Install the wheel drive shaft inboard flange to the inner axle shaft bolts. Tighten Tighten the wheel drive shaft inboard flange to the inner axle shaft bolts to 79 N.m (58 lb ft). 48. Connect the wire harness to the inner axle shaft housing and differential carrier. 49. Connect the electrical connector to the front axle actuator. 50. Fill the differential carrier assembly with axle lubricant. Use the proper fluid. Refer to Lubricant Replacement - Front Drive Axle in the Front Axle sub-section of the Service Manual. 51. Install the front engine protection shield. Refer to Engine Protection Shield Replacement in the Frame and Underbody sub-section of the service manual. 52. Lower the vehicle. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Tires/Wheels - Tire Slowly Goes Flat/Warning Light ON Wheels: Customer Interest Tires/Wheels - Tire Slowly Goes Flat/Warning Light ON TECHNICAL Bulletin No.: 08-03-10-006C Date: April 27, 2010 Subject: Tire Slowly Goes Flat, Tire Air Loss, Low Tire Pressure Warning Light Illuminated, Aluminum Wheel Bead Seat Corrosion (Clean and Resurface Wheel Bead Seat) Models: 2000-2011 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2009 HUMMER H2 2006-2010 HUMMER H3 2005-2009 Saab 9-7X Supercede: This bulletin is being revised to update the model years. Please discard Corporate Bulletin Number 08-03-10-006B (Section 03 - Suspension). Condition Some customers may comment on a tire that slowly loses air pressure over a period of days or weeks. Cause Abrasive elements in the environment may intrude between the tire and wheel at the bead seat. There is always some relative motion between the tire and wheel (when the vehicle is driven) and this motion may cause the abrasive particles to wear the wheel and tire materials. As the wear continues, there may also be intrusion at the tire/wheel interface by corrosive media from the environment. Eventually a path for air develops and a 'slow' leak may ensue. This corrosion may appear on the inboard or outboard bead seating surface of the wheel. This corrosion will not be visible until the tire is dismounted from the wheel. Notice This bulletin specifically addresses issues related to wheel bead seat corrosion that may result in an air leak. For issues related to porosity of the wheel casting that may result in an air leak, please refer to Corporate Bulletin Number 05-03-10-006F - Low Tire Pressure, Leaking Cast Aluminum Wheels (Repair with Adhesive Sealant) Correction In most cases, this type of air loss can be corrected by following the procedure below. Important DO NOT replace a wheel for slow air loss unless you have evaluated and/or tried to repair the wheel with the procedure below. Notice The repair is no longer advised or applicable for chromed aluminum wheels. 1. Remove the wheel and tire assembly for diagnosis. Refer to Tire and Wheel Removal and Installation in SI. 2. After a water dunk tank leak test, if you determine the source of the air leak to be around the bead seat of the wheel, dismount the tire to examine the bead seat. Shown below is a typical area of bead seat corrosion.Typical Location of Bead Seat Corrosion Page 11032 Tighten the compressor discharge hose nut to 16 N.m (12 lb ft). 7. Install the lower bolts to the hood latch support bracket. Tighten Tighten the compressor discharge hose nut to 9 N.m (80 lb in). 8. Install the tie bar to radiator brace bolts (1). Access the bolts from the rear of the upper radiator support. Tighten Tighten the compressor discharge hose nut to 9 N.m (80 lb in). 9. Install the grille. 10. Evacuate and recharge the system. Refer to Refrigerant Recovery and Recharging. 11. Leak test the fittings of the component using the J 39400-A. Ignition System - New Spark Plugs & Gapping Info. Spark Plug: Technical Service Bulletins Ignition System - New Spark Plugs & Gapping Info. INFORMATION Bulletin No.: 03-06-04-060B Date: July 30 2008 Subject: Information on New Spark Plugs and Gapping Models Attention: Please disregard the Set Gap Per Vehicle Specification statement on the side of an ACOelco(R) Iridium Spark Plug Box. The statement will be removed from the boxes in the future. Supercede: This bulletin is being revised to add the Chevrolet SSR and the 2005 Pontiac GTO. Please discard Corporate Bulletin Number 03-06-04-060A (Section 06 - Engine/Propulsion System). ^ A new spark plug has been released for use in the above vehicles. The new spark plug has an Iridium tip instead of the current Platinum tip. Due to the different tip design the gap of the spark plug has also changed. ^ The new spark plug P/N 12571164 with AC Delco P/N 41-985 is gapped to 1.01 mm (0.040 in) when the spark plug is made. Notice: The spark plug gap is set during manufacturing and should not be changed or damage to the spark plug may result. Any new spark plug found to not be properly gapped should not be used. Disclaimer Page 3002 9.1. Push the mud flap to make contact with the front side of the underbody cross sill and mark location of the hole (5) of the mud flap. 9.2. Center punch the marked location and drill a 5.159 mm (13/64 in) hole. 9.3. Install the screw. Tighten Tighten the screw to 4 N.m (35 lb in). 9.4. Repeat the above steps for hole location 6. 10. Repeat the above steps for the opposite side. Parts Information Parts are expected to be available from GMSPO on June 30, 2004. Warranty Information Please advise the customer that the mud flaps can be purchased as an accessory. Installation and/or cost of the mud flaps will not be covered under the vehicle's warranty. Disclaimer Page 15567 Tail/Stop Lamp - Right Page 16162 Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips SPLICING COPPER WIRE USING SPLICE CLIPS IMPORTANT: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. TOOLS REQUIRED J 38125-D Terminal Repair Kit 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-D in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. Page 10473 1. Install the wheel hub and bearing (3) to the vehicle. 2. Install the wheel hub and bearing retaining bolts. ^ Tighten the bolts to 180 Nm (132 ft. lbs.). 3. Notice: Refer to Fastener Notice in Service Precautions. Install the wheel drive shaft retaining nut. ^ Tighten the nut to 250 Nm (184 ft. lbs.). 4. Install the retainer (3) and cotter pin (2) to the wheel drive shaft nut. 5. Install the dust cap (4). 6. Install the brake rotor. 7. Install the tire and wheel. 8. Lower the vehicle. Page 7999 Speed Sensor: Service and Repair Transfer Case - NVG 261-NP2 Transfer Case Speed Sensor Replacement Removal Procedure 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. Disconnect the speed sensor electrical connector (4). 3. Remove the speed sensor. Installation Procedure 1. Notice: Refer to Fastener Notice in Service Precautions. Install the speed sensor. ^ Tighten the sensor to 15 Nm (11 ft. lbs.). Page 15777 Door Switch: Diagrams Door Latch Assembly (Door Jamb Switch) - Front Passenger C2 Door Latch Assembly (Door Jamb Switch) - Front Passenger C2 Page 13039 1. To receive credit, submit a claim with the information above. Disclaimer 2001 and Older Model Year Vehicles (Except Saab Vehicles) 2001 and Older Model Year Vehicles (Except Saab Vehicles) Important: 2001 and older model year vehicles require the removal of the battery power from the OnStar(R) vehicle interface unit (VIU) to eliminate the possibility of an inadvertent OnStar(R) or emergency/airbag call. 1. Locate and gain access to the OnStar® VIU. Refer to OnStar Vehicle Interface Unit Replacement in SI. Important: Complete removal of the VIU is usually not required. Perform only the steps required to gain access to the C2 32-way blue connector. Residing in the C2 connector are the battery positive (+) circuits. Removal of the C2 connector will deactivate the unit and eliminate the possibility of an inadvertent OnStar(R) or emergency/airbag call. Page 14991 Service Procedure Classic Silverado and Sierra (GMT400) The following procedure provides instructions for inspecting, and if necessary, replacing the rear endgate (tailgate) support cables and inspecting the right side tailgate hinge for damage, and replacing if recessary. Notice: It is recommended that a support be placed under the open tailgate in the next step to prevent the tailgate from being damaged in the event that it drops when disconnecting, inspecting, and replacing the support cables. Hinge Inspection - Classic CK and Sierra 1. Release (unhook) the RIGHT side tailgate support cable from the pickup box. 2. With the tailgate (1) completely open as shown in the upper part of the illustration, pull the RIGHT SIDE of the tailgate rearward as shown in the lower illustration. Do not pull on the left side of the tailgate. - If the tailgate hinge (2) will NOT disengage from the pickup box on the right side, no repair is needed to the hinge. Proceed to the section titled, "Support Cable Replacement" and replace both support cables. - If the tailgate hinge (3) WILL disengage from the pickup box on the right side, proceed to the next step. 3. With the right side of the tailgate disengaged from the pickup box, inspect the hinge on the right side of the tailgate for damage. The illustration above shows an undamaged hinge (1) and a damaged or bent hinge (2). - If the hinge is NOT damaged, no repair is needed to the hinge. Proceed to the section titled, "Support Cable Replacement" and replace both support cables. - If the hinge IS damaged or bent, the hinge needs to be replaced. Proceed to the section titled, "Hinge Replacement" before proceeding with the replacement of the support cables. Hinge Replacement - Classic CK and Sierra Automatic Transmission - 4L60-E/4L65-E Transmission Position Switch/Sensor: Service and Repair Automatic Transmission 4L60-E/4L65-E Park/Neutral Position Switch Replacement ^ Tools Required J 41364-A Park Neutral Switch Aligner Removal Procedure 1. Apply the park brake. 2. Shift the transmission into neutral. 3. If equipped with 4-wheel drive (4WD), remove the front propeller shaft. 4. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 5. Disconnect the park/neutral position (PNP) switch electrical connector (2). 6. Remove the manual shaft lever nut. Page 13111 The module uses a default value for the missing parameter. Conditions for Clearing the DTC A current DTC clears when the malfunction is no longer present. A history DTC clears when the module ignition cycle counter reaches the reset threshold, without a repeat of the malfunction. Diagnostic Aids When multiple Loss of Communication DTCs are set concurrently, the cause is likely to be 2 opens in the ring portion of the class 2 serial data circuit. Use the Control Modules and Devices ‐ Description and Identification Number table in order to determine which modules are not communicating. Use the class 2 serial data circuit schematic in order to determine the location of the opens. Test Description Page 8329 8. Disconnect the 2 way ABS pump motor connector. 9. Remove the bolts (1) from the EBCM (2). 10. Notice: Do not use a tool to pry the EBCM or the BPMV. Excessive force will damage the EBCM. Important: Do not reuse the EBCM mounting bolts. Always install new bolts. Remove the EBCM (2) from the BPMV (3). Removal may require a light amount of force. 11. Clean the EBCM to BPMV mounting surfaces with a clean cloth. Installation Procedure 1. Important: Do not use RTV or any other type of sealant on the EBCM gasket or mating surfaces. Install the EBCM (2) onto BPMV (3). 2. Important: Do not reuse the old mounting bolts. Always install new bolts with the new BPMV. Install the four EBCM bolts. ^ Tighten the four bolts to 5 Nm (39 inch lbs.) in an X-pattern. 3. Connect the 2 way ABS pump motor connector to the EBCM. 4. Install the BPMV (3) to BPMV bracket (5). 5. Install the BPMV to bracket retaining bolts (4). ^ Tighten the bolts to 9 Nm (7 ft. lbs.). 6. Install the EHCU assembly (1, 2) to the vehicle frame (5). Page 15879 Turn Signal Lamp: Diagrams Park/Turn Signal Lamp - LF Page 4345 Door Control Module Diagram 2 Part 2 Page 5508 Intake Air Temperature (IAT)/Mass Air Flow (MAF) Sensor Page 4993 Put unused material on the shelf for future use. Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Page 5304 3. Install the following parts onto the fuel pressure regulator (9), if necessary. - Backup ring (10) - Regulator seal O-ring (11) - Regulator filter (12) - Regulator seal O-ring (13) 4. Lubricate the fuel pressure regulator O-rings (11, 13) with clean engine oil. 5. Install the fuel pressure regulator (9). IMPORTANT: Whenever the fuel pressure regulator is removed from the fuel rail NEW O-rings and a NEW retaining clip should be used on reinstallation. 6. Install the NEW fuel pressure regulator retainer (8). 7. Install the fuel pressure regulator vacuum hose. 8. Install the fuel fill cap. 9. Connect the negative battery cable. 10. Use the following procedure in order to inspect for leaks: 10.1. Turn the ignition ON, with the engine OFF, for 2 seconds. 10.2. Turn the ignition OFF for 10 seconds. 10.3. Turn the ignition ON, with the engine OFF. 10.4. Inspect for fuel leaks. Page 7653 4. Inspect the rear output shaft bushing for scoring or wear. 5. Remove the rear output shaft bushing if required, using the J 45380. ^ Install the finger section of the J 45380 in front of the bushing. ^ Install the tube and forcing screw to the finger section. Ensure the forcing screw is backed out. ^ Using a wrench on the forcing screw, remove the rear output shaft bushing. Installation Procedure 1. Install a NEW rear output shaft bushing, if required, using the J 45380. ^ Install the bushing or the finger section of the J 45380. ^ Install the finger section to the main body of the J 45380. ^ Position the bushing and tool to the case. ^ Using a hammer and the J 45380, install the bushing. Page 15184 Control Module References Part 6 Page 9627 Fuse Block - Underhood - Secondary Wire Entry (With RPO Code HP2) Part 4 Page 10836 Tighten Tighten the screws to 1.6 N.m (14 lb in). 6. Install the center console. 7. Install the floor air outlet duct extension (1) to the floor air duct (2). Mode Actuator(Without RPO Code D07) MODE ACTUATOR REPLACEMENT (W/O D07) REMOVAL PROCEDURE 1. Remove the floor air outlet duct extension (1) from the floor duct (2). 2. Remove the Body Control Module. 3. Disconnect the electrical connection at the mode actuator (10). Locations Knock Sensors Page 13230 ^ SP303 The following modules, components, and splice pack are connected to the star portion of the class 2 serial data circuit: ^ SP300 ^ Audio amplifier ^ Driver door module (DDM) ^ Driver door switch assembly (DDSA) ^ Memory seat module (MSM) ^ Left rear door module (LRDM) AND ^ SP303 ^ Antenna module ^ Front passenger door module (FPDM) ^ Rear integration module (RIM) ^ Right rear door module (RRDM) ^ Theft deterrent module (TDM) ^ Vehicle communication interface module (VCIM). Refer to Data Communication Schematics and Data Link Communications Description and Operation in SI. Part 2 Conditions for Running the DTC Voltage supplied to the module is in the normal operating voltage range of 9 - 16 volts. DTCs B1327, B1328, U1300, U1301, U1305 are not set as current. The vehicle power mode requires serial data communication to occur. Conditions for Setting the DTC A message containing a critical operating parameter has not been received within the last 5 seconds after establishing class 2 serial data communication. Action Taken When the DTC Sets The module uses a default value for the missing parameter. Conditions for Clearing the DTC A current DTC clears when the malfunction is no longer present. A history DTC clears when the module ignition cycle counter reaches the reset threshold, without a repeat of the malfunction. Diagnostic Aids When a malfunction such as an open fuse to a module occurs while modules are communicating, a DTC U1001-1254 Loss of XXX Communications is set current. When the modules stop communicating the current DTC U1001-1254 Loss of XXX Communications is cleared but the history DTC remains. When the modules begin to communicate again, the module with the open fuse will not be learned by the other modules so U1000 or U1255 is set current by the other modules. If the malfunction occurs when the modules are not communicating, only U1000 or U1255 is set. Page 3830 Body Control Module (BCM) - C5 Automatic Transmission - 4L60-E/4L65-E Shift Solenoid: Locations Automatic Transmission - 4L60-E/4L65-E Automatic Transmission Electronic Component Views (M30/M32) Automatic Transmission Electronic Component Views (M30/M32) Electronic Components Page 3259 6. Slowly release the tension on the A/C belt tensioner. 7. Remove the ratchet from the A/C belt tensioner. 8. Inspect the A/C belt for proper installation and alignment. 9. Install the engine shield. Notice: Refer to Fastener Notice in Service Precautions. 10. Install the engine shield bolts. ^ Tighten the bolts to 20 Nm (15 ft. lbs.). 11. Lower the vehicle. 12. Install the accessory drive belt. Steering - Underhood Clunk Heard/Felt in Steering Wheel Steering Shaft: All Technical Service Bulletins Steering - Underhood Clunk Heard/Felt in Steering Wheel TECHNICAL Bulletin No.: 00-02-35-003N Date: March 26 2008 Subject: Clunking Noise Under Hood and Can Be Felt in Steering Wheel and/or Steering Column (Replace Upper Intermediate Steering Shaft [I-Shaft] Assembly) Models: 2002-2006 Cadillac Escalade Models 1999-2007 Chevrolet Silverado Models (Classic) 2000-2006 Chevrolet Suburban, Tahoe Models 2002-2006 Chevrolet Avalanche 1999-2007 GMC Sierra Models (Classic) 2000-2006 GMC Yukon, Yukon XL Models 2003-2006 HUMMER H2 Attention: This Service Bulletin DOES NOT include Mid-Size Utilities such as Buick Rainier, Chevrolet TrailBlazer Models, GMC Envoy Models or Oldsmobile Bravada. Refer to Service Bulletin 02-02-35-006A or newer for Mid-Size Utilities. Supercede: This bulletin is being revised to add diagnostic information (refer to Diagnostic Tips) to check the lower steering column bearing as a potential source of the noise. Please discard Corporate Bulletin Number 00-02-35-003M (Section 02-Steering). Condition Some customers may comment on a clunk-type noise coming from under the hood that also can be felt in the steering wheel. These conditions may be more noticeable when turning at low speeds on rough road surfaces. Diagnostic Tips Use the information below to help diagnose the source of the noise. ^ The lower steering column bearing may create the same noise as the intermediate shaft. Before replacing the I-shaft, verify the noise isn't being caused by movement from the lower steering column bearing. Check the bearing for movement by pushing up and down on the I-shaft where it attaches to the steering column. ^ Frame Snap and/or Popping Type Noise - A frame snap or popping type noise can be duplicated on rough or smooth road surfaces with steering wheel input to the left or the right. This type of noise can be HEARD and is typically louder with the windows rolled down. For additional information refer to Corporate Bulletin Number 03-08-61-002F or newer - Snap/Popping Type Noise Coming from Front of Vehicle (Remove Front Crossmember Change Fastener Orientation). ^ Intermediate Shaft Clunk - Intermediate shaft clunk is heard and FELT in the steering wheel and/or steering column area typically while driving on rough road surfaces with steering wheel input. Correction Important: ^ I-shaft P/N 19153614 has been designed to replace previous designed dampened and non-dampened I-shafts. The physical difference in the yoke size will accommodate all vehicles listed in this bulletin. ^ Due to the design of the new I-shaft, it is not possible to lubricate/grease the I-shaft. Replace the steering column upper intermediate shaft with an improved design shaft that will eliminate the clunk noise using the procedure listed below. Page 1726 INSTALLATION PROCEDURE NOTE: Refer to Fastener Notice in Service Precautions. 1. If required, install the fuel composition sensor to the bracket and install the bolts. Tighten Tighten bolts to 10 N.m (89 lb in). 2. Install the fuel composition sensor. 3. Install the fuel composition sensor nuts. Tighten Tighten nuts to 17 N.m (13 lb ft). 4. Connect the fuel pipes to the fuel composition sensor. 5. Install the fuel line retainers (1). Page 14183 8. Connect the inside door handle control rod to the lock assembly. 9. Connect the inside door lock rod to the handle retainer clip. 10. Install the water deflector. 11. Install the door trim panel. 12. Inspect the operation of all the related components. Page 1946 Parts Information Warranty Information (excluding Saab U.S. Models) Warranty Information (Saab U.S. Models) Page 12151 For vehicles repaired under warranty use, the table. Disclaimer Page 2636 Body Harness Campaign - HVAC Blower Not Functional Runs Continuously Control Module HVAC: All Technical Service Bulletins Campaign - HVAC Blower Not Functional Runs Continuously SPECIAL COVERAGE Bulletin No.: 11046 Date: April 07, 2011 Subject: 11046 - Special Coverage Adjustment - Heating, Ventilation, and Air Conditioning Blower Not Fully Functional on All Blower Speeds, Inoperative, or Runs Continuously with the Ignition Off Models: 2003-2006 Chevrolet Avalanche, Suburban, Tahoe 2003-2007 Chevrolet Silverado 2003-2006 GMC Yukon, Yukon XL 2003-2007 GMC Sierra Equipped with Manual HVAC (CJ3) or Heavy Duty Heater (C42) Due to part availability, owner letters will be released in phases starting with older model year first. Owners for model year vehicles not included in first phase owner mailing will receive an owner advisory letter. The letter will inform the customer that parts are not yet available and that another letter will be sent to them when parts become available. A copy of this letter will be attached to the dealer message announcing this bulletin. In the meantime, if a customer brings their vehicle to the dealership with the condition described in this bulletin, repair the vehicle using the parts called out in this bulletin. Condition On some 2003-2006 model year Chevrolet Avalanche, Suburban, Tahoe; GMC Yukon, Yukon XL; and 2003-2007 model year Chevrolet Silverado and GMC Sierra vehicles equipped with a manual heating, ventilation, and air conditioning (HVAC) system (CJ3) or heavy duty heater (C42), the interface between the electrical terminals of the relay resistor module and the wiring connector that powers the module may be incapable of conducting higher current levels for sustained periods of blower motor operation. In addition, moisture and other contaminants may enter the fresh air intake plenum and contact the internal circuit of the module or corrode the terminals. Either of the above may cause the relay resistor module or wiring connector to overheat, resulting in one or more of the following symptoms: - The HVAC blower may not function on certain or all blower speed settings - A burning plastic smell or smoke may be present in the vehicle - The HVAC blower may run continually with the ignition in the OFF position In very rare events, if the above symptoms are ignored, a fire could occur. Special Coverage Adjustment This special coverage covers the condition described above for a period of 10 years or 240,000 km, whichever occurs first, from the date the vehicle was originally placed in service, regardless of ownership. Dealers are to install a new blower motor resistor and resistor module connector. The repairs will be made at no charge to the customer. For vehicles covered by Vehicle Service Contracts, all eligible claims with repair orders on or after April 8, 2011 are covered by this special coverage and must be submitted using the labor operation codes provided with this bulletin. Claims with repair orders prior to April 8, 2011 must be submitted to the Service Contract provider. Vehicles Involved Involved are certain 2003-2006 model year Chevrolet Avalanche, Suburban, Tahoe; GMC Yukon, Yukon XL; and 2003-2007 model year Chevrolet Silverado and GMC Sierra vehicles equipped with a manual HVAC (CJ3) or heavy duty heater (C42). Important Dealers are to confirm vehicle eligibility prior to beginning repairs by using the Applicable Warranties section in the Global Warranty Management system. Parts Information Page 14407 Door Control Module Diagram 2 Part 1 Page 3290 Installation Procedure 1. Lubricate the O-ring seal with clean engine oil. 2. Install a NEW O-ring seal onto the oil level indicator tube, if required. 3. Install the oil level indicator tube between the exhaust manifold and engine block. 4. Raise and suitably support the vehicle. 5. Install the oil level indicator tube into the block. The tube must be installed with the collar flush to the block. 6. Lower the vehicle. Notice: Refer to Fastener Notice in Service Precautions. 7. Install the oil level indicator tube bolt ^ Tighten the bolt to 25 Nm (18 ft. lbs.). 8. Install the oil level indicator. Page 4542 Steps 15 - 17 Page 3108 Do not reuse the nut. A new nut must be used when installing the wheel drive shaft. Remove the wheel driveshaft assembly retaining nut (2) and washer (3) from the wheel driveshaft. 7. Disengage the wheel drive shaft from the wheel hub and bearing using J 45859 or equivalent. 8. Remove the wheel hub and the 15-series bearing mounting bolts (4). 9. Remove the wheel hub and bearing (4) mounting bolts, 25/35 series. 10. Remove the wheel hub and bearing and splash shield from the vehicle. 11. Remove the O-ring seal from the steering knuckle bore, 25/35 series. 12. Remove the wheel speed sensor mounting bolt (5). 13. Clean and inspect the O-ring seal, 25/35 series. 14. Replace the seal if the following conditions exist: ^ Nicks ^ Cuts A/C - Refrigerant Recovery/Recycling/Equipment Refrigerant: Technical Service Bulletins A/C - Refrigerant Recovery/Recycling/Equipment Bulletin No.: 08-01-38-001 Date: January 25, 2008 INFORMATION Subject: Information On New GE-48800 CoolTech Refrigerant Recovery/Recharge Equipment Models: 2008 and Prior GM Passenger Cars and Light Duty Trucks (Including Saturn) 2008 and Prior HUMMER H2, H3 2005-2008 Saab 9-7X Attention: This bulletin is being issued to announce the release of GM approved Air Conditioning (A/C) Refrigerant Recovery and Recharging Equipment that meets the new Society of Automotive Engineers (SAE) J2788 Refrigerant Recovery Standards. The ACR2000 (J-43600) cannot be manufactured in its current state after December 2007 and will be superseded by GE-48800. The new J2788 standard does not require that GM Dealers replace their ACR2000 units. ACR2000's currently in use are very capable of servicing today's refrigerant systems when used correctly and can continue to be used. Details regarding the new SAE J2788 standard are outlined in GM Bulletin 07-01-38-004. Effective February 1 2008, new A/C Refrigerant Recovery/Recharging equipment (P/N GE-48800) will be released as a required replacement for the previously essential ACR2000 (J-43600). This equipment is SAE J2788 compliant and meets GM requirements for A/C Refrigerant System Repairs on all General Motors vehicles, including Hybrid systems with Polyolester (POE) refrigerant oil. This equipment will not be shipped as an essential tool to GM Dealerships. In addition, this equipment is Hybrid compliant and designed to prevent oil cross contamination when servicing Hybrid vehicles with Electric A/C Compressors that use POE refrigerant oil. The ACR2000 (J-43600) will need to be retrofitted with a J-43600-50 (Hose - ACR2000 Oil Flush Loop) to be able to perform Hybrid A/C service work. All Hybrid dealers will receive the J-43600-50, with installation instructions, as a component of the Hybrid essential tool package. Dealerships that do not sell Hybrids, but may need to service Hybrids, can obtain J-43600-50 from SPX Kent Moore. Refer to GM Bulletin 08-01-39-001 for the ACR2000 Hose Flush procedure. The High Voltage (HV) electric A/C compressor used on Two Mode Hybrid vehicles uses a Polyolester (POE) refrigerant oil instead of a Polyalkylene Glycol (PAG) synthetic refrigerant oil. This is due to the better electrical resistance of the POE oil and its ability to provide HV isolation. Failure to flush the hoses before adding refrigerant to a Hybrid vehicle with an electric A/C compressor may result in an unacceptable amount of PAG oil entering the refrigerant system. It may cause a Battery Energy Control Module Hybrid Battery Voltage System Isolation Lost Diagnostic Trouble Code (DTC P1AE7) to be set. Additionally, the A/C system warranty will be voided. Warranty Submission Requirements The Electronically Generated Repair Data (snapshot summary) and printer functions have been eliminated from the GE-48800. The VGA display and temperature probes were eliminated to reduce equipment costs. As a result, effective immediately the 18 digit "Snapshot/Charge Summary" code is no longer required for Air Conditioning (A/C) refrigerant system repairs that are submitted for warranty reimbursement. The charge summary data from before and after system repairs will continue to required, but documented on the repair order only. Both high and low pressures and the recovery and charge amounts should be noted during the repair and entered on the repair order. If using ACR2000 (J-43600), the "Snapshot/Charge Summary" printouts should continue to be attached to the shops copy of the repair order. The labor codes that are affected by this requirement are D3000 through D4500. Disclaimer Page 12909 3. Notice: Refer to Fastener Notice in Service Precautions. Install a new 4 mm bolt (1), with LOCTITETM , to the brake pedal position sensor. ^ Tighten the bolt to 9 Nm (80 inch lbs.). 4. Calibrate the brake pedal position sensor. Page 4867 3. If equipped with a 6.0L engine, connect the HO2S electrical connector. 4. If equipped with a 4.8L or 5.3L engine, connect the HO2S electrical connector. 5. Install the HO2S connector clip to the frame. 6. Disconnect the CPA retainer. 7. Lower the vehicle. Page 4486 Electrical Symbols Part 9 Engine, A/T - Shift/Driveability Concerns/MIL ON Air Filter Element: Customer Interest Engine, A/T - Shift/Driveability Concerns/MIL ON Bulletin No.: 04-07-30-013B Date: February 01, 2007 INFORMATION Subject: Automatic Transmission Shift, Engine Driveability Concerns or Service Engine Soon (SES) Light On as a Result of the Use of an Excessively/Over-Oiled Aftermarket, Reusable Air Filter Models: 2007 and Prior GM Cars and Light Duty Trucks 2007 and Prior Saturn Models 2003-2007 HUMMER H2 2006-2007 HUMMER H3 2005-2007 Saab 9-7X Supercede: This bulletin is being revised to add models and model years. Please discard Corporate Bulletin Number 04-07-30-013A (Section 07 - Transmission/Transaxle). The use of an excessively/over-oiled aftermarket, reusable air filter may result in: Service Engine Soon (SES) light on Transmission shift concerns, slipping and damaged clutch(es) or band(s) Engine driveability concerns, poor acceleration from a stop, limited engine RPM range The oil that is used on these air filter elements may be transferred onto the Mass Air Flow (MAF) sensor causing contamination of the sensor. As a result, the Grams per Second (GPS) signal from the MAF may be low and any or all of the concerns listed above may occur. When servicing a vehicle with any of these concerns, be sure to check for the presence of an aftermarket reusable, excessively/over-oiled air filter. The MAF, GPS reading should be compared to a like vehicle with an OEM air box and filter under the same driving conditions to verify the concern. The use of an aftermarket reusable air filter DOES NOT void the vehicle's warranty. If an aftermarket reusable air filter is used, technicians should inspect the MAF sensor element and the air induction hose for contamination of oil prior to making warranty repairs. Transmission or engine driveability concerns (related to the MAF sensor being contaminated with oil) that are the result of the use of an aftermarket reusable, excessively/over-oiled air filter are not considered to be warrantable repair items. Page 8982 Fuse: Application and ID Fuse Block - I/P Location View Page 12576 Involved are certain vehicles within the VIN breakpoints shown above. PARTS INFORMATION -- Saab US Only Customer Notification General Motors will notify customers of this special coverage on their vehicles (see copy of typical customer letter shown in this bulletin - actual divisional letter may vary slightly). Tire Monitor System - TPM Sensor Information Tire Pressure Monitor Receiver / Transponder: Technical Service Bulletins Tire Monitor System TPM Sensor Information INFORMATION Bulletin No.: 08-03-16-003 Date: May 12, 2008 Subject: Warranty Reduction - Transfer of Tire Pressure Monitoring (TPM) Sensors to Replacement Wheels and Allowable TPM Sensor Replacements Models: 2000-2009 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2009 HUMMER H2 2006-2009 HUMMER H3 2005-2009 Saab 9-7x with On-Wheel TPM Sensors TPM Sensor / Wheel Warranty Reviews During the last warranty review period it was noted that wheels being returned under the GM New Vehicle Warranty were being shipped back to General Motors with the TPM sensor still attached to the wheel. Return rates ran as high as 60% with the TPM sensors still attached. Operational TPM sensors should not be returned to GM and are to be transferred to replacement wheels if they become necessary. Important: Operational TPM Sensors that are returned under warranty to General Motors will be charged back to the dealer.Sensors have a 10 year /150,000 mile (240,000 km) battery life, and should be transferred if one or more wheels are replaced. TPM Valve Stem / Grommet (0-ring) Replacement When the TPM sensors are transferred to new wheels you should replace the component used to seal the TPM sensor stem to the wheel. On sensors with an aluminum stem and visible nut on the outside of the wheel a replacement grommet (0-ring) should be used to assure a proper seal. The sensor retaining nut (except Aveo) should be tightened to 7 N.m (62 lb in) for all vehicles except Pontiac Vibe (4.0 N.m (35.4 lb in)). Important: ^ DO NOT overtorque the retaining nut. Notice: ^ Factory installed TPM Sensors come with plastic aluminum or nickel-plated brass stem caps. These caps should not be changed. Chrome plated steel caps may cause corrosion of aluminum valve stems due to incompatibility of the metals. On current style sensors the entire rubber stem is replaceable. The service interval on the revised TPM sensor with replaceable stem is the same as for any other traditional valve stem. Replace the stem at the time of tire replacement sensor transfer or whenever air seepage is suspected at the valve stem. When replacing the valve stem tighten the screw to 1.3 N.m (11.5 lb in). For either style of TPM sensor see the service parts guide for the correct GM part numbers to order and use. Disclaimer Page 2666 Fuse Block- I/P C2 Page 1968 Speed Sensor: Service and Repair Transfer Case - NVG 263-NP1 Transfer Case Speed Sensor Replacement Removal Procedure 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. Disconnect the speed sensor electrical connector. 3. Remove the speed sensor. Installation Procedure 1. Notice: Refer to Fastener Notice in Service Precautions. Install the speed sensor. ^ Tighten the sensor to 15 Nm (11 ft. lbs.). Page 2616 Application Tabel Part 1 Page 8000 2. Connect the speed sensor electrical connector (4). 3. Lower the vehicle. Page 5916 For vehicles repaired under warranty, use the table. Disclaimer Page 13252 Electrical - Aftermarket Fuse Warning Fuse: All Technical Service Bulletins Electrical - Aftermarket Fuse Warning Bulletin No.: 07-08-45-002 Date: September 05, 2007 ADVANCED SERVICE INFORMATION Subject: Service Alert: Concerns With Aftermarket Fuses in GM Vehicles Models: 2008 and Prior GM Passenger Cars and Light Duty Trucks (including Saturn) 2008 and Prior HUMMER H2, H3 2008 and Prior Saab 9-7X Concerns with Harbor Freight Tools "Storehouse" Branded Blade Type Fuses General Motors has become aware of a fuse recall by Harbor Freight Tools/Storehouse for a variety of aftermarket fuses. In two cases, these fuses have not provided protection for the wiring system of the vehicles they were customer installed in. Upon testing the 15 amp version, it was found that the fuse still would not "open" when shorted directly across the battery terminals. How to Identify These Fuses Packed in a 120 piece set, the fuse has a translucent, hard plastic, blue body with the amperage stamped into the top. There are no white painted numbers on the fuse to indicate amperage. There are no identifying marks on the fuse to tell who is making it. The fuses are known to be distributed by Harbor Freight Tools but there may be other marketers, and packaging of this style of fuse. It would be prudent to replace these fuses if found in a customers vehicle. Likewise, if wiring overheating is found you should check the fuse panel for the presence of this style of fuse. All GM dealers should use genuine GM fuses on the vehicles they service. You should also encourage the use of GM fuses to your customers to assure they are getting the required electrical system protection. GM has no knowledge of any concerns with other aftermarket fuses. If additional information becomes available, this bulletin will be updated. Disclaimer Page 890 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Weather Pack Connectors WEATHER PACK CONNECTORS The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. Page 11356 Cabin Temperature Sensor / Switch: Service and Repair INSIDE AIR TEMPERATURE SENSOR ASSEMBLY REPLACEMENT REMOVAL PROCEDURE 1. Remove the left windshield garnish molding. 2. Remove the left center pillar assist handle. 3. Remove the left center pillar garnish molding. 4. Remove the left sunshade. 5. Gently pull down the headliner. 6. Disconnect the electrical connector from the inside air temperature sensor. 7. Partially remove the inside air temperature sensor from the headliner. 8. Remove the sensor grille from the inside air temperature sensor. 9. Remove the inside air temperature sensor from the headliner. INSTALLATION PROCEDURE 1. Install the new sensor grille to the headliner. Page 9087 Fuse Block - Underhood - Secondary Wire Entry (With RPO Code HP2) Part 4 Page 1647 Heated Oxygen Sensor (HO2S) Bank 2 Sensor 1 Page 8504 Tighten Tighten the nuts to 50 N.m (37 lb-ft). 3. Install the booster pump rod to the lever. 4. Install the stop lamp switch to the lever. 5. Install the booster pump rod retainer. 6. Connect the power brake booster outlet hose, the steering gear inlet hose, and the power brake booster inlet hose. Tighten ^ Tighten the power brake booster inlet hose to 28 N.m (20 lb-ft). ^ Tighten the steering gear inlet hose to 28 N.m (20 lb-ft). 7. Install the master cylinder. 8. Install the mounting nuts. Tighten Tighten the mounting bolts to 50 Nm (37 lb-ft). 9. Install the electrical connectors to the electrohydraulic pump and the flow switch. 10. Fill the hydraulic pump reservoir. Important: Maintain the fluid level throughout the bleed procedure. 11. Remove the pump reservoir cap. Important: Page 13491 Trailer Connector - Heavy Duty Part 2 Brakes/Wheels - Excessive Debris Build Up Brake Caliper: Customer Interest Brakes/Wheels - Excessive Debris Build Up Bulletin No.: 04-05-23-005 Date: June 22, 2004 INFORMATION Subject: Availability of Rear Wheel Mud Flaps to Reduce Debris Build-up on Rear Brake Calipers and/or Rear Wheels Models: 1999-2004 Chevrolet Silverado Pickup Models 1999-2004 GMC Sierra Pickup Models This bulletin is to inform dealers of the release of rear wheel mud flaps. The above models that are exposed to extensive off-paved roads may benefit from the mud flaps. The mud flaps have been developed to minimize the amount of stones and/or mud that can impact and collect on the rear caliper and/or wheel rim. Please advise customers that the installation of these mud flaps and following the recommended off-road driving information provided in their Owner's Manual should greatly reduce the possibility of accelerated rear brake component wear and/or rim damage. Install the mud flap forward of each rear wheel using the following procedure. Important: Always work from outboard to inboard, drilling one hole at a time and securing with a fastener. Follow the sequence of the procedure. This will prevent distortion of the mud flap. 1. Raise the vehicle. Support the vehicle. 2. Locate the pickup box side panel rear brace. 3. Remove the existing outboard upper fastener on the brace. 4. Install the mud flap through the "V" of the brace. Install the previously removed fastener in the hole (2) of the mud flap to the brace. Do not tighten the fastener at this time. 5. Using the mud flap as a template, locate and mark the location of the hole (1) in the pickup box wheel house. Page 2955 Some customers may use penetrating oils, grease or other lubricants on wheel studs to aid in removal or installation. Always use a suitable cleaner/solvent to remove these lubricants prior to installing the wheel and tire assemblies. Lubricants left on the wheel studs may cause improper readings of wheel nut torque. Always install wheels to clean, dry wheel studs ONLY. Notice Lubricants left on the wheel studs or vertical mounting surfaces between the wheel and the rotor or drum may cause the wheel to work itself loose after the vehicle is driven. Always install wheels to clean, dry wheel studs and surfaces ONLY. Beginning with 2011 model year vehicles, put a light coating of grease, GM P/N 1051344 (in Canada, P/N 9930370), on the inner surface of the wheel pilot hole to prevent wheel seizure to the axle or bearing hub. Wheel Stud and Lug Nut Damage Always inspect the wheel studs and lug nuts for signs of damage from crossthreading or abuse. You should never have to force wheel nuts down the stud. Lug nuts that are damaged may not retain properly, yet give the impression of fully tightening. Always inspect and replace any component suspected of damage. Tip Always start wheel nuts by hand! Be certain that all wheel nut threads have been engaged BEFORE tightening the nut. Important If the vehicle has directional tread tires, verify the directional arrow on the outboard side of the tire is pointing in the direction of forward rotation. Wheel Nut Tightening and Torque Improper wheel nut tightening can lead to brake pulsation and rotor damage. In order to avoid additional brake repairs, evenly tighten the wheel nuts to the proper torque specification as shown for each vehicle in SI. Always observe the proper wheel nut tightening sequence as shown below in order to avoid trapping the wheel on the wheel stud threads or clamping the wheel slightly off center resulting in vibration. The Most Important Service You Provide While the above information is well known, and wheel removal so common, technicians run the risk of becoming complacent on this very important Initial Inspection and Diagnostic Overview Garage Door Opener Transmitter: Initial Inspection and Diagnostic Overview DIAGNOSTIC STARTING POINT - GARAGE DOOR OPENER Begin the system diagnosis by reviewing the system Description and Operation. Reviewing the Description and Operation information will help you determine the correct symptom diagnostic procedure to use when a malfunction exists. Reviewing the Description and Operation information will also help you determine if the condition described by the customer is normal operation. Refer to Symptoms - Garage Door Opener in order to identify the correct procedure for diagnosing the system and where the procedure is located. See: Symptom Related Diagnostic Procedures/Garage Door Opener Inoperative Navigation Radio - Adaptation After Radio/Battery R&R; Navigation System: All Technical Service Bulletins Navigation Radio - Adaptation After Radio/Battery R&R; INFORMATION Bulletin No.: 08-08-44-023 Date: June 18, 2008 Subject: Information On Navigation Radio Not Displaying Accurate Vehicle Location After Radio Replacement, Power Loss Or Battery Replacement Models: 2009 and Prior GM Passenger Cars and Trucks (Including Saturn) 2009 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X with Navigation Radio The purpose of this bulletin is to inform technicians and customers that the Navigation Radio may not display the vehicle location icon on the map accurately after a radio or battery has been replaced or after battery power has been removed from the radio. The vehicle location icon accuracy may be degraded if the GPS signal is not available and the GPS displayed icon has a red line through it. The Navigation Radio does not keep learned GPS information or gyroscope and vehicle speed signals stored when the battery power is removed from the radio. The Navigation radio continually uses GPS, gyroscope and vehicle speed data to maintain the vehicle location icon positioned accurately on the displayed map. There may be periods of time during a drive cycle when the GPS signal may not be available and the vehicle location icon still appears to be accurate. This is due to the radio having internal gyroscopes and receiving a vehicle speed signal to maintain accuracy if the radio had received a good GPS signal earlier in the drive cycle. Normal driving will improve the accuracy of the vehicle location icon on the displayed map. It may be necessary for the vehicle to be driven up to 40 km (25 mi) with 15 left and 15 right turns while the vehicle location icon is matched to roads on the displayed map. Do not replace the radio for this condition. Disclaimer Fuel Rail Assembly Replacement Fuel Rail: Service and Repair Fuel Rail Assembly Replacement FUEL RAIL ASSEMBLY REPLACEMENT REMOVAL PROCEDURE IMPORTANT: The L59 E85 fuel rail is comprised of a material that is compatible with fuel that has a concentration of up to 85 percent ethanol. The E85 fuel rail also uses an E85 Denso fuel injectors. Because of this, special procedures will be used in servicing the fuel rail and associated components. The screws that fasten the retaining clips for the crossover pipe to the fuel rails are thread cutting and therefore should NOT be removed from the fuel rail. The fuel rail will be serviced as an entire component. - An 8-digit identification number (1) is located on the fuel rail. Refer to this model identification number if service or part replacement is required. 1. Relieve the fuel system pressure. Refer to Fuel Pressure Relief Procedure. 2. Remove the wire harness bracket nut (2). 3. Disconnect the evaporative emission (EVAP) purge solenoid electrical connector (1). 4. Disconnect the generator electrical connector (3). Page 1717 Mass Air Flow (MAF) Sensor: Service and Repair MASS AIR FLOW (MAF)/INTAKE AIR TEMPERATURE (IAT) SENSOR REPLACEMENT REMOVAL PROCEDURE IMPORTANT: Use care when handling the mass air flow/intake air temperature (MAF/IAT) sensor. Do not dent, puncture, or otherwise damage the honeycell located at the air inlet end of the MAF/IAT. Do not touch the sensing elements or allow anything including cleaning solvents and lubricants to come in contact with them. Use a small amount of a non-silicone based lubricant, on the air duct only, to aid in installation. 1. Remove the air cleaner outlet duct. 2. Pull out the gray connector position assurance (CPA) retainer. 3. Push down on the black clip in order to disconnect the MAF/IAT sensor electrical connector (4). 4. Loosen the MAF/IAT clamp. 5. Remove the MAF/IAT sensor from the air cleaner assembly. INSTALLATION PROCEDURE IMPORTANT: The embossed arrow on the MAF/IAT sensor indicates the proper air flow direction. The arrow must point toward the engine. Page 4541 Steps 11 - 14 Page 15452 Door Latch Assembly (Door Jamb Switch) - LR - C2 (Crew Cab Only) Interior - Seat Cover Wrinkle/Crease/Burn Info Seat Cover: All Technical Service Bulletins Interior - Seat Cover Wrinkle/Crease/Burn Info INFORMATION Bulletin No.: 04-08-50-006D Date: September 09, 2010 Subject: Minor Wrinkles/Creases, Discoloration, Cigarette Burns and Customer Induced Cuts and Stains on Front and Rear Driver and Passenger Seats with Leather, Vinyl or Cloth Seat Covers Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks 2009 and Prior HUMMER H2 2010 and Prior HUMMER H3 2009 and Prior Saab 9-7X 2010 and Prior Saturn Supercede: This bulletin is being revised to add a model year. Please discard Corporate Bulletin Number 04-08-50-006C (Section 08 - Body and Accessories). If a customer comes in to your dealership due to certain conditions of the seat covers (splits, wrinkles, loose stitching, etc.), you must examine the seat cover in order to determine the validity of the customer claim. Some components from the above listed vehicles have been returned to the Warranty Parts Center (WPC) and analysis of these parts showed "customer induced damage" or No Trouble Found (NTF). The dealer should pay particular attention to the following conditions: - Cigarette burns Page 15207 Cigarette Lighter: Diagnostic Aids Basic Knowledge Required BASIC KNOWLEDGE REQUIRED Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the Service Data. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories CHECKING AFTERMARKET ACCESSORIES Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: - Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions INDUCING INTERMITTENT FAULT CONDITIONS In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: - Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. Page 11912 7.3. If equipped, connect the rear seat heater's connector and install the switch. 8. Install the floor console: 8.1. Install the floor console's retaining bolts (C) and retaining nuts (F). 8.2. Align the rear cover; make sure that the air duct connects firmly to the air nozzle. Screw in the cover (E). 8.3. Install the ashtray/cover (D). 8.4. Install the ignition switch cover (B). 8.5. Plug in the immobilizer unit (A) connector. Install the unit, bayonet fitting. 9. Remove the OnStar(R) control modules and secure the wiring: 9.1. Remove the right-hand rear luggage compartment trim in accordance with WIS - 8. Body - Interior equipment - Adjustment/Replacement. 9.2. Unplug the connectors (A) from the OnStar(R) control modules. 9.3. Remove the console (B) together with the OnStar(R) control modules. Page 9291 4. Push on the top part until it clicks in place. 5. Connect the harness to the front of the junction block. 6. Install the cover to the junction block until it clicks in place. 7. Hand tighten the retaining nut until seated. Page 10658 Important: After drilling the holes, apply the appropriate anti-corrosion primer. Refer to the GM Refinish Material Booklet # 4901 M-D (English) or # 4901-D-F (French) for additional information. 6. Center punch the marked location and drill a 6.35 mm (1/4 in) hole. Install the plastic retainer in the hole (1) of the mud flap. 7. Tighten fastener at the hole (2) location of the mud flap. Tighten Tighten the fastener to 25 N.m (18 lb ft). 8. For vehicles with short box, use the following procedure: 8.1. Push the mud flap to make contact with the rear side of the underbody cross sill and mark the location of the hole (3) of the mud flap. 8.2. Center punch the marked location and drill a 5.159 mm (13/64 in) hole. 8.3. Install the screw. Tighten Tighten the screw to 4 N.m (35 lb in). 8.4. Repeat the above steps for hole locations 4 and 6. 9. For vehicles with long box, use the following procedure: Page 333 ^ I/O check Any faults detected during the initialization self-test shall generate a DTC. All nodes also continuously perform a self-test while in an active state. DTCs and their associated telltales will set as a result of unprogrammed or unlearned information. DTCs, which are defined for system configuration (e.g. Vehicle Option Content not programmed) do not support the history status bit (set =0). Warning indicator bit is also set, when applicable, while this DTC is present. Action Taken When the DTCs Sets The module suspends all message transmission. The module uses default values for all parameters received on the serial data circuits. The module inhibits the setting of all other communication DTCs. Conditions for Clearing the DTC A current DTC clears when the malfunction is no longer present. A history DTC clears when the module ignition cycle counter reaches the reset threshold of 50, without a repeat of the malfunction. Circuit/System Verification Refer to Data Link References to determine which serial data system is used for a specific module. The DTCs cannot be retrieved with a current status. Diagnosis is accomplished using the following symptom procedures: Scan Tool Does Not Communicate with High Speed GMLAN Device in SI. OR Scan Tool Does Not Communicate with Low Speed GMLAN Device in SI. DTC U1300, U1301, or U1305 Circuit Description Modules connected to the Class 2 serial data circuit monitor for serial data communications during normal vehicle operation. Operating information and commands are exchanged among the modules. In addition to this, Node Alive messages are transmitted by each module on the Class 2 serial data circuit about once every 2 seconds. When the module detects one of the following conditions on the Class 2 serial data circuit for approximately 3 seconds, the setting of all other Class 2 serial communication DTCs is inhibited and a DTC will set. Conditions for Running the DTCs Voltage supplied to the module is in the normal operating voltage range. The vehicle power mode requires serial data communication to occur. Conditions for Setting the DTCs No valid messages are detected on the Class 2 serial data circuit. The voltage level detected on the Class 2 serial data circuit is in one of the following conditions: Page 14573 Seat Memory Switch: Service and Repair MEMORY SEAT SWITCH REPLACEMENT REMOVAL PROCEDURE 1. Remove the front door trim panel. 2. Disconnect the electrical connector. 3. Release the front seat memory switch assembly retaining clips in order to remove the switch. 4. Remove the front seat memory switch assembly. INSTALLATION PROCEDURE 1. Install the front seat memory switch assembly to the front trim panel by pressing into place until fully seated. 2. Connect the electrical connector to the front seat memory switch assembly. 3. Install the front trim panel. Page 3705 8. Connect the oxygen sensor electrical connectors (1, 2). 9. Connect the CPA retainers. 10. Clip the oxygen sensors electrical connectors to the following: ^ Hose clip ^ Transmission crossmember 11. Connect the oxygen sensor electrical connectors. 12. Connect the CPA retainers. 13. Install the clip around the engine harness and the oxygen sensor pigtail. 14. Connect the oxygen sensor electrical connector. 15. If equipped, clip the oxygen sensor connection to the floor reinforcement. 16. Lower the vehicle. Page 15146 Electrical Symbols Part 10 Page 3110 9. Install the nut (2) and washer (3) retaining the wheel drive shaft assembly to the wheel hub and bearing. ^ Tighten the nut to 240 Nm (177 ft. lbs.). 10. Install the wheel speed sensor and brake hose mounting bracket bolt to the steering knuckle. ^ Tighten the brake hose clip bolt to 12 Nm (106 inch lbs.). 11. Install the rotor. Refer to Brake Rotor Replacement - Front in Disc Brakes. 12. Install the tire and wheel. 13. Lower the vehicle. Page 3416 Disclaimer Page 1929 9. Disassemble the harness connector (1) from the encoder. 10. Remove the encoder from the output shaft using a flat tip screwdriver. Installation Procedure 1. Assemble the harness to the NEW encoder with the connector legend "TOP" (1) and the encoder part number facing up. 2. Assemble the output shaft into the encoder, being sure to align the encoder tab with the groove on the shaft. 3. Ensure the encoder is seating properly on the output gear. 4. Place the output shaft encoder on the casting. 5. Place the grommet harness on the casting slot, the flat area on the grommet will be facing up. Page 7373 Page 16042 Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips SPLICING COPPER WIRE USING SPLICE CLIPS IMPORTANT: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. TOOLS REQUIRED J 38125-D Terminal Repair Kit 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-D in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. Page 8283 Brake Caliper: Service and Repair Brake Caliper Overhaul - Front Brake Caliper Overhaul - Front ^ Tools Required J 45515 Brake Caliper Piston Boot Seal Installer Caution: Refer to Brake Dust Caution in Service Precautions. Caution: Refer to Brake Fluid Irritant Caution in Service Precautions. Notice: Refer to Brake Fluid Effects on Paint and Electrical Components Notice in Service Precautions. 1. Replace all the components included in the repair kits used to service this brake caliper. 2. Lubricate the rubber parts with new Delco Supreme 11®, GM P/N 12377967 (Canadian P/N 992667) or equivalent DOT-3 brake fluid to make assembly easier. 3. If any hydraulic component is removed or disconnected, it may be necessary to bleed all or part of the brake system. 4. The torque values specified are for dry, non-lubricated fasteners. 5. Perform the service operations on a clean bench, free from all mineral oil materials. 6. Remove the brake caliper from vehicle. Refer to Brake Caliper Replacement - Front. 7. Drain the brake fluid from the brake caliper. 8. Caution: Do not place your fingers in front of the piston in order to catch or protect the piston while applying compressed air. This could result in serious injury. Notice: Use clean cloths to pad interior of caliper housing during piston removal. Use just enough air to ease the pistons out of the bores. If the pistons are blown out, even with the padding provided, it may be damaged. Place a 25 mm (1 inch) block of wood between the caliper and the piston. 9. Install a large C-clamp over the body of the brake caliper with the C-clamp ends against the rear of the caliper body and against the block of wood. 10. Carefully remove the brake caliper piston by directing low pressure compressed air into the brake caliper inlet hole. 11. Remove the C-clamp form the caliper. 12. Remove the block of wood from the caliper. 13. Install clean cloths to pad the interior of the caliper housing between the remaining caliper piston and the caliper body. 14. To cover the open caliper bore place a 25 mm (1 inch) block of wood between the caliper body and the brake caliper dust boot seal. 15. Install a large C-clamp over the body of the brake caliper with the C-clamp ends against the rear of the caliper body and against the block of wood. 16. Carefully remove the brake caliper piston by directing low pressure compressed air into the brake caliper inlet hole. 17. Remove the C-clamp form the caliper. 18. Remove the block of wood from the caliper. Page 12243 ^ For U.S. Saturn retailer claim submission, use Net Item code "M" and Case Type VW. Page 9567 Fuse Block- I/P C1 Part 1 Page 14862 Seat Lumbar Motor/Position Sensor - Driver (With RPO Code AN3) Page 9633 Location View Page 6457 1. Place the steering column shift lever back into the park (P) position. 2. Raise the vehicle. 3. Ensure that the transmission manual shaft lever is in the park (P) position. 4. Pull the white cover (1) back to expose the natural colored lock (2). Under the lock (2), insert a flat bladed screwdriver under the lock ramp located at the top of the lock. The lock will pop up, and the transmission end will move slightly away from the shifter end. 5. Push the end of the transmission end (3) inside the shifter end (1) until the blue spring (2) on the transmission end (3) is fully compressed, this will engage the inner wire and lock both wires together. Page 9294 Relay Box: Service and Repair I/P Electrical Center or Junction Block Replacement - Right INSTRUMENT PANEL ELECTRICAL CENTER OR JUNCTION BLOCK REPLACEMENT - RIGHT REMOVAL PROCEDURE 1. Remove the right side end panel. 2. Push in the tabs in order to remove the fuse block. 3. Pull out the fuse block out of the I/P in order to remove the retaining bolt. 4. Loosen the bolt. 5. Insert a screw driver between the wire harness block and fuse block in order to separate. 6. Separate the fuse block from the I/P harness block. 7. Remove the I/P wiring harness block from the vehicle. INSTALLATION PROCEDURE 1. Install the fuse block to the I/P wire harness block. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the retaining bolt. Tighten Tighten the bolt to 6 N.m (53 lb in) 3. Install the fuse block to the I/P until it clicks in place. Page 6164 For vehicles repaired under warranty, use the table. Disclaimer Page 9947 1. Loosen the jam nut on the tie rod (2). 2. Rotate the inner tie rod (1) to the required toe specification setting. Refer to Wheel Alignment Specifications. 3. Notice: Refer to Fastener Notice in Service Precautions. ^ Tighten the jam nut on the tie rod. ^ Tighten the tie rod jam to 68 Nm (50 ft. lbs.). 4. Check the toe setting after tightening. 5. Re-adjust the toe setting if necessary. Rear Toe Adjustment Rear Toe Adjustment 1. Loosen the jam nut on the tie rod (1). 2. Rotate the inner tie rod to the required toe specification setting. Refer to Wheel Alignment Specifications. 3. Notice: Refer to Fastener Notice in Service Precautions. ^ Tighten the jam nut on the tie rod. ^ Tighten the tie rod jam to 65 Nm (48 ft. lbs.). 4. Check the toe setting after tightening. 5. Re-adjust the toe setting if necessary. Page 2650 Fuse Block - Underhood C2 Part 6 Page 13400 Electrical Symbols Part 13 Page 4206 Disclaimer Page 12718 2. Click on the Analog-to-Digital Program link to start the ordering process. 3. To order a kit, you will need the information shown above. 4. After submitting the order, the "Terms and Conditions of Your OnStar(R) Service" page will display. This is your confirmation that the upgrade kit order has been created. U.S. Dealers will also receive an e-mail from Autocraft within several hours of ordering an upgrade kit (Canadian Dealers will receive an e-mail from MASS Electronics). 5. Print the "Terms and Conditions of Your OnStar(R) Service" page, and have the customer sign a copy. 6. A copy of this form should be stapled to the customer's copy of the Repair Order and one copy should be retained in the customer service folder. 7. If the kit you ordered is available, you will receive the upgrade kit within 4 business days of entering your order through the OnStar(R) Online Enrollment webpage. 8. To check on kit availability or the status of your order, U.S. Dealers can log onto the distributor's website at www.autocraft.com. Canadian dealers can call MASS Electronics at 877-410-6277. Upgrade Kit Installation 1. Skip to the next step if the vehicle to be upgraded is not shown above. Page 3622 Notice: Refer to Fastener Notice in Service Precautions. 2. Install the fan shroud bolts. Tighten the bolts to 9 Nm (80 inch lbs.). 3. Install the fan shroud retainers. 4. Connect the TCM electrical connectors (1). 5. Install the TCM and cover. 6. Tighten the TCM electrical connector bolts. Tighten the bolts to 8 Nm (71 inch lbs.). 7. Install the TCM cover to the fan shroud. 8. Install the TCM cover bolts. Tighten the bolts to 9 Nm (80 inch lbs.). Page 10770 Wheel Fastener: Specifications TORQUE SPECIFICATIONS Torque Specifications Wheel Nuts .......................................................................................................................................... ................................................. 190 Nm (140 ft. lbs.) Page 15895 Turn Signal Multifunction Switch - C4 (With RPO Code K34) Page 13163 ^ Pay the dealer the regular retail price (no discounts are available) for one of the following 1-year, non-refundable OnStar(R) Analog-to-Digital Transition (ADT) Service Subscription Plans: ^ 1-year Safe & Sound Subscription: $199 ($289 in Canada) ^ 1-year Directions & Connections Subscription: $399 ($579 in Canada) ^ Pay the dealer the applicable state and local sales taxes on the subscription: ^ U.S. Dealers: Taxes only apply in these states: CT, DC, FL, HI, ND, NJ, NM, NY, SC, SD, TX, and WV ^ Canadian Dealers: All applicable taxes ^ Pay the dealer a one-time charge of $15 for the upgrade: ^ U.S. Dealers: Do not collect taxes on the $15 ^ Canadian Dealers: Collect all applicable taxes on the $15 Note: Dealers should NOT remit OnStar(R) ADT-related taxes to their taxing authority as OnStar(R) is responsible for tax remittance. Please Be Sure To Read these Important Points: ^ The 1-year OnStar(R) subscription is not refundable or transferable to another person. Upgraders can apply unused subscription months to a new or Certified Pre-Owned digital OnStar-equipped GM vehicle purchase or lease. As noted above, the digital upgrade program requires the subscriber to purchase a one-year prepaid OnStar(R) subscription. Assuming the subscriber intends to keep their vehicle, but subsequently purchases or leases a 2006 model year or newer OnStar(R)-equipped new or certified used GM vehicle, in the interest of subscriber satisfaction, they may apply remaining unused whole months of the subscription to the new vehicle. The subscription may not be applied to another person's vehicle. Important: This is a customer satisfaction measure that would usually occur several months after an upgrade. It is not intended to be leveraged as part of a new/used vehicle purchase or lease transaction. ^ The $15 charge is not refundable. ^ Dealer ADT kit orders are VIN specific. Dealer kit orders require a VIN and must be exchanged with the OnStar(R) unit in the vehicle with that VIN. Proper activation and enrollment depends on this step. ^ You must put the actual miles on the Repair Order. Do not estimate. ^ Customers will receive a Hands-Free Calling number once the digital hardware is installed and configured. ^ Any nametags that were stored in the old system will need to be re-set by the subscriber once the new hardware is installed. ^ Customers are responsible for the charges described above regardless of whether their vehicle is in or out of the New Vehicle Warranty period. In addition, customers should not be charged labor costs. Dealers can charge GM the labor for the upgrade as specified at the end of this bulletin using the listed labor operation. ^ Vehicles eligible for an OnStar(R) hardware upgrade are listed in this bulletin. Vehicle upgradeability can also be determined by typing the VIN into the field entitled "Determine VIN Hardware Functionality" on the OnStar(R) Online Enrollment website, located in the sales or service workbench tab of GM GlobalConnect. Canadian Dealers can use a similar tool that is available within InfoNET. ^ Access to the sales and/or service workbench in the GM GlobalConnect website can be granted by the dealership's Partner Security Coordinator (PSC). If you are unsure who the PSC is, check with the Sales Manager. Ordering the Upgrade Kit/Upgrade kit Installation Ordering the Upgrade Kit 1. To order a kit, you will need to access the OnStar(R) Online Enrollment webpage, located under the sales or service workbench of GM GlobalConnect (infoNET for Canadian upgrade orders). These kits cannot be ordered from GMSPO. Page 8818 Control Module References Part 6 Page 14868 Seat Horizontal Position Sensor - Driver (With RPO Code AN3) OnStar(R) - Negative Impact of Cloth/Vinyl Roofs Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Negative Impact of Cloth/Vinyl Roofs INFORMATION Bulletin No.: 02-08-44-007D Date: May 12, 2009 Subject: Negative Impact of Dealer-Installed Cloth/Vinyl Roofs on XM Radio and/or OnStar(R) Systems Models: 2002-2009 Passenger Cars and Trucks (Including Saturn) 2003-2009 HUMMER H2 2006-2009 HUMMER H3 2005-2009 Saab 9-7X with XM Radio (RPO U2K) and/or OnStar(R) (RPO UE1) .............................................................................................................................................................. .................................................................................. Supercede: This bulletin is being revised to include the 2009 model year. Please discard Corporate Bulletin Number 02-08-44-007C (Section 08 - Body and Accessories). .............................................................................................................................................................. .................................................................................. Dealers should not install a cloth or vinyl roof on vehicles that have been ordered with the XM radio option (RPO U2K) and/or OnStar(R) (RPO UE1). The performance of these systems may be negatively impacted by the installation of the cloth/vinyl roof. Additionally, water leaks may result from installing a cloth or vinyl roof on vehicles with roof-mounted antenna systems. Relocating the antenna to another spot on the vehicle exterior, in order to install a cloth or vinyl roof, is not advised either. The performance of the OnStar(R) and XM Radio antennas has been optimized for their current locations. Relocating the antennas may result in a performance degradation. Disclaimer Page 9164 3. Prepare the surface of the used defroster tab (not required for new tabs on new-style full-size utility models) and the defroster buss bar with fine grain (500 grit) sandpaper or Emery cloth. It is not necessary to remove all of the original solder, but it should be scuffed sufficiently so that no oxidation is present. The photo above shows a close up of a properly prepared surface. Tip You may want to mask the glass around the contact area with tape. This is easy to do and will allow you to safely prepare the contact surface without the risk of scratching the glass or the black painted shading. Important Most rear glass has a black painted masking around the edge of the glass. When cleaning up the connection surface, be very careful not to damage the surface of the black shading or the surface of the glass. 4. Wipe the newly prepared contact area with Kent Automotive* Acrysol(TM) (or equivalent) to remove any residual oil or dirt. Important Memory Seat Calibration Procedure Memory Positioning Module: Service and Repair Memory Seat Calibration Procedure MEMORY SEAT CALIBRATION PROCEDURE The memory seat module uses position sensor inputs to establish soft stop locations for the adjuster motors several millimeters ahead of the physical limits of the adjuster assembly. After replacing a memory seat module or adjuster components, it may be necessary to reset the adjuster motor soft stop locations. When the repair procedure has been completed, operate the seat adjuster switch in every direction until the seat adjuster reaches its mechanical hard stop by repeatedly pressing and releasing the switch as necessary. Page 2111 3.2. Reinstall any loose boot. Service and Repair Expansion Block/Orifice Tube: Service and Repair EXPANSION (ORIFICE) TUBE REPLACEMENT TOOLS REQUIRED - J 26549-E Orifice Tube Remover - J 39400-A Halogen Leak Detector REMOVAL PROCEDURE 1. Recover the refrigerant. Refer to Refrigerant Recovery and Recharging . 2. Loosen the nut from the evaporator tube fitting. 3. Use the J 26549-E in order to remove the orifice tube (1) from the evaporator tube (2). 4. Cap or plug the open line. INSTALLATION PROCEDURE 1. Uncap or unplug the evaporator tube. 2. Lubricate the new O-ring using new 525 viscosity refrigerant oil. 3. Install the new O-ring seal. 4. Install the orifice tube (1) to the evaporator tube (2). 4.1. Coat the O-ring seal with 525 viscosity refrigerant oil. 4.2. Insert the short screen end of the new orifice (1) into the evaporator tube. NOTE: Refer to Fastener Notice in Service Precautions. 5. Connect the evaporator tube at the fitting. Tighten Tighten the fitting to 25 N.m (18 lb ft). 6. Evacuate and recharge the system. Refer to Refrigerant Recovery and Recharging. 7. Leak test the fittings of the repaired component using J 39400-A. Page 822 Junction Block - Rear Lamps - C2 Page 14736 Seat Cushion Frame Replacement - Front Seat Cushion Frame Replacement - Front Removal Procedure 1. Remove the seat trim panel. 2. Remove the seat cushion trim cover and pad. 3. Remove the following components from the seat cushion frame: * The frame springs (1) * The frame suspension (2) * The plastic retainers (3) 4. Remove the seat cushion frame from the vehicle. Installation Procedure 1. Install the following components to the seat cushion frame: * The plastic retainers (3) * The frame suspension (2) * The frame springs (1) 2. Install the seat cushion trim cover and pad. 3. Install the seat trim panel. 4. Re-zero the inflatable restraint passenger presence system. Refer to Passenger Presence System Rezeroing Procedure in SIR. See: Restraint Systems/Air Bag Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Related Tests and Procedures/Passenger Presence System Rezeroing Procedure Seat Cushion Frame Replacement - Rear Seat Cushion Frame Replacement - Rear Removal Procedure Page 11383 Low Pressure Sensor / Switch: Locations Right Side Of The Engine Compartment Page 12092 OnStar(R) Microphone The OnStar(R), or cellular microphone, can be a part of the rearview mirror assembly, or on some vehicle lines, a separate, stand alone unit. In either case, the VCIM supplies approximately 10 volts to the microphone on the cellular microphone signal circuit, and voice data from the user is sent back to the VCIM over the same circuit. A cellular microphone low reference circuit or a drain wire provides a ground for the microphone. Cellular and GPS Antennas The vehicle will be equipped with one of the following types of antennas: ^ Separate, stand-alone cellular and navigation (GPS) antennas. ^ A combination cellular and navigation (GPS) antenna, which brings the functions of both into a single part. ^ A cellular, GPS, and digital radio receiver (DRR) antenna, which also incorporates the functionality of the DRR satellite antenna (XM). The cellular antenna is the component that allows the OnStar(R) system to send and receive data using electromagnetic waves by means of cellular technology. The antenna is connected at the base to a coax cable that plugs directly into the VCIM. The GPS antenna is used to collect the signals of the orbiting GPS satellites. Within the antenna is housed a low noise amplifier that allows for a more broad and precise reception of this data. The antenna is connected at the base to a coax cable that plugs directly into the VCIM. The cable also provides a path for DC current for powering the antenna. The OnStar(R) Call Center also has the capability of communicating with the vehicle during an OnStar(R) call to retrieve the latest GPS location and transmit it to the OnStar(R) Call Center. A history location of the last recorded position of the vehicle is stored in the module and marked as aged, for as long as the module power is not removed. Actual GPS location may take up to 10 minutes to register in the event of a loss of power. Audio System Interface When the OnStar(R) requires audio output, a serial data message is sent to the audio system to mute all radio functions and transmit OnStar(R) originated audio. The OnStar(R) audio is transmitted to the vehicle audio system by a dedicated signal circuit and a low reference circuit. The audio system will mute and an audible ring will be heard though the speakers if the vehicle receives a call with the radio ON. On some vehicles, the HVAC blower speed may be reduced when the OnStar(R) system is active to aid in reducing interior noise. When the system is no longer active, the blower speed will return to its previous setting. OnStar(R) Steering Wheel Controls Some vehicles may have a button on the steering wheel, that when pushed can engage the OnStar(R) system. The button may be a symbol of a face with sound waves, or may say MUTE, or be a symbol of a radio speaker with a slash through it. By engaging the OnStar(R) system with this feature, the user can interact with the system by use of voice commands. A complete list of these commands is supplied in the information provided to the customer. If the information is not available for reference, at any command prompt, the user can say "HELP" and the VCIM will return an audible list of available commands. The steering wheel controls consist of multiple momentary contact switches and a resistor network. The switches and resistor network are arranged so that each switch has a different resistance value. When a switch is pressed, a voltage drop occurs in the resistor network. This produces a specific voltage value unique to the switch selected, to be interpreted by the radio or the body control module (BCM). OnStar(R) Power Moding (DRX or Sleep Cycle) The OnStar(R) system uses a unique sleep cycle to allow the system to receive cellular calls while the ignition is in the OFF position and retained accessory power (RAP) mode has ended. A green status LED on the OnStar(R) keypad normally indicates an active OnStar(R) account. The OnStar(R) system will stay powered up after ignition off for an extended time in order to allow for remote services like door unlock, horn honk, light flash, etcetera to take place as requested by the customer. Power cycle (also referred to as DRX) times vary depending on the generation of the OnStar(R) system. Technicians may identify the OnStar(R) system generation by using a Tech 2 and following this menu path: (Body>VCIM>Module ID Information>Module Information 2) or by accessing www.onstarenrollment.com All Generation 6 digital systems are powered up continuously for 48 hours from ignition OFF. After 48 hours, the Generation 6 systems will enter a 9 minute OFF, 1 minute ON power cycle for an additional 72 hours. At the beginning and end of the 1 minute ON stage, you may or may not experience a short spike of current at the beginning and at the end. This allows for calls from OnStar to be received by the system. After 120 hours from ignition OFF, Page 8897 SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-D. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: - The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair Tools Required J 38125-D Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-D. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Page 13570 Body Control Module: Electrical Diagrams Door Control Module Diagram 1 Page 3942 Camshaft Position Sensor: Service and Repair CAMSHAFT POSITION (CMP) SENSOR REPLACEMENT REMOVAL PROCEDURE IMPORTANT: Clean the area around the CMP sensor before removal in order to prevent debris from entering the engine. 1. Remove the camshaft position (CMP) sensor bolt. 2. Remove the CMP sensor. INSTALLATION PROCEDURE 1. Install the CMP sensor. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the CMP sensor bolt. Tighten Tighten the bolt to 29 N.m (21 lb ft). Page 1560 Coolant Temperature Sensor/Switch (For Computer): Service and Repair ENGINE COOLANT TEMPERATURE (ECT) SENSOR REPLACEMENT REMOVAL PROCEDURE NOTE: Use care when handling the coolant sensor. Damage to the coolant sensor will affect the operation of the fuel control system. 1. Drain the cooling system to a level below the engine cooling temperature (ECT) sensor. Refer to Draining and Filling Cooling System in Cooling System. 2. Disconnect the ECT sensor electrical connector (5). 3. Remove the ECT sensor. INSTALLATION PROCEDURE NOTE: Replacement components must be the correct part number for the application. Components requiring the use of the thread locking compound, lubricants, corrosion inhibitors, or sealants are identified in the service procedure. Some replacement components may come with these coatings already applied. Do not use these coatings on components unless specified. These coatings can affect the final torque, which may affect the operation of the component. Use the correct torque specification when installing components in order to avoid damage. - Use care when handling the coolant sensor. Damage to the coolant sensor will affect the operation of the fuel control system. Page 8046 4. connect the chassis electrical connectors to the EBCM. 5. Lower the vehicle. 6. Connect the negative battery cable. 7. Revise the tire calibration using the Scan Tool Tire Size Calibration function. 8. Return to Diagnostic Starting Point - Antilock Brake System. Page 6382 Vehicle Speed Sensor (VSS) Tow/Haul Switch Location Page 8396 3. Relieve the tension from the park brake cable by pulling down on the park brake cable in front of the equalizer and removing the left park brake cable from the equalizer bar. 4. Remove the cable from the mounting bracket by depressing the locking tabs. 5. Remove the cable at the lower shock absorber mount by removing the bolt. Specifications Idle Speed: Specifications Information not supplied by manufacturer. Page 14690 Disclaimer Body - Bumps or Rust Colored Spots in Paint Paint: All Technical Service Bulletins Body - Bumps or Rust Colored Spots in Paint TECHNICAL Bulletin No.: 05-08-51-008C Date: June 22, 2009 Subject: Bumps or Rust Colored Spots in Paint Due to Rail or Iron Dust (Remove Rail Dust) Models: 1994-2010 GM Passenger Cars and Trucks (Including Saturn) 2003-2010 HUMMER H2 2006-2010 HUMMER H3 2005-2009 Saab 9-7X Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 05-08-51-008B (Section 08 - Body and Accessories). Condition Visible rust colored spots or bumps on a vehicle's paint surface from rail or iron dust. Cause Rail dust comes from tiny iron particles produced from the friction between train wheels and the tracks and gets deposited on the vehicle surfaces. Iron dust can get deposited on the surface if the vehicle is stored near any operation producing iron dust such as an iron ore yard. Either material can lay on top of, or become embedded in, the paint surface. Correction Because the severity of the condition varies, proper diagnosis of the damage is critical to the success of repairs. Diagnosis should be performed on horizontal surfaces (hood, roof, deck lid, pick up box, etc.) after the vehicle has been properly cleaned. There are two types of repair materials recommended to repair rail dust or iron dust: 1. GEL TYPE OXALIC ACID: - Has the characteristics of the liquid type oxalic acid but stays where you put it because of its gel consistency. 2. CLAY TYPE NON-ACID BASED: - Requires surface lubricant during use. - Has different grades available. Caution Rail dust remover (Oxalic Acid) is an acidic substance containing chemicals that will break down the iron particles embedded in the finish. When working with rail dust remover, use the necessary safety equipment, including gloves and goggles. Follow the chemical manufacturer's directions closely because it may require special handling and disposal. If, upon inspection, some particles are still present, the various chemical manufacturer's processes can be repeated. After the removal process, small pits may remain in the clearcoat and can be corrected, in most cases, with a finesse/polish operation. Procedure 1. Move the vehicle to a cool shaded area and make sure that the vehicle surfaces are cool during the removal process. DO NOT PERFORM THE REMOVAL PROCESS IN DIRECT SUNLIGHT OR ON A VEHICLE WITH HOT OR WARM BODY PANELS. 2. Wash the vehicle with soap and water. Dry it immediately and clean the affected areas with a wax and grease remover. 3. Perform the removal process according to the chemical manufacturer's directions. Once the damage has been repaired, the final step involves a polishing process. Rail Dust Remover Manufacturers Use the chemical manufacturers listed below, or equivalent: Page 4460 5. Connect the fuel pump electrical connector. 6. Install the sending unit. Page 904 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-8 (12085115) crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-8 (12085115) until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes SPLICING INLINE HARNESS DIODES Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate Service Data wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. 9. Tape the diode to the harness or connector using electrical tape. Page 4459 2. Install the fuel level sensor retaining clip. 3. Connect the fuel level sensor electrical connector. 4. Install the fuel level sensor electrical connector retaining clip. Technician Safety Information Positive: Technician Safety Information CAUTION: Batteries produce explosive gases. Batteries contain corrosive acid. Batteries supply levels of electrical current high enough to cause burns. Therefore, in order to reduce the risk of personal injury while working near a battery, observe the following guidelines: - Always shield your eyes. - Avoid leaning over the battery whenever possible. - Do not expose the battery to open flames or sparks. - Do not allow battery acid to contact the eyes or the skin. - Flush any contacted areas with water immediately and thoroughly. - Get medical help. Page 12571 Page 7389 Four Wheel Drive Selector Switch: Service and Repair Transfer Case - NVG 263-NP1 Transfer Case Shift Control Switch Replacement Removal Procedure 1. Remove the instrument panel (IP) cluster bezel. 2. Pull the tabs on the side of the transfer case driver control switch out. 3. Pull the transfer case driver control switch straight out from the panel. Installation Procedure 1. Important: Make sure that the transfer case control switch is seated properly in the instrument panel before installing the instrument panel trim bezel. Install the transfer case driver control switch into the instrument panel. 2. Install the IP cluster bezel. Page 11671 9. Remove the upper anchor bolt. 10. Remove the retractor from the seat. INSTALLATION PROCEDURE 1. Position the seat belt retractor onto the seat. Line up the tab on the retractor to the tab on the seat frame. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the upper anchor bolt. Tighten Tighten the bolt to 53 N.m (39 lb ft). Page 2719 Fuse Block - Underhood - Secondary Wire Entry (With RPO Code HP2) Part 3 Page 992 Fuel Pump Relay: Locations Fuel Pump Relay Secondary - With Dual Tanks FUEL PUMP RELAY - SECONDARY (Vehicles with Dual Tanks Only) Fuel Pump Relay-Secondary-With Dual Tanks The Fuel Pump Relay - Secondary is attached to the Underhood Fuse Block Bracket. The Underhood Fuse Block is located at the left side of the engine compartment, to the rear of the battery. Page 16260 Windshield Moulding / Trim: Service and Repair Windshield Side Reveal Molding Replacement Windshield Side Reveal Molding Replacement Removal Procedure 1. Pull back the front door sealing weatherstrip (1) to expose the windshield reveal molding screws. 2. Remove the screws from the windshield reveal molding. 3. Remove the windshield reveal molding from the windshield pillar. Installation Procedure 1. Install the windshield reveal molding to the windshield pillar. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the screws to the windshield reveal molding. Tighten the screws to the windshield reveal molding to 2 N.m (18 lb in). 3. Install the front door sealing weatherstrip (1) to the pinch-weld. 4. Close the door. Page 11451 Inflatable Restraint Sensing And Diagnostic Module: Description and Operation INFLATABLE RESTRAINT SENSING AND DIAGNOSTIC MODULE (SDM) The sensing and diagnostic module (SDM) is a microprocessor and the control center for the SIR system. The SDM contains internal sensors along with several external sensors, if equipped, mounted at various locations on the vehicle. In the event of a collision, the SDM performs calculations using the signals received from the internal and external sensors. The SDM compares the results of the calculations to values stored in memory. When these calculations exceed the stored value, the SDM will cause current to flow through the appropriate deployment loops to deploy the air bags. The SDM records the SIR system status when a deployment occurs and requests the instrument panel cluster (IPC) to turn the AIR BAG indicator ON. The SDM performs continuous diagnostic monitoring of the SIR system electrical components and circuitry when the ignition is turned ON. If the SDM detects a malfunction, a DTC will be stored and the SDM will request the IPC to turn the AIR BAG indicator ON. In the event that ignition 1 voltage is lost during a collision, the SDM maintains a 23-volt loop reserve (23 VLR) for deployment of the air bags. It is important to note, when disabling the SIR system for servicing or rescue operations to allow the 23 VLR to dissipate, which could take up to 1 minute. Page 5000 Extended Cab Short Box Shown Below, Other Configurations Similar 6. Install the new canister vent valve solenoid to the fuel tank clip or mounting bracket as shown above. The valve port closest to the electrical connector must point towards the canister. 7. Cut bulk 5/8" heater hose to a length of approximately 76 mm (3 in). Install the hose between the solenoid and the canister pipe and secure using clamps. 8. Attach bulk 5/8" heater hose to the vent port and secure using a clamp. Run a length as needed along the frame rail routing to the area above the transmission. 9. Cut the hose to determined length and install the supplied filter box. Secure using a clamp. 10. Remove the transmission support and lower the transmission assembly as necessary to allow for access to the new filter box location. 11. Secure the filter box to the transmission vent hose just forward of the hose tee-section using a tie strap. DO NOT pinch or restrict the transmission vent hose. The filter box opening should be pointing downward. 12. Raise the transmission and reinstall the transmission support. 13. Connect the EVAP canister vent valve electrical connector. 14. Tie strap the hose as needed along the frame rail in order to keep the hose away from pinch-points and heat sources. 15. Lower the vehicle. Correction (2007-2010 New Style Models) After following the published SI diagnostics and determining that the EVAP canister vent valve is the cause of the MIL light, replace the EVAP canister vent valve assembly and relocate the remote filter box. To ensure correct installation, follow the procedures below. Important DO NOT replace the EVAP canister assembly for this concern unless it fails the leak test. Use Service Kit P/N 19207763 1. Raise the vehicle. Suitably support the vehicle. 2. Disconnect the EVAP canister vent valve electrical connector. Page 4879 7. Remove the transmission control lever from the manual shaft. 8. Remove the PNP switch bolts. 9. Remove the PNP switch from the manual shaft. If the PNP switch did not slide off the manual shaft, file the outer edge of the manual shaft in order to remove any burrs. Installation Procedure 1. Install the PNP switch to the transmission manual shaft by aligning the switch hub flats with the manual shaft flats. 2. Slide the PNP switch onto the transmission manual shaft until the switch mounting bracket contacts the mounting bosses on the transmission. 3. Important: If a NEW PNP switch is being installed, the switch will come with a positive assurance bracket. The positive assurance bracket aligns the new switch in its proper position for installation and the use of the park neutral switch aligner will not be necessary. Install the PNP switch bolts finger tight. 4. Install J 41364-A onto the PNP switch. Ensure that the two slots on the switch where the manual shaft is inserted are lined up with the lower two tabs on the tool. 5. Notice: Refer to Fastener Notice in Service Precautions. Rotate the tool until the upper locator pin on the tool is lined up with the slot on the top of the switch. ^ Tighten the bolts to 25 Nm (18 ft. lbs.). 6. Remove the J 41364-A from the switch. If installing a new switch, remove the positive assurance bracket at this time. 7. Install the transmission control lever to the manual shaft with the nut. ^ Tighten the nut to 25 Nm (18 ft. lbs.). Engine Controls - MIL ON/Misfire/Misfire DTC's Set Engine Control Module: All Technical Service Bulletins Engine Controls - MIL ON/Misfire/Misfire DTC's Set Bulletin No.: 06-06-04-046 Date: September 12, 2006 INFORMATION Subject: Information on Engine Misfire MIL/SES Light Illuminated or Flashing DTC P0300, P0301, P0302, P0303, P0304, P0305, P0306, P0307, P0308, P0420 or P0430 Models: 1999-2007 Cadillac, Chevrolet, GMC Full-Size Pickup and/or Utility Trucks with 4.8L, 5.3L, 5.7L, 6.0L or 6.2L VORTEC GEN III, GEN IV, V-8 Engine (VINs V, C, T, Z, B, 3, M, 0, J, R, U, N, Y, K, 8 - RPOs LR4, LY2, LM7, L59, L33, LC9, LH6, LMG, LY5, L31, LQ4, LQ9, L76, LY6, L92) with Active Fuel Management(TM) and E85 Flex Fuel If you encounter vehicles that exhibit the above conditions, refer to SI for the appropriate DTC(s) set. If no trouble is found, the cause may be due to an ECM ground terminal that has corroded with rust over time. Inspect the main engine wiring harness ground terminal (G103) for this condition. The wire terminal (G103) attaches either to the front or to the rear of the right side cylinder head, depending on the model year of the Full Size Pickup and/or Utility Trucks. If the ECM ground terminal has been found to be corroded, then follow the service procedure outlined in this bulletin to correct the corrosion issue. Remove either the nut or bolt securing the main engine wiring harness ground terminal (G103) to the right cylinder head. Refer to the above illustration to determine where the ground is located on the vehicle (1). Keyless Entry - Inoperative Keyless Entry Module: All Technical Service Bulletins Keyless Entry - Inoperative Bulletin No.: 04-08-52-005 Date: June 15, 2004 TECHNICAL Subject: Remote Keyless Entry (RKE) System Inoperative (Reprogram Passenger Door Module (PDM)) Models: 2004 Cadillac Escalade, Escalade ESV, Escalade EXT 2004 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2004 GMC Sierra, Yukon, Yukon XL Condition Some customers may comment on any of the following conditions: ^ The RKE key fob does not function. ^ The "Service Tire Pressure Monitoring System" message is displayed, if equipped. ^ The passenger door will not unlock from the passenger's or driver's door switches. ^ The passenger door window is inoperative. Correction Reprogram the PDM with the Tech 2(R). Currently the Tech 2(R) software is not available for the 2004 model year. Engineering is aware of this and are working to release a new service calibration. In the meantime, build the Tech 2(R) as a 2003 model year and perform the reprogram using the procedure listed below. 1. Turn the ignition switch to the ON position. 2. Connect the Tech 2(R) to the vehicle's diagnostic link connector (DLC), power it up and press enter. ^ Select: Diagnostics. ^ Select model year: 2003. ^ Select: Light truck. ^ Select: Body. ^ Select the proper Product line. ^ Select the proper HVAC Type. ^ Select the proper Radio System type. ^ Select: Passenger Door Module. ^ Select: Special Functions. ^ Select: Refresh. Important: You must remove the described fuse in the next step for the "Refresh" program to be performed. If you do not remove the fuse for five seconds, the Tech 2 will continue to display "Test in Progress" and the program will not complete. ^ Remove the PDM fuse for 5 seconds from the fuse center located behind the panel on the left end of the instrument panel. Locations Coolant Temperature Sensor/Switch (For Computer): Locations Full Engine View Left Side Diagrams Trailer Connector: Diagrams Trailer Connector - Heavy Duty Part 1 Initial Inspection and Diagnostic Overview Auxiliary Power Outlet: Initial Inspection and Diagnostic Overview Diagnostic Starting Point DIAGNOSTIC STARTING POINT - POWER OUTLETS Begin the system diagnosis with the Diagnostic System Check - Power Outlets. The Diagnostic System Check will provide the following information: - The identification of the control module(s) which command the system. - The ability of the control modules to communicate through the serial data circuit. - The identification of any stored diagnostic trouble codes (DTCs) and their status. The use of the Diagnostic System Check will identify the correct procedure for diagnosing the system and where the procedure is located. Diagnostic System Check - Power Outlets DIAGNOSTIC SYSTEM CHECK - POWER OUTLETS TEST DESCRIPTION Steps 1-2 Page 4329 Control Module References Part 5 Page 8137 3. Locate the auxiliary fuel tank vent hose. The vent hose is the smaller diameter of the two hoses that comes from the auxiliary fuel tank and feeds into the main tank vent hose. 4. Disconnect the auxiliary tank vent hose from the main tank vent hose connection. 5. Install the cap supplied with kit, P/N 15213990, to the main tank vent hose connector where the auxiliary tank vent hose was just removed. 6. Locate the section of vent hose on the main tank between the fuel filler neck and the metal pipe. The smaller of the two hoses on the filler neck. 7. Cut the main tank vent hose between the filler neck and the metal pipe using an appropriate cutting tool. 8. Install the "T" and the two hose clamps supplied with kit, P/N 15213990, into the main tank vent hose. Tighten Tighten the hose clamps to 2.5 N.m (22 lb in). 9. Install the new auxiliary tank vent hose and clamp supplied with kit, P/N 15213990, to the "T" that was just installed. Tighten Tighten the hose clamp to 2.5 N.m (22 lb in). 10. Connect the new vent hose to the original auxiliary tank hose. 11. Secure the newly installed vent hose and the original auxiliary tank vent hose with plastic ties supplied in kit, P/N 15213990. 12. If necessary, reinstall the left rear tires/wheels assemblies. Page 9254 Multiple Junction Connector: Diagrams C404 - C411 C404 Left Clearance Lamp Harness To License Lamp Harness (With RPO Codes NYS Or R05) Page 15152 High Temperature Conditions Tools Required J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency MEASURING FREQUENCY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage MEASURING VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop MEASURING VOLTAGE DROP NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Page 888 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the cover up until the dress cover releases. Repeat this procedure for the other locking tab. 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. 5. If the connector has a nose piece, use a small flat-blade tool to remove the nose piece by inserting the blade into the slot on the front of the connector and prying up on the nose piece. IMPORTANT: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 6. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. IMPORTANT: Be careful not to angle or rock the J 38125-13A tool when inserting it into the connector or the tool may break. Page 14353 Electrical Symbols Part 14 Page 14319 WA9800/77 - WA994L/67 Service and Repair Idler Pulley: Service and Repair Drive Belt Idler Pulley Replacement (4.8L, 5.3L, and 6.0L Engines) Removal Procedure 1. Loosen the drive belt idler pulley bolt. 2. Remove the accessory drive belt. 3. Remove the drive belt idler pulley and bolt. Installation Procedure 1. Install the drive belt idler pulley and bolt to the generator bracket.Snug the bolt finger tight. 2. Install the drive belt. Notice: Refer to Fastener Notice in Service Precautions. 3. Tighten the drive belt idler pulley bolt. ^ Tighten the bolt to 50 Nm (37 ft. lbs.). Diagrams HVAC System - Manual A/C Low Pressure Switch Page 14127 Door Module: Electrical Diagrams Door Control Module Diagram 1 Page 8576 Claim Information Refer to the General Motors WINS Claims Processing Manual for details on Product Recall Claim Submission. Customer Notification -- For US and Canada General Motors will notify customers of this recall on their vehicle (see copy of customer letter shown in this bulletin). Customer Notification -- For Letters will be sent to known owners of record located within areas covered by the US National Traffic and Motor Vehicle Safety Act. For owners outside these areas, dealers should notify customers using the sample letter. Dealer Recall Responsibility -- For US and Export (US States, Territories and Possessions) The US National Traffic and Motor Vehicle Safety Act provides that each vehicle which is subject to a recall of this type must be adequately repaired within a reasonable time after the customer has tendered it for repair. A failure to repair within sixty days after tender of a vehicle is prima facie evidence Locations Steering Wheel and Column Sub-System Components Page 9882 Important The following information MUST be documented on the repair order. Failure to do so may result in a chargeback. - Customer vehicle condition. - Was a Service Lamp or Service Message illuminated? If yes, specify which Service Lamp or Service Message. - Was a DTC(s) set? If yes, specify which DTC(s) were set. - After following the procedure contained within this bulletin, could the condition be duplicated? ‹› If the condition was not duplicated, then document the affected module/component connector name and number on the repair order. - If the condition was duplicated after the procedure contained within this bulletin was followed, and additional diagnosis led to the replacement of a module or component, the SI Document ID Number MUST be written on the repair order. Parts Information Alternate Distributor For All of North America Note NyoGel(R) 760G Lubricant* is equivalent to GMSPO P/N 12377900, and P/N 10953529 (Canada), specified for use to correct the condition in this bulletin. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to: Warranty Information (Saab Models) Capacity Specifications Brake Fluid: Capacity Specifications Information not supplied by the manufacturer. Page 10015 9. Remove the steering knuckle. Installation Procedure 1. Clean all grease and contaminants from the tapered section and the threads of the upper ball joint, the lower ball joint, and the tie rod end. 2. Clean and inspect the taper holes and the mounting surfaces of the steering knuckle. If any of the tapered holes are elongated, out of round, or damaged, replace the steering knuckle. 3. Install the steering knuckle. 4. Notice: Refer to Fastener Notice in Service Precautions. Connect the lower ball joint to the steering knuckle and install the retaining nut. ^ Tighten the lower control arm retaining nut to 100 Nm (74 ft. lbs.). 5. Connect the upper ball joint to the steering knuckle and install the retaining nut. ^ Tighten the upper control arm retaining nut to 50 Nm (37 ft. lbs.). 6. Install the brake hose and the bracket retaining bolt to the steering knuckle ^ Tighten the bolt to 9 Nm (80 inch lbs.). 7. Connect the outer tie rod to the steering knuckle. Refer to Tie Rod Replacement in Steering Linkage (Non-Rack and Pinion). 8. Install the wheel hub and bearing assembly. Refer to Wheel Hub, Bearing, and Seal Replacement (RWD) Wheel Hub, Bearing, and Seal Replacement (4WD). 9. Install the tire and wheel. 10. Remove the lower control arm support. 11. Lower the vehicle. 12. Align the vehicle. Refer to Measuring Wheel Alignment (w/Rear Wheel Steering) Measuring Wheel Alignment (w/o Rear Wheel Steering) in Page 16098 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-8 (12085115) crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-8 (12085115) until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes SPLICING INLINE HARNESS DIODES Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate Service Data wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. 9. Tape the diode to the harness or connector using electrical tape. Page 9004 LR Of The Engine Compartment (With RPO Code 9L4) Connector Views Tail Lamp: Connector Views Tail/Stop Lamp - Left Page 9516 Location View Page 6114 6. Install the J 29714-A. 7. Compress the servo cover with J 29714-A. Important: Flat-faced servo cover retaining rings that have been removed when servicing a transmission for any reason should not be re-used. 8. Remove the servo cover retaining ring. 9. Install the new round wire servo cover ring, P/N 24232065. 10. Remove J 29714-A. 11. Clean the servo cover area with Brake Clean and shop air. 12. Lower the vehicle. 13. Fill the transmission to the proper level with DEXRON(R)III transmission fluid. Refer to the appropriate SI Document. Parts Information Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use the table. Page 3380 Engine Oil Pressure: Testing and Inspection Oil Pressure Diagnosis and Testing ^ Tools Required J 21867 Pressure Gage - J 42907 Oil Pressure Testing Tool 1. With the vehicle on a level surface, run the vehicle for a few minutes. Allow adequate drain down time, 2-3 minutes, and measure the oil level. 2. If required, add the recommended grade engine oil and fill the crankcase until the oil level measures full on the oil level indicator. 3. Run the engine briefly, 10-15 seconds, and verify low or no oil pressure on the vehicle gage or light. 4. Listen for a noisy valve train or a knocking noise. 5. Inspect for the following conditions: ^ Oil diluted by water or glycol anti freeze ^ Foamy oil 6. Remove the oil filter and install the J 42907. 7. Install J 21867 or equivalent to the J 42907. 8. Run the engine and measure the engine oil pressure. 9. Compare the readings to Specifications. 10. If the engine oil pressure is below specifications, inspect the engine for one or more of the following conditions: ^ Oil pump worn or dirty ^ Oil pump-to-engine block bolts loose ^ Oil pump screen loose, plugged, or damaged ^ Oil pump screen O-ring seal missing or damaged ^ Malfunctioning oil pump pressure regulator valve ^ Excessive bearing clearance ^ Cracked, porous, or restricted oil galleries ^ Oil gallery plugs missing or incorrectly installed ^ Broken valve lifters. Repair as necessary. 11. If the oil pressure reading on the J 21867 or equivalent is within specifications, inspect for the following conditions: ^ Plugged or incorrect oil filter and/or malfunctioning oil bypass valve ^ Malfunctioning oil pressure gage or sensor. Repair as necessary. Page 2346 2. Connect the power steering inlet hose to the power steering pump (5).Install the retaining clamp. 3. Connect the power steering outlet hose (4) to the power steering gear (3).Install the retaining clamp. 4. Bleed the power steering system. Refer to Bleeding the Power Steering System. 5. Inspect all the hose connections for leaks. 6. Install the front grille. Refer to Grille Replacement (GMC) Grille Replacement (Chevrolet) in Exterior Trim. (With Hydroboost) Power Steering Cooler Pipe/Hose Replacement (With Hydroboost) Removal Procedure 1. Remove the front grille. Refer to Grille Replacement (GMC) Grille Replacement (Chevrolet) in Exterior Trim. 2. Notice: Refer to Power Steering Hose Disconnected Notice in Service Precautions. Place a drain pan under the vehicle. 3. Siphon the fluid from the reservoir to prevent excess spillage. 4. Remove the clamp retaining the power steering cooler inlet hose (3) to the power steering gear (2). 5. Remove the clamp retaining power steering cooler outlet hose (5) to the power steering pump (1). 6. Remove the bolts (2) retaining the power steering cooler from the radiator support. 7. Remove the power steering cooler from the vehicle. Installation Procedure Steering - 'Service Rear Wheel Steering' Message Body Control Module: All Technical Service Bulletins Steering - 'Service Rear Wheel Steering' Message Bulletin No.: 05-02-118-002 Date: February 03, 2005 TECHNICAL Subject: DTC C0455, "Service Rear Wheel Steering", System Jumps from 4-Wheel Steer to 2-Wheel Steer (Reprogram BCM) Models: 2003-2005 Chevrolet Silverado, Suburban 2003-2005 GMC Sierra, Yukon XL with 4-Wheel Steer (RPO NYS) Condition Some customers may comment that the system will jump from 4-wheel steer to 2-wheel steer and the DIC displays the message "Service Rear Wheel Steering". Diagnosis will show DTC C0455-Front Steering Position Sensor malfunction. Cause This condition may be caused by a Class2 communication issue. Correction Reprogram the BCM. 2005 Model Year Vehicles: New software calibration, P/N 15248410, was released on TIS version 12 - broadcast to dealers on December 4, 2004. 2003-2004 Model Year Vehicles: New software calibration, P/N 15259330 ('03 Model Year) and P/N 15259331 ('04 04 Model Year), was released on TIS version 1.75 - broadcast to dealers on January 24, 2005. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 10781 9. Install the nut (2) and washer (3) retaining the wheel drive shaft assembly to the wheel hub and bearing. ^ Tighten the nut to 240 Nm (177 ft. lbs.). 10. Install the wheel speed sensor and brake hose mounting bracket bolt to the steering knuckle. ^ Tighten the brake hose clip bolt to 12 Nm (106 inch lbs.). 11. Install the rotor. Refer to Brake Rotor Replacement - Front in Disc Brakes. 12. Install the tire and wheel. 13. Lower the vehicle. Page 9452 Auxiliary Power Outlet - Console (With RPO Code UQ7) Page 11318 The new calibrations have been updated to compensate for the actuator overtravel condition, the actuator hunting and the ticking/clicking noises. The new calibrations effectively eliminate the codes listed above, the default position of the doors associated with the DTCs and opens up the feedback position value. The new calibrations should not be used unless the vehicle has one or more of the customer concerns listed above or a DTC listed above has been set. The new calibrations will not correct any other DTC or NC system performance concern. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 6530 6. Install the cooler line into the quick connect fitting. 7. Insert the cooler line end into the quick connect fitting until a click is either heard or felt. 8. Do not use the plastic cap on the cooler line in order to install the cooler line into the fitting. 9. Pull back sharply on the cooler line in order to ensure that the cooler line is fastened into the quick connect fitting. 10. Important: Do not manually depress the retaining clip when installing the plastic cap. Position (snap) the plastic cap onto the fitting. Do not manually depress the retaining ring when installing the plastic cap onto the quick connect fitting. 11. Ensure that the plastic cap is fully seated against the fitting. 12. Ensure that no gap is present between the cap and the fitting. Transfer Case - NVG 149-NP3 Speed Sensor: Service and Repair Transfer Case - NVG 149-NP3 Transfer Case Speed Sensor Replacement Removal Procedure 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. Disconnect the speed sensor electrical connector (4). 3. Remove the speed sensor. Installation Procedure 1. Install the speed sensor. ^ Tighten the sensor to 15 Nm (11 ft. lbs.). Notice: Refer to Fastener Notice in Service Precautions. Page 10601 hot particles embed themselves in the chrome layer and create a small pit. If the material is allowed to sit on the wheel while it is exposed to moisture or salt, it will corrode the wheel beneath the chrome leaving a pit or small blister in the chrome. Heavy brake dust build-up should be removed from wheels by using GM Chrome Cleaner and Polish, P/N 1050173 (in Canada use 10953013). For moderate cleaning, light brake dust build-up or water spots use GM Swirl Remover Polish, P/N 12377965 (in Canada, use Meguiars Plast-X(TM) Clear Plastic Cleaner and Polish #G12310C**). After cleaning, the wheel should be waxed using GM Cleaner Wax, P/N 12377966 (in Canada, use Meguiars Cleaner Wax #M0616C**), which will help protect the wheel from brake dust and reduce adhesion of any brake dust that gets on the wheel surface. For general maintenance cleaning, PEEK Metal Polish† may be used. It will clean and shine the chrome and leave behind a wax coating that may help protect the finish. Warranty of Stardust Corroded Chrome Wheels Wheels returned with pitting or spotting as a result of neglect and brake dust build-up may be replaced one time. Important Notify the customer that this is a one time replacement. Please stress to the customer the vital importance of keeping the wheels clean and free of prolonged exposure to brake dust build-up. "GM of Canada" dealers require prior approval by the District Manager - Customer Care and Service Process (DM-CCSP). Customer Assistance and Instructions GM has looked for ways customers may improve the appearance of wheels damaged by acidic cleaners. The following product and procedure has been found to dramatically improve the appearance of stained wheels. For wheels that have milky stains caused by acidic cleaners try the following: Notice THE 3M CHROME AND METAL POLISH REQUIRED FOR THIS PROCEDURE IS AN EXTREMELY AGGRESSIVE POLISH/CLEANER. THE WHEELS MUST BE CLEANED BEFORE APPLICATION TO AVOID SCRATCHING THE WHEEL SURFACE. THIS PRODUCT WILL REDUCE THE THICKNESS OF THE CHROME PLATING ON THE WHEEL AND IF USED INCORRECTLY OR EXCESSIVELY MAY REMOVE THE CHROME PLATING ALL TOGETHER, EXPOSING A LESS BRIGHT AND BRASSY COLORED SUB-LAYER. FOLLOW INSTRUCTIONS EXACTLY. 1. Wash the wheels with vigorously with soap and water. This step will clean and may reduce wheel staining. Flood all areas of the wheel with water to rinse. 2. Dry the wheels completely. Notice Begin with a small section of the wheel and with light pressure buff off polish and examine results. ONLY apply and rub with sufficient force and time to remove enough staining that you are satisfied with the results. Some wheels may be stained to the extent that you may only achieve a 50% improvement while others may be able to be restored to the original lustre. IN ALL CASES, only apply until the results are satisfactory. 3. Apply 3M Chrome and Metal Polish #39527* with a clean terry cloth towel. As you apply the polish, the staining will be diminished. 4. When dry, buff off the polish with a clean portion of the towel. 5. Repeat application of the 3M Chrome and Metal Polish until satisfied with the results. If continued applications fail to improve the appearance further discontinue use. This procedure will improve the appearance of the wheels and may, with repeated applications, restore the finish dramatically. For wheels that exhibit spotting from road chemicals the above procedure may marginally improve the condition but will not restore the finish or remove the pitting. In this type of staining the wheel finish has actually been removed in spots and no manner of cleaning will restore the finish. †*We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Parts Information Fuel System/Body - Fuel Filler Cap Tether Too Short Fuel Door: All Technical Service Bulletins Fuel System/Body - Fuel Filler Cap Tether Too Short Bulletin No.: 05-06-04-043A Date: August 02, 2005 TECHNICAL Subject: Fuel Cap Tether Too Short to Hook On Fuel Door While Fueling Vehicle (Install Fuel Filler Housing and Cap) Models: 2004-2005 Cadillac Escalade Models 2004-2005 Chevrolet Silverado, Suburban, Tahoe Models 2004-2005 GMC Sierra, Yukon Models Supercede: This bulletin is being revised to correct the fuel filler cap P/N. P/N 15225006 is released for 2006 and 2007 model year vehicles only. The correct fuel cap for the 2004 and 2005 model year is P/N 15225005. Dealers who currently have P/N 15225006 on order (possibly back-ordered) for this concern should cancel their order and re-order P/N 15225005. Please discard Corporate Bulletin Number 05-06-04-043 (Section 06 - Engine/Propulsion System). Built Prior to the VIN Breakpoints shown. Condition Some customers may comment that the fuel cap tether is too short to hook on the fuel door while fueling the vehicle. Cause The existing fuel cap tether is too short. The existing fuel filler housing elongated hole is too small to accommodate the new fuel cap tether. Correction Page 15110 Rear Door Weatherstrip: Service and Repair Weatherstrip Replacement - Rear Door Window Weatherstrip Replacement - Rear Door Window Removal Procedure 1. Remove the window. 2. Pull the weatherstrip from the front window run channel. 3. Pull the weatherstrip from the rear window run channel. 4. Pull the weatherstrip from the window frame flange. Installation Procedure 1. Align the weatherstrip in the window frame flange. 2. Press the weatherstrip into the window frame flange until fully seated. 3. Press the weatherstrip into the rear window run channel until fully seated. 4. Press the weatherstrip into the front window run channel until fully seated. 5. Install the window. Page 12682 The number above refers to the step number on the diagnostic table. DTC U0073 or U2100 DTC Descriptors DTC U0073 00: Control Module Communication Bus Off DTC U0073 71: ECU HS Bus Off DTC U0073 72: ECU LS Bus Off DTC U2100 00: Controller Area Network (CAN) Bus Communication DTC U2100 47: Controller Area Network (CAN) Bus Communication Circuit/System Description The serial data circuits are serial data buses used to communicate information between the control modules. The serial data circuits also connect directly to the data link connector (DLC). Conditions for Running the DTCs Supply voltage at the modules are in the normal operating range. The vehicle power mode requires serial data communications. Conditions for Setting the DTC The module setting the DTC has attempted to establish communications on the serial data circuits more than 3 times. Page 14571 Memory/Heated Seat Switch - Driver (DDM C5) Part 1 Page 2622 Application Table Part 3 Engine, A/T - Shift/Driveability Concerns/MIL ON Air Filter Element: All Technical Service Bulletins Engine, A/T - Shift/Driveability Concerns/MIL ON Bulletin No.: 04-07-30-013B Date: February 01, 2007 INFORMATION Subject: Automatic Transmission Shift, Engine Driveability Concerns or Service Engine Soon (SES) Light On as a Result of the Use of an Excessively/Over-Oiled Aftermarket, Reusable Air Filter Models: 2007 and Prior GM Cars and Light Duty Trucks 2007 and Prior Saturn Models 2003-2007 HUMMER H2 2006-2007 HUMMER H3 2005-2007 Saab 9-7X Supercede: This bulletin is being revised to add models and model years. Please discard Corporate Bulletin Number 04-07-30-013A (Section 07 - Transmission/Transaxle). The use of an excessively/over-oiled aftermarket, reusable air filter may result in: Service Engine Soon (SES) light on Transmission shift concerns, slipping and damaged clutch(es) or band(s) Engine driveability concerns, poor acceleration from a stop, limited engine RPM range The oil that is used on these air filter elements may be transferred onto the Mass Air Flow (MAF) sensor causing contamination of the sensor. As a result, the Grams per Second (GPS) signal from the MAF may be low and any or all of the concerns listed above may occur. When servicing a vehicle with any of these concerns, be sure to check for the presence of an aftermarket reusable, excessively/over-oiled air filter. The MAF, GPS reading should be compared to a like vehicle with an OEM air box and filter under the same driving conditions to verify the concern. The use of an aftermarket reusable air filter DOES NOT void the vehicle's warranty. If an aftermarket reusable air filter is used, technicians should inspect the MAF sensor element and the air induction hose for contamination of oil prior to making warranty repairs. Transmission or engine driveability concerns (related to the MAF sensor being contaminated with oil) that are the result of the use of an aftermarket reusable, excessively/over-oiled air filter are not considered to be warrantable repair items. Page 2710 Application Table Part 4 Page 1865 Fluid Pressure Sensor/Switch: Connector Locations Page 1477 Door Latch Assembly (Door Jamb Switch) - RR - C2 (Crew Cab Only) Page 2044 Verify Original Equipment Condition of the Vehicle - Verify that Original Equipment Tires and Wheels or Official GM Accessory Tires and Wheels are on the vehicle. - Verify that aftermarket suspension "Lift" or "Lowering" Kits or other suspension alterations have NOT been done to the vehicle. - Check for accidental damage to the vehicle; for example, severe pothole or curb impacts, collision damage that may have affected the wheel alignment of the vehicle; e.g., engine cradles, suspension control arms, axles, wheels, wheel covers, tires may show evidence of damage/impact. - Check to be sure vehicle has seen "Normal Use" rather than abuse; e.g., very aggressive driving may show up by looking at the tires and condition of the vehicle. - Check for other additional equipment items that may significantly affect vehicle mass such as large tool boxes, campers, snow plow packages (without the snowplow RPO), etc., especially in trucks and cutaway/incomplete vehicles. Significant additional mass can affect trim height and wheel alignment of the vehicle and may necessitate a customer pay wheel alignment when placed semi-permanently in the vehicle (Upfitter instructions are to realign the vehicle after placement of these types of items. (This typically applies to trucks and incomplete vehicles that can be upfit with equipment such as the above.) Customer Concerns, "Normal Operation" Conditions and "Mileage Policy" Possible Concerns The following are typical conditions that may require wheel alignment warranty service: 1. Lead/Pull: defined as "at a constant highway speed on a typical straight road, the amount of effort required at the steering wheel to maintain the vehicle's straight heading." Important Please evaluate for the condition with hands-on the steering wheel. Follow the "Vehicle Leads/Pulls" diagnostic tree located in SI to determine the cause of a lead/pull concern. Lead/Pull concerns can be due to road crown or road slope, tires, wheel alignment or even in rare circumstances a steering gear issue. Lead/pull concerns due to road crown are considered "Normal Operation" and are NOT a warrantable condition -- the customer should be advised that this is "Normal Operation." Important Some customers may comment on a "Lead/Pull" when they hold the steering wheel in a level condition. If so, this is more likely a "steering wheel angle" concern because the customer is "steering" the vehicle to obtain a "level" steering wheel. 2. Steering wheel angle to the left or right (counter-clockwise or clockwise, respectively): Defined as the steering wheel angle (clocking) deviation from "level" while maintaining a straight heading on a typical straight road. 3. Irregular or Premature tire wear: Slight to very slight "feathering" or "edge" wear on the shoulders of tires is NOT considered unusual and should even out with a tire rotation; if the customer is concerned about a "feathering" condition of the tires, the customer could be advised to rotate the tires earlier than the next scheduled mileage/maintenance interval (but no later than the next interval). Be sure to understand the customer's driving habits as this will also heavily influence the tire wear performance; tire wear from aggressive or abusive driving habits is NOT a warrantable condition. Important Slight or mild feathering, cupping, edge or heel/toe wear of tire tread shoulders is "normal" and can show up very early in a tire/vehicle service mileage; in fact, some new tires can show evidence of feathering from the factory. These issues do NOT affect the overall performance and tread life of the tire. Dealer personnel should always check the customer's maintenance records to ensure that tire inflation pressure is being maintained to placard and that the tires are being rotated (modified-X pattern) at the proper mileage intervals. Wheel alignments are NOT to be performed for the types of "Normal" Tire Feathering shown in Figures 1-4 below. Page 1696 5. Connect the VSS electrical connector (2). 6. Lower the vehicle. 7. Refill the fluid as required. Page 4156 6. Connect the fuel composition sensor electrical connector. 7. Lower the vehicle. 8. Use the following procedure in order to inspect for leaks: 8.1. Turn the ignition ON, with the engine OFF, for 2 seconds. 8.2. Turn the ignition OFF for 10 seconds. 8.3. Turn the ignition ON, with the engine OFF. 8.4. Inspect for fuel leaks. Page 12857 8.2. Remove the console (A) together with the OnStar(R) control modules. 8.3. Remove the connectors (B). Important: The optic cable must not be bent with a radius less than 25 mm (1 in). Important: Secure the wiring harness so that there is no risk of chafing and rattling. 8.4. Fold back the wiring harness and tape over the connectors (C). Fold back the wiring harness once more and secure with cable ties (D). Page 11064 The new calibrations have been updated to compensate for the actuator overtravel condition, the actuator hunting and the ticking/clicking noises. The new calibrations effectively eliminate the codes listed above, the default position of the doors associated with the DTCs and opens up the feedback position value. The new calibrations should not be used unless the vehicle has one or more of the customer concerns listed above or a DTC listed above has been set. The new calibrations will not correct any other DTC or NC system performance concern. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Procedures Power Door Lock Switch: Procedures Switch Replacement - Door Lock and Side Window - Driver SWITCH REPLACEMENT - DOOR LOCK AND SIDE WINDOW - DRIVER REMOVAL PROCEDURE 1. Remove the front door trim panel. 2. Disconnect the electrical connectors. 3. Remove the screw that retains the switch panel bezel (1) from the front door panel. 4. Remove the switch panel bezel from the door panel using a flat-bladed tool. 5. Using a wide plastic flat-bladed tool, release the retaining clips on both sides of the door module. Page 14076 High Temperature Conditions Tools Required J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency MEASURING FREQUENCY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage MEASURING VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop MEASURING VOLTAGE DROP NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Molding Replacement - Body Side (Standard Cab) Upper Side Moulding / Trim: Service and Repair Molding Replacement - Body Side (Standard Cab) Molding Replacement - Body Side (Standard Cab) Tools Required J 25070 Heat Gun Removal Procedure Important: Be careful not to scratch or chip the paint. 1. Heat the body side molding using a heat gun J 25070. Hold the heat gun approximately 152 mm (6 in) from the surface. Apply heat using a circular motion for about 30 seconds. 2. Starting from one end of the molding, peel off the body off the molding from the panel surface using a flat-bladed tool. 3. Remove all adhesive from the body panel using a 3M(TM) scotch brite molding adhesive remover disk P/N 07501 or equivalent. Installation Procedure Important: Apply the molding in an environment free of dust and dirt. Dust and dirt could come in contact with the adhesive surface and prevent proper adhesion. 1. Clean the area where the replacement molding is to be mounted. Use a suitable solvent such as flash naphtha or a mixture of 50 percent isopropyl alcohol and 50 percent water. 2. Dry the area thoroughly. 3. Warm the body panel to a temperature range of 16-41°C (60-105°F) with a heat lamp or heat gun J 25070. 4. Ensure the molding is at a minimum temperature of 16°C (60°F). If the temperature of the molding is below 16°C (60°F), warm up molding with a heat lamp or heat gun J 25070. Important: Do not touch the adhesive surface when the tape is removed. 5. Remove the protective tape. 6. Without allowing the adhesive surface to touch the body, ensure the molding is aligned. 7. Press on the molding in order to install to the body. Diagrams Seat Belt Buckle Switch: Diagrams Seat Belt Switch - Driver Page 2020 Control Module References Part 5 Page 8889 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Micro-Pack 100W Connectors MICRO-PACK 100W CONNECTORS TOOLS REQUIRED J 38125-D Terminal Repair Kit REMOVAL PROCEDURE There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2)has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. IMPORTANT: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Page 16049 Control Module References Part 3 Page 3670 3. Ensure the 3 retaining ring ears can be seen from the inside of the connector and the retaining ring can move freely in the slots. 4. Install the radiator outlet hose (2) onto the radiator quick connector fitting until a click is heard or felt.Pull back on the radiator outlet hose (2) to ensure a proper connection. Campaign - Unwanted Repeat Calls to OnStar(R) Technical Service Bulletin # 10037 Date: 100420 Campaign - Unwanted Repeat Calls to OnStar(R) CUSTOMER SATISFACTION Bulletin No.: 10037 Date: April 20, 2010 Subject: 10037 - Unwanted Repeat Calls to OnStar(R) Models: 2003 Buick LeSabre 2004-2006 Buick Rendezvous 2005 Buick LeSabre, Terraza 2005-2006 Buick LaCrosse/Allure 2006-2008 Buick Lucerne 2008 Buick LaCrosse/Allure 2008-2009 Buick Enclave 2003 Cadillac CTS 2004 Cadillac Escalade 2004-2005 Cadillac CTS-V, Deville 2005 Cadillac Escalade ESV, SRX 2005-2006 Cadillac STS 2005-2008 Cadillac CTS 2006-2008 Cadillac DTS 2007 Cadillac Escalade, Escalade EXT 2007-2008 Cadillac Escalade ESV 2008 Cadillac SRX, STS 2002 Chevrolet Impala 2003-2008 Chevrolet Suburban 2003-2009 Chevrolet Silverado 2004-2008 Chevrolet Impala 2005 Chevrolet Colorado, Corvette, Malibu 2005-2006 Chevrolet Uplander 2005-2008 Chevrolet Avalanche, Tahoe, TrailBlazer 2006 Chevrolet HHR, Monte Carlo 2006-2008 Chevrolet Equinox 2007-2008 Chevrolet Corvette 2008 Chevrolet HHR 2008-2009 Chevrolet Cobalt, Colorado, Malibu, Uplander 2003 GMC Envoy XL, Sierra, Yukon XL 2004-2008 GMC Yukon 2005-2009 GMC Sierra 2005-2008 GMC Yukon XL 2006-2008 GMC Envoy 2007 GMC Canyon 2007-2009 GMC Acadia 2006 HUMMER H2 2006-2008 HUMMER H3 2008 HUMMER H2 2003 Oldsmobile Silhouette 2005 Montana SV6 2005-2008 Pontiac Grand Prix 2006 Pontiac G6, Vibe 2007 Pontiac Montana SV6 2007-2008 Pontiac Solstice 2008 Pontiac G6, Torrent 2008-2009 Pontiac G5, G8 2009 Pontiac G3, Montana SV6 2005-2007 Saturn ION 2006-2009Saturn VUE 2007-2008 Saturn AURA, OUTLOOK, SKY Equipped with OnStar(R) (RPO UE1) Page 10922 Control Module References Part 3 Page 1767 Impact Sensor: Diagrams Inflatable Restraint Front End Sensor - Left Page 7350 4. Position the J 41364-A onto the PNP switch. Ensure that the two slots on the switch where the manual shaft is inserted are lined up with the lower two tabs on the tool. 5. Notice: Refer to Fastener Notice in Service Precautions. Rotate J 41364-A until the upper locator pin on the tool is lined up with the slot on the top of the switch. ^ Tighten the bolts to 25 Nm (18 ft. lbs.). 6. Remove J 41364-A from the PNP switch. If installing a new switch, remove the positive assurance bracket at this time. 7. Install the control lever to the manual shaft with the nut. 8. Install the manual shaft nut. ^ Tighten the nut to 25 Nm (18 ft. lbs.). 9. Install the range selector cable end (2) to the range selector lever ball stud (1). Page 4096 3. If equipped with a 6.0L engine, connect the HO2S electrical connector. 4. If equipped with a 4.8L or 5.3L engine, connect the HO2S electrical connector. 5. Install the HO2S connector clip to the frame. 6. Disconnect the CPA retainer. 7. Lower the vehicle. Page 9470 Energy Storage Control Module (ESCM) Page 6772 14. Separate the right carrier case half from the left carrier case half. 15. Remove the differential case assembly from the carrier. 16. Place the differential case in a vise. 17. Remove the differential side bearings using the J 22888-20A. 18. Remove the differential case from the vise. Important: The ring gear bolts have left-hand threads. 19. Remove the ring gear bolts. 20. Remove the ring gear from the differential case. Drive the ring gear off with a brass drift if necessary. 21. Remove the pinion shaft pin. Use a hammer and a drift pin in order to drive out the pin. 22. Remove the pinion shaft. 23. Roll the differential pinion gears out of the case with the pinion gear thrust washers. 24. Remove the differential side gears and the side gear thrust washers. Mark the pinion gears and thrust washers top and bottom and the differential side gears and thrust washers left and right. 25. Lubricate the pinion and side gears using axle lubricant. Use the proper fluid. Refer to the Maintenance and Lubrication subsection. 26. Install the differential side gear thrust washers to the differential side gears. 27. Install the differential side gears and thrust washers into the new differential case. 28. Install the differential pinion gears and thrust washers by performing the following steps: 28.1. Position one pinion gear between the differential side gears. 28.2. Position the second pinion gear between the differential side gear directly opposite of the first gear. 28.3. Rotate the differential side gears until the pinion gears are directly opposite the opening in the differential case. 28.4. Install the thrust washers. Rotate the pinion gears toward the differential case opening in order to permit the sliding in of the thrust washers. 29. Install the pinion gear shaft. 30. Install the pinion gear shaft lock pin using a hammer and a brass drift. Important: The mating surface of the ring gear and the differential case must be clean and free of burrs before installing the ring gear. Page 2857 3. Disconnect the vent valve pipe quick connect from the canister. 4. Either cut the existing valve vent pipe and leave the remaining section of pipe in the vehicle or remove along with the valve. 5. Push in the retainer and remove the existing canister vent valve from the fuel tank clip or mounting bracket. 6. Cut back the existing canister pipe approximately 51 mm (2 in) and retain the pipe for use with new valve. 7. Connect the canister pipe quick connect to the canister. 2500 Crew Cab Short Box Shown Below, Other Configurations Similar 1500 Extended Cab Short Box Shown Below, Other Configurations Similar 8. Install the new canister vent valve solenoid to the fuel tank clip or mounting bracket as shown above. The valve port closest to the electrical connector must point towards the canister. 9. Cut bulk 5/8" heater hose to a length of approximately 76 mm (3 in). Install the hose between the solenoid and the canister pipe and secure using clamps. 10. Attach bulk 5/8" heater hose to the vent port and secure using a clamp. Run a length as needed along the frame rail routing to the passenger side area above the transmission. 11. Cut the hose to determined length and install the supplied filter box. Secure using a clamp. 12. Remove the transmission heat shield, if necessary. 13. Remove the transmission support and lower the transmission assembly as necessary to allow for access to the new filter box location. 14. Secure the filter box to the transmission vent hose just forward of the hose tee-section using a tie strap. DO NOT pinch or restrict the transmission vent hose. The filter box opening should be pointing downward. 15. Raise the transmission and reinstall the transmission support. 16. Reinstall the transmission heat shield. 17. Connect the EVAP canister vent valve electrical connector. 18. Tie strap the hose as needed along the frame rail in order to keep the hose away from pinch-points and heat sources. 19. Lower the vehicle. Parts Information Page 10360 Maintain the sensor position. Do not turn the sensor. Remove the rear wheel position sensor (2) from the steering gear. Installation Procedure 1. Important: Make sure the O-ring (1) is installed. Install the rear wheel position sensor (2) to the steering gear. 2. Important: Be careful to maintain the position of the replacement sensor. Remove the pin retaining the position of the new sensor and immediately install the sensor to the steering gear. 3. Notice: Refer to Fastener Notice in Service Precautions. Install the rear wheel position sensor retaining bolts. Apply LOCTITE 242 blue. ^ Tighten the bolts to 4 Nm (35 inch lbs.). 4. Install the rear wheel position sensor cover (4). 5. Connect the electrical connector (1). 6. Install the steering gear protection shield (1) and retaining bolts (3). ^ Tighten the steering gear protection shield retaining bolts to 180 Nm (132 ft. lbs.). Page 4535 The controller area network (CAN) serial data line does not communicate with the scan tool via the DLC. CAN serial data information is interpreted by the modules that are on the class 2 also, and transmitted to the scan tool. The following modules communicate on the CAN serial data line: The engine control module (ECM) - The transmission control module (TCM) - The fuel injection control module (FICM) - The glow plug control module, w/LLY The CAN serial data line, based on J1939 SAE standard, is high speed serial data bus used to communicate information among the modules. Typical data-transmission speeds must be high enough to ensure that the required real-time response is maintained. The addressing scheme employed with CAN assigns a label to every message, with each message receiving a unique identifier. The identifier classifies the content of the message. Each module processes only those messages whose identifiers are stored in the module's acceptance list. This is CAN's form of message filtering. The identifier labels both the data content and the priority of the message being sent. Each module can begin transmitting its most important data as soon as the bus is unoccupied. When more than one module starts to transmit simultaneously, the message with the highest priority is assigned first access. A module responds to failure to gain access by automatically switching to receive mode, the module then repeats the transmission attempt as soon as the bus is free again. HIGH SPEED GMLAN SERIAL DATA LINE (PHT) The data link connector (DLC) allows a scan tool to communicate with the high speed GMLAN serial data circuit through the CANdi module. The serial data is transmitted on two twisted wires that allow speed up to 500 Kbps. The twisted pair is terminated with two 120 ohms resistors, one is internal to the ECM and the other is internal to the ESCM. The resistors are used to reduce noise on the high speed GMLAN bus during normal vehicle operation. The high speed GMLAN is a differential bus. The high speed GMLAN serial data bus (+) and high speed GMLAN serial data (-) are driven to opposite extremes from a rest or idle level. The idle level which is approximately 2.5 volts is considered a recessive transmitted data and is interpreted as a logic 1. Driving the lines to their extremes adds 1 volt to high speed GMLAN serial data bus (+) and subtracts 1 volt from high speed GMLAN serial data bus (-) wire. This dominant state is interpreted as a logic 0. GMLAN network management supports selective start up and is based on virtual networks. A virtual network is a collection of signals started in response to a vehicle event. The starting of a virtual network signifies that a particular aspect of the vehicles's functionality has been requested. A virtual network is supported by virtual devices which represents a collection of signals owned by a single physical device. So, any physical device can have one or more virtual devices. The signal supervision is the process of determining whether an expected signal is being received or not. Failsofting is the ability to substitute a signal with a default value or a default algorithm, in the absence of a valid signal. Some messages are also interpreted as a 'heartbeat' of a virtual device. If such a signal is lost, the application will set a no communication code against the respective virtual device. This code is mapped as a code against the physical device. Note that a loss of serial data DTC does not normally represent a failure of the module that set it. The powertrain control module (PCM) and hybrid control module (HCM) are functionally communicating on both class 2 and high speed GMLAN data links. However the diagnostic communication of the above modules with the scan tool is performed on class 2 data link only. All diagnostic trouble codes (DTCs) set by the high speed GMLAN modules, including HCM, are reported by the PCM on class 2. Data displaying, output controls and programming of the control modules connected to high speed GMLAN only, is performed through high speed GMLAN link. The GMLAN serial data communications circuit is in a linear topology. The following modules are connected to the link, in order from DLC to the end of the linear configuration: - The energy storage control module (ESCM) - The starter/generator control module (SGCM) - The electro-hydraulic power steering (EHPS) - The hybrid control module (HCM) - The powertrain control module (PCM) Page 7797 1. The shift lock control actuator must lock the shift lever clevis when the shift lever clevis is put into the park position. 2. Depress the brake pedal to move the shift lever out of the park position. 3. The actuator will be energized. 4. Readjust the shift lock control actuator if needed. 5. Install the BCM. 6. Enable the SIR system. Page 4088 Oxygen Sensor: Service and Repair Heated Oxygen Sensor (HO2S) Replacement Bank 1 Sensor 2 HEATED OXYGEN SENSOR (HO2S) REPLACEMENT BANK 1 SENSOR 2 REMOVAL PROCEDURE 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. If equipped, disconnect the fuel composition sensor electrical connector. 3. Disconnect the connector position assurance (CPA) retainer. NOTE: Refer to Heated Oxygen and Oxygen Sensor Notice in Service Precautions. 4. If equipped with a fuel composition sensor, remove the heated oxygen sensor (HO2S) electrical connector from the fuel line clip. 5. If equipped with a 4.8L or 5.3L engine, disconnect the HO2S electrical connector (2). 6. If equipped with a 6.0L engine, disconnect the HO2S electrical connector (2). Page 8228 13. Lower vehicle. 14. Adjust park brake cable. Refer to Park Brake Adjustment. (15 Series W/NYS) Disc Brake Backing Plate Replacement - Rear (15 Series W/NYS) Caution: Refer to Brake Dust Caution in Service Precautions. Removal Procedure 1. Release the park brake. 2. Raise and support the vehicle. Refer Vehicle Lifting 3. Remove the tire and wheel assembly. 4. Relieve the tension from the park brake cable by pulling down on the intermediate cable then release the cable from the equalizer bar. 5. Remove the rear park brake bracket bolt. Page 733 The new calibrations have been updated to compensate for the actuator overtravel condition, the actuator hunting and the ticking/clicking noises. The new calibrations effectively eliminate the codes listed above, the default position of the doors associated with the DTCs and opens up the feedback position value. The new calibrations should not be used unless the vehicle has one or more of the customer concerns listed above or a DTC listed above has been set. The new calibrations will not correct any other DTC or NC system performance concern. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Initial Inspection and Diagnostic Overview Accessory Delay Module: Initial Inspection and Diagnostic Overview Diagnostic Starting Point DIAGNOSTIC STARTING POINT Begin the system diagnosis with the Diagnostic System Check - Accessory Delay Module. The diagnostic system check will provide the following information: - The identification of the control modules which command the system - The ability of the control modules to communicate through the serial data circuit - The identification of any stored diagnostic trouble codes DTCs and their status The use of the Diagnostic System Check will identify the correct procedure for diagnosing the system and where the procedure is located. Diagnostic System Check DIAGNOSTIC SYSTEM CHECK TEST DESCRIPTION Page 490 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Micro-Pack 100W Connectors MICRO-PACK 100W CONNECTORS TOOLS REQUIRED J 38125-D Terminal Repair Kit REMOVAL PROCEDURE There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2)has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. IMPORTANT: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Page 2375 Coolant: Technical Service Bulletins Cooling System - Coolant Recycling Information Bulletin No.: 00-06-02-006D Date: August 15, 2006 INFORMATION Subject: Engine Coolant Recycling and Warranty Information Models: 2007 and Prior GM Passenger Cars and Trucks (Including Saturn) 2007 and Prior HUMMER Vehicles 2005-2007 Saab 9-7X Attention: Please address this bulletin to the Warranty Claims Administrator and the Service Manager. Supercede: This bulletin is being revised to adjust the title and Include Warranty Information. Please discard Corporate Bulletin Number 00-06-02-006C (Section 06 - Engine/Propulsion System). Coolant Reimbursement Policy General Motors supports the use of recycled engine coolant for warranty repairs/service, providing a GM approved engine coolant recycling system is used. Recycled coolant will be reimbursed at the GMSPO dealer price for new coolant plus the appropriate mark-up. When coolant replacement is required during a warranty repair, it is crucial that only the relative amount of engine coolant concentrate be charged, not the total diluted volume. In other words: if you are using two gallons of pre-diluted (50:50) recycled engine coolant to service a vehicle, you may request reimbursement for one gallon of GM Goodwrench engine coolant concentrate at the dealer price plus the appropriate warranty parts handling allowance. Licensed Approved DEX-COOL(R) Providers Important: USE OF NON-APPROVED VIRGIN OR RECYCLED DEX-COOL(R) OR DEVIATIONS IN THE FORM OF ALTERNATE CHEMICALS OR ALTERATION OF EQUIPMENT, WILL VOID THE GM ENDORSEMENT, MAY DEGRADE COOLANT SYSTEM INTEGRITY AND PLACE THE COOLING SYSTEM WARRANTY UNDER JEOPARDY. Shown in Table 1 are the only current licensed and approved providers of DEX-COOL(R). Products that are advertised as "COMPATIBLE" or "RECOMMENDED" for use with DEX-COOL(R) have not been tested or approved by General Motors. Non-approved coolants may degrade the Initial Inspection and Diagnostic Overview Information Bus: Initial Inspection and Diagnostic Overview DIAGNOSTIC STARTING POINT - DATA LINK COMMUNICATIONS Begin the diagnosis of the Data Link Communications by performing the Diagnostic System Check for the system in which the customer concern is apparent. The Diagnostic System Check will direct you to the correct procedure within the Data Link Communications section when a communication malfunction is present. Front Drive Axle Seals and Gaskets: Service and Repair Front Drive Axle Inner Axle Seal and/or Bearing Replacement Front Drive Axle Inner Shaft Seal and Inner Shaft Bearing Replacement - J 8092 Universal Driver Handle - 3/4 in - 10 - J 2619-01 Slide Hammer - J 29369-1 Bushing and Bearing Remover - J 29369-2 Bushing and Bearing Remover (2-3 inch) - J 36609 Axle Tube Bearing Installer - J 45225 Axle Seal Installer Removal Procedure 1. Raise the vehicle. 2. Drain the differential carrier assembly. 3. Remove the right side seal and/or bearing by performing the following steps: 3.1. Remove the inner axle shaft and housing assembly from the differential carrier case assembly. 3.2. Remove the clutch fork assembly components and the inner axle shaft from the inner axle shaft housing. 3.3. Install the inner axle shaft housing into a vise. - Clamp only on the mounting flange of the inner axle shaft housing. 3.4. Install the J 29369-1, 8.25 inch axle, or the J 29369-2, 9.25 inch axle, behind the inner axle shaft seal or the inner axle shaft bearing as necessary. 3.5. Install the J 2619-01 (2) to the J 29369-1 or the J 29369-2 (1). 3.6. Remove the inner axle shaft seal and/or the inner axle shaft bearing using the J 2619-01. Page 11260 and close between 275-317 kPa (40-46 psi). 11. Remove special tool GE-47742 after diagnosis is complete. 12. Install a new O-ring on the A/C low pressure switch port on the accumulator. Lightly coat the new O-ring seal with mineral base 525 viscosity refrigerant oil. 13. Install the A/C low pressure switch onto the accumulator. Tighten Tighten the A/C low pressure switch to 6 Nm (44 lb in). Important Remember to install the seal back onto the A/C low pressure switch wire harness connector. Failure to replace the seal could result in terminal corrosion. 14. Reconnect the wire harness to the A/C low pressure switch. Disclaimer Page 6417 Page 8827 1. Install the generator cable (2) to the junction block. 2. Install the generator cable nut. Tighten Tighten the nut to 9 N.m (80 lb in). 3. Close the positive cable junction block. 4. Install the generator cable to the generator, perform the following: 4.1. Install the generator cable to the stud. 4.2. Install the generator cable nut. Tighten Tighten the nut to 9 N.m (80 lb in). 4.3. Position the boot to cover the stud. 5. If necessary, install the engine sight shield. 6. Connect the negative battery cable Page 15988 Steps 8-12 Page 13885 Upper Side Moulding / Trim: Service and Repair Molding Replacement - Body Side (Extended Cab) Molding Replacement - Body Side (Extended Cab) Tools Required J 25070 Heat Gun Removal Procedure Important: Be careful not to scratch or chip the paint. 1. Heat the body side molding using a heat gun J 25070. Hold the heat gun approximately 152 mm (6 in) from the surface. Apply heat using a circular motion for about 30 seconds. 2. Starting from one end of the molding, peel off the molding from the panel surface using a flat-bladed tool. 3. Remove all adhesive from the body panel using a 3M(TM) scotch brite molding adhesive remover disk P/N 07501 or equivalent. Installation Procedure Important: Apply the molding in an environment free of dust and dirt. Dust and dirt could come in contact with the adhesive surface and prevent proper adhesion. 1. Clean the area where the replacement molding is to be mounted. Use a suitable solvent such as flash naphtha or a mixture of 50 percent isopropyl alcohol and 50 percent water. 2. Dry the area thoroughly. 3. Warm the body panel to a temperature range of 16-41°C (60-105°F) with a heat lamp or heat gun J 25070. 4. Ensure the molding is at a minimum temperature of 16°C (60°F). If the temperature of the molding is below 16°C (60°F), warm up molding with a heat lamp or heat gun J 25070. Important: Do not touch the adhesive surface when the tape is removed. 5. Remove the protective tape. 6. Without allowing the adhesive surface to touch the body, ensure the molding is aligned. 7. Press on the molding in order to install to the body. Page 12458 Important: Secure the wiring harness so that there is no risk of chafing and rattling. 9.4. Fold back the wiring harness and tape over the connectors (C). Fold back the wiring harness once more and secure with cable ties (D). 9.5. Install the right-hand rear luggage compartment in accordance with WIS - 8. Body - Interior equipment - Adjustment/Replacement. 10. Install the ground cable to the battery's negative terminal. 11. Clear the diagnostic trouble codes. 12. Set the date and time, see WIS - 3. Electrical system - Information display (SID_ - Technical description. 2003-2005 Saab 9-3 (9400) 4D/5D; 2004-2005 Saab 9-3 (9400) CV 2003-2005 Saab 9-3 (9440) 4D/5D; 2004-2005 Saab 9-3 (9440) CV Notice: Handle the fiber optic cables with care or the signal may be distorted. ^ It is very important that the two leads in the connector are not confused with one another. ^ Do not splice the cables. ^ Do not bend the cable in a radius smaller than 25 mm (1 in). ^ Do not expose the cable to temperatures exceeding 185°F (85°C). ^ Keep the cable ends free from dirt and grime. ^ Do not expose the cable to impact as this may cause the transparent plastic to whiten, thereby reducing the intensity of the light and causing possible communication interruptions. ^ The cable should not lie against any sharp edges as this may cause increased signal attenuation. 1. Remove the ECU CU with a Tech 2(R) according to the following: Fault diagnosis - Select model year - Select Saab 9-3 Sport (9440) - All - Add/Remove - Control Module - CU/PU - Remove. 2. Remove the ground cable from the battery's negative terminal. 3. Remove the floor console in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 4. Pry out the signal line from the SRS control module to the OnStar(R) control module and secure it: Page 5402 Fuel Filler Hose: Service and Repair Filler Tube Replacement - 1 FILLER TUBE REPLACEMENT (PICKUP) REMOVAL PROCEDURE 1. Remove the fuel tank filler housing to body TORX(R) screws (1) and pushpin retainer (2). 2. Remove the fuel tank filler housing to fuel tank fill pipe bolts. 3. Remove the fuel tank filler housing. 4. Raise and suitably support the vehicle half way. Refer to Vehicle Lifting. 5. Remove the fuel tank fill pipe ground wire bolt (1). Electrical - Information For Electrical Ground Repair Wiring Harness: All Technical Service Bulletins Electrical - Information For Electrical Ground Repair INFORMATION Bulletin No.: 10-08-45-001B Date: October 25, 2010 Subject: Information for Electrical Ground Repair - Use New Replacement Fasteners with Conductive Finish Models: 2011 and Prior GM Passenger Cars and Trucks (including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X Supercede: This bulletin is being revised to add the 2011 model year and update the Warranty Information. Please discard Corporate Bulletin Number 10-08-45-001A (Section 08 - Body and Accessories). Electrical Ground Repair Overview Proper electrical system function relies on secure, stable and corrosion-free electrical ground connections. Loose, stripped, or corroded connections increase the possibility of improper system function and loss of module communication. These conditions may also lead to unnecessary repairs and component replacement. In general, electrical ground connections are accomplished using one, or a combination of the following attachment methods: - Welded M6 stud and nut - Welded M6 nut and bolt - Welded M8 nut and bolt Determine which attachment method is used and perform the appropriate or alternative repair as described in this bulletin. M6 Weld Stud Replacement Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. Select a location adjacent the damaged or missing M6 ground stud having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the M6 conductive rivet stud flange. 2. Using GM approved residue-free solvent or equivalent, remove any grease from the repair site and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 3. Drill a 10 mm (0.40 in) diameter hole through the panel. 4. Remove paint and primer from the area surrounding the 10 mm (0.40 in) hole until bare metal is visible. Page 7393 9. Disassemble the harness connector (1) from the encoder. 10. Remove the encoder from the output shaft using a flat tip screwdriver. Installation Procedure 1. Assemble the harness to the NEW encoder with the connector legend "TOP" (1) and the encoder part number facing up. 2. Assemble the output shaft into the encoder, being sure to align the encoder tab with the groove on the shaft. 3. Ensure the encoder is seating properly on the output gear. 4. Place the output shaft encoder on the casting. 5. Place the grommet harness on the casting slot, the flat area on the grommet will be facing up. Page 14302 WA8555/41 - WA8555/41 Page 12529 The control module ID number list above provides a method for determining which module is not communicating. A module with a class 2 serial data circuit malfunction or which loses power during the current ignition cycle will have a Loss of Communication DTC set by other modules that depend on information from that failed module. The modules that can communicate will set a DTC indicating the module that cannot communicate. Diagnostic Order When more than one Loss of Communication DTC is set in either one module or in several modules, diagnose the DTCs in the following order: 1. Current DTCs before history DTCs unless told otherwise in the diagnostic table. 2. The DTC which is reported the most times. 3. From the lowest number DTC to the highest number DTC. Conditions for Running the DTC The following DTCs do not have a current status: ^ B1327 ^ B1328 ^ U1300 ^ U1301 ^ U1305 AND ^ The vehicle power mode requires serial data communication to occur. Conditions for Setting the DTC A node alive message has not been received from a module with a learned identification number within the last 5 seconds. Action Taken When the DTC Sets Page 12094 ^ An OnStar(R) Call Center button press WILL NOT connect the vehicle with OnStar(R). The vehicle must be upgraded to reactivate the account. The customer will hear a demo message stating that there is not a current OnStar(R) subscription for the vehicle. The message will also instruct the customer how to upgrade and reactivate services. ^ OnStar(R) personal calling (OPC) will not be available, as this feature requires the customer to have a current OnStar(R) account. Attempts to use this feature will result in cellular connection failure messages and the inability to connect to the number dialed. Note For deactivated vehicles, a no connect response should be considered normal system operation. Further diagnosis and subsequent repair is only necessary should the customer elect to become an active OnStar(R) subscriber and upgrade the account subscription. OnStar(R) Cellular, GPS, and Diagnostic Limitations The proper operation of the OnStar(R) System is dependent on several elements outside the components integrated into the vehicle. These include the National Cellular Network Infrastructure, the cellular telephone carriers within the network, and the GPS. The cellular operation of the OnStar(R) system may be inhibited by factors such as the users range from a digital cellular tower, the state of the cellular carrier's equipment, and the location where the call is placed. Making an OnStar(R) key press in areas that lack sufficient cellular coverage or have a temporary equipment failure will result in either the inability of a call to complete with a data transfer or the complete inability to connect to the OnStar(R) Call Center. The OnStar(R) system may also experience connection issues if the identification numbers for the module, station identification number (STID), electronic serial number (ESN) or manufacturers electronic ID (MEID), are not recognized by the cellular carriers local signal receiving towers. The satellites that orbit earth providing the OnStar system with GPS data have almost no failures associated with them. In the event of a no GPS concern, the failure will likely lie with the inability of the system to gain GPS signals because of its location, i.e. in a parking structure, hardware failure, or being mistaken with an OnStar(R) call which has reached the Call Center without vehicle data. During diagnostic testing of the OnStar(R) system, the technician should ensure the vehicle is located in an area that has a clear unobstructed view of the open sky, and preferably, an area where digital cellular calls have been successfully placed. These areas can be found by successfully making an OnStar(R) keypress in a known good OnStar(R) equipped vehicle and confirming success with the OnStar(R) Call Center advisor. Such places can be used as a permanent reference for future OnStar(R) testing. Mobile Identification Number and Mobile Directory Number The vehicle communication interface module (VCIM) utilizes 2 numbers for cellular device identification, call routing and connection. They are: ^ A mobile identification number (MIN) ^ A mobile directory number (MDN) Note The MIN represents the number used by the cellular carrier for call routing purposes. The MDN represents the number dialed to reach the cellular device. Diagnostic Information Symptoms - Cellular Communication The following steps must be completed before using the symptom table. 1. Perform the Diagnostic System Check - Vehicle, before using the Symptom Tables in order to verify that the following are true: ^ There are no DTCs set. ^ The control modules can communicate via the serial data link. 2. Review the system operation in order to familiarize yourself with the system functions. Refer to Radio/Audio System Description and Operation in SI. Diagnostic Starting Point - Displays and Gages Begin the displays and gages system diagnosis with Diagnostic System Check - Vehicle or the audible warning system diagnosis with Diagnostic System Automatic Transmission - 4L60-E/4L65-E Valve Body: Service and Repair Automatic Transmission - 4L60-E/4L65-E Valve Body and Pressure Switch Replacement Removal Procedure 1. Ensure that removal of the valve body is necessary before proceeding. ^ Important: The following components can be serviced without removing the valve body from the transmission: The torque converter clutch solenoid (1) ^ The pressure control solenoid (2) ^ The internal wiring harness (3) ^ The 2-3 shift solenoid (4) ^ The 1-2 shift solenoid (5) ^ The transmission fluid pressure manual valve position switch (6) ^ The 3-2 shift solenoid (7) ^ The torque converter clutch pulse width modulation (TCC PWM) solenoid (8) 2. Remove the fluid level indicator. 3. Remove the auxiliary pump, if equipped with RPO HP2. 4. Remove the transmission filter. 5. Disconnect the internal wiring harness electrical connectors from the following components: ^ The transmission fluid pressure manual valve position switch (1) ^ The 1-2 shift solenoid (2) ^ The 2-3 shift solenoid (3) ^ The pressure control solenoid (4) ^ The TCC PWM solenoid (5) ^ The 3-2 shift solenoid (6) Page 15017 The following procedure should only be performed if the right side of the tailgate could be disengaged for the pickup truck and the hinge was damaged or bent. 1. Release (unhook) the left side tailgate support cable from the pickup box. 2. Remove the tailgate from the vehicle. 3. Remove the bolt (1) attaching the right side hinge (2) to the side of the tailgate. 4. Locate and drill out the large weld (2) attaching the hinge (1) to the backside of the tailgate bracket (3). Remove the hinge. Important: Because the new hinge must be welded to the bracket on the tailgate in the next steps, do not paint the hinge until after installation. After welding is complete, the new hinge must be primed and painted in the body color. 5. Install a new hinge to the tailgate and install the bolt. Tighten Tighten the bolt to 27 Nm (20 lb-ft). 6. Weld the backside of the new hinge to the original bracket on the tailgate. 7. Tape off the area around the hinge and prime and paint the hinge as required. 8. Reinstall the tailgate on the vehicle and proceed to the section titled, "Support Cable Replacement". Support Cable Replacement - Classic CK and Sierra The following procedure provides instruction for replacing the rear endgate (tailgate) support cables. Page 14038 5. Install the rear window lower molding. 6. Install the coat hook, if removed. Trim Panel Replacement - Rear Quarter (Extended Cab) Trim Panel Replacement - Rear Quarter (Extended Cab) Removal Procedure 1. Remove the rear seat, if necessary. 2. Remove the rear window molding. 3. Remove the armrest screw. 4. Remove the armrest. 5. Remove the sill trim plates. 6. Remove the quarter panel trim screws. 7. Pull the panel out, and remove the seat belt assembly. Refer to Seat Belt Retractor Replacement - Rear (Extended Cab) Seat Belt Retractor Replacement - Rear (Crew Cab) in Seat Belts. 8. Remove the quarter panel from the vehicle. Installation Procedure 1. Install the seat belt assembly. 2. Install the quarter panel to the vehicle. Page 9348 of the possible harness chafing/pinching. Also, on any of the above listed vehicles, the PCM wiring harness may be chafing against the precharge pump bracket or the battery tray. Correction On RPO AN3 vehicles, inspect the routing of the seat wiring harness. Reroute the seat wiring harness and attaching harness fastener (1) to the opposite side of the seat module bracket. Repair the harness as necessary. Refer to Wiring Repairs in the Wiring Systems sub-section of SI. The seat may have to be removed for ease of access and proper repair of the wiring harness. Inspect the routing of the PCM wiring harness at the precharge pump bracket and the battery tray. Repair the harness as necessary. Refer to Wiring Repairs in the Wiring Systems sub-section of SI. If any of the above conditions still remain after this repair, refer to SI for further diagnostic information. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 14852 5. Using a wide plastic flat-bladed tool, release the retaining clips on both sides of the door module. 6. Remove the door module from the switch panel bezel. INSTALLATION PROCEDURE 1. Install the door module into the switch panel bezel until it snaps into place. 2. Install the switch panel bezel and module to the door panel. NOTE: Refer to Fastener Notice in Service Precautions. 3. Install the screw that retains the switch panel bezel (1) to the front door panel. Tighten Tighten the screw to 2 N.m (18 lb in). 4. Connect the electrical connectors. Interior - Erratic Memory Seat Operation Power Seat Control Module: All Technical Service Bulletins Interior - Erratic Memory Seat Operation Bulletin No.: 04-08-50-016C Date: August 12, 2005 TECHNICAL Subject: Memory Seat May Not Return to Requested Position (Reprogram Driver Seat Module) Models: 2003-2005 Cadillac Escalade, Escalade ESV, Escalade EXT 2003-2005 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2003-2005 GMC Sierra, Yukon, Yukon XL, Yukon Denali All with Seat FRT, Individual (Non BKT) (RPO AN3) 2003-2005 HUMMER H2 with Seat, Front Bucket Deluxe (RPO AR9) Supercede: This bulletin is being revised to update the correction information. Please discard Corporate Bulletin Number 04-08-50-016B (Section 08 - Body and Accessories). Condition Some customers may comment that with repeated cycling of the memory seat between the "exit" and one of the "presets", the position of the seat may "creep" forward or rearward out of expected adjustment. Cause There is a coding deficiency in the software for the memory seat module. Correction Technicians are to reprogram the driver seat module with an updated software calibration. The previous bulletin stated to use a service calibration that was released with TIS satellite data update version 4.5. Feedback has proved that calibration to be ineffective in eliminating the memory seat creep condition. An updated service calibration was released with TIS satellite data update version 6.5 available June 13, 2005. This new calibration has additional memory seat creep protection. As always, make sure your Tech 2(R) is updated with the latest software version. Important: After programming is complete, move the seat all the way rearward and down, then bump the seat slightly forward and up. This position will be just off the end of travel hard stops. Reset both memory seat exit positions at this position. Having the seat set at just off the hard stops will aid in reducing the creep condition. Warranty Information Page 13165 2. Skip to the next step if the vehicle to be upgraded is not shown above. 3. Skip to the next step if the vehicle to be upgraded is not a 2005 Cadillac STS. The 2005 Cadillac STS kit may include a new inside rearview (ISRV) mirror assembly and a new ISRV mirror wiring cover. If the kit you receive includes these parts, please remove the existing ISRV mirror and wire cover from the vehicle and install the ones provided in the kit per the instructions in SI. 4. Skip this step if the vehicle to be upgraded is not listed below. ^ 2003-2004 Saturn L-Series ^ 2003 Saturn ION ^ 2002-2003 Saturn VUE 1. Locate and remove the Right Audio output signal terminal 7 from Connector C2 at the Vehicle Communication Interface Module (VCIM). 2. Remove the terminal end and strip the wire. 3. Locate the Left Audio output signal wire from terminal 1 in Connector C2. 4. Splice the Right Audio output signal wire from terminal 7 with the Left Audio output signal wire from terminal 1. 5. See Wiring Repairs in SI for approved splicing methods. Page 14657 Power Seat Switch: Removal and Replacement Seat Switch Replacement - Power Removal Procedure 1. Remove the power seat switch bezel from the seat. 2. Remove the power seat switch to bezel screws. 3. Remove the power seat switch. Installation Procedure Notice: Refer to Fastener Notice in Service Precautions. 1. Install the power seat switch to bezel screws. Tighten the screws to 2 N.m (18 lb in). 2. Install the power seat switch bezel to the seat. Page 4885 7. Use the modified screw extractor in order to remove the plug. 8. Remove the parking pawl shaft retainer, shaft and pawl. 9. Important: If the manual shaft binds in the case during removal, file or sand the shaft in the area adjacent to the detent lever. Remove the manual shaft. 10. Remove the manual shaft seal. Installation Procedure 1. Install the pawl shaft. 2. Install the parking pawl. 3. Install the plug using a 8 mm or (5/16 inch) rod with Loctite® or equivalent. 4. Install the retainer. 5. Install the pawl return spring. 6. Install the detent lever to the actuator. 7. Install the actuator over the parking pawl. 8. Install the manual shaft seal. 9. Lubricate the manual shaft with transmission oil and install the manual shaft into the case. 10. Install the nut on the shaft. 11. Install the roll pin. 12. Notice: Refer to Fastener Notice in Service Precautions. Page 8911 Auxiliary Power Outlet: Connector Views Auxiliary Power Outlet - Bin (With RPO Code Y91) Page 645 7. Disconnect the BPMV electrical connector from the EBCM. 8. Clean the BPMV to EBCM mounting surfaces with a clean cloth. Installation Procedure Important: ^ Do not reuse the old mounting screws. Always install new mounting screws with the new EBCM. ^ Do not use RTV or any other type of sealant on the EBCM gasket or mating surfaces. 1. Connect the BPMV electrical connector to the EBCM. Page 6536 13. Ensure that the yellow identification band on the tube is hidden within the quick connect fitting. 14. A hidden yellow identification band indicates proper joint seating. 15. Fill the transmission to the proper level with DEXRON® III transmission fluid. Transmission Fluid Auxiliary Cooler Replacement Transmission Fluid Auxiliary Cooler Replacement Removal Procedure 1. Remove the grille assembly. 2. Remove the transmission fluid cooler hoses from the auxiliary cooler. 3. Remove the auxiliary oil cooler bolts (1). 4. Remove the auxiliary oil cooler push pins (2) 5. Remove the auxiliary oil cooler from the vehicle. Installation Procedure Page 7660 2. Important: Ensure the drain hole on the boot of the rear output shaft seal is facing down toward the ground. Using the J 37668-A, install the rear output shaft seal. 3. Install the rear propeller shaft. 4. Check the fluid level, add fluid if necessary. 5. Install the transfer case shield, if equipped. Transfer Case Input Shaft Seal Replacement Transfer Case Input Shaft Seal Replacement ^ Tools Required J 42738 Seal Installer Removal Procedure 1. Remove the transfer case. 2. using a flat-tipped screwdriver, remove the input shaft seal. Installation Procedure OnStar(R) - Cellular Antenna Replacement Parts Antenna, Navigation: All Technical Service Bulletins OnStar(R) - Cellular Antenna Replacement Parts Bulletin No.: 00-08-46-002A Date: April 12, 2005 INFORMATION Subject: OnStar(R) System Cellular Antenna Replacement Parts Availability Models: 1996-2005 Passenger Cars and Light Duty Trucks 2003-2005 HUMMER H2 with OnStar(R) and Glass Mounted Antennas Supercede: This bulletin is being revised to update the model years, models and parts information. Please discard Corporate Bulletin Number 00-08-46-002 (Section 08 - Body & Accessories). Replacement parts for the OnStar(R) system cellular antenna are available as follows: ^ Cellular Antenna Kit - If the antenna mast or exterior base is damaged or missing or if the antenna base has separated from the exterior glass surface. ^ Cellular Antenna Inner Coupling - If the antenna coupling on the inside of the glass requires replacement. Important: If glass replacement is required, both the Cellular Antenna Kit and the Cellular Antenna Inner Coupling are required. The kits listed contain all the necessary parts and instructions needed to properly install a new cellular antenna exterior base or interior coupling to the glass surface. To obtain maximum adhesion during installation, the instructions included in the kits must be followed carefully and exactly as written. Important: Do not attempt to reinstall the original cellular antenna exterior base or interior coupling using any type of glue, adhesive tapes, etc. Doing so may eliminate the cellular signal transfer through the glass and reduce the maximum performance of the system that includes air bag deployment notification. Important: To obtain maximum adhesion between the new cellular exterior base or interior coupling and the glass surface, the base, coupling and glass must be kept dry and above 15°C (60°F) during the installation and for the 24 hours immediately following the installation. Not keeping the vehicle dry and above the temperature listed for 24 hours may result in the new cellular antenna exterior base or interior coupling coming off. Parts Information Parts are currently available from GMSPO. Below Rear Seat (HP2) Below Rear Seat (HP2) Page 5288 next fill-up. 18. Advise the customer to change brands of fuel and to add GM Port Fuel Injector Cleaner every 5,000 km (3,000 mi). GM Port Fuel Injector Cleaner contains the same additives that the fuel companies are removing from the fuel to reduce costs. Regular use of GM Port Fuel Injector Cleaner should keep the customer from having to repeat the injector cleaning procedure. 19. Road test the vehicle to verify that the customer concern has been corrected. Locations Horn Switch: Locations Upper Steering Column Page 14045 Utility Storage Compartment: Service and Repair Tool Storage Compartment Cover Support Assembly Replacement Tool Storage Compartment Cover Support Assembly Replacement Removal Procedure 1. Open the lid of the tool storage box. Caution: Eye protection must be worn when drilling rivets to reduce the chance of personal injury. Important: The storage box lid has spring tension. Be sure to secure the lid when removing the support assembly, if the storage box is not inside the vehicle. 2. Remove the rivets (1) from the upper lid (2). 3. Remove the rivets (3) from the lower box (4). 4. Remove the support assembly from the tool storage box. Installation Procedure 1. Install the support assembly to the storage box. 2. Install the rivets (3) to the lower box (4). 3. Install the rivets (1) to the upper lid (2). 4. Close the lid on the tool storage box. Automatic Transmission - 4L60-E/4L65-E Transmission Position Switch/Sensor: Adjustments Automatic Transmission - 4L60-E/4L65-E Park/Neutral Position Switch Adjustment Important: ^ The following procedure is for vehicles that have not had the park/neutral position (PNP) switch removed or replaced. If the PNP switch has been removed or replaced, refer to Park/Neutral Position Switch Replacement for the proper adjustment procedure. ^ Apply the park brake. ^ The engine must start in the park (P) or neutral (N) positions only. ^ Check the PNP switch for proper operation. If adjustment is required, proceed as follows: 1. Place the transmission range selector in the neutral (N) position. 2. With an assistant in the drivers seat, raise and suitably support the vehicle. Refer to Vehicle Lifting. 3. Loosen the park/neutral position (PNP) switch bolts. 4. With the vehicle in the neutral (N) position, rotate the switch while the assistant attempts to start the engine. 5. Following a successful start, turn the engine off. 6. Notice: Refer to Fastener Notice in Service Precautions. ^ Tighten the PNP switch bolts. ^ Tighten the bolts to 25 Nm (18 ft. lbs.). 7. Lower the vehicle. 8. Check the PNP switch for proper operation. The engine must start in the park (P) or neutral (N) positions only. 9. Replace the PNP switch if proper operation can not be achieved. Page 14401 Front Passenger Door Module (FPDM) - C3 (With RPO Code YE9) Part 1 Page 10486 Page 4258 Intake Air Temperature (IAT)/Mass Air Flow (MAF) Sensor Brakes/Wheels - Excessive Debris Build Up Wheels: Customer Interest Brakes/Wheels - Excessive Debris Build Up Bulletin No.: 04-05-23-005 Date: June 22, 2004 INFORMATION Subject: Availability of Rear Wheel Mud Flaps to Reduce Debris Build-up on Rear Brake Calipers and/or Rear Wheels Models: 1999-2004 Chevrolet Silverado Pickup Models 1999-2004 GMC Sierra Pickup Models This bulletin is to inform dealers of the release of rear wheel mud flaps. The above models that are exposed to extensive off-paved roads may benefit from the mud flaps. The mud flaps have been developed to minimize the amount of stones and/or mud that can impact and collect on the rear caliper and/or wheel rim. Please advise customers that the installation of these mud flaps and following the recommended off-road driving information provided in their Owner's Manual should greatly reduce the possibility of accelerated rear brake component wear and/or rim damage. Install the mud flap forward of each rear wheel using the following procedure. Important: Always work from outboard to inboard, drilling one hole at a time and securing with a fastener. Follow the sequence of the procedure. This will prevent distortion of the mud flap. 1. Raise the vehicle. Support the vehicle. 2. Locate the pickup box side panel rear brace. 3. Remove the existing outboard upper fastener on the brace. 4. Install the mud flap through the "V" of the brace. Install the previously removed fastener in the hole (2) of the mud flap to the brace. Do not tighten the fastener at this time. 5. Using the mud flap as a template, locate and mark the location of the hole (1) in the pickup box wheel house. Page 13150 8.2. Remove the console (A) together with the OnStar(R) control modules. 8.3. Remove the connectors (B). Important: The optic cable must not be bent with a radius less than 25 mm (1 in). Important: Secure the wiring harness so that there is no risk of chafing and rattling. 8.4. Fold back the wiring harness and tape over the connectors (C). Fold back the wiring harness once more and secure with cable ties (D). Page 9410 Electrical Symbols Part 9 Page 11174 Heater Hose: Service and Repair Heater Hose Replacement - Outlet HEATER HOSE REPLACEMENT - OUTLET TOOLS REQUIRED J 43181 Quick Connect Connector Removal Tool REMOVAL PROCEDURE 1. Drain the cooling system. Refer to Draining and Filling Cooling System (with HP2)Draining and Filling Cooling System (without HP2) in Cooling System. 2. Remove the air intake tube. 3. Remove the heater and surge tank hose from the mounting clip. 4. Using the J 43181 disconnect the heater hose from the heater core outlet. 4.1. Install the J 43181 to the heater core pipe. 4.2. Close the tool around the heater core pipe. 4.3. Firmly pull the tool into the quick connect end of the heater hose. 4.4. Firmly grasp the heater hose. Pull the heater hose forward in order to disengage the hose from the heater core. 5. Remove the outlet heater hose from the engine. Page 8552 Yukon XL vehicles built within the VIN breakpoints shown. Important: Dealers should confirm vehicle eligibility through GMVIS (GM Vehicle Inquiry System) before beginning recall repairs. [Not all vehicles within the above breakpoints may be involved.] For US For dealers with involved vehicles, a Campaign Initiation Detail Report containing the complete Vehicle Identification Number, customer name and address data has been prepared and will be loaded to the GM DealerWorld, Recall Information website. Dealers that have no involved vehicles currently assigned will not have a report available in GM DealerWorld. For Canada For dealers with involved vehicles, a Campaign Initiation Detail Report containing the complete Vehicle Identification Number, customer name and address data has been prepared and is being furnished to involved dealers. Dealers that have no involved vehicles currently assigned will not receive a report with the recall bulletin. For Export For dealers with involved vehicles, a Campaign Initiation Detail Report containing the complete Vehicle Identification Number, customer name and address data has been prepared and is being furnished to involved dealers. Dealers that have no involved vehicles currently assigned will not receive a report with the recall bulletin. The Campaign Initiation Detail Report may contain customer names and addresses obtained from Motor Vehicle Registration Records. The use of such motor vehicle registration data for any other purpose other than follow-up necessary to complete this recall is a violation of law in several states/provinces/countries. Accordingly, you are urged to limit the use of this report to the follow-up necessary to complete this program. Parts Information A very small number of vehicles (less than 90 world-wide) will require the replacement of the hydraulic brake booster. Do not order boosters for shelf stock. When a replacement is required, order the appropriate booster from GMSPO. All replaced boosters (excluding Export) must be returned to the Warranty Parts Center. Hold the booster until you receive the request for return. Special Tool Beginning February 18, 2005, each dealer was shipped a Hydro-Boost Checking Tool, CH 47950, for use in this recall. This tool is being furnished at no charge. Additional tools, if required, may be purchased by contacting SPX Kent-Moore at 1-800-468-6657. Courtesy Transportation The General Motors Courtesy Transportation program is intended to minimize customer inconvenience when a vehicle requires a repair that is covered by the New Vehicle Limited Warranty. The availability of courtesy transportation to customers whose vehicles are within the warranty coverage period and involved in a product recall is very important in maintaining customer satisfaction. Dealers are to ensure that these customers understand that shuttle service or some other form of courtesy transportation is available and will be provided at no charge. Dealers should refer to the General Motors Service Policies and Procedures Manual for Courtesy Transportation guidelines. Page 926 Door Control Module Diagram 2 Part 2 Service and Repair Parking Brake Warning Switch: Service and Repair Park Brake Warning Lamp Switch Replacement Removal Procedure 1. Caution: Refer to Battery Disconnect Caution in Service Precautions. Disconnect the negative battery cable. 2. Remove the MID-bussed electrical center from the bracket. 3. Disconnect the park brake warning lamp switch electrical connector. 4. Remove the park brake warning lamp switch mounting bolt. 5. Remove the park brake warning lamp switch. Installation Procedure Page 389 5. Choose the outstanding core you wish to process, by selecting the Virtual Core Button on the far right side of the screen. 6. Enter the information in the required fields and select the submit button. Record the confirmation number. Canadian Dealers 1. Return the removed Analog / Digital-Ready OnStar(R) VCIM to the Parts Manager. 2. The Parts Manager will log onto https://adt.onstar.gm.mass.ca and enter information as prompted. All Dealers If the website indicates that the VCIM needs to be physically returned to the distributor, please use the pre-paid shipping label that was included in the kit to return the removed VCIM. Important: To avoid a $250 core non-return charge, you must do one of the following within 30 days of kit shipment: 1. Submit the necessary VCIM data through the website, as indicated above. 2. Mail the removed core from the customer's vehicle back to the distributor. 3. Return the unused digital upgrade kit back to the distributor using the pre-paid shipping label that is included in the kit box. Returning the Upgraded Vehicle to the Customer Returning the Upgraded Vehicle to the Customer 1. Place the new OnStar Subscriber Information (Owner's Manual kit) in the customer's vehicle where they can review some of the new features of the Digital-Capable system. The continuous digit dialing feature should be highlighted to the customer to avoid a return to the dealership for dialing instructions. Advise the customer to discard any existing OnStar(R) Owner's Manuals that may be in the vehicle. 2. Have the Service Advisor, Service Manager or Sales Consultant review the new OnStar(R) Hands-Free Calling procedure with the customer. The customer is uses to their analog OnStar(R) Hands-Free Calling system, which uses individual digit dial to make a call. The Generation 6 Digital-Capable system uses continuous digit dial, and the customer needs to be made aware of this change. 3. U.S. Dealers Only: Staple the "Tip Sheet - OnStar(R) Generation 6 Digitally-Capable System", that was included in the kit, to the customer's copy of the repair order. This tip sheet will help your customer better understand their new OnStar(R) system. 4. Canadian Dealers Only: Refer the customer to the Hands-Free Calling Quick Review Card from the new OnStar(R) Owner's Manual kit for help with the new dialing procedure. 5. Fill out the form entitled "GM Limited Warranty for Upgraded OnStar(R) Digital Equipment Program Participants" and staple a copy of this to the customer's repair order. You may want to keep a copy for your records. 6. Encourage your customer to press their blue OnStar(R) button the next day. The OnStar(R) Advisor will be able to review some of the new features of their digital OnStar(R) system. Closing the Onstar(R) Upgrade Exchange Closing the OnStar(R) Upgrade Exchange 1. Collect payment from the customer. Your dealership's open account (sales) will be charged for the cost of the chosen subscription plan, any applicable subscription taxes, and the $15 upgrade charge after the vehicle has been configured through the TIS2WEB process. 2. None of the costs associated with the OnStar Digital Upgrade program may be claimed as a GM goodwill event. These costs must be paid by the customer, and may not be included in any goodwill offered to the customer. GM employees or representatives or field personnel are not able to offer goodwill for this program. If the dealership decides to pay for the upgrade for their customer, be aware that your GM or OnStar(R) contact will not be able to reimburse you for this cost. 3. Use labor code Z2096 to submit your claim for the labor time published below plus 0.2 hr Administrative Allowance and an additional $20.00 Net Amount. ^ For all dealer claim submissions (excluding U.S. Saturn), use Complaint Code MH - Technical Bulletin, and Failure Code 93 - Technical Service Bulletin. Page 16023 When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage TESTING FOR A SHORT TO VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity TESTING FOR CONTINUITY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents TESTING FOR ELECTRICAL INTERMITTENTS Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground - Testing for Continuity - Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 msRECORD and emits an audible tone (beep). Page 9936 Alignment: Specifications Fastener Tightening Specifications Fastener Tightening Specifications Description and Operation Malfunction Lamp / Indicator: Description and Operation AIR BAG INDICATOR The AIR BAG indicator, located on the instrument panel cluster (IPC) is used to notify the driver of SIR system malfunctions and to verify that the sensing and diagnostic module (SDM) is communicating with the IPC. When the ignition is turned ON, the SDM is supplied with ignition 1 voltage and requests the IPC to flash the AIR BAG indicator 7 times. While flashing the indicator, the SDM conducts test on all SIR system components and circuits. If no malfunctions are detected the SDM will communicate with the IPC through the class 2 serial data circuit and request the IPC to turn the AIR BAG indicator OFF. The SDM provides continuous monitoring of the air bag circuits by conducting a sequence of checks. If a malfunction is detected the SDM will store a DTC and request the IPC to turn the AIR BAG indicator ON. The presence of a SIR system malfunction could result in non-deployment of the air bags. The AIR BAG indicator will remain ON until the malfunction has been repaired. Page 1486 Fog/Driving Lamp Switch: Service and Repair Fog Lamp Switch Replacement - Rear FOG LAMP SWITCH REPLACEMENT - REAR REMOVAL PROCEDURE 1. Remove the instrument panel bezel. 2. Pull out the accessary switch housing. 3. Disconnect the electrical connectors. 4. Remove the fog lamp switch from the accessary switch housing. INSTALLATION PROCEDURE 1. Install the fog lamp switch into accessary switch housing. 2. Connect the electrical connectors. 3. Install the accessary switch housing. 4. Install the instrument panel bezel. Page 8380 5. Install the park brake cable taking care to correctly route the cable though the guides and the body mounts. 6. Pull down on the park brake cable in front of the equalizer and install the left park brake cable to the equalizer bar. 7. Remove the safety stands. 8. Lower the vehicle. Page 10909 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. REPLACEMENT PROCEDURE After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Insure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the Terminal Removal Procedure. Repairing Connector Terminals REPAIRING CONNECTOR TERMINALS TOOLS REQUIRED J 38125-D Terminal Repair Kit Use the following repair procedures in order to repair the following: - Push to Seat terminals - Pull to Seat terminals - Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-D contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100 World terminals. Soldering Micro-Pack 100 World terminals may damage the terminal. Circuit Protection - Circuit Breakers CIRCUIT PROTECTION - CIRCUIT BREAKERS A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Page 12099 Page 12421 Memory/Heated Seat Switch - Driver (DDM C5) Part 1 Page 12612 ^ For U.S. Saturn retailer claim submission, use Net Item code "M" and Case Type VW. Page 15162 7. Insert the J 38125-13A (GM P/N 12031876-1) tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the Terminal Repair Kit to ensure that the correct release tool is used. 8. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. REPAIR PROCEDURE Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. Page 2993 Provide all information required on the form. Make a copy of the completed form for the customer to keep in the vehicle along with their Owner's Manual. File the original completed form in the Dealership's Vehicle Service History folder. Because this is not a warranty repair, dealers will incur a charge to obtain a VCI number. A VCI number will only be available for the following models: 1999-2007 Chevrolet Silverado and GMC Sierra (1500 Series Only) EXCLUDES 1999-2000 vehicles equipped with 4.3L engine (RPO L35) EXCLUDES vehicles equipped with Quadrasteer (RPO NYS) EXCLUDES Parallel Hybrid Truck (RPO HP2) EXCLUDES 2001-2004 vehicles equipped with Traction Control (RPO NW7) combined with 3.42 Axle Ratio (RPO GU6) Refer to the Model Application Chart to in the beginning of this bulletin to verify usage. Calibrations are not available for 1999 and 2000 model year vehicles with 3.08 axle. Calibrations are not available for 1999 and 2000 model year vehicles equipped with 4.3L engine (RPO L35). If original equipment tires/wheels are reinstalled, it will be necessary to reset the programming of the PCM and the ABS module to the original specifications. Labels After installing the recommended P275/55R20 tires, place the provided label on the vehicle. The label should be located on the doorjamb, near the original tire label, and should not cover up the original tire label. Be sure that the surface is clean and dry. The surface temperature should not be less than 21°C (70°F). The label is provided as a guide for tire inflation pressures and information relevant to occupant/cargo capacities. Page 7289 For vehicles repaired under warranty, use the table. Disclaimer Page 3809 - Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-D in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-D if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Page 10195 24. From the technicians point of view, the FRONT of the sensor will have: ^ A flush rotor flange cuff (4) ^ A pin hole (2) for the centering pin. Note the location of the pin hole. ^ An alignment mark (3) on the flush rotor flange cuff (4) for installation ^ A foam ring (1) 25. Remove the connector from the sensor. 26. Remove the sensor from the adapter and bearing assembly. 27. To install the sensor, proceed to step 21 in the installation procedure. Installation Procedure 1. Important: If reusing the existing sensor, no centering of the sensor is required. If installing a new sensor, it will come with a pin installed in the sensor. Do not remove the pin until the sensor is seated. 2. From the technicians point of view, the FRONT of the sensor (1) connector will be on your right.From the technicians point of view, the BACK of the sensor (2) connector will be on your left. 3. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install into the adapter and bearing assembly. 4. Install the connector to the sensor. 5. From the technicians point of view, the FRONT of the sensor will have: ^ A foam ring (4) ^ A pin hole (7) for the centering pin. Note the location of the pin hole. ^ A flushed rotor flange cuff (6) ^ An alignment mark (5) for installation 6. From the technicians point of view, the BACK of the sensor will have: ^ Double D flats (1) Page 12977 Speaker: Service and Repair Speaker Replacement - Front Floor Console SPEAKER REPLACEMENT - FRONT FLOOR CONSOLE (SUBWOOFER SPEAKER) REMOVAL PROCEDURE 1. Remove the 2 front seats. 2. Move the center console rearward slightly in order to disconnect the wire connector. 3. Move the console rearward to gain access to the subwoofer speaker. 4. Remove the 4 retaining bolts from the speaker. 5. Disconnect the wire connector. 6. Remove the speaker from the subwoofer assembly. INSTALLATION PROCEDURE 1. Install the speaker into the subwoofer assembly. 2. Connect the wire connector. NOTE: Refer to Fastener Notice in Service Precautions. 3. Install the 4 retaining screws. Ensure the screw follows the same thread in the screw boss so that a new thread is not formed. Tighten Tighten the screws to 6 N.m (53 lb in). 4. Move the console forward in order to connect the wire connector. 5. Install the console to the I/P. 6. Install the 2 front seats. Speaker Replacement - Front SPEAKER REPLACEMENT - FRONT (WINDSHIELD PILLAR SPEAKER) REMOVAL PROCEDURE 1. Remove the windshield garnish molding (2). Page 6299 Fluid Pump: Technical Service Bulletins A/T - 4L65E, 4L60E, 4L60, 200-4R Oil Pump Spring Bulletin No.: 04-07-30-006 Date: February 11, 2004 INFORMATION Subject: 4L65-E, 4L60-E, 4L60 and 200-4R Automatic Transmission Oil Pump Spring First and Second Design Identification Models: 2004 and Prior Passenger Cars and Light Duty Trucks 2003-2004 HUMMER H2 with 4L65-E, 4L60-E, 4L60 or 200-4R Automatic Transmission The purpose of this bulletin is to identify the oil pump spring usage for the two different pump designs. Manufacturing of the first design oil pump springs ended December 15, 2003. Manufacturing of the second design oil pump spring began December 16, 2003 The first design oil pump springs (206) and (207) DO NOT have any identification markings. The first design springs (206) and (207) use an inner and outer spring, two springs. The second design oil pump spring (245) is identified with tapered ends on the spring (245) as shown above. The second design spring (245) is a single spring. When servicing either (first design or second design) oil pump body, use the new single oil pump spring (245) with tapered ends. Page 16230 Quarter Window Glass: Service and Repair Quarter Window Replacement Tools Required * J 24402-A Glass Sealant Cold Knife Remover * J 39032 Stationary Glass Removal Tool * Urethane Adhesive Kit GM P/N 12346392 or Equivalent * Isopropyl Alcohol or Equivalent * Cartridge-type Caulking Gun * Commercial-type Utility Knife * Razor Blade Scraper * Suction Cups * Plastic Paddle Removal Procedure Caution: If a window is cracked but still intact, crisscross the window with masking tape in order to reduce the risk of damage or personal injury. Important: Before cutting out a stationary window, apply a double layer of masking tape around the perimeter of the painted surfaces and the interior trim. 1. Open the side access door. 2. Remove the side access door trim, if equipped. Caution: When working with any type of glass or sheet metal with exposed or rough edges, wear approved safety glasses and gloves in order to reduce the chance of personal injury. Important: Keep the cutting edge of the tool against the window. This will allow the urethane adhesive to be separated from the window. 3. If the original reveal molding on the window is damaged it must be replaced, if equipped. * Leave a base of urethane on the pinchweld flange. * The only suitable lubrication is clear water. * Use J 24402-A, J 39032 or equivalent in order to remove the window. 4. With the aid of an assistant, remove the window from the opening. Installation Procedure 1. Install a stationary window into the opening. 2. Install the side access door trim, if equipped. 3. Remove the double layer of masking tape around the perimeter of the painted surfaces and the interior trim. Page 10052 3. Notice: Refer to Power Steering Hose Disconnected Notice in Service Precautions. Install a drain pan under the vehicle. 4. Remove the power steering gear inlet hose (3) from the power steering pump (1). 5. Remove the power steering gear inlet hose from the power steering gear. 6. Remove the power steering gear inlet hose from the vehicle. Installation Procedure 1. Notice: Refer to Installing Hoses Without Twists or Bends Notice in Service Precautions. Route the hose in the same position the hose occupied prior to removal. 2. Install the power steering gear inlet hose (3) to the power steering pump (1). Hand tighten only. 3. Notice: Refer to Fastener Notice in Service Precautions. Install the power steering gear inlet hose to the power steering gear. ^ Tighten both power steering gear inlet hose fittings to 28 Nm (20 ft. lbs.). 4. Remove the drain pan from under the vehicle. 5. Install the engine protection shield. 6. Lower the vehicle. 7. Bleed the power steering system. Refer to Bleeding the Power Steering System. (Recirculating Ball) Power Steering Gear Outlet Pipe/Hose Replacement (Recirculating Ball) Removal Procedure Page 5862 1. Notice: Refer to Fastener Notice in Service Precautions. Install the left rear speed sensor. ^ Tighten the speed sensor to 15 Nm (11 ft. lbs.). 2. Connect the left rear speed sensor electrical connector (4) 3. Lower the vehicle. Transfer Case Speed Sensor Replacement - Right Rear Transfer Case Speed Sensor Replacement - Right Rear Removal Procedure 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. Disconnect the right rear speed sensor electrical connector (3). Page 5740 Pay particular attention to the terminal connections at the module. Spread or open terminal connections may create an intermittent contact. Do a pin drag test. Refer to the terminal testing information in the table shown. ^ After repairs are complete, ALWAYS clear DTCs from the module prior to a system function test. If codes are not cleared first, the system will not function after repair. The technician may erroneously think that the system is still down and that further repairs are needed. Warranty Dealers who unnecessarily replace the TCCM that are found to have No Trouble Found (NTF) at the WPC will be returned to the AVM (Area Service Manager), or the DSM (District Service Manager) in Canada, through the Regional Feedback Process and may be charged back for the repair through the WINS system. Disclaimer Page 10916 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Page 5364 17. Connect the negative battery cable. 18. Perform the following procedure in order to inspect for leaks. 18.1. Turn the ignition ON, with the engine OFF, for 2 seconds. 18.2. Turn the ignition OFF for 10 seconds. 18.3. Turn the ignition ON, with the engine OFF. 18.4. Inspect for fuel leaks. Crossmember Replacement - Front Engine (4WD) Cross-Member: Service and Repair Crossmember Replacement - Front Engine (4WD) Crossmember Replacement - Front Engine (4WD) Removal Procedure 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Remove the differential carrier shield. 3. Remove the bolts retaining the crossmember to the frame. 4. Remove the crossmember from the vehicle. Installation Procedure Page 15614 Door Latch Assembly (Door Jamb Switch) - Driver - C2 Page 10344 1. Install the crossmember to the vehicle. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the bolts retaining the crossmember to the frame. Tighten the crossmember retaining bolts to 120 N.m (88 lb ft). 3. Install the differential carrier shield. 4. Lower the vehicle. Page 3970 Fuel Level Sensor: Service and Repair Fuel Level Sensor Replacement - 2 FUEL LEVEL SENSOR REPLACEMENT REMOVAL PROCEDURE 1. Remove the sending unit. 2. Disconnect the fuel pump electrical connector. 3. Remove the fuel level sensor electrical connector retaining clip. 4. Disconnect the fuel level sensor electrical connector. Page 8849 1. If equipped with a 8.1L engine, install the starter heat shield. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the starter heat shield bolts, and nut. Tighten Tighten the bolts to 3 N.m (35 lb in). - Tighten the nut to 5 N.m (44 lb in). 1. If equipped with a 4.8L, 5.3L, or 6.0L engine, install the starter heat shield. 2. Install the starter motor. Page 483 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground TESTING FOR SHORT TO GROUND NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting With A Digital Multimeter TROUBLESHOOTING WITH A DIGITAL MULTIMETER NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TROUBLESHOOTING WITH A TEST LAMP Page 5105 Evaporative Emissions Hose: Service and Repair EVAP System Hoses/Pipes Replacement Cab/Chassis) EVAPORATIVE EMISSION (EVAP) SYSTEM HOSES/PIPES REPLACEMENT (PICKUP AND CAB/CHASSIS) REMOVAL PROCEDURE IMPORTANT: Clean the evaporative emission (EVAP) pipe connections and surrounding area prior to disconnecting the fittings in order to avoid possible fuel system contamination. 1. Remove the fuel tank. 2. Disconnect and remove the EVAP purge line (2) from the sending unit and retaining clips. 3. Disconnect and remove the EVAP fuel level vent valve (FLVV) line (3) from the sending unit and retaining clips. 4. Cap the fuel feed and EVAP openings in order to prevent possible fuel/EVAP system contamination. INSTALLATION PROCEDURE 1. Remove the caps from the fuel feed and EVAP lines. 2. Install and connect the EVAP FLVV line (3) line to the sending unit and retaining clips. 3. Install and connect the EVAP purge line (2) to the sending unit and retaining clips. 4. Install the fuel tank. EVAP System Hoses/Pipes Replacement EVAPORATIVE EMISSION (EVAP) SYSTEM HOSES/PIPES REPLACEMENT REMOVAL PROCEDURE IMPORTANT: Clean the evaporative emission (EVAP) line connections and surrounding areas prior to disconnecting the fittings in order to avoid possible fuel system contamination. Page 4508 9. Use J 38125-12A to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. REPAIR PROCEDURE The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. 1. Cut the wire as close to the terminal as possible. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. Wheels - Changing Procedures/Precautions Wheels: All Technical Service Bulletins Wheels - Changing Procedures/Precautions INFORMATION Bulletin No.: 06-03-10-010A Date: June 09, 2010 Subject: Information on Proper Wheel Changing Procedures and Cautions Models: 2011 and Prior GM Passenger Cars and Trucks 2010 and Prior HUMMER Models 2005-2009 Saab 9-7X 2005-2009 Saturn Vehicles Attention: Complete wheel changing instructions for each vehicle line can be found under Tire and Wheel Removal and Installation in Service Information (SI). This bulletin is intended to quickly review and reinforce simple but vital procedures to reduce the possibility of achieving low torque during wheel installation. Always refer to SI for wheel lug nut torque specifications and complete jacking instructions for safe wheel changing. Supercede: This bulletin is being revised to include the 2011 model year and update the available special tool list. Please discard Corporate Bulletin Number 06-03-10-010 (Section 03 Suspension). Frequency of Wheel Changes - Marketplace Driven Just a few years ago, the increasing longevity of tires along with greater resistance to punctures had greatly reduced the number of times wheels were removed to basically required tire rotation intervals. Today with the booming business in accessory wheels/special application tires (such as winter tires), consumers are having tire/wheel assemblies removed - replaced - or installed more than ever. With this increased activity, it opens up more of a chance for error on the part of the technician. This bulletin will review a few of the common concerns and mistakes to make yourself aware of. Proper Servicing Starts With the Right Tools The following tools have been made available to assist in proper wheel and tire removal and installation. - J 41013 Rotor Resurfacing Kit (or equivalent) - J 42450-A Wheel Hub Resurfacing Kit (or equivalent) Corroded Surfaces One area of concern is corrosion on the mating surfaces of the wheel to the hub on the vehicle. Excessive corrosion, dirt, rust or debris built up on these surfaces can mimic a properly tightened wheel in the service stall. Once the vehicle is driven, the debris may loosen, grind up or be washed away from water splash. This action may result in clearance at the mating surface of the wheel and an under-torqued condition. Caution Before installing a wheel, remove any buildup on the wheel mounting surface and brake drum or brake disc mounting surface. Installing wheels with poor metal-to-metal contact at the mounting surfaces can cause wheel nuts to loosen. This may cause a wheel to come off when the vehicle is moving, possibly resulting in a loss of control or personal injury. Whenever you remove the tire/wheel assemblies, you must inspect the mating surfaces. If corrosion is found, you should remove the debris with a die grinder equipped with a fine sanding pad, wire brush or cleaning disc. Just remove enough material to assure a clean, smooth mating surface. The J 41013 (or equivalent) can be used to clean the following surfaces: - The hub mounting surface - The brake rotor mounting surface - The wheel mounting surface Use the J 42450-A (or equivalent) to clean around the base of the studs and the hub. Lubricants, Grease and Fluids Page 11681 Seat Sensor/Switch: Diagrams Inflatable Restraint Seat Position Switch - Left (With RPO Code AL0) Page 4380 Crankshaft Position Sensor: Service and Repair Crankshaft Position (CKP) Sensor Replacement CRANKSHAFT POSITION (CKP) SENSOR REPLACEMENT REMOVAL PROCEDURE IMPORTANT: Perform the CKP System Variation Learn Procedure whenever the crankshaft position sensor is removed or replaced. 1. Remove the starter. 2. Disconnect the crankshaft position (CKP) sensor electrical connector. 3. Clean the area around the CKP sensor before removal in order to avoid debris from entering the engine. 4. Remove the CKP sensor bolt. 5. Remove the CKP sensor. INSTALLATION PROCEDURE Page 4533 Data Link Connector (DLC) Diagram 5 Page 2118 Spark Plug: Testing and Inspection SPARK PLUG INSPECTION - Verify that the correct spark plug is installed. An incorrect spark plug causes driveability conditions. Refer to Ignition System Specifications for the correct spark plug. - Ensure that the spark plug has the correct heat range. An incorrect heat range causes the following conditions: Spark plug fouling - Colder plug - Pre-ignition causing spark plug and/or engine damage - Hotter plug - Inspect the terminal post (1) for damage. Inspect for a bent or broken terminal post (1). - Test for a loose terminal post (1) by twisting and pulling the post. The terminal post (1) should not move. - Inspect the insulator (2) for flashover or carbon tracking, or soot. This is caused by the electrical charge traveling across the insulator (2) between the terminal post (1) and ground. Inspect for the following conditions: Inspect the spark plug boot for damage. - Inspect the spark plug recess area of the cylinder head for moisture, such as oil, coolant, or water. A spark plug boot that is saturated will cause arcing to ground. Page 10121 Rear Wheel Steering Actuator: Service and Repair Steering Gear Actuator and Cover Replacement Steering Gear Actuator and Cover Replacement Removal Procedure 1. Notice: Refer vehicle Lifting. Raise the vehicle. Refer to Vehicle Lifting. 2. Remove the tire and wheel. 3. Remove the drain plug (2) and drain the fluid from the differential housing. 4. Remove the bolts (3) retaining the steering gear protection shield. 5. Disconnect the electrical connectors from the control module (2). 6. Disconnect the electrical connector (1) from the rear position sensor. 7. Remove the outer tie rod ends from the steering knuckle. Refer to Rear Wheel Steering Tie Rod End Replacement - Outer. Page 16142 Refer to the table as a guide in selecting the correct test adapter for frontprobing connectors: Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure SCAN TOOL SNAPSHOT PROCEDURE Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: - Snapshot - taken from the Snapshot menu choice - Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information Page 1102 1. Connect the brake pedal position sensor (2) electrical connector (1). 2. Align the brake pedal position sensor (1) with the actuation arm (2) on the brake pedal and the brake pedal position sensor mounting bracket. Page 12171 2007 Model Year Vehicles and Newer all have Digital OnStar(R) Modules. Part 1 OnStar(R) Description and Operation This OnStar(R) digital system consists of the following components: ^ Vehicle Communication Interface Module (VCIM) ^ OnStar(R) button assembly ^ Microphone ^ Cellular antenna ^ Navigation antenna Note This system also interfaces with the factory installed vehicle audio system. Vehicle Communication Interface Module (VCIM) The vehicle communication interface module (VCIM) is a cellular device that allows the user to communicate data and voice signals over the national cellular network. Power is provided by a dedicated, fused B+ circuit. Ground is provided through the vehicle wiring harness attached to the module. The ignition state is determined by the VCIM through serial data messaging. Dedicated circuits are used to connect the VCIM to a microphone, the button assembly, and to command the status LED. The VCIM communicates with the rest of the vehicle modules using the serial data bus. The module houses 2 technology systems, one to process GPS data, and another for cellular information. The cellular system connects the OnStar(R) system to the cellular carrier's communication system by interacting with the national cellular infrastructure. The module sends and receives all cellular communications over the cellular antenna and cellular antenna coax. GPS satellites orbiting earth are constantly transmitting signals of their current location. The OnStar(R) system uses the GPS signals to provide location on demand. The module also has the capability of activating the horn, initiating door lock/unlock, or activating the exterior lamps using the serial data circuits. These functions can be commanded by the OnStar(R) Call Center per: a customer request. OnStar(R) Button Assembly The OnStar(R) button assembly may be part of the rearview mirror, or a separate, stand alone unit. The button assembly is comprised of 3 buttons and a status LED. The buttons are defined as follows: ^ The answer/end call button, which is black with a white phone icon, allows the user to answer and end calls or initiate speech recognition. ^ The blue OnStar(R) call center button, which displays the OnStar(R) logo, allows the user to connect to the OnStar(R) call center. ^ The emergency button, which displays a white cross with a red background, sends a high priority emergency call to the OnStar(R) call center when pressed. The VCIM supplies 10 volts to the OnStar(R) button assembly on the keypad supply voltage circuit. When pressed, each button completes a circuit across a resistor allowing a specific voltage to be returned to the VCIM on the keypad signal circuit. Depending upon the voltage range returned the VCIM is able to identify which button has been pressed. The OnStar(R) status LED is located with the button assembly. The LED is green when the system is ON and operating normally. When the status LED is green and flashing, it is an indication that a call is in progress. When the LED is red, this indicates a system malfunction is present. In the event there is a system malfunction and the OnStar(R) system is still able to make a call, the LED will flash red during the call. If the LED does not illuminate, this may indicate that the customers OnStar(R) subscription is not active or has expired. Push the blue OnStar button to connect to an advisor who can then verify the account status. Each LED is controlled by the VCIM over dedicated LED signal circuits. Ground for the LED is provided by the wiring harness attached to the button assembly. Page 11324 Parts required to complete this special coverage are to be obtained from General Motors Customer Care and Aftersales (GMCC&A;). Service Procedure Note The resistor module connector and blower motor resistor will need to be replaced if one or more of the symptoms below is present. - The HVAC blower may not function on certain or all blower speed settings - A burning plastic smell or smoke may be present in the vehicle - The HVAC blower may run continually with the ignition in the OFF position Determine if one or more of the above symptoms is present. If required refer to HVAC diagnostic information in SI. Refer to Resistor Module Connector and Blower Motor Resistor Replacement in this bulletin if one or more of the symptoms is present. Other HVAC repairs are NOT covered in this product safety special coverage bulletin. Resistor Module Connector and Blower Motor Resistor Replacement 1. Remove the blower fuses (Htr A/C & HVAC 1 fuses). 2. Lower the close-out panel enough to gain access to the resistor module connector. 3. Disconnect the connector from the resistor module. Note Connector replacement is required even if the connector was replaced on a previous service repair. 4. Remove the tape from the wiring harness to expose the wiring. 5. Cut the wires back far enough from the connector to eliminate any melted insulation on the wire. Note Use the old connector as a map for splicing the wires for the new connector. Be sure to use the correct crimping tool from the terminal repair kit J 38125. Use only Duraseal splice sleeves. Other splice sleeves may not protect the splice from moisture or provide a good electrical connection. 6. Install the new connector. Use the yellow splice sleeves provided with the connector. 7. Install the new blower motor resistor. 8. Reinstall the fuses. Test the blower motor to make sure all speeds are functional. 9. Reinstall the hush panel/close-out panel. Customer Reimbursement Customer requests for reimbursement of previously paid repairs to correct the condition described in this bulletin are to be submitted to the dealer prior to or by December 31, 2012. Repairs must have occurred within the 10 years of the date the vehicle was originally placed in service, or 240,000 kilometres, whichever occurs first. When a customer requests reimbursement, they must provide the following: Page 5104 Evaporative Emissions Hose: Service and Repair EVAP Hoses/Pipes Replacement - Engine EVAPORATIVE EMISSION (EVAP) HOSES/PIPES REPLACEMENT - ENGINE REMOVAL PROCEDURE IMPORTANT: Clean the evaporative emission (EVAP) line connections and surrounding areas prior to disconnecting the fittings in order to avoid possible system contamination. 1. Remove the engine sight shield. 2. Disconnect the EVAP tube from the EVAP canister purge solenoid (1). 2.1. Push the large side white retainer portion in. 2.2. Push down, while pulling up slightly in order to disengage the tube. 3. Disconnect the EVAP tube from the chassis EVAP pipe (2). 3.1. Push the large side white retainer portion in. 3.2. Push down, while pulling up slightly in order to disengage the tube. 4. Remove the EVAP tube. 5. Cap the EVAP canister purge solenoid and EVAP chassis pipe in order to prevent possible EVAP system contamination. INSTALLATION PROCEDURE 1. Remove the caps from the EVAP canister purge solenoid and EVAP chassis pipe. 2. Install the EVAP tube. 3. Connect the EVAP tube to the EVAP chassis pipe (2). 4. Connect the EVAP tube to the EVAP purge solenoid (1). 5. Install the engine sight shield. Page 410 2. Install the module on the bracket. NOTE: Refer to Fastener Notice in Service Precautions. 3. Install the retaining nuts (2). Tighten Tighten the nuts to 1.6 N.m (14 lb in). 4. Connect the coaxial cable (3) to the module. 5. Connect the wire connectors (2) to the module. 6. Install the I/P trim panel. IMPORTANT: After replacing the vehicle communication interface module, you must reconfigure the Onstar(R) system. Failure to reconfigure the system will result in an additional customer visit for repair. In addition, pressing and holding the white dot button on the keypad will NOT reset this version of the Onstar(R) system. This action will cause a DTC to set. 7. Reconfigure the Onstar(R) system. Refer to OnStar Reconfiguration. See: Testing and Inspection/Programming and Relearning Page 16268 Washer Fluid Level Switch Page 14435 Disclaimer Page 14825 3. Take one of the adhesive sachets and carefully cut the flag tip off the notched end spout in line with the notch. 4. While holding the sachet vertical, slowly dribble the adhesive into the edge of the bolt hole as shown, ensuring that the adhesive flows into the joint between the seat rail and the zinc block. DO NOT pour the adhesive down the center of the hole. The object is to let the adhesive "wick" between the zinc block and the seat rail in order to bond the two pieces together. Important: If the bolt thread strips or the proper torque cannot be achieved, then the entire seat adjuster mechanism must be replaced. 5. Replace the previous bolt with a new M8 bolt (1) (included) and install using a "click torque wrench" preset to 9 N.m (79 lb in). 6. Remove the second M8 mounting bolt from the rail and discard. 7. Repeat steps 2 through 5 for the second bolt. 8. Repeat steps 2 through 6 for the opposite mounting rail. 9. Before installing the seat into the vehicle, verify that the seat will function correctly and does not make any unusual noises during forward and rearward travel motion. 10. Install the seat. Refer to the applicable Seats sub-section of SI. 11. While sitting in the seat, verify seat function and listen for any unusual noises. Page 1607 Manifold Pressure/Vacuum Sensor: Service and Repair MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR REPLACEMENT REMOVAL PROCEDURE 1. Remove the engine sight shield. 2. Disconnect the manifold absolute pressure (MAP) sensor electrical connector (1). 3. Remove the MAP sensor (1). INSTALLATION PROCEDURE IMPORTANT: Lightly coat the MAP sensor seal with clean engine oil before installing the sensor. 1. Install the MAP sensor (1). Page 13730 1. Install the weatherstrip (1) to the door opening flange. 2. Install the rear quarter trim panel. 3. Install the center pillar molding. 4. Install the rear door sill plate. 5. Close the rear door. OnStar(R) - Loss of GPS Signal/Hands Free Issues Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Loss of GPS Signal/Hands Free Issues Bulletin No.: 02-08-46-007C Date: November 19, 2007 INFORMATION Subject: Information on OnStar(R) System - Possible Loss of GPS Signal, Hands-Free Calling Minutes Expire Prematurely and/or Inability to Add Hands-Free Calling Minutes Models: 2001-2008 GM Passenger Cars and Light Duty Trucks (Including Saturn) 2003-2008 HUMMER H2 2006-2008 HUMMER H3 2005-2008 Saab 9-7X with OnStar(R) System (RPO UE1) Supercede: This bulletin is being revised to add the 2008 model year, warranty information and to provide GPS signal recovery steps (under Dealer Action heading) to do PRIOR to determining if the VIU/VCIM needs replacement. Please discard Corporate Bulletin Number 02-08-46-007B (Section 08 - Body & Accessories). If the vehicle currently has analog-upgradable OnStar(R) hardware, then the customer should be made aware of the digital upgrade program per the latest version of Service Bulletin # 05-08-46-006. Any analog OnStar system that is not upgraded prior to the end of 2007 will be deactivated due to the upcoming phase-out of the analog cellular network in the U.S. and Canada. If the vehicle has recently been upgraded or has had a service replacement unit installed, this bulletin may not be applicable. Certain 2001-2008 model year vehicles equipped with OnStar(R) may exhibit a condition with the Global Positioning System (GPS) that causes inaccuracies in the GPS clock. The GPS system is internal to the OnStar(R) Vehicle Interface Unit (VIU) or the Vehicle Communication Interface Module (VCIM). This inaccuracy can result in a symptom where the OnStar(R) Call Center is unable to obtain an accurate GPS signal, hands-Free Calling minutes expire prematurely and/or the inability to add Hands-Free calling minutes. Customer Notification OnStar(R) will notify the customer by mail with instructions to contact their dealership service department. Dealer Action Not all vehicles will require VIU/VCIM replacement. The GPS signal in some vehicles may be recoverable. To determine if the signal is recoverable, simply connect the Tech2(R) and using the GPS information data display option, observe the GPS date and time. If the date/time stamps are equal to a date approximately 19 years in the future, the GPS clock has exceeded its capacity and the VIU/VCIM will need to be replaced. If the date/time stamp is in the past or near future, the GPS clock has simply generated an inaccurate value and may be recoverable by performing the following power-up reset. To initiate a power-up reset, battery voltage (batt. +) must be removed from the VIU/VCIM. The preferred methods, in order, of initiating the reset are outlined below. Remove the fuse that supplies Battery positive (Batt. +) voltage to the module (refer to the applicable Service Information schematics for the appropriate fuse). The next preferred method is to remove the connector to the OnStar(R) unit that Batt + is contained. The least preferable method is to remove the negative terminal of the vehicle battery. This will not only initiate the power-up reset, but it may also result in the loss of radio presets and other stored personalization information/settings in other modules as well. After initiating the power-up reset, the GPS data will be set to the defaulted date and time and will require an acquisition of the GPS signal in order to gain the proper date and time. Acquiring the GPS signal requires running the vehicle in an open/unobstructed view of the sky. First, contact OnStar(R) Technical Support by pressing the blue button. Allow the OnStar(R) Technical Advisor to activate the GPS recovery process. This should take approximately 10 minutes. Continue to Page 266 2. Skip to the next step if the vehicle to be upgraded is not shown above. 3. Skip to the next step if the vehicle to be upgraded is not a 2005 Cadillac STS. The 2005 Cadillac STS kit may include a new inside rearview (ISRV) mirror assembly and a new ISRV mirror wiring cover. If the kit you receive includes these parts, please remove the existing ISRV mirror and wire cover from the vehicle and install the ones provided in the kit per the instructions in SI. 4. Skip this step if the vehicle to be upgraded is not listed below. ^ 2003-2004 Saturn L-Series ^ 2003 Saturn ION ^ 2002-2003 Saturn VUE 1. Locate and remove the Right Audio output signal terminal 7 from Connector C2 at the Vehicle Communication Interface Module (VCIM). 2. Remove the terminal end and strip the wire. 3. Locate the Left Audio output signal wire from terminal 1 in Connector C2. 4. Splice the Right Audio output signal wire from terminal 7 with the Left Audio output signal wire from terminal 1. 5. See Wiring Repairs in SI for approved splicing methods. Page 9365 Note The rivet stud and surrounding panel area MUST BE properly refinished PRIOR to the installation of the electrical ground wire terminal and conductive nut to maintain a secure, stable and corrosion-free electrical ground. 11. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 12. Allow the refinished repair area to cure sufficiently before removing the protective material applied to the rivet stud threads. 13. Remove the painters tape or equivalent from the rivet stud threads. 14. Using GM approved residue-free solvent or equivalent, thoroughly clean the rivet stud threads to remove any adhesive and allow to dry. 15. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive rivet stud. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 16. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 17. Install the electrical ground wire terminal to the M6 conductive rivet stud. 18. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 19. Install the M6 conductive nut to the rivet stud and: Tighten Tighten to 8 Nm (71 lb in) 20. Verify proper system operation. Parts Information Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use: Warranty Information (Saab Models) Wheels/Tires - Refinishing Aluminum Wheels Wheels: All Technical Service Bulletins Wheels/Tires - Refinishing Aluminum Wheels INFORMATION Bulletin No.: 99-08-51-007E Date: March 17, 2011 Subject: Refinishing Aluminum Wheels Models: 2012 and Prior GM Passenger Cars and Trucks Supercede: This bulletin is being revised to add additional model years. Please discard Corporate Bulletin Number 99-08-51-007D (Section 08 - Body and Accessories). This bulletin updates General Motor's position on refinishing aluminum wheels. GM does not endorse any repairs that involve welding, bending, straightening or re-machining. Only cosmetic refinishing of the wheel's coatings, using recommended procedures, is allowed. Evaluating Damage In evaluating damage, it is the GM Dealer's responsibility to inspect the wheel for corrosion, scrapes, gouges, etc. The Dealer must insure that such damage is not deeper than what can be sanded or polished off. The wheel must be inspected for cracks. If cracks are found, discard the wheel. Any wheels with bent rim flanges must not be repaired or refinished. Wheels that have been refinished by an outside company must be returned to the same vehicle. The Dealer must record the wheel ID stamp or the cast date on the wheel in order to assure this requirement. Refer to Refinisher's Responsibility - Outside Company later in this bulletin. Aluminum Wheel Refinishing Recommendations - Chrome-plated aluminum wheels Re-plating these wheels is not recommended. - Polished aluminum wheels These wheels have a polyester or acrylic clearcoat on them. If the clearcoat is damaged, refinishing is possible. However, the required refinishing process cannot be performed in the dealer environment. Refer to Refinisher's Responsibility - Outside Company later in this bulletin. - Painted aluminum wheels These wheels are painted using a primer, color coat, and clearcoat procedure. If the paint is damaged, refinishing is possible. As with polished wheels, all original coatings must be removed first. Media blasting is recommended. Refer to GM Aluminum Refinishing Bulletin #53-17-03A for the re-painting of this type of wheel. - Bright, machined aluminum wheels These wheels have a polyester or acrylic clearcoat on them. In some cases, the recessed "pocket" areas of the wheel may be painted. Surface refinishing is possible. The wheel must be totally stripped by media blasting or other suitable means. The wheel should be resurfaced by using a sanding process rather than a machining process. This allows the least amount of material to be removed. Important Do not use any re-machining process that removes aluminum. This could affect the dimensions and function of the wheel. Painting is an option to re-clearcoating polished and bright machined aluminum wheels. Paint will better mask any surface imperfections and is somewhat more durable than clearcoat alone. GM recommends using Corsican SILVER WAEQ9283 for a fine "aluminum-like" look or Sparkle SILVER WA9967 for a very bright look. As an option, the body color may also be used. When using any of the painting options, it is recommended that all four wheels be refinished in order to maintain color uniformity. Refer to GM Aluminum Refinishing Bulletin #53-17-03A for specific procedures and product recommendations. Refinisher's Responsibility - Outside Company Important Some outside companies are offering wheel refinishing services. Such refinished wheels will be permanently marked by the refinisher and are warranted by the refinisher. Any process that re-machines or otherwise re-manufactures the wheel should not be used. A refinisher's responsibility includes inspecting for cracks using the Zyglo system or the equivalent. Any cracked wheels must not be refinished. No welding, hammering or reforming of any kind is allowed. The wheel ID must be recorded and follow the wheel throughout the process in order to assure that the same wheel is returned. A plastic media blast may be used for clean up of the wheel. Hand and/or lathe sanding of the machined surface and the wheel window is allowed. Material removal, though, must be kept to a minimum. Re-machining of the wheel is not allowed. Paint and/or clear coat must not be present on the following surfaces: the nut chamfers, the wheel mounting surfaces and the wheel pilot hole. The refinisher must permanently ID stamp the wheel and warrant the painted/clearcoated surfaces for a minimum of one year or the remainder of the new vehicle warranty, whichever is Page 8321 Brake Hose/Line: Service and Repair Brake Hose Replacement - Rear (Jounce) Brake Hose Replacement - Rear (Jounce) Removal Procedure Caution: Refer to Brake Fluid Irritant Caution in Service Precautions. Notice: Refer to Brake Fluid Effects on Paint and Electrical Components Notice in Service Precautions. 1. Raise and support the vehicle. 2. Clean all dirt and foreign material from the brake hose and brake pipe fittings. 3. Important: Install a rubber cap or plug to the exposed brake pipe fitting ends in order to prevent brake fluid loss and contamination. Use a backup wrench on the hose fitting, disconnect the brake pipe fitting from the brake hose, then cap or plug the brake pipe fitting end. 4. Remove the brake hose retaining clip from the hose mounting bracket. 5. Remove the jounce hose from the bracket. 6. Important: Install a rubber cap or plug to the exposed brake pipe fitting ends in order to prevent brake fluid loss and contamination. Disconnect the rear brake pipes from the junction block on the rear axle and cap or plug the brake pipe fitting ends. 7. Remove the junction block retaining bolt from the axle. 8. Remove the brake hose from the vehicle. Installation Procedure 1. Install the rear brake hose 2. Notice: Page 1267 Wheel Speed Sensor: Service and Repair Wheel Speed Sensor Replacement (4WD) Caution: Refer to Brake Dust Caution in Service Precautions. Removal Procedure 1. Raise and support the vehicle. 2. Remove the tire and wheel. 3. Remove the brake rotor (2) shown on the 1500 series. Refer to Brake Rotor Replacement - Front in Disc Brakes. 4. Remove the WSS cable mounting clip from the knuckle. 5. Remove the WSS cable mounting clip from the upper control arm. 6. Remove the WSS cable mounting clip from the frame attachment point. 7. Remove the WSS cable electrical connector. Page 14197 5. Install the front door trim panel. 6. If equipped with camper mirrors program the door module. Refer to Service Programming System (SPS) in Programming. Description and Operation Seat Belt Reminder Lamp: Description and Operation FASTEN SAFETY BELT INDICATOR The fasten safety belt indicator may only be illuminated during RUN. The instrument panel cluster (IPC) illuminates the fasten safety belt indicator under the following conditions: - During bulb check. - The inflatable restraint sensing and diagnostic module (SDM) sends the status of the driver's seat belt switch to the IPC via a class 2 message. If the driver's seat belt is unfastened, the IPC will illuminate the fasten safety belt indicator for 72 seconds or until the driver's seat belt is fastened. If the driver's seat belt is unfastened within 8 seconds following the bulb check, the IPC will send a class 2 serial message requesting 5 chimes to sound. Page 7330 Page 10107 6. Disconnect the electrical connector (3) from the power steering pump (4) by pressing downward on the rear of the locking tab and pulling the connector outward. 7. Remove the power steering pump wiring harness from the vehicle. Installation Procedure 1. Install the power steering wiring harness to the vehicle. 2. Connect the power steering pump wiring harness electrical connector (3) to the power steering pump (4). Page 8607 3. Remove the master cylinder nuts. Do not remove the pipes from the master cylinder. Position the master cylinder away from the booster head. Secure the master cylinder in an upright position. 4. Disconnect the power brake booster inlet hose, the steering gear inlet hose, and the power brake booster outlet hose from the booster assembly. 5. Remove the booster pump rod retainer from the lever. 6. Remove the stop lamp switch from the lever. 7. Remove the booster pump rod from the lever. 8. Remove the nuts at the booster. 9. Remove the booster assembly. Installation 1. Install the booster assembly to the vehicle. 2. Install the nuts at the booster. Page 13154 Important: The optic cable must not be bent with a radius less than 25 mm (1 in). 12.5. Cars with brackets for e.g. an amplifier: Fit the cable tie (11 900 515) to the wiring harness approx. 100 mm (4 in) from H2-9, fit the cable tie (H) to the bracket. Gather the optic cable in a gentle loop (I) and then place the loop behind the bracket. Important: The optic cable must not be bent with a radius less than 25 mm (1 in). 12.6. Cars without brackets for e.g. an amplifier: Gather the optic cable in a gentle loop (J) and secure with cable tie. 13. CV: Fit the left-hand, rear side hatch trim in accordance with WIS - 8. Body - Interior equipment - Adjustment/Replacement. 14. Fit the ground cable to the battery's negative terminal. 15. Carry out procedures after disconnecting the battery, see WIS - 3. Electrical System - Charging system - Adjustment/Replacement. Important: Follow Tech 2(R) on-screen instructions. 16. Add ECU ICM, choose without OnStar(R). See WIS-General-Tech 2(R) - Description and Operation - Add/Remove. 2000-2004 Saab 9-5 2000-2004 Saab 9-5 Specifications Flywheel: Specifications Flywheel bolts. first pass in sequence .......................................................................................................................... .................................................. 20 Nm (15 ft. lbs.) second pass in sequence ................................... ..................................................................................................................................... 50 Nm (37 ft. lbs.) final pass in sequence ................................................................................................................. ........................................................ 100 Nm (74 ft. lbs.) Page 16012 Electrical Symbols Part 8 Page 16038 circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links CIRCUIT PROTECTION - FUSIBLE LINKS Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Flat Wire Repairs FLAT WIRE REPAIRS NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Heated Oxygen Sensor (HO2S) Wiring Repairs HEATED OXYGEN SENSOR (HO2S) WIRING REPAIRS TOOLS REQUIRED J 38125-D Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: - Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-D. Repairing Damaged Wire Insulation REPAIRING DAMAGED WIRE INSULATION Page 3878 Page 11162 INSTALLATION PROCEDURE 1. Install the heater core (1) to the HVAC module assembly (2). 2. Install the heater core cowl gasket (1) to the HVAC module assembly (2). 3. Install the heater core cover (1) to the HVAC module assembly (2). NOTE: Refer to Fastener Notice in Service Precautions. 4. Install the screws to the heater core cover (1). Tighten Page 4862 Oxygen Sensor: Service and Repair Heated Oxygen Sensor (HO2S) Replacement Bank 2 Sensor 1 HEATED OXYGEN SENSOR (HO2S) REPLACEMENT BANK 2 SENSOR 1 REMOVAL PROCEDURE 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. Disconnect the connector position assurance (CPA) retainer. 3. Remove the heated oxygen sensor (HO2S) from the clips NOTE: Refer to Heated Oxygen and Oxygen Sensor Notice in Service Precautions. 4. If equipped with a 4.8L or 5.3L engine, disconnect the HO2S electrical connector. Electrical - MIL ON/DTC's Set By Various Control Modules Relay Module: All Technical Service Bulletins Electrical - MIL ON/DTC's Set By Various Control Modules TECHNICAL Bulletin No.: 09-06-03-004D Date: December 08, 2010 Subject: Intermittent No Crank/No Start, No Module Communication, MIL, Warning Lights, Vehicle Messages or DTCs Set by Various Control Modules - Diagnosing and Repairing Fretting Corrosion (Disconnect Affected Connector and Apply Dielectric Lubricant) Models: 2011 and Prior GM Passenger Cars and Trucks Attention: This repair can be applied to ANY electrical connection including, but not limited to: lighting, body electrical, in-line connections, powertrain control sensors, etc. DO NOT over apply lubricant to the point where it prevents the full engagement of sealed connectors. A light coating on the terminal surfaces is sufficient to correct the condition. Supercede: This bulletin is being revised to update the Attention statement and add the 2011 model year. Please discard Corporate Bulletin Number 09-06-03-004C (Section 06 Engine/Propulsion System). Condition Some customers may comment on any of the following conditions: - An intermittent no crank/no start - Intermittent malfunction indicator lamp (MIL) illumination - Intermittent service lamp illumination - Intermittent service message(s) being displayed The technician may determine that he is unable to duplicate the intermittent condition. Cause This condition may be caused by a buildup of nonconductive insulating oxidized debris known as fretting corrosion, occurring between two electrical contact surfaces of the connection or connector. This may be caused by any of the following conditions: - Vibration - Thermal cycling - Poor connection/terminal retention - Micro motion - A connector, component or wiring harness not properly secured resulting in movement On low current signal circuits this condition may cause high resistance, resulting in intermittent connections. On high current power circuits this condition may cause permanent increases in the resistance and may cause a device to become inoperative. Representative List of Control Modules and Components The following is only a representative list of control modules and components that may be affected by this connection or connector condition and DOES NOT include every possible module or component for every vehicle. - Blower Control Module - Body Control Module (BCM) - Communication Interface Module (CIM) - Cooling Fan Control Module - Electronic Brake Control Module (EBCM) - Electronic Brake and Traction Control Module (EBTCM) - Electronic Suspension Control (ESC) Module - Engine Control Module (ECM) - Heating, Ventilation and Air Conditioning (HVAC) Control Module Page 11851 Lock Cylinder Switch: Description and Operation PASSLOCK(TM) SENSOR The Passlock(TM) sensor is inside the ignition cylinder lock housing. The Passlock(TM) sensor contains 2 hall effect sensors. The tamper hall effect sensor is on the top. The security hall effect sensor is under the tamper hall effect sensor. Both of the hall effect sensors monitor the magnet of the lock cylinder through an opening. The tamper hall effect sensor is physically placed on top of the security hall effect sensor. This arrangement enables the tamper hall effect sensor to engage first if an intruder attempts to bypass the Passlock(TM) sensor by placing a large magnet around that area of the steering column. There is a tamper resistor inside the Passlock(TM) sensor in order to help prevent tamper to the system. Passlock(TM) equipped vehicles have a selection of 10 different security resistors ranging from 0.5K ohms up to 13.6K ohms. Installing one of the security resistors inside the Passlock(TM) sensor will generate a unique Passlock(TM) code. All 10 combinations of the Passlock(TM) sensor have the same part number. However, you cannot simply replace the Passlock(TM) sensor and expect the system to operate properly. Always start by performing the Diagnostic System Check first and following the instructions. Page 6670 1. Install the 8 checkballs (9 for some models) into the transmission case passages. ^ The checkball marked as number 2, is used on RCP, RDP, ZJP and ZLP models only ^ To hold the checkballs in place, use the J 36850. 2. Install the PWM screen into the valve body. 3. Install a new manual 2-1 band servo piston seal (2) onto the manual 2-1 band servo piston (3). 4. Install the manual 2-1 band servo piston pin (1) into the manual 2-1 band servo piston (3). 5. Install the manual 2-1 band servo piston pin retainer ring (4). 6. Install the manual 2-1 band servo piston cushion spring (2). 7. Important: Make certain that the tapered end of the manual 2-1 band servo piston pin contacts the manual 2-1 band. Install the manual 2-1 band servo piston (1). Page 6443 Shift Solenoid: Service and Repair Control and Shift Solenoids Replacement Removal Procedure 1. Remove the transmission filter. 2. Important: Removal of the 1-2 accumulator is necessary only if servicing the pressure control solenoid. Remove the 1-2 accumulator, if necessary. 3. Disconnect the internal wiring harness electrical connectors from the following components: ^ Transmission fluid pressure switch (1) ^ 1-2 shift control solenoid (2) ^ 2-3 shift control solenoid (3) ^ Pressure control solenoid (4) ^ torque converter clutch pulse width modulation (TCC PWM) solenoid (5) ^ 3-2 control solenoid (6) 4. Remove the pressure control solenoid retainer bolt (364A) and retainer (378). 5. Remove the pressure control solenoid (377). Page 8230 6. Install the park brake cable to the equalizer bar. 7. Install the tire and wheel assembly. 8. Lower the vehicle. Brake Rotor Assembled Lateral Runout (LRO) Correction Brake Rotor Assembled Lateral Runout (LRO) Correction Important: ^ Brake rotor thickness variation MUST be checked BEFORE checking for assembled lateral runout (LRO). Thickness variation exceeding the maximum acceptable level can cause brake pulsation. Refer to Brake Rotor Thickness Variation Measurement. ^ Brake rotor assembled lateral runout (LRO) exceeding the maximum allowable specification can cause thickness variation to develop in the brake rotor over time, usually between 4,800-11,300 km (3,000-7,000 mi). Refer to Brake Rotor Assembled Lateral Runout (LRO) Measurement. Review the following acceptable methods for bringing the brake rotor assembled LRO to within specifications. Determine which method to use for the specific vehicle being repaired. ^ Brake Rotor Assembled Lateral Runout (LRO) Correction - Indexing The indexing method of correcting assembled LRO is most effective when the LRO specification is only exceeded by a relatively small amount: 0.025-0.127 mm (0.001-0.005 inch). Indexing is used to achieve the best possible match of high spots to low spots between related components. ^ Brake Rotor Assembled Lateral Runout (LRO) Correction - On-Vehicle Lathe The on-vehicle brake lathe method is used to bring the LRO to within specifications through compensating for LRO while refinishing the brake rotor. If the assembled LRO cannot be corrected using these methods, then other components must be suspected as causing and/or contributing to the LRO concern. Brake Rotor Assembled Lateral Runout (LRO) Correction - Indexing Brake Rotor Assembled Lateral Runout (LRO) Correction - Indexing ^ Tools Required J 39544-KIT Torque-Limiting Socket Set, or equivalent - J 45101-100 Conical Brake Rotor Washers Caution: Refer to Brake Dust Caution in Service Precautions. Important: ^ Brake rotor thickness variation MUST be checked BEFORE checking for assembled lateral runout (LRO). Thickness variation exceeding the maximum acceptable level can cause brake pulsation. Refer to Brake Rotor Thickness Variation Measurement. ^ Brake rotor assembled lateral runout (LRO) exceeding the maximum allowable specification can cause thickness variation to develop in the brake rotor over time, usually between 4 800-11 300 km (3,000-7,000 mi). Refer to Brake Rotor Assembled Lateral Runout (LRO) Measurement. Page 5770 Tow/Haul Switch: Testing and Inspection 4L80-E/4L85-E Transmission Tow/Haul Switch/Indicator Always On or Inoperative Circuit Description Tow/haul mode enables the operator to achieve enhanced shift performance when towing or hauling a load. When tow/haul mode is selected, the tow/haul switch input signal to the body control module (BCM) is momentarily toggled to zero volts. This signals the powertrain control module (PCM) to extend the length of time between up shifts and increase transmission line pressure. Cycling the tow/haul switch again disables tow/haul mode and returns the transmission to a normal shift pattern. Diagnostic Aids If the electrical circuit checks are OK and the tow/haul shift pattern is not occurring, there may be a mechanical/hydraulic condition that prevents tow/haul operation. Refer to Symptoms - Automatic Transmission. Page 12449 Involved are certain vehicles within the VIN breakpoints shown above. PARTS INFORMATION -- Saab US Only Customer Notification General Motors will notify customers of this special coverage on their vehicles (see copy of typical customer letter shown in this bulletin - actual divisional letter may vary slightly). Page 13030 Page 7815 Shift Solenoid: Diagrams Automatic Transmission - 4L80-E/4L85-E Page 5010 Disclaimer Page 9287 5. Push on the tab (3) so that the electrical center can be rotated on the studs located at (2). 6. Remove all connectors by removing the bolt (1) for each connector. 7. Disconnect all connectors from the electrical center block. 8. Push on the tabs (2) in order to lift the electrical center (1) out of the housing. 9. To replace the engine electrical center bracket remove the 4 retaining bolts (1). 10. Remove the engine electrical center bracket assembly from the fender. INSTALLATION PROCEDURE Locations Fuel Composition Sensor Component Locations Fluid Pressure Sensor/Switch: Component Locations Automatic Transmission - 4L60-E/4L65-E Automatic Transmission Electronic Component Views (M30/M32) Electronic Components Page 8377 3. Relieve the tension from the park brake cable by pulling down on the park brake cable in front of the equalizer and removing the left park brake cable from the equalizer bar. 4. Remove the cable from the mounting bracket by depressing the locking tabs. 5. Remove the cable at the lower shock absorber mount by removing the bolt. Page 7057 Page 11858 11. Release the microphone electrical connector clip from the console. 12. Disconnect the radio volume compensator microphone (2) electrical connector. 13. Remove the screws (1) that retaining the radio volume compensator microphone (2) to the floor console trim panel. 14. Remove the radio volume compensator microphone (2) from the floor console side trim panel. INSTALLATION PROCEDURE 1. Install the radio volume compensator microphone (2) to the floor console side trim panel. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the radio volume compensator microphone screws (1). Tighten Tighten the screws to 2 N.m (18 lb in). 3. Align the side trim panel to the floor console and connect the radio volume compensator microphone (2) electrical connector. 4. Install the electrical connector hold down clip to the floor console. 5. Align the trim panel to the floor console, push the panel towards the floor console to engage the panel clips. Page 13547 Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips SPLICING COPPER WIRE USING SPLICE CLIPS IMPORTANT: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. TOOLS REQUIRED J 38125-D Terminal Repair Kit 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-D in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. Page 5285 Steps 6 - 7 The numbers below refer to the step numbers on the diagnostic table. Fuel Injector Balance Test Example (Typical) 5. If the pressure drop value for each fuel injector is within 10 kPa (1.5 psi) of the average pressure drop value, the fuel injectors are flowing properly. Calculate the pressure drop value for each fuel injector by subtracting the second pressure reading from the first pressure reading. Page 3960 Crankshaft Position Sensor: Service and Repair Crankshaft Position (CKP) Sensor Replacement CRANKSHAFT POSITION (CKP) SENSOR REPLACEMENT REMOVAL PROCEDURE IMPORTANT: Perform the CKP System Variation Learn Procedure whenever the crankshaft position sensor is removed or replaced. 1. Remove the starter. 2. Disconnect the crankshaft position (CKP) sensor electrical connector. 3. Clean the area around the CKP sensor before removal in order to avoid debris from entering the engine. 4. Remove the CKP sensor bolt. 5. Remove the CKP sensor. INSTALLATION PROCEDURE Page 7677 Four Wheel Drive Selector Switch: Service and Repair Transfer Case - NVG 263-NP1 Transfer Case Shift Control Switch Replacement Removal Procedure 1. Remove the instrument panel (IP) cluster bezel. 2. Pull the tabs on the side of the transfer case driver control switch out. 3. Pull the transfer case driver control switch straight out from the panel. Installation Procedure 1. Important: Make sure that the transfer case control switch is seated properly in the instrument panel before installing the instrument panel trim bezel. Install the transfer case driver control switch into the instrument panel. 2. Install the IP cluster bezel. Locations Electronic Throttle Actuator: Locations EGR, TAC Motor And Ignition Coils 2, 4, 6, 8 Page 7422 Page 7539 Fluid - Transfer Case: Fluid Type Specifications NVG 149-NP3 ................................................................................................... Manual Transmission Fliod GM P/N 8861800 (Canadian P/N 88861801) NVG 246-NP8 ......................................................................................... Auto-Trak II, transfer case fluid, GM P/N 12378508 (Canadian P/N 10953626) NVG 261-NP2 ................................................................................................... Manual Transmission Fliod GM P/N 8861800 (Canadian P/N 88861801) NVG 263-NP1 ................................................................................................... Manual Transmission Fliod GM P/N 8861800 (Canadian P/N 88861801) Page 367 Important: The optic cable must not be bent with a radius less than 25 mm (1 in). 6.17. Fold back the wiring harness and tape over the connectors (G). Fold back the wiring harness once more and secure with cable ties (H). 6.18. Secure the new optic cable on the parcel shelf along the existing wiring harness by the ordinary securing points and by the speaker (I). 6.19. Thread the optic cable down next to the old cable from the parcel shelf to the left-hand wheel housing, next to REC. The cable is secured in the existing clips. 6.20. Fit the right-hand C-pillar trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.21. Fit the parcel shelf trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.22. Fit the passenger seat in accordance with WIS - 8. Body - Seats - Adjustment/Replacement. 6.23. Fit the right-hand side bolster in accordance with WIS - 8. Body - Seats Adjustment/Replacement. 6.24. Fold up the rear seat backrest. 6.25. Fit the right-hand B-pillar trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.26. Fit the A-pillar's lower side piece. 7. M04-05, 4D: Removing the OnStar® control modules and securing the wiring: Engine Controls - Aftermarket Accessory Usage Engine Control Module: All Technical Service Bulletins Engine Controls - Aftermarket Accessory Usage INFORMATION Bulletin No.: 04-06-04-054B Date: November 18, 2010 Subject: Info - Non-GM Parts and Accessories (Aftermarket) Models: 2011 and Prior GM Passenger Cars and Trucks Supercede: This bulletin is being revised to add model years and update to the new U.S. Fixed Operation Manager (FOM) and Canada Warranty Manager (WM) names. Please discard Corporate Bulletin Number 04-06-04-054A (Section 06 - Engine/Propulsion System). The recent rise and expansion of companies selling non-GM parts and accessories has made it necessary to issue this reminder to dealers regarding GM's policy on the use and installation of these aftermarket components. When a dealer is performing a repair under the New Vehicle Limited Warranty, they are required to use only genuine GM or GM-approved parts and accessories. This applies to all warranty repairs, special policy repairs or any repairs paid for by GM. Parts and accessories advertised as being "the same" as parts manufactured by GM, but not sold through GM, do not qualify for use in warranty repairs, special policy repairs or any repairs paid for by GM. During a warranty repair, if a GM original equipment part is not available through GM Customer Care and Aftersales (GM CC&A;), ACDelco(R) distributors, other GM dealers or approved sources, the dealer is to obtain comparable, non-GM parts and clearly indicate, in detail, on the repair order the circumstances surrounding why non-GM parts were used. The dealer must give customers written notice, prior to the sale or service, that such parts or accessories are not marketed or warranted by General Motors. It should also be noted that dealers modifying new vehicles and installing equipment, parts and accessories obtained from sources not authorized by GM are responsible for complying with the National Traffic and Motor Vehicle Safety Act. Certain non-approved parts or assemblies, installed by the dealer or its agent not authorized by GM, may result in a change to the vehicle's design characteristics and may affect the vehicle's ability to conform to federal law. Dealers must fully understand that non-GM approved parts may not have been validated, tested or certified for use. This puts the dealer at risk for potential liability in the event of a part or vehicle failure. If a GM part failure occurs as the result of the installation or use of a non-GM approved part, the warranty will not be honored. A good example of non-authorized modification of vehicles is the result of an ever increasing supply of aftermarket devices available to the customer, which claim to increase the horsepower and torque of the Duramax(TM) Diesel Engines. These include the addition of, but are not limited to one or more of the following modifications: - Propane injection - Nitrous oxide injection - Additional modules (black boxes) that connect to the vehicle wiring systems - Revised engine calibrations downloaded for the engine control module - Calibration modules which connect to the vehicle diagnostic connector - Modification to the engine turbocharger waste gate Although the installation of these devices, or modification of vehicle components, can increase engine horsepower and torque, they may also negatively affect the engine emissions, reliability and/or durability. In addition, other powertrain components, such as transmissions, universal joints, drive shafts, and front/rear axle components, can be stressed beyond design safety limits by the installation of these devices. General Motors does not support or endorse the use of devices or modifications that, when installed, increase the engine horsepower and torque. It is because of these unknown stresses, and the potential to alter reliability, durability and emissions performance, that GM has adopted a policy that prevents any UNAUTHORIZED dealer warranty claim submissions to any remaining warranty coverage, to the powertrain and driveline components whenever the presence of a non-GM (aftermarket) calibration is confirmed - even if the non-GM control module calibration is subsequently removed. Refer to the latest version of Bulletin 09-06-04-026 (V8 Gas Engines) or 06-06-01-007 (Duramax(TM) Diesel Engines) for more information on dealer requirements for calibration verification. These same policies apply as they relate to the use of non-GM accessories. Damage or failure from the use or installation of a non-GM accessory will not be covered under warranty. Failure resulting from the alteration or modification of the vehicle, including the cutting, welding or disconnecting of the vehicle's original equipment parts and components will void the warranty. Additionally, dealers will NOT be reimbursed or compensated by GM in the event of any legal inquiry at either the local, state or federal level that Page 3837 Door Control Module Diagram 3 Part 2 Page 4606 Tighten Tighten the sensor to 42 N.m (31 lb ft). 3. If equipped with a 6.0L engine, connect the HO2S electrical connector (2). 4. If equipped with a 4.8L or 5.3L engine, connect the HO2S electrical connector (2). 5. If equipped with a fuel composition sensor, install the HO2S electrical connector to the fuel line clip. 6. Disconnect the CPA retainer. 7. If equipped, connect the fuel composition sensor electrical connector. 8. Lower the vehicle. Page 593 Disclaimer Page 3542 Ignition Cable: Testing and Inspection SPARK PLUG WIRE INSPECTION Spark plug wire integrity is vital for proper engine operation. A thorough inspection is necessary to accurately identify conditions that may affect engine operation. Inspect for the following conditions: 1. Correct routing of the spark plug wires-Incorrect routing may cause cross-firing. 2. Any signs of cracks or splits in the wires. 3. Inspect each boot for the following conditions: - Tearing - Piercing - Arcing - Carbon tracking - Corroded terminal If corrosion, carbon tracking or arcing are indicated on a spark plug wire boot or terminal, replace the wire and the component connected to the wire. Page 15816 Steering Wheel And Column Sub-System Components Page 1541 Mass Air Flow (MAF) Sensor: Service and Repair MASS AIR FLOW (MAF)/INTAKE AIR TEMPERATURE (IAT) SENSOR REPLACEMENT REMOVAL PROCEDURE IMPORTANT: Use care when handling the mass air flow/intake air temperature (MAF/IAT) sensor. Do not dent, puncture, or otherwise damage the honeycell located at the air inlet end of the MAF/IAT. Do not touch the sensing elements or allow anything including cleaning solvents and lubricants to come in contact with them. Use a small amount of a non-silicone based lubricant, on the air duct only, to aid in installation. 1. Remove the air cleaner outlet duct. 2. Pull out the gray connector position assurance (CPA) retainer. 3. Push down on the black clip in order to disconnect the MAF/IAT sensor electrical connector (4). 4. Loosen the MAF/IAT clamp. 5. Remove the MAF/IAT sensor from the air cleaner assembly. INSTALLATION PROCEDURE IMPORTANT: The embossed arrow on the MAF/IAT sensor indicates the proper air flow direction. The arrow must point toward the engine. Page 15317 For vehicles repaired under warranty, use the table. Disclaimer Page 5784 4. Position the J 41364-A onto the PNP switch. Ensure that the two slots on the switch where the manual shaft is inserted are lined up with the lower two tabs on the tool. 5. Notice: Refer to Fastener Notice in Service Precautions. Rotate J 41364-A until the upper locator pin on the tool is lined up with the slot on the top of the switch. ^ Tighten the bolts to 25 Nm (18 ft. lbs.). 6. Remove J 41364-A from the PNP switch. If installing a new switch, remove the positive assurance bracket at this time. 7. Install the control lever to the manual shaft with the nut. 8. Install the manual shaft nut. ^ Tighten the nut to 25 Nm (18 ft. lbs.). 9. Install the range selector cable end (2) to the range selector lever ball stud (1). Page 515 Driver Door Module (DDM) - C3 (With RPO Code YE9) Part 1 Page 2610 Location View Page 5692 Torque Converter Clutch Solenoid: Connector Locations Page 15475 Fuel Pump And Sender Assembly Components Page 8144 19. Important: Care must be used when removing the piston boot and seal from the caliper. Use a small plastic or wood tool for removal. Do not use a metal tool because it may damage the caliper bore or seal groove. Remove the piston boots from the brake caliper. 20. Remove the piston seals from the brake caliper. 21. Remove the brake caliper bleeder valve and cap from the brake caliper. 22. Important: Do not use abrasives to clean the brake caliper piston. Clean the brake caliper piston bore and seal counterbore, and the caliper piston with denatured alcohol, or equivalent. 23. Dry the caliper piston bores and counterbores, and the piston with non-lubricated, filtered air. 24. Inspect all of the brake caliper parts as follows. ^ Piston - Inspect for scoring, nicks, cracks, wear, or corrosion. Replace the pistons if any damage is found. ^ Caliper Bore - Inspect for scoring, nicks, cracks, wear, or corrosion. Use crocus cloth to polish out light corrosion. Otherwise, replace the caliper. Do not hone the caliper bore. ^ Seal groove in the caliper bore for nicks or burrs. If found, replace the caliper. 25. Install the brake caliper bleeder valve and bleeder valve cap into the brake caliper. 26. Lubricate the new piston seal with Delco Supreme 11®, GM P/N 12377967 (Canadian P/N 10953488) or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. 27. Install the lubricated, new piston seals into the caliper bores. 28. Install the caliper piston into the caliper bore. 29. Install the new piston dust boot seal over the piston. 30. Using the J 45515 , fully seat the piston dust boot seal in the caliper. 31. Install the brake caliper to the vehicle. Refer to Brake Caliper Replacement - Front. Page 3143 1. Lubricate the valve rocker arms and pushrods with clean engine oil. 2. Lubricate the flange of the valve rocker arm bolts with clean engine oil.Lubricate the flange or washer surface of the bolt that will contact the valve rocker arm. 3. Install the valve rocker arm pivot support. 4. Important: Make sure that the pushrods seat properly to the valve lifter sockets. Install the pushrods. 5. Important: Make sure that the pushrods seat properly to the ends of the rocker arms. DO NOT tighten the rocker arm bolts at this time. Install the rocker arms and bolts. Page 10705 5. Tighten the wheel bearing adjusting nut using the J 2222-C. ^ Rotate the hub in the opposite direction to the way the adjuster nut is turning. ^ Ensure the inner bearing and the seal seats against the spindle shoulder. TIGHTEN ^ Adjusting nut to 70 Nm (52.0 lb ft). 6. Turn the adjusting nut counterclockwise until the nut is loose using the J 2222-C. 7. Turn the adjusting nut clockwise until the nut contacts the bearing cone. Torque on the nut must be zero to finger tight. 8. Insert the adjusting nut lock key into the keyway using one of the following procedures: ^ If the adjusting nut slot is in alignment with the keyway in the axle spindle, insert the adjusting nut lock key into the keyway in the axle spindle. IMPORTANT: Do not turn the adjusting nut more than one slot counterclockwise in order to align the adjusting nut slot with the keyway in the axle spindle. ^ If the adjusting nut slot is not aligned with the keyway in the axle spindle, turn the adjusting nut counterclockwise until the adjusting nut slot is in alignment with the keyway in the axle spindle and insert the adjusting nut lock key. Page 1166 Seat Adjuster Switch - Driver (AG1) Page 4327 Control Module References Part 3 Page 4902 5. Connect the VSS electrical connector (2). 6. Lower the vehicle. 7. Refill the fluid as required. Page 1997 Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA and/or the secondary locks. Micro .64 Connectors MICRO .64 CONNECTORS TOOLS REQUIRED J 38125-D Terminal Repair Kit REMOVAL PROCEDURE Follow the steps below in order to remove terminals from Micro 64 connectors. 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. 2. Disconnect the connector from the component. Page 3353 19. Disconnect the oil level sensor electrical connector (3). 20. Remove the battery cable channel bolt. 21. Slide the channel pin out of the oil pan tab. TPMS System - Service And Re-Learning Sensor IDs Tire Pressure Module: Technical Service Bulletins TPMS System - Service And Re-Learning Sensor IDs INFORMATION Bulletin No.: 10-03-16-001 Date: July 19, 2010 Subject: TPMS System Service and Re-Learning Sensor IDs Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks 2010 and Prior HUMMER H2 2009 and Prior HUMMER H3 2010 and Prior Saturn Models 2009 and Prior Saab 9-7X with Wheel-Mounted Tire Pressure Sensors In the event that the spare tire, which is normally not equipped with a tire pressure monitor (TPM) sensor, is installed in place of one of the road tires and the vehicle is driven above 40 km/h (25 mph) for 20 minutes or more, the TPM indicator icon on the instrument panel cluster (IPC) will flash for approximately one minute and then remain on steady each time the ignition is turned ON, indicating a diagnostic trouble code (DTC) has been set. The driver information center (DIC), if equipped, will also display a SERVICE TIRE MONITOR type message. When the road tire is repaired and reinstalled in the original location, the TPM indicator icon illumination and DIC message may remain displayed until the DTC is cleared. To ensure that the TPM indicator and the DIC message are cleared after service, it is necessary to clear any TPM DTCs using a scan tool. If a scan tool is unavailable, performing the TPM relearn procedure using a TPM diagnostic tool will provide the same results. It is advised to perform the relearn procedure away from other vehicles to prevent picking up a stray sensor signal. If one or more of the TPM sensors are missing or damaged and have been replaced, then the relearn procedure must be performed. Disclaimer Page 8913 Auxiliary Power Outlet - Front (Except Z75) Page 13258 Page 11644 1. Install the buckle assembly. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the bolt (13) that retains the buckle assembly (14) to the seat frame. Tighten Tighten the bolts to 53 N.m (39 lb ft). 3. Install the rear seat cushion and cover. Page 642 Electronic Brake Control Module (ECBCM) - C2 (30 Series and HP2 Page 12707 Diagnostic Tips Review # 3 - Denso Navigation Radios Page 9461 Cigar Lighter/Auxiliary Outlets Diagram 4 (2 Of 2) Page 5551 1. Install the CKP sensor. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the CKP sensor bolt. Tighten Tighten the bolt to 25 N.m (18 lb ft). 3. Connect the CKP sensor electrical connector. 4. Install the starter. 5. Perform the CKP system variation learn procedure. See: Testing and Inspection/Programming and Relearning Steering Wheel Position Sensor or Steering Shaft Lower Bearing Replacement Steering Column Position Sensor: Service and Repair Steering Wheel Position Sensor or Steering Shaft Lower Bearing Replacement Steering Wheel Position Sensor or Steering Shaft Lower Bearing Replacement (Centering Required) ^ Tools Required J 42640 Steering Column Anti-Rotation Pin Removal Procedure 1. Set the front wheels in the straight-ahead position. 2. Install J 42640 or set the steering wheel in the LOCKED position. 3. Caution: Refer to SIR Caution in Service Precautions. Disconnect the negative battery cable. 4. Disable the SIR. 5. Important: You MUST make an alignment mark on the upper intermediate shaft to the steering column shaft, where they connect. You will need the alignment marks for installation. Make an alignment mark on the upper intermediate shaft and the steering column shaft, where they connect, before removal. 6. Remove the nut and the bolt from the upper to the lower steering shaft connection. Slide the lower shaft down. 7. Remove the steering wheel position sensor connector by using a suitable tool in order to pull the connector down around the right side of the steering column for accessibility. 8. Important: Do not apply force to the steering wheel position sensor and the adapter and bearing assembly in a sideways direction. If reusing the existing steering wheel position sensor, it MUST be centered before removal. Verify the type of steering wheel position sensor before removal. Refer to Steering Wheel Position Sensor Centering. 9. Remove the steering wheel position sensor and adapter and bearing assembly from the steering column jacket by pulling the assembly straight out. 10. Remove the steering wheel position sensor from the clips in the adapter and bearing assembly. Installation Procedure 1. Important: A new sensor MUST come with a pin installed. If pin is not installed, return and reorder sensor. Verify the following before installing the steering wheel position sensor: ^ The front wheels are in the straight-ahead position. ^ That J 42640 is installed or the steering wheel is in the LOCKED position. 2. If reusing the existing steering wheel position sensor, verify the type of sensor you have before installing. Refer to Steering Wheel Position Sensor Centering. 3. Install the steering wheel position sensor into the adapter and bearing assembly. 4. Install the adapter and bearing assembly into the steering column jacket. 1. Align the notches on the adapter and bearing assembly and the steering column jacket. 2. Important: Air Conditioning - Diagnose A/C Low Pressure Switch Low Pressure Sensor / Switch: Technical Service Bulletins Air Conditioning - Diagnose A/C Low Pressure Switch INFORMATION Bulletin No.: 04-01-38-010A Date: January 21, 2010 Subject: Diagnostic Information to Accurately Diagnose A/C Low Pressure Switch Using Kent Moore Special Tool GE-47742 Models: 2002-2006 Cadillac Escalade, Escalade EXT 2003-2006 Cadillac Escalade ESV 1999-2007 Chevrolet Silverado 2000-2006 Chevrolet Suburban, Tahoe 2002-2007 Chevrolet Avalanche 1999-2007 GMC Sierra 2000-2006 GMC Yukon, Yukon XL 2001-2006 GMC Yukon Denali XL 2001-2007 GMC Sierra Denali, Yukon Denali XL 2003-2008 HUMMER H2 with Air Conditioning Supercede: This bulletin is being revised to update the model years. Please discard Corporate Bulletin Number 04-01-38-010 (Section 01 - HVAC). Currently, technicians cannot accurately determine the air conditioning (A/C) low pressure switch open/close pressure point by measuring pressure at the low side service port. This is because the evaporator is between the low side service port and the A/C low pressure switch. Correlating pressures measured at the low side service port to actual pressures at the A/C low pressure switch port is difficult because of the multiple variables that impact pressure drop across the evaporator. Providing a pressure range that would take into account all these variables would result in a pressure range that would be too broad to be useful for diagnostic purposes. Kent Moore special tool GE-47742 will allow technicians to monitor the actual pressures at which the A/C low pressure switch opens and closes under actual operating conditions. Technicians are to use the following steps to install and use Kent Moore special tool GE-47742 to measure A/C low pressure switch opening and closing pressures: 1. Disconnect the wire harness from the A/C low pressure switch. 2. Remove the A/C low pressure switch from the accumulator. 3. Install the A/C low pressure switch, using the threaded port with an O-ring, onto special tool GE-47742. 4. Install special tool GE-47742, with the A/C low pressure switch attached, onto the accumulator. Important Removing the seal from the A/C low pressure switch wire harness connector is required. Failure to remove the seal before plugging it into the switch will lead to misdiagnosis. The "plunger effect" of plugging the connector with a seal into the A/C low pressure switch induces a pressure on the back side of the switch. This pressure will skew the opening/closing characteristics of the switch 34-69 kPa (5-10 psi) until the pressure bleeds off. The time required for the connection induced pressure to bleed off can be 20 minutes or longer. 5. Remove the seal from the A/C low pressure switch wire harness connector. 6. Connect the wire harness, without the seal, to the A/C low pressure switch. 7. Connect the low side service hose from the ACR2000(R) or GE-48800 to the service port on special tool GE-47742. 8. Connect a Tech2(R) to the vehicle. 9. Start the vehicle and maintain an engine speed of 1500 RPM. Set the HVAC controls as follows: - Set the A/C control switch to ON. - Set the mode control switch to A/C and engage recirculation mode. - Set the blower motor speed to LOW. - Set the temperature control to full cold. - Set the auxiliary blower motor speed to LOW. If equipped. - Set the auxiliary temperature control to full cold. If equipped. - The vehicle must be operating with no sun load (in the shade). 10. Use the Tech2(R) to determine the A/C low pressure switch status and the ACR2000(R) or GE-48800 to determine the A/C low side pressure. Simultaneously monitor the switch status and the pressure at which the A/C low pressure switch opens and closes. The Tech2(R) will display switch status as "Normal" for Closed and "Low Pressure" for Open. A properly operating switch should open between 138-172 kPa (20-25 psi) Steering - 'Service Rear Wheel Steering' Message Body Control Module: All Technical Service Bulletins Steering - 'Service Rear Wheel Steering' Message Bulletin No.: 05-02-118-002 Date: February 03, 2005 TECHNICAL Subject: DTC C0455, "Service Rear Wheel Steering", System Jumps from 4-Wheel Steer to 2-Wheel Steer (Reprogram BCM) Models: 2003-2005 Chevrolet Silverado, Suburban 2003-2005 GMC Sierra, Yukon XL with 4-Wheel Steer (RPO NYS) Condition Some customers may comment that the system will jump from 4-wheel steer to 2-wheel steer and the DIC displays the message "Service Rear Wheel Steering". Diagnosis will show DTC C0455-Front Steering Position Sensor malfunction. Cause This condition may be caused by a Class2 communication issue. Correction Reprogram the BCM. 2005 Model Year Vehicles: New software calibration, P/N 15248410, was released on TIS version 12 - broadcast to dealers on December 4, 2004. 2003-2004 Model Year Vehicles: New software calibration, P/N 15259330 ('03 Model Year) and P/N 15259331 ('04 04 Model Year), was released on TIS version 1.75 - broadcast to dealers on January 24, 2005. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 15434 Ambient Air Temperature Sensor - Outside Page 4325 Control Module References Part 1 Junction Block - I/P Relay Box: Locations Junction Block - I/P Location View Location View A/C - Refrigerant Recovery/Recycling/Equipment Refrigerant: Technical Service Bulletins A/C - Refrigerant Recovery/Recycling/Equipment Bulletin No.: 08-01-38-001 Date: January 25, 2008 INFORMATION Subject: Information On New GE-48800 CoolTech Refrigerant Recovery/Recharge Equipment Models: 2008 and Prior GM Passenger Cars and Light Duty Trucks (Including Saturn) 2008 and Prior HUMMER H2, H3 2005-2008 Saab 9-7X Attention: This bulletin is being issued to announce the release of GM approved Air Conditioning (A/C) Refrigerant Recovery and Recharging Equipment that meets the new Society of Automotive Engineers (SAE) J2788 Refrigerant Recovery Standards. The ACR2000 (J-43600) cannot be manufactured in its current state after December 2007 and will be superseded by GE-48800. The new J2788 standard does not require that GM Dealers replace their ACR2000 units. ACR2000's currently in use are very capable of servicing today's refrigerant systems when used correctly and can continue to be used. Details regarding the new SAE J2788 standard are outlined in GM Bulletin 07-01-38-004. Effective February 1 2008, new A/C Refrigerant Recovery/Recharging equipment (P/N GE-48800) will be released as a required replacement for the previously essential ACR2000 (J-43600). This equipment is SAE J2788 compliant and meets GM requirements for A/C Refrigerant System Repairs on all General Motors vehicles, including Hybrid systems with Polyolester (POE) refrigerant oil. This equipment will not be shipped as an essential tool to GM Dealerships. In addition, this equipment is Hybrid compliant and designed to prevent oil cross contamination when servicing Hybrid vehicles with Electric A/C Compressors that use POE refrigerant oil. The ACR2000 (J-43600) will need to be retrofitted with a J-43600-50 (Hose - ACR2000 Oil Flush Loop) to be able to perform Hybrid A/C service work. All Hybrid dealers will receive the J-43600-50, with installation instructions, as a component of the Hybrid essential tool package. Dealerships that do not sell Hybrids, but may need to service Hybrids, can obtain J-43600-50 from SPX Kent Moore. Refer to GM Bulletin 08-01-39-001 for the ACR2000 Hose Flush procedure. The High Voltage (HV) electric A/C compressor used on Two Mode Hybrid vehicles uses a Polyolester (POE) refrigerant oil instead of a Polyalkylene Glycol (PAG) synthetic refrigerant oil. This is due to the better electrical resistance of the POE oil and its ability to provide HV isolation. Failure to flush the hoses before adding refrigerant to a Hybrid vehicle with an electric A/C compressor may result in an unacceptable amount of PAG oil entering the refrigerant system. It may cause a Battery Energy Control Module Hybrid Battery Voltage System Isolation Lost Diagnostic Trouble Code (DTC P1AE7) to be set. Additionally, the A/C system warranty will be voided. Warranty Submission Requirements The Electronically Generated Repair Data (snapshot summary) and printer functions have been eliminated from the GE-48800. The VGA display and temperature probes were eliminated to reduce equipment costs. As a result, effective immediately the 18 digit "Snapshot/Charge Summary" code is no longer required for Air Conditioning (A/C) refrigerant system repairs that are submitted for warranty reimbursement. The charge summary data from before and after system repairs will continue to required, but documented on the repair order only. Both high and low pressures and the recovery and charge amounts should be noted during the repair and entered on the repair order. If using ACR2000 (J-43600), the "Snapshot/Charge Summary" printouts should continue to be attached to the shops copy of the repair order. The labor codes that are affected by this requirement are D3000 through D4500. Disclaimer Page 4109 8. Connect the PNP switch electrical connector (2). 9. If equipped with 4WD, install the front propeller shaft. 10. Lower the vehicle. 11. Check the switch for proper operation. The engine must start in the park (P) or neutral (N) positions only. If proper operation of the switch can not be obtained, replace the switch. Page 6633 other debris or restrictions are found, then reassemble the valve body and install in the transmission. If the valve body has been contaminated with debris from another transmission component failure, then disassemble all bores for complete cleaning of all valve body components. If possible, keep individual bore parts separated for ease of reassembly. Use the illustrations in this bulletin for a positive identification and location of individual parts: Using GM Brake Clean, or equivalent, in a safe and clean environment (clean aluminum pan), clean the valve body and dry it with compressed air. Use appropriate eye protection. Clean individual valve body components with GM Brake Clean, or equivalent. Coat each valve with clean ATF and reassemble in each bore. Check each valve for free movement during assembly of each bore. Disclaimer Page 5436 Fuel Gauge Sender: Service and Repair Fuel Level Sensor Replacement - 2 FUEL LEVEL SENSOR REPLACEMENT REMOVAL PROCEDURE 1. Remove the sending unit. 2. Disconnect the fuel pump electrical connector. 3. Remove the fuel level sensor electrical connector retaining clip. 4. Disconnect the fuel level sensor electrical connector. Page 2279 1. Coat the O-rings (2) with 525 viscosity refrigerant oil. 2. Install the O-rings (2) to the evaporator tube. 3. Install the A/C refrigerant filter (3) to the evaporator tube (2) with the flow arrow pointing towards the evaporator. NOTE: Refer to Fastener Notice in Service Precautions. 4. Install the nuts (4) to the A/C refrigerant filter (1). Tighten Tighten the nuts to 15 N.m (11 lb ft). 5. Recharge the A/C system. Refer to Refrigerant Recovery and Recharging. Page 9033 Fuse Block- I/P C2 Engine Controls - Aftermarket Accessory Usage Engine Control Module: All Technical Service Bulletins Engine Controls - Aftermarket Accessory Usage INFORMATION Bulletin No.: 04-06-04-054B Date: November 18, 2010 Subject: Info - Non-GM Parts and Accessories (Aftermarket) Models: 2011 and Prior GM Passenger Cars and Trucks Supercede: This bulletin is being revised to add model years and update to the new U.S. Fixed Operation Manager (FOM) and Canada Warranty Manager (WM) names. Please discard Corporate Bulletin Number 04-06-04-054A (Section 06 - Engine/Propulsion System). The recent rise and expansion of companies selling non-GM parts and accessories has made it necessary to issue this reminder to dealers regarding GM's policy on the use and installation of these aftermarket components. When a dealer is performing a repair under the New Vehicle Limited Warranty, they are required to use only genuine GM or GM-approved parts and accessories. This applies to all warranty repairs, special policy repairs or any repairs paid for by GM. Parts and accessories advertised as being "the same" as parts manufactured by GM, but not sold through GM, do not qualify for use in warranty repairs, special policy repairs or any repairs paid for by GM. During a warranty repair, if a GM original equipment part is not available through GM Customer Care and Aftersales (GM CC&A;), ACDelco(R) distributors, other GM dealers or approved sources, the dealer is to obtain comparable, non-GM parts and clearly indicate, in detail, on the repair order the circumstances surrounding why non-GM parts were used. The dealer must give customers written notice, prior to the sale or service, that such parts or accessories are not marketed or warranted by General Motors. It should also be noted that dealers modifying new vehicles and installing equipment, parts and accessories obtained from sources not authorized by GM are responsible for complying with the National Traffic and Motor Vehicle Safety Act. Certain non-approved parts or assemblies, installed by the dealer or its agent not authorized by GM, may result in a change to the vehicle's design characteristics and may affect the vehicle's ability to conform to federal law. Dealers must fully understand that non-GM approved parts may not have been validated, tested or certified for use. This puts the dealer at risk for potential liability in the event of a part or vehicle failure. If a GM part failure occurs as the result of the installation or use of a non-GM approved part, the warranty will not be honored. A good example of non-authorized modification of vehicles is the result of an ever increasing supply of aftermarket devices available to the customer, which claim to increase the horsepower and torque of the Duramax(TM) Diesel Engines. These include the addition of, but are not limited to one or more of the following modifications: - Propane injection - Nitrous oxide injection - Additional modules (black boxes) that connect to the vehicle wiring systems - Revised engine calibrations downloaded for the engine control module - Calibration modules which connect to the vehicle diagnostic connector - Modification to the engine turbocharger waste gate Although the installation of these devices, or modification of vehicle components, can increase engine horsepower and torque, they may also negatively affect the engine emissions, reliability and/or durability. In addition, other powertrain components, such as transmissions, universal joints, drive shafts, and front/rear axle components, can be stressed beyond design safety limits by the installation of these devices. General Motors does not support or endorse the use of devices or modifications that, when installed, increase the engine horsepower and torque. It is because of these unknown stresses, and the potential to alter reliability, durability and emissions performance, that GM has adopted a policy that prevents any UNAUTHORIZED dealer warranty claim submissions to any remaining warranty coverage, to the powertrain and driveline components whenever the presence of a non-GM (aftermarket) calibration is confirmed - even if the non-GM control module calibration is subsequently removed. Refer to the latest version of Bulletin 09-06-04-026 (V8 Gas Engines) or 06-06-01-007 (Duramax(TM) Diesel Engines) for more information on dealer requirements for calibration verification. These same policies apply as they relate to the use of non-GM accessories. Damage or failure from the use or installation of a non-GM accessory will not be covered under warranty. Failure resulting from the alteration or modification of the vehicle, including the cutting, welding or disconnecting of the vehicle's original equipment parts and components will void the warranty. Additionally, dealers will NOT be reimbursed or compensated by GM in the event of any legal inquiry at either the local, state or federal level that Page 14101 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-8 (12085115) crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-8 (12085115) until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes SPLICING INLINE HARNESS DIODES Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate Service Data wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. 9. Tape the diode to the harness or connector using electrical tape. Page 12103 The module uses a default value for the missing parameter. Conditions for Clearing the DTC A current DTC clears when the malfunction is no longer present. A history DTC clears when the module ignition cycle counter reaches the reset threshold, without a repeat of the malfunction. Diagnostic Aids When multiple Loss of Communication DTCs are set concurrently, the cause is likely to be 2 opens in the ring portion of the class 2 serial data circuit. Use the Control Modules and Devices ‐ Description and Identification Number table in order to determine which modules are not communicating. Use the class 2 serial data circuit schematic in order to determine the location of the opens. Test Description Page 1522 Turn Signal Switch: Diagrams Turn Signal Multifunction Switch - C1 Page 1459 Upper Steering Column Page 5455 3. Locate the auxiliary fuel tank vent hose. The vent hose is the smaller diameter of the two hoses that comes from the auxiliary fuel tank and feeds into the main tank vent hose. 4. Disconnect the auxiliary tank vent hose from the main tank vent hose connection. 5. Install the cap supplied with kit, P/N 15213990, to the main tank vent hose connector where the auxiliary tank vent hose was just removed. 6. Locate the section of vent hose on the main tank between the fuel filler neck and the metal pipe. The smaller of the two hoses on the filler neck. 7. Cut the main tank vent hose between the filler neck and the metal pipe using an appropriate cutting tool. 8. Install the "T" and the two hose clamps supplied with kit, P/N 15213990, into the main tank vent hose. Tighten Tighten the hose clamps to 2.5 N.m (22 lb in). 9. Install the new auxiliary tank vent hose and clamp supplied with kit, P/N 15213990, to the "T" that was just installed. Tighten Tighten the hose clamp to 2.5 N.m (22 lb in). 10. Connect the new vent hose to the original auxiliary tank hose. 11. Secure the newly installed vent hose and the original auxiliary tank vent hose with plastic ties supplied in kit, P/N 15213990. 12. If necessary, reinstall the left rear tires/wheels assemblies. Page 14379 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves SPLICING COPPER WIRE USING SPLICE SLEEVES TOOLS REQUIRED J 38125-D Terminal Repair Kit IMPORTANT: Use only GM splice sleeves, other splice sleeves may not protect the splice from moisture or a provide good electrical connection. Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. Engine Controls - MIL ON/Misfire/Misfire DTC's Set Engine Control Module: Customer Interest Engine Controls - MIL ON/Misfire/Misfire DTC's Set Bulletin No.: 06-06-04-046 Date: September 12, 2006 INFORMATION Subject: Information on Engine Misfire MIL/SES Light Illuminated or Flashing DTC P0300, P0301, P0302, P0303, P0304, P0305, P0306, P0307, P0308, P0420 or P0430 Models: 1999-2007 Cadillac, Chevrolet, GMC Full-Size Pickup and/or Utility Trucks with 4.8L, 5.3L, 5.7L, 6.0L or 6.2L VORTEC GEN III, GEN IV, V-8 Engine (VINs V, C, T, Z, B, 3, M, 0, J, R, U, N, Y, K, 8 - RPOs LR4, LY2, LM7, L59, L33, LC9, LH6, LMG, LY5, L31, LQ4, LQ9, L76, LY6, L92) with Active Fuel Management(TM) and E85 Flex Fuel If you encounter vehicles that exhibit the above conditions, refer to SI for the appropriate DTC(s) set. If no trouble is found, the cause may be due to an ECM ground terminal that has corroded with rust over time. Inspect the main engine wiring harness ground terminal (G103) for this condition. The wire terminal (G103) attaches either to the front or to the rear of the right side cylinder head, depending on the model year of the Full Size Pickup and/or Utility Trucks. If the ECM ground terminal has been found to be corroded, then follow the service procedure outlined in this bulletin to correct the corrosion issue. Remove either the nut or bolt securing the main engine wiring harness ground terminal (G103) to the right cylinder head. Refer to the above illustration to determine where the ground is located on the vehicle (1). Description and Operation Passenger Compartment Cross Beam: Description and Operation Magnesium Instrument Panel Support Instrument Panel Support The Instrument Panel Support is a one-piece component comprised of a magnesium steering column support (Fig. 1.21), which holds the instrumentation and steering column; a die-formed tube attaches to the passenger side and supports the dashboard. This assembly functions as a structural cross-vehicle beam, air-bag support, and instrument panel carrier, which consolidates many different steel and plastic components. The magnesium instrument panel support is designed to deform and absorb energy generated by a severe impact. NOTE: Under no circumstance is the magnesium support to be repaired in any way. If any of the following conditions are present after a collision, the magnesium support must be replaced: - Steering column capsules have released or column has collapsed. - The steel knee bolster brackets are bent. - The parts which attach to the magnesium support do not fit. Page 5656 Pressure Regulating Solenoid: Service and Repair Automatic Transmission - 4L80-E/4L85-E Pressure Regulator Replacement ^ Tools Required J 36850 Transjel Removal Procedure 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. Remove the transmission filter. 3. Caution: Valve springs can be tightly compressed. Use care when removing retainers and plugs. Personal injury could result. Remove the reverse boost valve bushing retainer ring (2). 4. Remove the following from the reverse boost valve cylinder: ^ The reverse boost valve bushing ^ The reverse boost valve ^ The pressure regulator spring retainer ^ The pressure regulator spring ^ The pressure regulator valve ^ The reverse boost valve bushing Installation Procedure 1. Install the pressure regulator valve using J 36850. 2. Pre-assemble the following parts: A/T - 4L60-E/4L65-E New Pump/Seal/Case/Service Seals and Gaskets: All Technical Service Bulletins A/T - 4L60-E/4L65-E New Pump/Seal/Case/Service Bulletin No.: 04-07-30-023 Date: May 12, 2004 INFORMATION Subject: Oil Pump Assembly Seal and Transmission Case Change Models: 2002-2004 Cars and Light Duty Trucks with 4L60-E or 4L65-E Automatic Transmissions (RPOs M30, M32 or M33) An improved oil pump to case seal design has been made to the 4L60-E/4L65-E transmission. The new design affects the oil pump, the oil pump seal, the transmission pan bolts and the transmission case. The complete design was implemented in three phases. The first phase, beginning in September 2002, relocated the machining of the oil pump 0-ring seal groove in the pump body. The 0-ring seal groove moved 1.6 mm (0.62 in) inward on the pump body in order to place the sealing surface deeper into the case bore. The relocated pump body groove can be identified by measuring the groove location. Pump bodies that measure 2.3 mm (0.09 in) from the machined surface to the groove opening have the relocated 0-ring seal groove. Pump bodies that measure 3.9 mm (0.15 in) are prior to September 2002 design. Page 10479 The torque specification for the wheel drive shaft nut has been revised as shown in the table. Disclaimer Engine Controls - MIL ON/Rough Idle/Misfire/DTC's Set Oxygen Sensor: Customer Interest Engine Controls - MIL ON/Rough Idle/Misfire/DTC's Set Bulletin No.: 05-06-04-063 Date: October 12, 2005 TECHNICAL Subject: LM7, L59 or L33 Engines with Cold Start Rough or Incorrect Idle, Misfire, Malfunction Indicator Lamp (MIL) or Flashing Requiring 02 Sensor Replacement (Reprogram PCM) Models: 2004-2005 Cadillac Escalade 2004-2005 Chevrolet Avalanche, Silverado 1500, Suburban, Tahoe 2005 Chevrolet Silverado Hybrid (HP2) 2004-2005 GMC Sierra 1500, Yukon, Yukon XL 2005 GMC Sierra Hybrid (PH2) with Vortec 5300 5.3L V-8 Engine (VINs T, Z, B - RPOs LM7, L59, L33) Condition Some customers may comment on a Malfunction Indicator Lamp (MIL) On or that the MIL is flashing. An actual engine misfire may or may not be felt along with an incorrect idle speed. Typically this occurs during cold winter months, on cold engine starts. Some vehicles may have been previously serviced for the same condition. Technicians may also find the following DTCs stored with the Tech 2(R) P0131, P0133, P0134, P0137, P0138, P0140, P0151, P0153, P0154, P0157, P1133, which may be in conjunction with P0171, P0174, P0300 and P1138. Cause Water shock occurs when water droplets are present in the exhaust. The water in the exhaust contacts the sensor element inside the H02 sensor, causing the H02 sensor element to crack. Correction Upon diagnostic investigation, the technician may find that the H02 sensor requires replacement. In addition to replacing the affected H02 sensor, these vehicles should also be reflashed with the latest PCM calibration. An updated PCM calibration will be available to dealerships as part of TIS 2000 incremental satellite update 11.0 (NAO version 25.010) or greater. Always, make sure your Tech 2 is updated with the latest software version. Important: If a DTC P0420 or P0430 is stored along with DTC(s) P0300, the catalytic converter diagnostics in Service Information (SI) must be followed to determine if the catalytic converters are operating properly. Warranty Information For vehicles repaired under warranty, use the table. Page 4323 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-8 (12085115) crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-8 (12085115) until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes SPLICING INLINE HARNESS DIODES Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate Service Data wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. 9. Tape the diode to the harness or connector using electrical tape. Interior - Erratic Memory Seat Operation Memory Positioning Module: All Technical Service Bulletins Interior - Erratic Memory Seat Operation Bulletin No.: 04-08-50-016C Date: August 12, 2005 TECHNICAL Subject: Memory Seat May Not Return to Requested Position (Reprogram Driver Seat Module) Models: 2003-2005 Cadillac Escalade, Escalade ESV, Escalade EXT 2003-2005 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2003-2005 GMC Sierra, Yukon, Yukon XL, Yukon Denali All with Seat FRT, Individual (Non BKT) (RPO AN3) 2003-2005 HUMMER H2 with Seat, Front Bucket Deluxe (RPO AR9) Supercede: This bulletin is being revised to update the correction information. Please discard Corporate Bulletin Number 04-08-50-016B (Section 08 - Body and Accessories). Condition Some customers may comment that with repeated cycling of the memory seat between the "exit" and one of the "presets", the position of the seat may "creep" forward or rearward out of expected adjustment. Cause There is a coding deficiency in the software for the memory seat module. Correction Technicians are to reprogram the driver seat module with an updated software calibration. The previous bulletin stated to use a service calibration that was released with TIS satellite data update version 4.5. Feedback has proved that calibration to be ineffective in eliminating the memory seat creep condition. An updated service calibration was released with TIS satellite data update version 6.5 available June 13, 2005. This new calibration has additional memory seat creep protection. As always, make sure your Tech 2(R) is updated with the latest software version. Important: After programming is complete, move the seat all the way rearward and down, then bump the seat slightly forward and up. This position will be just off the end of travel hard stops. Reset both memory seat exit positions at this position. Having the seat set at just off the hard stops will aid in reducing the creep condition. Warranty Information Page 9073 Fuse Block: Application and ID Fuse Block - Underhood Location View Description and Operation Pedal Positioning Switch: Description and Operation Brake Pedal Position Sensor Calibration Description and Operation Calibration Criteria The brake pedal position (BPP) sensor receives a low reference signal and a 5-volt reference signal from the electro-hydraulic power steering (EHPS). Whenever the brake pedal is applied, the brake pedal position sensor applies a variable voltage signal to the EHPS through the BPP sensor signal circuit. Brake pedal position sensor calibration must be performed after the brake pedal position sensor or EHPS system have been serviced. The calibration procedure will set brake pedal position sensor home value. This value is used by the EHPS to determine the brake pedal position and the brake pedal rate. These two outputs are provided to the hybrid control module (HCM) via GMLAN. Calibration Procedure 1. Install a scan tool. 2. Turn ON the ignition, with the engine OFF. 3. Important: Make sure the brake pedal is not depressed before sending BPP sensor calibration command. Navigate to the Special Functions screen on the scan tool and select BPP Sensor Calibration in order to perform the brake pedal position sensor calibration. A/T - 4T80E, Slips in Gear/L/H Axle Seal Leaks Clutch: All Technical Service Bulletins A/T - 4T80E, Slips in Gear/L/H Axle Seal Leaks TECHNICAL Bulletin No.: 08-07-30-009B Date: May 01, 2008 Subject: HYDRA-MATIC(R) Front Wheel Drive 4T80-E (MH1) Left Front Axle Seal Leak, Transmission Slips in Gear (Replace Third Clutch Housing with Revised Service Part) Models: 2001-2008 GM Passenger Cars with HYDRA-MATIC(R) Front Wheel Drive 4T80-E Automatic Transmission (RPO - MH1) Supercede: This bulletin is being updated to revise the Warranty Information. Please discard Corporate Bulletin Number 08-07-30-009A (Section 07 - Transmission/Transaxle). Condition Some customers may comment on a transmission oil leak and/or that the transmission slips in gear. Cause An oil leak may be caused by bushing wear in the third clutch housing, causing excessive fluid build-up at axe sea. Correction Important: DO NOT replace the transmission for above concerns. Replace the third clutch housing with service P/N 8682114, which has revised bushing material to extend life and reduce left front axle seal leaks. Refer to Automatic/Transaxle - 4T80-E Transmission Off-Vehicle Repair Instructions for the replacement of the third clutch housing in SI. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 9427 7. Insert the J 38125-13A (GM P/N 12031876-1) tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the Terminal Repair Kit to ensure that the correct release tool is used. 8. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. REPAIR PROCEDURE Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. Page 9602 Relay Block - I/P C8 (With RPO Codes 5G4/5X7/5Y0/TRW) Manual Transmission - NV 3500 Vehicle Speed Sensor: Service and Repair Manual Transmission - NV 3500 Vehicle Speed Sensor (VSS) Replacement Removal Procedure 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. Disconnect the vehicle speed sensor (VSS) electrical connector (1). 3. Remove the VSS and O-ring seal. Installation Procedure Page 13882 The moldings are available in factory colors; however, quantities are limited. When these quantities are exhausted, the moldings will only be available in paint to match only. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 5426 Fuel Gauge Sender: Specifications FUEL LEVEL SPECIFICATIONS Page 4520 Control Module References Part 1 Page 14697 Page 12460 Important: Secure the wiring harness so that there is no risk of chafing or rattling. 6.1. Remove the passenger seat in accordance with WIS 8. Body - Seats Adjustment/Replacement. 6.2. Remove the right-hand B-pillar trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.3. Remove the right-hand C pillar trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.4. Fold the rear seat backrest forward. 6.5. Remove the right-hand side bolster in accordance with WIS - 8. Body - Seats Adjustment/Replacement. 6.6. Remove the A-pillar's lower side piece. 6.7. Open the cover on the right-hand wiring harness channels. 6.8. Loosen the locking strip (A) on the 2-pin connector (H2-11) for the optic cable, located by the right-hand A-pillar. 6.9. Loosen the catch (B) and remove the optic cable that runs backward in the car. 6.10. Dismantle the end cap from the new optic cable (12 783 577) and connect it to the connector H2-11. Push in the optic cable and make sure the catch (B) locks and refit the locking strip (A). 6.11. Secure the connector and the old optic cable using the cable tie for the existing wiring harness (C). Page 9049 Junction Block - Rear Lamps - C4 Relay Block - I/P C1 Page 6868 Seat the pinion yoke onto the pinion shaft by tapping it with a soft-faced hammer until a few pinion shaft threads show through the yoke. 5. Install the washer. 6. Install the new pinion nut 7. Install the J 8614-01 onto the pinion yoke as shown. 8. Notice: Refer to Fastener Notice in Service Precautions. Tighten the pinion nut while holding the J 8614-01. ^ Tighten the pinion nut to 370 Nm (273 ft. lbs.). 9. Install the propeller shaft to the rear axle pinion yoke. 10. Inspect and add axle lubricant to the axle housing, if necessary. 11. Lower the vehicle. Drive Pinion Housing and/or Seal Replacement Drive Pinion Housing and/or Seal Replacement ^ Tools Required J 44414 Pinion Seal Installer - J 22912-01 Bearing Puller - J 24433 Pinion Cone and Side Bearing Installer - J 37624 Pinion Bearing Installer - J 8092 Driver Handle Page 14244 Seat Memory Switch: Service and Repair MEMORY SEAT SWITCH REPLACEMENT REMOVAL PROCEDURE 1. Remove the front door trim panel. 2. Disconnect the electrical connector. 3. Release the front seat memory switch assembly retaining clips in order to remove the switch. 4. Remove the front seat memory switch assembly. INSTALLATION PROCEDURE 1. Install the front seat memory switch assembly to the front trim panel by pressing into place until fully seated. 2. Connect the electrical connector to the front seat memory switch assembly. 3. Install the front trim panel. Campaign - Unwanted Repeat Calls to OnStar(R) Technical Service Bulletin # 10037 Date: 100420 Campaign - Unwanted Repeat Calls to OnStar(R) CUSTOMER SATISFACTION Bulletin No.: 10037 Date: April 20, 2010 Subject: 10037 - Unwanted Repeat Calls to OnStar(R) Models: 2003 Buick LeSabre 2004-2006 Buick Rendezvous 2005 Buick LeSabre, Terraza 2005-2006 Buick LaCrosse/Allure 2006-2008 Buick Lucerne 2008 Buick LaCrosse/Allure 2008-2009 Buick Enclave 2003 Cadillac CTS 2004 Cadillac Escalade 2004-2005 Cadillac CTS-V, Deville 2005 Cadillac Escalade ESV, SRX 2005-2006 Cadillac STS 2005-2008 Cadillac CTS 2006-2008 Cadillac DTS 2007 Cadillac Escalade, Escalade EXT 2007-2008 Cadillac Escalade ESV 2008 Cadillac SRX, STS 2002 Chevrolet Impala 2003-2008 Chevrolet Suburban 2003-2009 Chevrolet Silverado 2004-2008 Chevrolet Impala 2005 Chevrolet Colorado, Corvette, Malibu 2005-2006 Chevrolet Uplander 2005-2008 Chevrolet Avalanche, Tahoe, TrailBlazer 2006 Chevrolet HHR, Monte Carlo 2006-2008 Chevrolet Equinox 2007-2008 Chevrolet Corvette 2008 Chevrolet HHR 2008-2009 Chevrolet Cobalt, Colorado, Malibu, Uplander 2003 GMC Envoy XL, Sierra, Yukon XL 2004-2008 GMC Yukon 2005-2009 GMC Sierra 2005-2008 GMC Yukon XL 2006-2008 GMC Envoy 2007 GMC Canyon 2007-2009 GMC Acadia 2006 HUMMER H2 2006-2008 HUMMER H3 2008 HUMMER H2 2003 Oldsmobile Silhouette 2005 Montana SV6 2005-2008 Pontiac Grand Prix 2006 Pontiac G6, Vibe 2007 Pontiac Montana SV6 2007-2008 Pontiac Solstice 2008 Pontiac G6, Torrent 2008-2009 Pontiac G5, G8 2009 Pontiac G3, Montana SV6 2005-2007 Saturn ION 2006-2009Saturn VUE 2007-2008 Saturn AURA, OUTLOOK, SKY Equipped with OnStar(R) (RPO UE1) Page 9305 Relay Box: Locations Relay Block - I/P Location View Page 9857 8. Install the left side end panel. Page 9827 Junction Block - I/P Wire Entry Part 1 Page 15220 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Micro-Pack 100W Connectors MICRO-PACK 100W CONNECTORS TOOLS REQUIRED J 38125-D Terminal Repair Kit REMOVAL PROCEDURE There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2)has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. IMPORTANT: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Page 13393 Electrical Symbols Part 5 Page 8744 14. If equipped with a 4.8L, 5.3L, or 6.0L engine, install the battery cable bracket and bolt to the power steering pump. Tighten Tighten the bolt to 25 N.m (18 lb ft). 15. Connect the negative battery cable. Audio Amplifier C1 - With RPO Code UQ7, Without RPO Code Y91 Amplifier: Diagrams Audio Amplifier C1 - With RPO Code UQ7, Without RPO Code Y91 Audio Amplifier C1 - With RPO Code UQ7, Without RPO Code Y91 - Part 1 Page 14389 Door Module: Connector Views Driver Door Module (DDM) - C1 (With RPO Code YE9) Engine - Rough Idle/Misfire/MIL ON/DTC P0300 Intake Air Plenum Gasket: All Technical Service Bulletins Engine - Rough Idle/Misfire/MIL ON/DTC P0300 Bulletin No.: 05-06-04-029A Date: June 24, 2005 TECHNICAL Subject: Flexible Fuel (RPO L59) Rough Idle, Misfire, MIL DTC P0300 (Install Intake Manifold Gaskets With Teal Green Gasket Material) Models: 2002-2004 Chevrolet Silverado, Suburban, Tahoe 2002-2004 GMC Sierra, Yukon, Yukon XL with 5.3L Engine and Flexible Fuel (VIN Z - RPO L59) This bulletin may apply to the following engines using regular fuel: 4.8L, 5.3L, 6.0L (VINs V, T, P, U, N - RPOs LR4, LM7, LM4, LQ4, LQ9). Supercede: This bulletin is being revised to add additional diagnostic information. Please discard Corporate Bulletin Number 05-06-04-029 (Section 06 - Engine/Propulsion System). Important: Always begin your diagnosis with the Diagnostic System Check - Engine Controls (SI Document ID # 1289827) for any MIL or driveability concern. The Diagnostic System Check directs you to the next logical step in your diagnosis. Follow the instructions in this bulletin should the rough idle, misfire, or DTC P0300 diagnostic procedure point to an air leak in the intake manifold gasket. Following the published diagnostic procedures will improve diagnostic accuracy and support our fix it right the first time approach. Condition Some customers may comment that the vehicle may have a rough idle, misfires and/or a MIL illuminated with a stored DTC P0300. Cause The L59 engine is calibrated for ethanol fuel (E85). Due to the low volatility of ethanol, the PCM provides higher fuel flow through the injector, which may pool on the upper manifold to head gasket material. Overtime (usually 12 months and longer), the gasket material may degrade resulting in an unmetered air leak. Correction Replace the upper intake manifold gaskets with the teal green gasket material, P/N 89017589. Important: Do not replace the upper intake manifold gaskets with the original orange gasket material, P/N 17113557. Inspect Intake Manifold to Cylinder head Deck for Warpage Page 9363 Tighten Tighten to 8 Nm (71 lb in). Note The repair area MUST BE properly refinished to maintain a secure, stable and corrosion-free electrical ground. 12. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 13. Verify proper system operation. M8 Weld Nut Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M8 weld nut electrical ground location is accessible from both sides of the panel, a M8 conductive bolt and a M8 conductive nut may be used to secure the electrical ground wire terminal. Refer to the Parts Information section of this bulletin. 2. Select a location adjacent the M8 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the new electrical ground site. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the ground location and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 10 mm (0.40 in) diameter hole through the panel. 5. Remove paint and primer from the area surrounding the 10 mm (0.40 in) hole until bare metal is visible. 6. Select a M8 conductive bolt. Refer to the Parts Information section of this bulletin. 7. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M8 conductive bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 8. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 9. Install the electrical ground wire terminal and the M8 conductive bolt to the ground location. 10. Select a M8 conductive nut. Refer to the Parts Information section of this bulletin. 11. Install the M8 conductive nut to the bolt and: Tighten Tighten to 22 Nm (16 lb ft). Note The repair area MUST BE properly refinished to maintain a secure, stable and corrosion-free electrical ground. 12. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 13. Verify proper system operation. M8 Weld Nut Alternative Repair Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M8 weld nut electrical ground location is not accessible from both sides of the panel, a M6 conductive rivet stud and a M6 conductive nut may be used to secure the electrical ground wire terminal. 2. Select a location adjacent the damaged M8 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the M6 conductive rivet stud flange. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the repair site and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 10 mm (0.40 in) diameter hole through the panel. Page 8600 Claim Information Refer to the General Motors WINS Claims Processing Manual for details on Product Recall Claim Submission. Customer Notification -- For US and Canada General Motors will notify customers of this recall on their vehicle (see copy of customer letter shown in this bulletin). Customer Notification -- For Letters will be sent to known owners of record located within areas covered by the US National Traffic and Motor Vehicle Safety Act. For owners outside these areas, dealers should notify customers using the sample letter. Dealer Recall Responsibility -- For US and Export (US States, Territories and Possessions) The US National Traffic and Motor Vehicle Safety Act provides that each vehicle which is subject to a recall of this type must be adequately repaired within a reasonable time after the customer has tendered it for repair. A failure to repair within sixty days after tender of a vehicle is prima facie evidence Page 7567 12. Install the cover. Notice: Refer to Fastener Notice in Service Precautions. 13. Install 2 NEW screws (1) to the casting. ^ Tighten the screws to 2 Nm (18 inch lbs.). 14. Install 2 NEW longer screws (2) to the motor cover. ^ Tighten the screws to 3 Nm (26 inch lbs.). 15. Install the encoder motor. Page 9764 C320 Seat Jumper Harness To Seat Harness (With RPO Code AN3) Part 1 Brakes - Park Brake Shoe Retaining Clip Kit Parking Brake Shoe: Technical Service Bulletins Brakes - Park Brake Shoe Retaining Clip Kit Bulletin No.: 02-05-26-001C Date: January 19, 2005 INFORMATION Subject: Rear Parking Brake Shoe Retaining Spring Clip Service Kit for Drum-in-Hat (DIH) Equipped Vehicles Models: 2004-2005 Buick Rainier 2002-2005 Cadillac Escalade Models 2002-2005 Chevrolet Avalanche 1998-2005 Chevrolet Blazer 1999-2005 Chevrolet Silverado Models 2000-2005 Chevrolet Suburban, Tahoe 2002-2005 Chevrolet SSR, TrailBlazer Models 2003-2005 Chevrolet Astro, Express 1998-2005 GMC Jimmy 1999-2005 GMC Sierra Models 2000-2005 GMC Yukon Models 2002-2005 GMC Envoy Models 2003-2005 GMC Safari, Savana 1998-2004 Oldsmobile Bravada This Bulletin ONLY applies to 1500 series vehicles with four wheel disc brakes. Supercede: This bulletin is being revised to include additional models and clarify parts usage information. Please discard Corporate Bulletin Number 02-05-26-001B (Section 05 - Brakes). A rear parking brake retaining spring clip kit has been released for service. This kit consists of two parking brake hold down spring clips (2) and bolts (3). Note: Use J 46277 Rotor Removal Tool with J 6125-B Slide Hammer to remove the rotor from the vehicle. Place J 46277 between the rotor surfaces in the vent section of the rotor. DO NOT place J 46277 on the back side of the rotor surface, it may damage the rotor surface. During rear brake rotor removal, it is possible to damage the parking brake shoe retaining spring clip. Order this new kit when replacement of the clips is required but the parking brake shoes do not require replacement. Page 2367 Brake Fluid: Fluid Type Specifications HYDRAULIC BRAKE SYSTEM Delco Supreme II Brake Fluid or equivalent DOT-3 brake fluid. Page 9985 Looking at the FRONT of the sensor, align the sensor with the steering shaft and install into the adapter and bearing assembly. 24. Install the connector to the sensor. Page 16273 Washer Fluid Level Switch Page 5638 Spark Plug: Testing and Inspection SPARK PLUG INSPECTION - Verify that the correct spark plug is installed. An incorrect spark plug causes driveability conditions. Refer to Ignition System Specifications for the correct spark plug. - Ensure that the spark plug has the correct heat range. An incorrect heat range causes the following conditions: Spark plug fouling - Colder plug - Pre-ignition causing spark plug and/or engine damage - Hotter plug - Inspect the terminal post (1) for damage. Inspect for a bent or broken terminal post (1). - Test for a loose terminal post (1) by twisting and pulling the post. The terminal post (1) should not move. - Inspect the insulator (2) for flashover or carbon tracking, or soot. This is caused by the electrical charge traveling across the insulator (2) between the terminal post (1) and ground. Inspect for the following conditions: Inspect the spark plug boot for damage. - Inspect the spark plug recess area of the cylinder head for moisture, such as oil, coolant, or water. A spark plug boot that is saturated will cause arcing to ground. Page 10351 9. Remove the steering knuckle (2) from the vehicle. Installation Procedure 1. Install the steering knuckle (2) to the vehicle. 2. Install the upper ball joint. 3. Install the lower ball joint. 4. Notice: Refer to Fastener Notice in Service Precautions. Install the park brake cable retaining bolt (3) to the steering knuckle. ^ Tighten the bolt to 65 Nm (48 ft. lbs.). 5. Install the wheel hub and bearing. OnStar(R) - Negative Impact of Cloth/Vinyl Roofs Navigation System: All Technical Service Bulletins OnStar(R) - Negative Impact of Cloth/Vinyl Roofs INFORMATION Bulletin No.: 02-08-44-007D Date: May 12, 2009 Subject: Negative Impact of Dealer-Installed Cloth/Vinyl Roofs on XM Radio and/or OnStar(R) Systems Models: 2002-2009 Passenger Cars and Trucks (Including Saturn) 2003-2009 HUMMER H2 2006-2009 HUMMER H3 2005-2009 Saab 9-7X with XM Radio (RPO U2K) and/or OnStar(R) (RPO UE1) .............................................................................................................................................................. .................................................................................. Supercede: This bulletin is being revised to include the 2009 model year. Please discard Corporate Bulletin Number 02-08-44-007C (Section 08 - Body and Accessories). .............................................................................................................................................................. .................................................................................. Dealers should not install a cloth or vinyl roof on vehicles that have been ordered with the XM radio option (RPO U2K) and/or OnStar(R) (RPO UE1). The performance of these systems may be negatively impacted by the installation of the cloth/vinyl roof. Additionally, water leaks may result from installing a cloth or vinyl roof on vehicles with roof-mounted antenna systems. Relocating the antenna to another spot on the vehicle exterior, in order to install a cloth or vinyl roof, is not advised either. The performance of the OnStar(R) and XM Radio antennas has been optimized for their current locations. Relocating the antennas may result in a performance degradation. Disclaimer Page 14316 WA9539/47 - WA9566/13 Page 2865 Extended Cab Short Box Shown Below, Other Configurations Similar 6. Install the new canister vent valve solenoid to the fuel tank clip or mounting bracket as shown above. The valve port closest to the electrical connector must point towards the canister. 7. Cut bulk 5/8" heater hose to a length of approximately 76 mm (3 in). Install the hose between the solenoid and the canister pipe and secure using clamps. 8. Attach bulk 5/8" heater hose to the vent port and secure using a clamp. Run a length as needed along the frame rail routing to the area above the transmission. 9. Cut the hose to determined length and install the supplied filter box. Secure using a clamp. 10. Remove the transmission support and lower the transmission assembly as necessary to allow for access to the new filter box location. 11. Secure the filter box to the transmission vent hose just forward of the hose tee-section using a tie strap. DO NOT pinch or restrict the transmission vent hose. The filter box opening should be pointing downward. 12. Raise the transmission and reinstall the transmission support. 13. Connect the EVAP canister vent valve electrical connector. 14. Tie strap the hose as needed along the frame rail in order to keep the hose away from pinch-points and heat sources. 15. Lower the vehicle. Correction (2007-2010 New Style Models) After following the published SI diagnostics and determining that the EVAP canister vent valve is the cause of the MIL light, replace the EVAP canister vent valve assembly and relocate the remote filter box. To ensure correct installation, follow the procedures below. Important DO NOT replace the EVAP canister assembly for this concern unless it fails the leak test. Use Service Kit P/N 19207763 1. Raise the vehicle. Suitably support the vehicle. 2. Disconnect the EVAP canister vent valve electrical connector. Page 12423 Seat Memory Switch: Service and Repair MEMORY SEAT SWITCH REPLACEMENT REMOVAL PROCEDURE 1. Remove the front door trim panel. 2. Disconnect the electrical connector. 3. Release the front seat memory switch assembly retaining clips in order to remove the switch. 4. Remove the front seat memory switch assembly. INSTALLATION PROCEDURE 1. Install the front seat memory switch assembly to the front trim panel by pressing into place until fully seated. 2. Connect the electrical connector to the front seat memory switch assembly. 3. Install the front trim panel. Page 1170 Seat Bolster/Lumbar Switch - Front Passenger (With RPO Code AN3) Page 5327 Fuel Rail: Description and Operation Fuel System Description (Cab Chassis) FUEL RAIL ASSEMBLY The fuel rail assembly attaches to the engine intake manifold. The fuel rail assembly performs the following functions: Positions the injectors (3) in the intake manifold - Distributes fuel evenly to the injectors - Integrates the fuel pressure regulator (2) with the fuel metering system Page 8089 Wheel Speed Sensor: Service and Repair Wheel Speed Sensor Replacement (4WD) Caution: Refer to Brake Dust Caution in Service Precautions. Removal Procedure 1. Raise and support the vehicle. 2. Remove the tire and wheel. 3. Remove the brake rotor (2) shown on the 1500 series. Refer to Brake Rotor Replacement - Front in Disc Brakes. 4. Remove the WSS cable mounting clip from the knuckle. 5. Remove the WSS cable mounting clip from the upper control arm. 6. Remove the WSS cable mounting clip from the frame attachment point. 7. Remove the WSS cable electrical connector. Brake Caliper Replacement - Front Brake Caliper: Service and Repair Brake Caliper Replacement - Front Brake Caliper Replacement - Front Caution: Refer to Brake Dust Caution in Service Precautions. Caution: Refer to Brake Fluid Irritant Caution in Service Precautions. Removal Procedure 1. Inspect the fluid level in the brake master cylinder reservoir. 2. If the brake fluid level is midway between the maximum-full point and the minimum allowable level, no brake fluid needs to be removed from the reservoir before proceeding. 3. If the brake fluid level is higher than midway between the maximum-full point and the minimum allowable level, remove brake fluid to the midway point before proceeding. 4. Raise and support the vehicle. Refer Vehicle Lifting 5. Remove the tire and wheel assembly. 6. Compress the brake caliper pistons. ^ Install a large C-clamp over the top of the caliper housing and against the back of the outboard pad. ^ Slowly tighten the C-clamp until the pistons are pushed completely into the caliper bores. ^ Remove the C-clamp from the caliper. 7. Clean all dirt and foreign material from the brake hose end. 8. Important: Install a rubber cap or plug to the exposed brake pipe fitting end to prevent brake fluid loss and contamination. Remove the brake hose to caliper bolt from the brake caliper. 9. Remove and discard the 2 copper brake hose gaskets. These gaskets may be stuck to the brake caliper housing or the brake hose end. 10. Remove the brake hose from the caliper. Electrical - Aftermarket Fuse Warning Fuse: All Technical Service Bulletins Electrical - Aftermarket Fuse Warning Bulletin No.: 07-08-45-002 Date: September 05, 2007 ADVANCED SERVICE INFORMATION Subject: Service Alert: Concerns With Aftermarket Fuses in GM Vehicles Models: 2008 and Prior GM Passenger Cars and Light Duty Trucks (including Saturn) 2008 and Prior HUMMER H2, H3 2008 and Prior Saab 9-7X Concerns with Harbor Freight Tools "Storehouse" Branded Blade Type Fuses General Motors has become aware of a fuse recall by Harbor Freight Tools/Storehouse for a variety of aftermarket fuses. In two cases, these fuses have not provided protection for the wiring system of the vehicles they were customer installed in. Upon testing the 15 amp version, it was found that the fuse still would not "open" when shorted directly across the battery terminals. How to Identify These Fuses Packed in a 120 piece set, the fuse has a translucent, hard plastic, blue body with the amperage stamped into the top. There are no white painted numbers on the fuse to indicate amperage. There are no identifying marks on the fuse to tell who is making it. The fuses are known to be distributed by Harbor Freight Tools but there may be other marketers, and packaging of this style of fuse. It would be prudent to replace these fuses if found in a customers vehicle. Likewise, if wiring overheating is found you should check the fuse panel for the presence of this style of fuse. All GM dealers should use genuine GM fuses on the vehicles they service. You should also encourage the use of GM fuses to your customers to assure they are getting the required electrical system protection. GM has no knowledge of any concerns with other aftermarket fuses. If additional information becomes available, this bulletin will be updated. Disclaimer Page 7447 Notice: Refer to Fastener Notice in Service Precautions. 3. Install the transfer case adapter bolts. ^ Tighten the bolts to 50 Nm (37 ft. lbs.). 4. Install the transmission mount. 5. Install the transmission mount bolts. ^ Tighten the bolts to 47 Nm (35 ft. lbs.). 6. Install the crossmember. 7. Install the crossmember bolts. ^ Tighten the bolts to 70 Nm (52 ft. lbs.). Page 6022 Page 7055 5. Remove the bolts (6) and the yoke retainers (7) from the front axle pinion yoke (1). 6. Disconnect the propeller shaft (2) from the front axle pinion yoke (1). Wrap the bearing caps with tape in order to prevent the loss of bearing rollers. Notice: When removing the propeller shaft, do not attempt to remove the shaft by pounding on the yoke ears or using a tool between the yoke and the universal joint. If the propeller shaft is removed by using such means, the injection joints may fracture and lead to premature failure of the joint. Important: Do not drop the bearing cap assemblies of the yoke end. 7. Disconnect the boot from the groove on the OD of the transfer case output shaft. 8. Remove the propeller shaft from the transfer case output shaft by sliding the propeller shaft forward. Installation Procedure 1. Inspect the splines of the transfer case output shaft for a sufficient coating of lubricant. If the output shaft does not have a sufficient coating of lubricant, lubricate the shaft with grease, GM P/N 12345879 (Canadian P/N 10953511) or equivalent lubricant meeting GM Specification 9985830. 2. Install a new clamp onto the propeller shaft boot. 3. Install the propeller shaft splines into the transfer case output shaft. Page 12983 Tighten the screws to 2 N.m (53 lb in). 6. Install the door trim panel. 7. Verify the component operation. Speaker Replacement - Rear Door (Extended Cab) SPEAKER REPLACEMENT - REAR DOOR (EXTENDED CAB) REMOVAL PROCEDURE 1. Remove the door trim panel. 2. Remove the speaker by pushing down on the retainer. 3. Disconnect the electrical connector. INSTALLATION PROCEDURE 1. Install the electrical connector. 2. Install the speaker by snapping the speaker into place. 3. Install the door trim panel. 4. Verify the component's operation. Page 3649 Heater Hose: Service and Repair Heater Hose Replacement - Inlet (With RPO Code HP2 Rear) HEATER HOSE REPLACEMENT - INLET (W/ HP2 REAR) TOOLS REQUIRED J 43181 Quick Connect Connector Removal Tool REMOVAL PROCEDURE 1. Drain the cooling system. Refer to Draining and Filling Cooling System (with HP2)Draining and Filling Cooling System (without HP2) in Cooling System. 2. Using the J 43181 disconnect the heater hose from the heater core inlet. 2.1. Install the J 43181 to the heater core pipe. 2.2. Close the tool around the heater core pipe. 2.3. Firmly pull the tool into the quick connect end of the heater hose. 2.4. Firmly grasp the heater hose. Pull the heater hose forward in order to disengage the hose from the heater core. 3. Reposition the inlet heater hose clamp (2) from the auxiliary water pump (1). 4. Remove the inlet heater hose (3) from the auxiliary water pump (1). INSTALLATION PROCEDURE OnStar(R) - Number Incorrect/Incorrectly Assigned Navigation System: All Technical Service Bulletins OnStar(R) - Number Incorrect/Incorrectly Assigned INFORMATION Bulletin No.: 05-08-46-004C Date: December 23, 2010 Subject: OnStar(R) Phone Number Concerns (Phone Number Incorrect/Assigned to Another Vehicle/Phone) That Occur During Diagnosis of OnStar(R) System Models: 2000-2011 GM Passenger Cars and Trucks Equipped with OnStar(R) (RPO UE1) Supercede: This bulletin is being revised to update model years up to 2011. Please discard Corporate Bulletin Number 05-08-46-004B (Section 08 - Body and Accessories). During diagnosis of an OnStar(R) concern, the technician may be told that the OnStar(R) phone number is incorrect or tied to another vehicle and/or phone of some kind. To resolve these concerns, the Tech 2(R) with software version 22.005 (or higher), has the capability to change the OnStar(R) phone number. Service Procedure 1. With the Tech 2(R), build the vehicle to specifications within the Diagnostics area of the Tech 2(R). 2. For vehicles with physical-based diagnostics - under Body, go to the OnStar(R) section. Then select the Special Functions menu. For vehicles with functional-based diagnostics - under Body and Accessories, go to the Cellular Communication section. Select Module Setup and then Vehicle Communication Interface Module. 3. Locate the Program Phone Number prompt and select it. The original phone number will be displayed on the Tech 2(R) screen. 4. Contact the OnStar(R) team at the GM Technical Assistance Center (TAC) to obtain a new phone number. 5. Highlight the digits of the phone number one at a time and enter the new phone number using the number keys on the Tech 2(R). 6. Press the Soft key at the base of the screen for Done once these numbers have been changed on the screen. 7. Press the Soft key for Done again. The area code or new phone number has now been programmed into the phone. 8. Cycle the ignition to Off and open the driver's door. 9. Press the blue OnStar(R) button to make sure that a normal connection can be made to the OnStar(R) call center. If applicable, make sure the Hands-Free Calling (HFC) works properly by making a phone call. 10. If the system is working properly, fax or voicemail a case closing into the OnStar(R) team at TAC with the results. Dealers in Canada should submit case closing information through the GM infoNET. Please follow this diagnostic process thoroughly and complete each step. If the condition exhibited is resolved WITHOUT completing every step, the remaining steps do not need to be performed. If the procedure above does not resolve the condition, you must contact TAC for further assistance. This diagnostic approach was developed specifically for this condition and should not automatically be used for other vehicles with similar symptoms. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use: Warranty Information (Saab Models) For vehicles repaired under warranty, use the table. Page 9182 C115 Chassis Harness To I/P Harness (With RPO Code NYS) Part 1 Page 865 Electrical Symbols ELECTRICAL SYMBOLS Electrical Symbols Part 1 Page 11467 1. Align the block tooth on the upper shaft to the 12 o'clock position (1). NOTE: Ensure all fasteners are securely seated before applying needed torque. Failure to do so may result in component damage or malfunctioning of steering column. 2. Install the wave washer (1) to the steering column upper shaft. 3. A new SIR coil assembly will come pre-centered. However if centering is required, refer to Inflatable Restraint Steering Wheel Module Coil Centering in Steering Wheel and Column. 4. Align the SIR coil (2) with the horn tower on the turn signal cancel cam (1) IMPORTANT: Do not remove the tab on the SIR coil until installation is complete. 5. Install the pre-centered SIR coil (2) to the steering column upper shaft. Page 6832 3. Install the pinion yoke.Align the marks made during removal. 4. Notice: Refer to Pinion Flange/Yoke Installation Notice in Service Precautions. Seat the pinion yoke onto the pinion shaft by tapping it with a soft-faced hammer until a few pinion shaft threads show through the yoke. 5. Install the washer and a new pinion nut. 6. Install the J 8614-01 onto the pinion yoke as shown. 7. Notice: Refer to Fastener Notice in Service Precautions. Important: If the rotating torque is exceeded, the pinion will have to be removed and a new collapsible spacer installed. ^ Tighten the pinion nut while holding the J 8614-01. ^ Tighten the nut until the pinion end play is just taken up. Rotate the pinion while tightening the nut to seat the bearings. 8. Measure the rotating torque of the pinion. Compare this measurement with the rotating torque recorded during removal. ^ Tighten the nut in small increments, as needed, until the rotating torque is 0.40-0.57 Nm (3-5 inch lbs.) greater than the rotating torque recorded during removal. 9. Once the specified torque is obtained, rotate the pinion several times to ensure the bearings have seated. Recheck the rotating torque and adjust if necessary. 10. Install the propeller shaft (3) to the pinion yoke (4). Align the reference marks made during removal. 11. Install the propeller shaft yoke retaining clamps and the bolts. ^ Tighten the propeller shaft yoke retaining clamp bolts to 25 Nm (18 ft. lbs.). Page 13532 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly, Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Pull to Seat Connectors PULL TO SEAT CONNECTORS TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Engine Controls - MIL ON/Misfire/Misfire DTC's Set Engine Control Module: All Technical Service Bulletins Engine Controls - MIL ON/Misfire/Misfire DTC's Set Bulletin No.: 06-06-04-046 Date: September 12, 2006 INFORMATION Subject: Information on Engine Misfire MIL/SES Light Illuminated or Flashing DTC P0300, P0301, P0302, P0303, P0304, P0305, P0306, P0307, P0308, P0420 or P0430 Models: 1999-2007 Cadillac, Chevrolet, GMC Full-Size Pickup and/or Utility Trucks with 4.8L, 5.3L, 5.7L, 6.0L or 6.2L VORTEC GEN III, GEN IV, V-8 Engine (VINs V, C, T, Z, B, 3, M, 0, J, R, U, N, Y, K, 8 - RPOs LR4, LY2, LM7, L59, L33, LC9, LH6, LMG, LY5, L31, LQ4, LQ9, L76, LY6, L92) with Active Fuel Management(TM) and E85 Flex Fuel If you encounter vehicles that exhibit the above conditions, refer to SI for the appropriate DTC(s) set. If no trouble is found, the cause may be due to an ECM ground terminal that has corroded with rust over time. Inspect the main engine wiring harness ground terminal (G103) for this condition. The wire terminal (G103) attaches either to the front or to the rear of the right side cylinder head, depending on the model year of the Full Size Pickup and/or Utility Trucks. If the ECM ground terminal has been found to be corroded, then follow the service procedure outlined in this bulletin to correct the corrosion issue. Remove either the nut or bolt securing the main engine wiring harness ground terminal (G103) to the right cylinder head. Refer to the above illustration to determine where the ground is located on the vehicle (1). Page 359 2. Disconnect the C2 32-way blue connector from the VIU and tape the connector to a secure location. Refer to Cellular Communications Connector End Views and related schematics in SI, if required. Important: DO NOT perform the OnStar(R) reconfiguration and/or programming procedure. 3. Secure the VIU in its original brackets and/or mounting locations and reinstall the VIU and interior components that were removed to gain access to the VIU. Refer to OnStar Vehicle Interface Unit Replacement in SI. 2002 Through 2006 Model Year Vehicles (Except Saab Vehicles) 2002 through 2006 Model Year Vehicles (Except Saab Vehicles) Important: The Tech 2 diagnostic tool must be updated with version 28.002 or later in order to successfully perform the VCIM setup procedure and disable the analog system. 1. Connect the Tech 2 to the data link connector (DLC), which is located under the instrument panel of the vehicle. 2. Turn the Tech 2 ON by pressing the power button. Important: Tech 2 screen navigation to get to the setup procedure depends on the year and make of the vehicle. The actual name of the setup procedure (Setup New OnStar or VCIM Setup) depends on model year and vehicle make as well. Example Tech 2 navigation to the setup procedure Tech 2 screen is provided below. ^ Diagnostics >> (2) 2002 >> Passenger Car >> Body >> C >> OnStar >> Special Functions >> Setup New OnStar >> ^ Diagnostics >> (5) 2005 >> Passenger Car >> (4) Buick >> C >> Body >> Vehicle Comm. Interface Module >> Module Setup >> VCIM Setup >> 3. Setup VCIM using the Tech 2. Follow on-screen instructions when you have reached the setup Tech 2 screen. 2000-2002 Saab 9-3 (9400) 4D/5D; 2000-2003 Saab 9-3 (9400) CV 2000-2002 Saab 9-3 (9400) 4D/5D; 2000-2003 Saab 9-3 (9400) CV 1. Remove the ground cable from the battery's negative terminal. 2. Apply the handbrake brake. 3. Detach the floor console. 4. Remove the switch and the floor console: 3.1. Twist loose the immobilizer unit (A), bayonet fitting. Unplug the unit's connector. 3.2. Remove the ignition switch cover (B) by first undoing the rear edge of the cover and then unhooking the front edge. Unplug the ignition Page 2311 1. Install the discharge hose (1) to the vehicle. 2. Connect the electrical connector to the A/C recirculation switch. 3. Install the discharge hose to the condenser using new sealing washers. NOTE: Refer to Fastener Notice in Service Precautions. 4. Install the discharge hose nut to the condenser. Tighten Tighten the nut to 16 N.m (12 lb ft). 5. Install the upper air baffle. Page 14291 WA805K/62 - WA811K/87 Page 10775 1. Install the stud. 2. Install the 4 washers and the lug nut to the stud. 3. Tighten the lug nut in order to draw the stud into the flange until the stud fully seats. 4. Remove the lug nut and the washers. 5. Install the axle shaft for the vehicles with 9.5 in ring gear. 6. Install the rear hub assembly for the vehicles with 10.5/11.5 in ring gear, with single wheels. 7. Install the rear axle hub for vehicles with dual wheels. Refer to Rear Axle Hub, Bearing, Cup, and/or Seal Replacement. 8. Install the rotor, except dual wheels. 9. Install the tire and wheel. 10. Remove the safety stands. 11. Lower the vehicle. Page 6033 Park Neutral Position (PNP) Switch C175 Page 6971 A/T - 4T80E, Slips in Gear/L/H Axle Seal Leaks TECHNICAL Bulletin No.: 08-07-30-009B Date: May 01, 2008 Subject: HYDRA-MATIC(R) Front Wheel Drive 4T80-E (MH1) Left Front Axle Seal Leak, Transmission Slips in Gear (Replace Third Clutch Housing with Revised Service Part) Models: 2001-2008 GM Passenger Cars with HYDRA-MATIC(R) Front Wheel Drive 4T80-E Automatic Transmission (RPO - MH1) Supercede: This bulletin is being updated to revise the Warranty Information. Please discard Corporate Bulletin Number 08-07-30-009A (Section 07 - Transmission/Transaxle). Condition Some customers may comment on a transmission oil leak and/or that the transmission slips in gear. Cause An oil leak may be caused by bushing wear in the third clutch housing, causing excessive fluid build-up at axe sea. Correction Important: DO NOT replace the transmission for above concerns. Replace the third clutch housing with service P/N 8682114, which has revised bushing material to extend life and reduce left front axle seal leaks. Refer to Automatic/Transaxle - 4T80-E Transmission Off-Vehicle Repair Instructions for the replacement of the third clutch housing in SI. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Technical Service Bulletin # 08-07-30-009B Date: 080501 A/T - 4T80E, Slips in Gear/L/H Axle Seal Leaks TECHNICAL Bulletin No.: 08-07-30-009B Page 6458 6. Important: DO NOT hold the transmission end (1) during this operation, this will result in a mis-adjusted cable. Release the transmission end (3) and allow the spring (2) to tension/adjust the cable system. 7. Pull the white cover (5) on the shifter end (1) back. 8. Push the natural colored lock button (4) down to engage the locking teeth on the transmission end (3). 9. Release the white cover (1). 10. Verify the white cover (1) conceals the natural colored lock (2). Page 15228 SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-D. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: - The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair Tools Required J 38125-D Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-D. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Page 9314 Junction Block - I/P Wire Entry Part 1 Page 4226 6. The Melco(R) (1) ignition coil is a square design. 7. The Delphi(R) (2) ignition coil is a round design. 8. The Melco(R) ignition coil bracket (1) is a square design. 9. The Delphi(R) ignition coil bracket (2) is a round design. INSTALLATION PROCEDURE 1. Install the spark plug wire to the ignition coil. 2. Install the spark plug wire to the spark plug. 3. Inspect the spark plug wire for proper installation: 3.1. Push sideways on each boot in order to inspect the seating. EVAP Canister Vent Solenoid Valve Replacement 1 Canister Vent Valve: Service and Repair EVAP Canister Vent Solenoid Valve Replacement 1 EVAPORATIVE EMISSION (EVAP) CANISTER VENT SOLENOID VALVE REPLACEMENT (PICKUP) REMOVAL PROCEDURE IMPORTANT: Clean the evaporative emission (EVAP) connections and surrounding areas prior to disconnecting the fittings in order to avoid possible system contamination. 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. Remove the harness clip from the canister vent solenoid (CVS) line. 3. Disconnect the CVS electrical connector. 4. If the vehicle is equipped with a 6 ft box, disconnect the EVAP CVS line from the canister. 5. Remove the CVS clip from the frame crossmember. 6. Push in the retainer and remove the CVS from the fuel tank clip. Automatic Transmission - 4L60-E/4L65-E Transmission Position Switch/Sensor: Service and Repair Automatic Transmission 4L60-E/4L65-E Park/Neutral Position Switch Replacement ^ Tools Required J 41364-A Park Neutral Switch Aligner Removal Procedure 1. Apply the park brake. 2. Shift the transmission into neutral. 3. If equipped with 4-wheel drive (4WD), remove the front propeller shaft. 4. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 5. Disconnect the park/neutral position (PNP) switch electrical connector (2). 6. Remove the manual shaft lever nut. Page 5418 For vehicles repaired under warranty, use the table. Disclaimer Page 3841 Body Control Module: Removal and Replacement BODY CONTROL MODULE REPLACEMENT REMOVAL PROCEDURE CAUTION: Refer to Battery Disconnect Caution in Service Precautions. 1. Disconnect the negative battery cable(s). 2. Remove the knee bolster. 3. Disconnect the brown connector. 4. Disconnect all other connectors (1). 5. Remove the BCM from the sliding bracket. INSTALLATION PROCEDURE Page 15231 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Locations Page 6978 2. Drive the axle shaft bearing into the axle housing until the tool bottoms against the tube. 3. Install the axle shaft seal using the J 21128 (8.6 inch axle) or the J 29713 (9.5 inch axle). 4. Drive the tool into the bore until the axle shaft seal bottoms flush with the tube. 5. Install the axle shaft. 6. Install the rear axle housing cover. 7. Install the tire and wheel assembly. 8. Fill the rear axle. 9. Lower the vehicle. Page 3040 Wheels: Service and Repair Aluminum Wheel Refinishing Aluminum Wheel Refinishing A protective clear coating covers the surface of original equipment cast aluminum wheels. A surface degradation may develop if frequent automatic car wash cleaning wears off the factory applied protective clear coating. This can happen at some automatic car wash facilities that use aggressive brushes to clean whitewalls and tires. Once you damage the protective clear coating, exposure to caustic cleaners and road salt can cause further surface deterioration. Damage to the protective clear coating is corrected by replacing the damaged wheel. Refinishing is no longer recommended. Page 16099 IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. Splicing Twisted or Shielded Cable SPLICING TWISTED OR SHIELDED CABLE Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. - Rewrap the conductors with the mylar tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with mylar tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Control Module References Page 10133 3. Connect the electrical connectors to the module. 4. Program the control module. Refer to Service Programming System (SPS) in Programming. 5. Install the spare tire to the vehicle. 6. Lower the vehicle. 7. Perform a learn alignment. See: Testing and Inspection/Programming and Relearning Page 8505 Use clean, new power steering fluid only. 12. Fill the pump reservoir with fluid to the FULL COLD level. 13. Attach J 43485, Power Steering Bleeder Adapter, to J 35555, Metal Mityvac, or equivalent. 14. Place J 43485 on or in the pump reservoir filler neck. 15. Apply a vacuum of 68 kpa (20 in Hg) maximum. 16. Wait 1 minute. 17. Remove 1 J43485 and J 35555. 18. Reinstall the pump reservoir cap. 19. Start the engine. Allow the engine to idle. 20. Turn the steering wheel 180-360 degrees in both directions 5 times. 21. Switch the ignition off 22. Verify the fluid level. 23. Release the park brake and unblock the wheels. Page 7807 Electronic Components OnStar(R) - Negative Impact of Cloth/Vinyl Roofs Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Negative Impact of Cloth/Vinyl Roofs INFORMATION Bulletin No.: 02-08-44-007D Date: May 12, 2009 Subject: Negative Impact of Dealer-Installed Cloth/Vinyl Roofs on XM Radio and/or OnStar(R) Systems Models: 2002-2009 Passenger Cars and Trucks (Including Saturn) 2003-2009 HUMMER H2 2006-2009 HUMMER H3 2005-2009 Saab 9-7X with XM Radio (RPO U2K) and/or OnStar(R) (RPO UE1) .............................................................................................................................................................. .................................................................................. Supercede: This bulletin is being revised to include the 2009 model year. Please discard Corporate Bulletin Number 02-08-44-007C (Section 08 - Body and Accessories). .............................................................................................................................................................. .................................................................................. Dealers should not install a cloth or vinyl roof on vehicles that have been ordered with the XM radio option (RPO U2K) and/or OnStar(R) (RPO UE1). The performance of these systems may be negatively impacted by the installation of the cloth/vinyl roof. Additionally, water leaks may result from installing a cloth or vinyl roof on vehicles with roof-mounted antenna systems. Relocating the antenna to another spot on the vehicle exterior, in order to install a cloth or vinyl roof, is not advised either. The performance of the OnStar(R) and XM Radio antennas has been optimized for their current locations. Relocating the antennas may result in a performance degradation. Disclaimer Page 4857 7. Remove the HO2S. INSTALLATION PROCEDURE IMPORTANT: A special anti-seize compound is used on the HO2S threads. The compound consists of liquid graphite and glass beads. The graphite tends to burn away, but the glass beads remain, making the sensor easier to remove. New, or service replacement sensors already have the compound applied to the threads. If the sensor is removed from an exhaust component and if for any reason the sensor is to be reinstalled, the threads must have anti-seize compound applied before the reinstallation. 1. If reinstalling the old sensor, coat the threads with anti-seize compound GM P/N 12377953, or equivalent. NOTE: Refer to Component Fastener Tightening Notice in Service Precautions. 2. Install the HO2S. Tighten Tighten the sensor to 42 N.m (31 lb ft). Page 2750 Relay Box: Diagrams Junction Block - Rear Lamps - C1 Transfer Case - NVG 149-NP3 Fluid - Transfer Case: Service and Repair Transfer Case - NVG 149-NP3 Transfer Case Fluid Replacement Removal Procedure Important: When performing the following procedure, use only hand tools to remove and install the drain and fill plugs. 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. Remove the transfer case shield, if equipped. 3. Remove the fill plug. 4. Remove the drain plug. Important: Ensure that an approved drain pan is used when draining the transfer case. 5. Allow the transfer case to drain completely. Installation Procedure 1. Install the drain plug. ^ Tighten the plug to 20 Nm (15 ft. lbs.). Notice: Refer to Fastener Notice in Service Precautions. Important: Use only drain and fill plugs that are made from aluminum. Steel or brass plugs are not compatible with the magnesium case. Service and Repair Blower Motor Impeller: Service and Repair BLOWER MOTOR IMPELLER REPLACEMENT (VISTEON) REMOVAL PROCEDURE 1. Remove the sound insulator panel. 2. Disconnect the electrical connector (2) from the blower motor (1). 3. Remove the screws from the blower motor (1). 4. Remove the blower motor (1) from the HVAC module (3). 5. Remove the retainer from the blower motor impeller. Discard the retainer. 6. Remove the blower motor impeller from the blower motor (1). INSTALLATION PROCEDURE 1. Install the blower motor impeller to the blower motor (1). 2. Install the new retainer to the blower motor impeller. 3. Install the blower motor (1) to the HVAC module (3). NOTE: Refer to Fastener Notice in Service Precautions. 4. Install the screws to the blower motor (1). Tighten Tighten the screws to 2 N.m (18 lb in). 5. Connect the electrical connector (2) to the blower motor (1). 6. Install the sound insulator panel Underhood Electrical Center or Junction Block Replacement Relay Box: Service and Repair Underhood Electrical Center or Junction Block Replacement UNDERHOOD ELECTRICAL CENTER OR JUNCTION BLOCK REPLACEMENT REMOVAL PROCEDURE 1. Disconnect the negative battery cable. 2. Remove the left fender upper brace. 3. Remove the electrical center brace cover assemble by lifting the cover (3) outwards to clear the tabs. 4. Remove all fuses and relays. Component Locations Fluid Pressure Sensor/Switch: Component Locations Automatic Transmission - 4L60-E/4L65-E Automatic Transmission Electronic Component Views (M30/M32) Electronic Components Page 2758 Junction Block - I/P Wire Entry Part 3 Page 2713 Fuse Block: Application and ID Fuse Block - Underhood - Secondary Location View Page 12066 For vehicles repaired under warranty use, the table. Disclaimer Locations Discharge Air Temperature Sensor / Switch: Locations Air Temperature Sensors - Upper Left And Right Restraints - Passenger Presence System Information Seat Occupant Sensor: All Technical Service Bulletins Restraints - Passenger Presence System Information INFORMATION Bulletin No.: 06-08-50-009F Date: December 23, 2010 Subject: Information on Passenger Presence Sensing System (PPS or PSS) Concerns With Custom Upholstery, Accessory Seat Heaters or Other Comfort Enhancing Devices Models: 2011 and Prior GM Passenger Cars and Trucks Equipped with Passenger Presence Sensing System Supercede: This bulletin is being revised to update the model years. Please discard Corporate Bulletin Number 06-08-50-009E (Section 08 - Body and Accessories). Concerns About Safety and Alterations to the Front Passenger Seat Important ON A GM VEHICLE EQUIPPED WITH A PASSENGER SENSING SYSTEM, USE THE SEAT COVERS AND OTHER SEAT-RELATED EQUIPMENT AS RELEASED BY GM FOR THAT VEHICLE. DO NOT ALTER THE SEAT COVERS OR SEAT-RELATED EQUIPMENT. ANY ALTERATIONS TO SEAT COVERS OR GM ACCESSORIES DEFEATS THE INTENDED DESIGN OF THE SYSTEM. GM WILL NOT BE LIABLE FOR ANY PROBLEMS CAUSED BY USE OF SUCH IMPROPER SEAT ALTERATIONS, INCLUDING ANY WARRANTY REPAIRS INCURRED. The front passenger seat in many GM vehicles is equipped with a passenger sensing system that will turn off the right front passenger's frontal airbag under certain conditions, such as when an infant or child seat is present. In some vehicles, the passenger sensing system will also turn off the right front passenger's seat mounted side impact airbag. For the system to function properly, sensors are used in the seat to detect the presence of a properly-seated occupant. The passenger sensing system may not operate properly if the original seat trim is replaced (1) by non-GM covers, upholstery or trim, or (2) by GM covers, upholstery or trim designed for a different vehicle or (3) by GM covers, upholstery or trim that has been altered by a trim shop, or (4) if any object, such as an aftermarket seat heater or a comfort enhancing pad or device is installed under the seat fabric or between the occupant and the seat fabric. Aftermarket Seat Heaters, Custom Upholstery, and Comfort Enhancing Pads or Devices Important ON A GM VEHICLE EQUIPPED WITH A PASSENGER SENSING SYSTEM, USE ONLY SEAT COVERS AND OTHER SEAT-RELATED EQUIPMENT RELEASED AS GM ACCESSORIES FOR THAT VEHICLE. DO NOT USE ANY OTHER TYPE OF SEAT COVERS OR SEAT-RELATED EQUIPMENT, OR GM ACCESSORIES RELEASED FOR OTHER VEHICLE APPLICATIONS. GM WILL NOT BE LIABLE FOR ANY PROBLEMS CAUSED BY USE OF SUCH IMPROPER SEAT ACCESSORIES, INCLUDING ANY WARRANTY REPAIRS MADE NECESSARY BY SUCH USE. Many types of aftermarket accessories are available to customers, upfitting shops, and dealers. Some of these devices sit on top of, or are Velcro(R) strapped to the seat while others such as seat heaters are installed under the seat fabric. Additionally, seat covers made of leather or other materials may have different padding thickness installed that could prevent the Passenger Sensing System from functioning properly. Never alter the vehicle seats. Never add pads or other devices to the seat cushion, as this may interfere with the operation of the Passenger Sensing System and either prevent proper deployment of the passenger airbag or prevent proper suppression of the passenger air bag. Disclaimer Page 7265 module commands the TAC motor to increase or decrease the engine RPM. TAC Motor The TAC motor is part of the throttle body and controls the positions of the throttle. The motor is bi-directional and is controlled by the TAC module. The TAC motor increases or decreases the engine RPM. Page 4759 Accelerator Pedal Position Sensor: Service and Repair ACCELERATOR PEDAL POSITION (APP) SENSOR REPLACEMENT REMOVAL PROCEDURE NOTE: Handle the electronic throttle control components carefully. Use cleanliness in order to prevent damage. Do not drop the electronic throttle control components. Do not roughly handle the electronic throttle control components. Do not immerse the electronic throttle control components in cleaning solvents of any type. 1. Remove the connector position assurance (CPA) retainer. 2. Disconnect the accelerator pedal position (APP) sensor electrical connector. 3. Reposition the carpet to access the lower nut. 4. Remove the accelerator pedal nuts. 5. Remove the accelerator pedal assembly. INSTALLATION PROCEDURE Page 12995 Accessory Delay Module: Symptom Related Diagnostic Procedures A Symptoms SYMPTOMS IMPORTANT: Review the system operation in order to familiarize yourself with the system functions. Refer to Retained Accessory Power (RAP) Description and Operation. Visual/Physical Inspection Inspect for aftermarket devices which could affect the operation of the RAP feature. - Inspect the easily accessible or visible system components for obvious damage or conditions which could cause the symptom. Intermittent Faulty electrical connections or wiring may be the cause of intermittent conditions. Symptom List Refer to a symptom diagnostic procedure from the following list in order to diagnose the symptom: - Retained Accessory Power (RAP) On After Timeout - Retained Accessory Power (RAP) Inoperative Steps 1-3 Page 8672 Parts Information Parts are currently available from GMSPO. Warranty Information Page 10222 Electrical Symbols Part 6 Page 2667 Fuse Block- I/P C3 Part 1 Page 13291 ^ On 2002 Sevilles and DeVilles, the GPS jumper cable MUST be unclipped from the back seat cross brace, or unplugged from the VCIM first. DO NOT pull back on the mounting bracket until the GPS antenna jumper cable is unclipped from the back seat cross brace or unplugged from the VCIM. The short length of jumper cable does not allow the VCIM mounting bracket to be pulled back very far, and could lead to a break at the VCIM connector. ^ On 2000-2002 Bonnevilles and LeSabres and 2001-2002 Auroras you will need to follow these steps: 1. Remove the 4 nuts that secure the VCU/VIU bracket assembly to the rear seat back brace. Note: Save these nuts for later use. 2. Remove and discard the plastic VCU/VIU bracket assembly from the vehicle. 3. Remove the upper right stud (1) from the rear seat back brace and re-install in the middle lower slot (2) on the brace. Tighten the fastener to 4 Nm (36 lb in). 4. Position the new VCIM in the vehicle over the studs on the rear seat back brace. 5. Install two of the nuts saved from step (1). Tighten the nuts to 4 Nm (36 lb in). 6. Connect the new OnStar jumper harness supplied in the kit to the VCIM (two white connectors) and the body wiring harness (C345 connector). 7. Connect the small coaxial jumper cable supplied in the kit, to the VCIM, with the end that has a blue plastic housing connector. Plug the other end of this coaxial jumper cable to the OnStar Global Positioning Satellite (GPS) antenna coaxial cable at the right angle connector. Note: The GPS cable in the new OnStar jumper harness is not utilized. 8. Connect the cellular coaxial cable to the OnStar VCIM. On 2001 Impala and Monte Carlos you will need to follow these steps: 9. Remove the Vehicle Communications Unit (VCU) and Vehicle Interface Unit (VIU) following the procedures listed in SI. Save the bracket nuts for later use. Page 2347 1. Notice: Refer to Fastener Notice in Service Precautions. Install the power steering cooler (1) to the radiator support. ^ Tighten the bolts retaining the power steering cooler to 5 Nm (44 inch lbs.). 2. Install the power steering cooler outlet hose (3) to the power steering pump (2). 3. Install the retaining clamp. 4. Install the power steering inlet hose (5) to the power steering gear (1). 5. Install the retaining clamp. 6. Fill and bleed the power steering system. Refer to Bleeding the Power Steering System. 7. Inspect all the hose connections for leaks. 8. Install the front grille. Refer to Grille Replacement (GMC) Grille Replacement (Chevrolet) in Exterior Trim. (Without Hydroboost) Power Steering Cooler Pipe/Hose Replacement (Without Hydroboost) Removal Procedure 1. Remove the front grille. Refer to Grille Replacement (GMC) Grille Replacement (Chevrolet) in Exterior Trim. 2. Notice: Refer to Power Steering Hose Disconnected Notice in Service Precautions. Remove the clamp retaining the power steering outlet hose (3) from the power steering gear (4). 3. Remove the clamp retaining the power steering inlet hose from the power steering pump (5). Page 3802 6. Use fingers to squeeze the 2 locking legs of the cover. 7. Apply pressure and gently rock the cover until one locking leg is unseated. 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. Page 4735 Page 7278 Power Take-Off: Service and Repair POWER TAKE-OFF (PTO) SWITCH REPLACEMENT REMOVAL PROCEDURE 1. Remove the I/P cluster bezel. 2. Pull out the switch housing from the I/P. 3. Disconnect the wire connector to the PTO switch. 4. Remove the PTO switch from the switch housing. INSTALLATION PROCEDURE 1. Install the PTO switch to the housing 2. Connect the wire connector to the switch. 3. Install the switch housing to the I/P till it clicks into place. 4. Install the I/P cluster bezel. Drivetrain - Transfer Case Control Module Replacement Control Module: All Technical Service Bulletins Drivetrain - Transfer Case Control Module Replacement Bulletin No.: 05-04-21-002 Date: March 10, 2005 INFORMATION Subject: Guidelines for Replacement of Transfer Case Control Module (TCCM) Models: 2005 and Prior Light Duty Trucks with New Venture Gear (NVG) Transfer Case (RPOs NP1, NP4, NP8) Dealers are replacing the TCCM unnecessarily. Dealers are replacing the TCCM with codes stored in HISTORY only. The TCCM does not have a current fault condition when tested. Parts reviewed at the Warranty Parts Center (WPC) have a 75% No Trouble Found (NTF) rate. The only two legitimate reasons to replace the TCCM are: ^ Diagnostic Trouble Code (DTC) C0550 ^ NO Communication with a scan tool. DTC C0550 This DTC indicates that the module has an internal fault and should be replaced. No Communication ^ The no communication conditions referenced here are also caused by a module internal fault to a point where the module physically will not talk. A technician cannot pull DTCs from the module because it will not communicate. The module is electrically dead. ^ No communication is not to be confused with a U1026 code. This code tells the technician that the module may still be functioning but is temporarily off line. This code may be set by the Instrument Panel (IP) or the Powertrain Control Module (PCM) against the TCCM. The technician needs to figure out why the module went off line. These are typically caused by connection concerns. There is no need to replace a TCCM for a U1026 DTC. Diagnostic Aids ^ When diagnosing a transfer case electrical control system, ALWAYS check power and ground wiring first. ^ Test the connections for intermittent or poor connections, complete plug insertion, bent pins, pushed out terminals and water contamination. Page 833 Application Table Page 5189 Fuel Composition Sensor Locations Chassis And License Lamp Harnesses Hood Latch Replacement Hood Latch: Service and Repair Hood Latch Replacement Hood Latch Replacement Removal Procedure 1. Raise the hood. 2. Remove the upper radiator support baffle. 3. Remove the bolts (2) from the hood release latch (1). 4. Disconnect the hood ajar indicator switch connector, if equipped. 5. Disconnect the hood release cable end from the latch. 6. Remove the hood release latch from the vehicle. Installation Procedure 1. Connect the hood release cable end to the latch. 2. Connect the hood ajar indicator switch connector, if equipped. Page 1902 1. Lubricate the input speed sensor seal with automatic transmission fluid. 2. Install the input speed sensor (1). Notice: Refer to Fastener Notice in Service Precautions. 3. Install the input speed sensor bolt. ^ Tighten the bolt to 11 Nm (96 inch lbs.). 4. Connect the input speed sensor electrical connector (1). 5. Lower the vehicle. Page 15208 High Temperature Conditions Tools Required J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency MEASURING FREQUENCY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage MEASURING VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop MEASURING VOLTAGE DROP NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Page 8584 Tighten Tighten the nuts to 50 N.m (37 lb-ft). 3. Install the booster pump rod to the lever. 4. Install the stop lamp switch to the lever. 5. Install the booster pump rod retainer. 6. Connect the power brake booster outlet hose, the steering gear inlet hose, and the power brake booster inlet hose. Tighten ^ Tighten the power brake booster inlet hose to 28 N.m (20 lb-ft). ^ Tighten the steering gear inlet hose to 28 N.m (20 lb-ft). 7. Install the master cylinder. 8. Install the mounting nuts. Tighten Tighten the mounting bolts to 50 Nm (37 lb-ft). 9. Install the electrical connectors to the electrohydraulic pump and the flow switch. 10. Fill the hydraulic pump reservoir. Important: Maintain the fluid level throughout the bleed procedure. 11. Remove the pump reservoir cap. Important: Page 1992 When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage TESTING FOR A SHORT TO VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity TESTING FOR CONTINUITY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents TESTING FOR ELECTRICAL INTERMITTENTS Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground - Testing for Continuity - Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 msRECORD and emits an audible tone (beep). Coaxial Cable - Navigation and Cellular Telephone Antenna Global Positioning System Antenna: Service and Repair Coaxial Cable - Navigation and Cellular Telephone Antenna COAXIAL CABLE REPLACEMENT - NAVIGATION AND CELLULAR TELEPHONE ANTENNA REMOVAL PROCEDURE 1. Remove the I/P trim panel. 2. Lower the headliner. 3. Disconnect the cables from the antenna base. IMPORTANT: Observe the routing of the cables. 4. Remove the cable retainers from the roof and pillar. 5. Disconnect the cable (3) from the module. INSTALLATION PROCEDURE Page 10852 INSTALLATION PROCEDURE 1. Install the recirculation actuator (1) to the HVAC module assembly (2). NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the screws to the recirculation actuator (1). Tighten Tighten the screws to 2 N.m (18 lb in). 3. Install the evaporator core cover (1) to the HVAC module assembly (2). 4. Install the screws to the evaporator core cover (1). Tighten Tighten the screws to 2 N.m (18 lb in). 5. Install the HVAC module assembly. 6. Reprogram the recirculation actuator. Refer to Re-Calibrating Actuators. Page 2160 Drive Belt: Service and Repair Air Conditioning Drive Belt Replacement - Air Conditioning Removal Procedure 1. Remove the accessory drive belt. 2. Raise and suitably support the vehicle. 3. Remove the engine shield bolts. 4. Remove the engine shield. 5. Install a ratchet into the air conditioning (A/C) belt tensioner adapter opening. 6. Rotate the A/C belt tensioner clockwise in order to relieve tension on the belt. 7. Remove the A/C belt from the pulleys. 8. Slowly release the tension on the A/C belt tensioner. 9. Remove the ratchet from the A/C belt tensioner. 10. Clean and inspect the belt surfaces of all the pulleys. Installation Procedure 1. Install the A/C belt around the crankshaft balancer. 2. Install a ratchet into the A/C drive belt tensioner adapter opening 3. Rotate the A/C belt tensioner clockwise in order to relieve tension on the tensioner. 4. Install the A/C belt over the idler pulley. 5. Install the A/C belt around the A/C compressor pulley. Page 9100 8. Install the left side end panel. Page 8160 12. Wait 15 seconds, then repeat steps 10-11 until a firm pedal is obtained. This will properly seat the brake caliper pistons and brake pads. W/O NYS Brake Caliper Bracket Replacement - Rear (15/25 Series w/o NYS) Caution: Refer to Brake Dust Caution in Service Precautions. Removal Procedure 1. Raise and support the vehicle. Refer Vehicle Lifting 2. Remove the tire and wheel assembly. 3. Notice: Support the brake caliper with heavy mechanic's wire, or equivalent, whenever it is separated from its mount and the hydraulic flexible brake hose is still connected. Failure to support the caliper in this manner will cause the flexible brake hose to bear the weight of the caliper, which may cause damage to the brake hose and in turn may cause a brake fluid leak. Remove the brake caliper from the brake caliper mounting bracket and support the brake caliper with heavy mechanic's wire or equivalent. DO NOT disconnect the hydraulic brake hose from the brake caliper. 4. Remove the brake pads from the brake caliper mounting bracket. 5. Remove the anti-rattle clips from the brake caliper bracket. 6. Remove the brake caliper bracket mounting bolts (2). 7. Remove the brake caliper bracket (1). 8. Remove any contaminants or foreign material from the inside ends of the brake caliper bracket. 9. Clean the mounting surface and threads of the brake caliper bracket. Installation Procedure Engine Controls - MIL ON/Misfire/Misfire DTC's Set Ground Strap: All Technical Service Bulletins Engine Controls - MIL ON/Misfire/Misfire DTC's Set Bulletin No.: 06-06-04-046 Date: September 12, 2006 INFORMATION Subject: Information on Engine Misfire MIL/SES Light Illuminated or Flashing DTC P0300, P0301, P0302, P0303, P0304, P0305, P0306, P0307, P0308, P0420 or P0430 Models: 1999-2007 Cadillac, Chevrolet, GMC Full-Size Pickup and/or Utility Trucks with 4.8L, 5.3L, 5.7L, 6.0L or 6.2L VORTEC GEN III, GEN IV, V-8 Engine (VINs V, C, T, Z, B, 3, M, 0, J, R, U, N, Y, K, 8 - RPOs LR4, LY2, LM7, L59, L33, LC9, LH6, LMG, LY5, L31, LQ4, LQ9, L76, LY6, L92) with Active Fuel Management(TM) and E85 Flex Fuel If you encounter vehicles that exhibit the above conditions, refer to SI for the appropriate DTC(s) set. If no trouble is found, the cause may be due to an ECM ground terminal that has corroded with rust over time. Inspect the main engine wiring harness ground terminal (G103) for this condition. The wire terminal (G103) attaches either to the front or to the rear of the right side cylinder head, depending on the model year of the Full Size Pickup and/or Utility Trucks. If the ECM ground terminal has been found to be corroded, then follow the service procedure outlined in this bulletin to correct the corrosion issue. Remove either the nut or bolt securing the main engine wiring harness ground terminal (G103) to the right cylinder head. Refer to the above illustration to determine where the ground is located on the vehicle (1). Page 2596 For vehicles repaired under warranty, use the table. Disclaimer Page 1615 1. Apply sealant GM P/N 12346004, (Canadian P/N 10953480), or equivalent, to the threads of the oil pressure sensor. Notice: Refer to Fastener Notice in Service Precautions. 2. Using J 41712 or equivalent, install the oil pressure sensor. ^ Tighten the oil pressure sensor to 30 Nm (22 ft. lbs.). 3. Connect the oil pressure sensor electrical connector (1). 4. If necessary, install the engine sight shield. Page 4114 7. Use the modified screw extractor in order to remove the plug. 8. Remove the parking pawl shaft retainer, shaft and pawl. 9. Important: If the manual shaft binds in the case during removal, file or sand the shaft in the area adjacent to the detent lever. Remove the manual shaft. 10. Remove the manual shaft seal. Installation Procedure 1. Install the pawl shaft. 2. Install the parking pawl. 3. Install the plug using a 8 mm or (5/16 inch) rod with Loctite® or equivalent. 4. Install the retainer. 5. Install the pawl return spring. 6. Install the detent lever to the actuator. 7. Install the actuator over the parking pawl. 8. Install the manual shaft seal. 9. Lubricate the manual shaft with transmission oil and install the manual shaft into the case. 10. Install the nut on the shaft. 11. Install the roll pin. 12. Notice: Refer to Fastener Notice in Service Precautions. Page 764 Control Module HVAC: Service and Repair HVAC System - Manual HVAC CONTROL MODULE REPLACEMENT REMOVAL PROCEDURE 1. Remove the instrument cluster trim plate bezel. 2. Remove the instrument panel storage tray. 3. Remove the accessory switch assembly from the instrument panel. 4. Remove the screws from the HVAC control assembly. 5. Remove the HVAC control assembly, with the following procedure: 5.1. Release the retaining tabs. 5.2. Pull the control head out of the instrument panel carrier. 6. Disconnect the electrical connectors from the HVAC control assembly. INSTALLATION PROCEDURE IMPORTANT: The Key should be in the off position when connecting the electrical connectors to ensure proper calibration. 1. Connect the electrical connectors to the HVAC control assembly. 2. Install the HVAC control assembly. 3. Install the accessory switch assembly to the instrument panel. NOTE: Refer to Fastener Notice in Service Precautions. 4. Install the screws from the HVAC control assembly. Tighten Tighten the screws to 1.9 N.m (17 lb in). Page 5631 1. Install the knock sensors. Tighten Tighten the sensor to 20 N.m (15 lb ft). 2. Connect the knock sensor electrical connectors. 3. Push down on the rubber covers. 4. Install the intake manifold. Page 8347 1. Install the fluid level sensor until the locking tabs snap into place. 2. Connect the electrical connector to the fluid level sensor. Master Cylinder Overhaul Master Cylinder Overhaul Disassembly Procedure Caution: Refer to Brake Fluid Irritant Caution in Service Precautions. 1. Remove the brake master cylinder from the vehicle. 2. Secure the mounting flange of the brake master cylinder in a bench vise so that the rear of the primary piston is accessible. 3. Clean the outside of the master cylinder reservoir on and around the reservoir cap prior to removing the cap and diaphragm. 4. Remove the reservoir cap and diaphragm from the reservoir. 5. Inspect the reservoir cap and diaphragm for the following conditions. If any of these conditions are present, replace the affected component(s). ^ Cuts or cracks ^ Nicks or deformation 6. Remove the master cylinder reservoir from the master cylinder. 7. Using a smooth, round-ended tool, depress the primary piston (2) and remove the piston retainer. 8. Remove the primary piston assembly from the cylinder bore. 9. Plug the cylinder inlet ports and the rear outlet port. Apply low pressure, non-lubricated, filtered air into the front outlet port, in order the remove the secondary piston (1) with the primary (6) and secondary (5) seals, and the return spring. 10. Discard the primary piston assembly, the piston retainer, and the seals and seal retainer from the secondary piston. Assembly Procedure Page 5330 5. Disconnect the following electrical connectors: - Manifold absolute pressure (MAP) sensor (1) - Knock sensor (2) 6. Remove the knock sensor harness connector from the intake manifold. 7. Remove the connector position assurance (CPA) retainer. 8. Disconnect the following electrical connectors from both sides of the engine: - Main coil (2) - Fuel injectors 9. Remove the harness clips from the fuel rail (1). 10. Reposition the upper engine wire harness aside. IMPORTANT: When disconnecting the Multec(R) 2 fuel injector connectors, DO NOT use pliers or other hand tools, as the connector ends may become mangled and be rendered unusable. 11. Perform the following steps in order to disconnect the fuel injector electrical connectors: 11.1. Mark the connectors to their corresponding injectors to ensure correct reassembly. 11.2. Pull the connector position assurance (CPA) retainer (2) on the connector up 1 click. 11.3. Push the tab (1) on the connector in. 11.4. Disconnect the fuel injector connector electrical connector. 11.5. Repeat the steps for each injector connector. Component Locations Pressure Regulating Solenoid: Component Locations Automatic Transmission - 4L60-E/4L65-E Automatic Transmission Electronic Component Views (M30/M32) Electronic Components Page 4145 Intake Air Temperature (IAT)/Mass Air Flow (MAF) Sensor Page 8002 2. Connect the speed sensor electrical connector. 3. Lower the vehicle. Page 11079 Radio (With RPO Code UB7,Y91 Shown, Others Similar) Page 11973 Diagnostic Trouble Codes DTC U1000 and U1255 Circuit/System Description Modules connected to the Class 2 serial data circuit monitor for serial data communications during normal vehicle operation. Operating information and commands are exchanged among the modules. When a module receives a message for a critical operating parameter, the module records the identification number of the module which sent the message for State of Health monitoring. A critical operating parameter is one which, when not received, requires that the module use a default value for that parameter. When a module does not associate an identification number with at least one critical parameter within 5 seconds of beginning serial data communication, DTC U1000 or U1255 DTC is set. When more than one critical parameter does not have an identification number associated with it, the DTC will only be reported once. The Class 2 serial data communications circuit on this vehicle are in a hybrid ring and star configuration. Each module on the ring has 2 serial data circuits connected to it, except the following modules which have only 1 serial data circuit connected them: Page 15473 Fuel Gauge Sender: Specifications FUEL LEVEL SPECIFICATIONS Page 9731 C202 I/P Harness To Brake/Clutch Harness Part 2 Page 8808 Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips SPLICING COPPER WIRE USING SPLICE CLIPS IMPORTANT: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. TOOLS REQUIRED J 38125-D Terminal Repair Kit 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-D in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. Page 15604 Daytime Running Lamp: Description and Operation DAYTIME RUNNING LAMPS (DRL) The daytime running lamps (DRL) will operate when the ignition switch is in the RUN position, for automatic transmissions (A/T), the gear selector is not in the PARK position, the headlamp switch is in the AUTO position, and for manual transmissions (M/T), the park brake is released. When these conditions have been met and the ambient light sensor indicates daytime conditions, the DRL will illuminate. The ambient light sensor is a light sensitive transistor that varies its voltage signal to the body control module (BCM) in response to changes to the outside (ambient) light level. When the BCM receives this signal it will either turn on the DRL or the headlamps for auto headlamp operation. Any function or condition that turns on the headlights will cancel the daytime running lamps operation. The DRL can be manually turned OFF by depressing the AHL/DRL switch in the headlamp switch. The AHL/DRL defeat switch sends a ground signal through the DRL switch signal circuit to the BCM. The BCM then turns OFF the DRL and headlamps switch to manual control. When the AHL/DRL are manually turned OFF at the headlamp switch, the AHL/DRL will default to ON with the next ignition cycle. The DRL are separate lamps independent of the headlamps. With the headlight switch in the AUTO position, the DRL will either be turned ON or OFF, after an approximate 8-second delay depending on whether daylight or low light conditions are sensed. The DRL 10-amp fuse in the underhood fuse block supplies battery positive voltage to the DRL relay switch contacts and relay coil. When the BCM energizes the DRL relay , the DRL receive voltage on the DRL supply voltage circuit. Ground for the DRL is at G100. Powertrain Control Module (PCM) C1 Engine Control Module: Diagrams Powertrain Control Module (PCM) C1 Page 13273 7.1. Remove the console (A) together with the OnStar(R) control modules. 7.2. Remove the connectors (B). Important: The optic cable must not be bent with a radius less than 25 mm (1 in). Important: Secure the wiring harness so that there is no risk of chafing and rattling. 7.3. Fold back the wiring harness and tape over the connectors (C). Fold back the wiring harness once more and secure with cable ties (D). 7.4. Fit the parcel shelf trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 8. CV: Removing the OnStar(R) control modules and securing the wiring: Adjustment/Replacement. 8.1. Open the luggage compartment floor. Page 10689 Install a new spring bumper assembly for 2WD 1500 Series Only with 20" wheels. Reuse the nut from the original bumper. Install the nut to the spring bumper stud. Tighten Tighten the nut to 30 N.m (22 lb ft). Remove the safety stands. Lower the vehicle. Knee Bolster Deflector This modification is required for the following vehicles and ONLY applies to Extended Cab Long Box (K15953) Pickup models: 1999-2005 Chevrolet Silverado and GMC Sierra (1500 Series Only): 2005 Vehicles Built in Pontiac (VIN Code E) prior to VIN Breakpoint 5E100134 2005 Vehicles Built in Oshawa (VIN Code 1) prior to VIN Breakpoint 51113131 2005 Vehicles Built in Ft. Wayne (VIN Code Z) prior to VIN Breakpoint 5Z126605 The following procedure should be followed: Apply the parking brake to prevent the vehicle from moving. Remove the fuse panel cover. Remove the I/P cluster trim plate bezel. Remove the knee bolster. Remove the 2 mm (0.078 in) thick knee bolster deflector. Install the 1.5 mm (0.059 in) thick knee bolster deflector, P/N 12499966. A detailed instruction sheet will be provided with the service part. Re-Programming Page 13990 2001-2002 GMC Yukon Denali and Yukon Denali XL On these vehicles, if a replacement lock cylinder is needed, it can be ordered from GMSPO. The replacement lock cylinder comes already coded with two keys. See Group 16.650 of the appropriate GMSPO Parts Catalog for part number information. If only replacement keys are needed, they can be obtained directly from A-1 Security Mfg. Corporation. See the ordering information listed above. Additional Information Additional replacement lock cylinders (random codes) can also be ordered directly from A-1 in quantities of 10. Each comes complete with 2 keys on a ring and packaged in a poly bag. Listed below is the cost of 10 replacement lock cylinders and keys including shipping: 1 day delivery - $66.63 ' 2 day delivery - $49.28 3 day delivery - $44.97 UPS Ground - $37.29 Blank keys can also be ordered directly from A-1 in quantities of 10. The blanks come in a poly bag and can be used with a profile key cutter to duplicate an existing key. The cost of 10 blanks is $15.40, which includes UPS Ground shipping. Ordering When ordering from A-1, please provide your dealership name, location, and dealer code for identification and if applicable, the 3-digit code from the customer's lock cylinder or key. Additional Shipping Charges Add an additional charge of $10.00 to the above quoted prices when shipping to Alaska, Hawaii, Canada and Puerto Rico. Add an additional $20.00 to the above quoted prices when shipping to remote locations in Alaska, Hawaii and Canada. Payment Terms A credit card is preferred. An account can be set up upon request, payment net 30 days. References will be required. Disclaimer Page 12324 Garage Door Opener Transmitter: Diagnostic Aids Basic Knowledge Required BASIC KNOWLEDGE REQUIRED Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the Service Data. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories CHECKING AFTERMARKET ACCESSORIES Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: - Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions INDUCING INTERMITTENT FAULT CONDITIONS In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: - Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. Diagram Information and Instructions Power Window Switch: Diagram Information and Instructions Truck Zoning TRUCK ZONING Truck Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that corresponds to where they are located in the vehicle. The table explains the numbering system. Page 12842 Involved are certain vehicles within the VIN breakpoints shown above. PARTS INFORMATION -- Saab US Only Customer Notification General Motors will notify customers of this special coverage on their vehicles (see copy of typical customer letter shown in this bulletin - actual divisional letter may vary slightly). Page 1249 For vehicles repaired under warranty, use the table. Disclaimer Page 9784 C411 Left Rear Lamp Harness To Chassis Harness (With RPO Code T79) Page 488 7. Insert the J 38125-13A (GM P/N 12031876-1) tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the Terminal Repair Kit to ensure that the correct release tool is used. 8. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. REPAIR PROCEDURE Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. Junction Block - I/P Relay Box: Locations Junction Block - I/P Location View Location View Page 9982 24. From the technicians point of view, the FRONT of the sensor will have: ^ A flush rotor flange cuff (4) ^ A pin hole (2) for the centering pin. Note the location of the pin hole. ^ An alignment mark (3) on the flush rotor flange cuff (4) for installation ^ A foam ring (1) 25. Remove the connector from the sensor. 26. Remove the sensor from the adapter and bearing assembly. 27. To install the sensor, proceed to step 21 in the installation procedure. Installation Procedure 1. Important: If reusing the existing sensor, no centering of the sensor is required. If installing a new sensor, it will come with a pin installed in the sensor. Do not remove the pin until the sensor is seated. 2. From the technicians point of view, the FRONT of the sensor (1) connector will be on your right.From the technicians point of view, the BACK of the sensor (2) connector will be on your left. 3. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install into the adapter and bearing assembly. 4. Install the connector to the sensor. 5. From the technicians point of view, the FRONT of the sensor will have: ^ A foam ring (4) ^ A pin hole (7) for the centering pin. Note the location of the pin hole. ^ A flushed rotor flange cuff (6) ^ An alignment mark (5) for installation 6. From the technicians point of view, the BACK of the sensor will have: ^ Double D flats (1) Page 14040 4. Remove the quarter panel trim screws. 5. Remove the rear screw from the sill trim plate. 6. Remove the quarter panel. Installation Procedure 1. Install the quarter panel. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the quarter panel trim screws. Tighten the quarter panel trim screws to 2 N.m (18 lb in). 3. Install the rear screw into the sill trim plate. 4. Install the rear window lower molding. 5. Install the jack and tool stowage. 6. Install the coat hook. Page 8341 1. Install the fluid level sensor until the locking tabs snap into place. 2. Connect the electrical connector to the fluid level sensor. TPMS System - Service And Re-Learning Sensor IDs Tire Pressure Sensor: Technical Service Bulletins TPMS System - Service And Re-Learning Sensor IDs INFORMATION Bulletin No.: 10-03-16-001 Date: July 19, 2010 Subject: TPMS System Service and Re-Learning Sensor IDs Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks 2010 and Prior HUMMER H2 2009 and Prior HUMMER H3 2010 and Prior Saturn Models 2009 and Prior Saab 9-7X with Wheel-Mounted Tire Pressure Sensors In the event that the spare tire, which is normally not equipped with a tire pressure monitor (TPM) sensor, is installed in place of one of the road tires and the vehicle is driven above 40 km/h (25 mph) for 20 minutes or more, the TPM indicator icon on the instrument panel cluster (IPC) will flash for approximately one minute and then remain on steady each time the ignition is turned ON, indicating a diagnostic trouble code (DTC) has been set. The driver information center (DIC), if equipped, will also display a SERVICE TIRE MONITOR type message. When the road tire is repaired and reinstalled in the original location, the TPM indicator icon illumination and DIC message may remain displayed until the DTC is cleared. To ensure that the TPM indicator and the DIC message are cleared after service, it is necessary to clear any TPM DTCs using a scan tool. If a scan tool is unavailable, performing the TPM relearn procedure using a TPM diagnostic tool will provide the same results. It is advised to perform the relearn procedure away from other vehicles to prevent picking up a stray sensor signal. If one or more of the TPM sensors are missing or damaged and have been replaced, then the relearn procedure must be performed. Disclaimer Wheels/Tires - 20 Inch Wheels Available From GM Wheels: All Technical Service Bulletins Wheels/Tires - 20 Inch Wheels Available From GM Bulletin No.: 03-03-10-006F Date: September 27, 2006 INFORMATION Subject: 20" Wheels Available Through GM Accessories Models: 1999-2007 Chevrolet Silverado 1500 Series Only (Classic) 1999-2007 GMC Sierra 1500 Series Only (Classic) Excludes 1999-2000 Vehicles with 4.3L Engine (VIN W - RPO L35) Excludes Vehicles with Quadrasteer (RPO NYS) Excludes Parallel Hybrid Truck (RPO HP2) Excludes 2001-2004 Vehicles with Traction Control (RPO NW7) combined with 3.42 Axle Ratio (RPO GU6) Page 5028 Disclaimer Campaign - Unwanted Repeat Calls to OnStar(R) Technical Service Bulletin # 10037 Date: 100420 Campaign - Unwanted Repeat Calls to OnStar(R) CUSTOMER SATISFACTION Bulletin No.: 10037 Date: April 20, 2010 Subject: 10037 - Unwanted Repeat Calls to OnStar(R) Models: 2003 Buick LeSabre 2004-2006 Buick Rendezvous 2005 Buick LeSabre, Terraza 2005-2006 Buick LaCrosse/Allure 2006-2008 Buick Lucerne 2008 Buick LaCrosse/Allure 2008-2009 Buick Enclave 2003 Cadillac CTS 2004 Cadillac Escalade 2004-2005 Cadillac CTS-V, Deville 2005 Cadillac Escalade ESV, SRX 2005-2006 Cadillac STS 2005-2008 Cadillac CTS 2006-2008 Cadillac DTS 2007 Cadillac Escalade, Escalade EXT 2007-2008 Cadillac Escalade ESV 2008 Cadillac SRX, STS 2002 Chevrolet Impala 2003-2008 Chevrolet Suburban 2003-2009 Chevrolet Silverado 2004-2008 Chevrolet Impala 2005 Chevrolet Colorado, Corvette, Malibu 2005-2006 Chevrolet Uplander 2005-2008 Chevrolet Avalanche, Tahoe, TrailBlazer 2006 Chevrolet HHR, Monte Carlo 2006-2008 Chevrolet Equinox 2007-2008 Chevrolet Corvette 2008 Chevrolet HHR 2008-2009 Chevrolet Cobalt, Colorado, Malibu, Uplander 2003 GMC Envoy XL, Sierra, Yukon XL 2004-2008 GMC Yukon 2005-2009 GMC Sierra 2005-2008 GMC Yukon XL 2006-2008 GMC Envoy 2007 GMC Canyon 2007-2009 GMC Acadia 2006 HUMMER H2 2006-2008 HUMMER H3 2008 HUMMER H2 2003 Oldsmobile Silhouette 2005 Montana SV6 2005-2008 Pontiac Grand Prix 2006 Pontiac G6, Vibe 2007 Pontiac Montana SV6 2007-2008 Pontiac Solstice 2008 Pontiac G6, Torrent 2008-2009 Pontiac G5, G8 2009 Pontiac G3, Montana SV6 2005-2007 Saturn ION 2006-2009Saturn VUE 2007-2008 Saturn AURA, OUTLOOK, SKY Equipped with OnStar(R) (RPO UE1) Page 15893 Turn Signal Multifunction Switch - C2 Page 3060 18. Inspect and add axle lubricant to the axle housing, if necessary. 19. Lower the vehicle. Page 918 Body Control Module (BCM) - C3 Part 2 Page 12469 1. Remove the ground cable from the battery's negative cable. 2. Remove the center console, see WIS - Body - Interior. 3. Loosen the gear shift housing (A). AUT: Disconnect the 6-pin connector (B) to improve access to the gear shift housing screws. 4. Disconnect the signal cable from the SRS control module to the OnStar(R) control module and secure the cable. 4.1. Disconnect the connector (A) from the SRS control module and cut the cable tie (B). Page 9801 Junction Block - Rear Lamps - C4 Page 7964 12. Install the cover. Notice: Refer to Fastener Notice in Service Precautions. 13. Install 2 NEW screws (1) to the casting. ^ Tighten the screws to 2 Nm (18 inch lbs.). 14. Install 2 NEW longer screws (2) to the motor cover. ^ Tighten the screws to 3 Nm (26 inch lbs.). 15. Install the encoder motor. Page 12784 2007 Model Year Vehicles and Newer all have Digital OnStar(R) Modules. Part 1 OnStar(R) Description and Operation This OnStar(R) digital system consists of the following components: ^ Vehicle Communication Interface Module (VCIM) ^ OnStar(R) button assembly ^ Microphone ^ Cellular antenna ^ Navigation antenna Note This system also interfaces with the factory installed vehicle audio system. Vehicle Communication Interface Module (VCIM) The vehicle communication interface module (VCIM) is a cellular device that allows the user to communicate data and voice signals over the national cellular network. Power is provided by a dedicated, fused B+ circuit. Ground is provided through the vehicle wiring harness attached to the module. The ignition state is determined by the VCIM through serial data messaging. Dedicated circuits are used to connect the VCIM to a microphone, the button assembly, and to command the status LED. The VCIM communicates with the rest of the vehicle modules using the serial data bus. The module houses 2 technology systems, one to process GPS data, and another for cellular information. The cellular system connects the OnStar(R) system to the cellular carrier's communication system by interacting with the national cellular infrastructure. The module sends and receives all cellular communications over the cellular antenna and cellular antenna coax. GPS satellites orbiting earth are constantly transmitting signals of their current location. The OnStar(R) system uses the GPS signals to provide location on demand. The module also has the capability of activating the horn, initiating door lock/unlock, or activating the exterior lamps using the serial data circuits. These functions can be commanded by the OnStar(R) Call Center per: a customer request. OnStar(R) Button Assembly The OnStar(R) button assembly may be part of the rearview mirror, or a separate, stand alone unit. The button assembly is comprised of 3 buttons and a status LED. The buttons are defined as follows: ^ The answer/end call button, which is black with a white phone icon, allows the user to answer and end calls or initiate speech recognition. ^ The blue OnStar(R) call center button, which displays the OnStar(R) logo, allows the user to connect to the OnStar(R) call center. ^ The emergency button, which displays a white cross with a red background, sends a high priority emergency call to the OnStar(R) call center when pressed. The VCIM supplies 10 volts to the OnStar(R) button assembly on the keypad supply voltage circuit. When pressed, each button completes a circuit across a resistor allowing a specific voltage to be returned to the VCIM on the keypad signal circuit. Depending upon the voltage range returned the VCIM is able to identify which button has been pressed. The OnStar(R) status LED is located with the button assembly. The LED is green when the system is ON and operating normally. When the status LED is green and flashing, it is an indication that a call is in progress. When the LED is red, this indicates a system malfunction is present. In the event there is a system malfunction and the OnStar(R) system is still able to make a call, the LED will flash red during the call. If the LED does not illuminate, this may indicate that the customers OnStar(R) subscription is not active or has expired. Push the blue OnStar button to connect to an advisor who can then verify the account status. Each LED is controlled by the VCIM over dedicated LED signal circuits. Ground for the LED is provided by the wiring harness attached to the button assembly. Page 2405 Page 2696 Relay Block - I/P C9 Part 1 Page 16095 Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips SPLICING COPPER WIRE USING SPLICE CLIPS IMPORTANT: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. TOOLS REQUIRED J 38125-D Terminal Repair Kit 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-D in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. Page 3877 Page 5652 Pressure Regulating Solenoid: Connector Locations A/C - Blower Motor Runs After Vehicle Is Shut OFF Blower Motor Relay: Customer Interest A/C - Blower Motor Runs After Vehicle Is Shut OFF TECHNICAL Bulletin No.: 03-01-38-015A Date: October 27, 2008 Subject: HVAC Blower Motor May Run Continuously After Vehicle is Turned Off (Replace Blower Resistor Relay) Models: 2004 Chevrolet Avalanche, Silverado, Suburban, Tahoe, TrailBlazer, TrailBlazer EXT 2004 GMC Envoy, Envoy XL, Sierra, Yukon, Yukon XL with Manual Control HVAC (RPO CJ3) Built Prior to August, 2003 Supercede: This bulletin is being revised to update the parts information. Please discard Corporate Bulletin Number 03-01-38-015 (Section 01 - HVAC). Condition Some customers may comment on the HVAC blower motor running after the vehicle has been turned off. The blower may run for just a few minutes or continuously until the battery is discharged. Cause A new style HVAC blower relay/resistor may stick in the "on" position. When the HVAC fan blower relay has been energized, the contacts may "micro-weld" together. After this occurrence, the HVAC blower may not respond to the HVAC controller commands. Correction Replace the HVAC blower resistor/relay with the type used previous to the 2004 model year. The appropriate part numbers are listed in the table below. For specific repair procedures, refer to the 2004 Service Information (SI) under Blower Motor Resistor Assembly Replacement (SI Document ID # 526350 (C/K) or # 729996 (S/T). Parts Information Warranty Information Disclaimer Page 4136 Accelerator Pedal Position Sensor: Diagrams Accelerator Pedal Position (APP) Sensor Part 1 Page 6872 1. Install the inner pinion bearing cup into the pinion gear bearing retainer using the J 37624 (2) and the J 8092 (1). 2. Install the outer pinion bearing cup into the pinion gear bearing retainer using the J 8608 (2) and the J 8092 (1). 3. Install the inner pinion bearing using the J 24433.Press the bearing on until the cone seats on the pinion. 4. Install a new collapsible spacer. 5. Lubricate the pinion bearings with axle lubricant. Use the proper fluid. 6. Install the pinion into the pinion gear bearing retainer. 7. Install the outer pinion bearing onto the pinion. Page 11335 HVAC Control Module - C2 Part 2 Page 2961 of vibration is normally felt more in the "seat of the pants" than the steering wheel. 5. Next, record the Hertz (Hz) reading as displayed by the EVA onto the tire data worksheet found at the end of this bulletin. This should be done after a tire break-in period of at least 16 km (10 mi) at 72 km/h (45 mph) or greater, in order to eliminate any possible tire flat-spotting. This reading confirms what the vehicle vibration frequency is prior to vehicle service and documents the amount of improvement occurring as the result of the various steps taken to repair. Completing the Steering Wheel Shake Worksheet below is required. A copy of the completed worksheet must be saved with the R.O. and a copy included with any parts returned to the Warranty Parts Center for analysis. A reading of 35 to 50 Hz typically indicates a first order propshaft vibration. If this is the situation, refer to Corporate Bulletin Number 08-07-30-044D. Generally, a reading between 10 and 20 Hz indicates a tire/wheel vibration and if this is the reading obtained, continue using this bulletin. If the tire 1st order vibration goes away and stays away during this evaluation, the cause is likely tire flat-spotting. Tire flat-spotting vibration may come and go at any speed over 72 km/h (45 mph) during the first 10 minutes of operation, if vibration continues after 10 minutes of driving at speeds greater than 72 km/h (45 mph), tire flat-spotting can be ruled out as the cause for vibration. 6. If flat-spotting is the cause, provide the explanation that this has occurred due to the vehicle being parked for long periods of time and that the nature of the tire is to take a set. Refer to Corporate Bulletin Number 03-03-10-007E: Information on Tire/Wheel Characteristics (Vibration, Balance, Shake, Flat Spotting) of GM Original Equipment Tires. 7. If the road test indicates a shake/vibration exists, check the imbalance of each tire/wheel assembly on a known, calibrated, off-car dynamic balancer.Make sure the mounting surface of the wheel and the surface of the balancer are absolutely clean and free of debris. Be sure to chose the proper cone/collet for the wheel, and always use the pilot bore for centering. Never center the wheel using the hub-cap bore since it is not a precision machined surface. If any assembly calls for more than 1/4 ounce on either rim flange, remove all balance weights and rebalance to as close to zero as possible. If you can see the vibration (along with feeling it) in the steering wheel (driving straight without your hands on the wheel), it is very likely to be a tire/wheel first order (one pulse per revolution) disturbance. First order disturbances can be caused by imbalance as well as non-uniformities in tires, wheels or hubs. This first order frequency is too low for a human to hear, but if the amplitude is high enough, it can be seen. If a vibration or shake still exists after balancing, any out of round conditions, of the wheel, and force variation conditions of the tire, must be addressed. Equipment such as the Hunter GSP9700 can address both (it is also a wheel balancer). Tire radial force vibration (RFV) can be defined as the amount of stiffness variation the tire will produce in one revolution under a constant load. Radial force variation is what the vehicle feels because the load (weight) of the vehicle is always on the tires. Although free runout of tires (not under load) is not always a good indicator of a smooth ride, it is critical that total tire/wheel assembly runout be within specification. Equipment such as the Hunter GSP9700 loads the tire, similar to on the vehicle, and measures radial force variation of the tire/wheel assembly. Note that the wheel is affecting the tire's RFV measurement at this point. To isolate the wheel, its runout must be measured. This can be easily done on the Hunter, without the need to set up dial indicators. If the wheel meets the runout specification, the tire's RFV can then be addressed. After measuring the tire/wheel assembly under load, and the wheel alone, the machine then calculates (predicts) the radial force variation of the tire. However, because this is a prediction that can include mounting inaccuracies, and the load wheel is much smaller in diameter than used in tire production, this type of service equipment should NOT be used to audit new tires. Rather, it should be used as a service diagnostic tool to minimize radial force variation of the tire/wheel assembly. Equipment such as the Hunter GSP9700 does an excellent job of measuring wheel runout, and of finding the low point of the wheel (for runout) and the high point of the tire (for radial force variation). This allows the tire to be matched mounted to the wheel for lowest tire/wheel assembly force variation. The machine will simplify this process into easy steps. The following assembly radial force variation numbers should be used as a guide: When measuring RFV and match mounting tires perform the following steps. Measuring Wheel Runout and Assembly Radial Force Variation Important The completed worksheet at the end of this bulletin must be attached to the hard copy of the repair order. - Measure radial force variation and radial runout. - If a road force/balancing machine is used, record the radial force variation (RFV) on the worksheet at the end of this bulletin. It may be of benefit to have the lowest RFV assembly to the front left corner. If the machine is not available and the EVA data suggests there is an issue, swap the tire and wheel assemblies from the front to the back. Re-check on the EVA and if the problem still exists, test another vehicle to find tires that do not exhibit the same frequency and swap those tires onto the subject vehicle. - If a runout/balancing machine is used, record the radial runout of the tire/wheel assemblies on the worksheet at the end of this bulletin. If one or more of the tire/wheel assemblies are more than.040 in (1.02 mm), match mount the tire to the wheel to get below.040 in (1.02 mm). For sensitive customers, readings of 0.030 inch (0.76 mm) or less are preferable, it may also be of benefit to have the lowest runout assembly to the front left corner. If the machine is not available and the EVA data suggests there is an issue, swap the tire and wheel assemblies from the front to the back. Re-check on the EVA and if the problem still exists, test another vehicle to find tires that do not exhibit the same frequency and swap those tires Page 2712 Location View Page 7388 2. Connect the selector switch electrical connectors (2, 3). 3. Slide the selector switch into the housing until the switch snaps into place. Important: Make sure that the selector switch is seated properly in the housing before installing the I/P cluster bezel. 4. Install the I/P cluster bezel. Page 13274 8.2. Remove the console (A) together with the OnStar(R) control modules. 8.3. Remove the connectors (B). Important: The optic cable must not be bent with a radius less than 25 mm (1 in). Important: Secure the wiring harness so that there is no risk of chafing and rattling. 8.4. Fold back the wiring harness and tape over the connectors (C). Fold back the wiring harness once more and secure with cable ties (D). Page 16163 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Page 2720 Fuse Block - Underhood - Secondary Wire Entry (With RPO Code HP2) Part 4 Page 8575 Yukon XL vehicles built within the VIN breakpoints shown. Important: Dealers should confirm vehicle eligibility through GMVIS (GM Vehicle Inquiry System) before beginning recall repairs. [Not all vehicles within the above breakpoints may be involved.] For US For dealers with involved vehicles, a Campaign Initiation Detail Report containing the complete Vehicle Identification Number, customer name and address data has been prepared and will be loaded to the GM DealerWorld, Recall Information website. Dealers that have no involved vehicles currently assigned will not have a report available in GM DealerWorld. For Canada For dealers with involved vehicles, a Campaign Initiation Detail Report containing the complete Vehicle Identification Number, customer name and address data has been prepared and is being furnished to involved dealers. Dealers that have no involved vehicles currently assigned will not receive a report with the recall bulletin. For Export For dealers with involved vehicles, a Campaign Initiation Detail Report containing the complete Vehicle Identification Number, customer name and address data has been prepared and is being furnished to involved dealers. Dealers that have no involved vehicles currently assigned will not receive a report with the recall bulletin. The Campaign Initiation Detail Report may contain customer names and addresses obtained from Motor Vehicle Registration Records. The use of such motor vehicle registration data for any other purpose other than follow-up necessary to complete this recall is a violation of law in several states/provinces/countries. Accordingly, you are urged to limit the use of this report to the follow-up necessary to complete this program. Parts Information A very small number of vehicles (less than 90 world-wide) will require the replacement of the hydraulic brake booster. Do not order boosters for shelf stock. When a replacement is required, order the appropriate booster from GMSPO. All replaced boosters (excluding Export) must be returned to the Warranty Parts Center. Hold the booster until you receive the request for return. Special Tool Beginning February 18, 2005, each dealer was shipped a Hydro-Boost Checking Tool, CH 47950, for use in this recall. This tool is being furnished at no charge. Additional tools, if required, may be purchased by contacting SPX Kent-Moore at 1-800-468-6657. Courtesy Transportation The General Motors Courtesy Transportation program is intended to minimize customer inconvenience when a vehicle requires a repair that is covered by the New Vehicle Limited Warranty. The availability of courtesy transportation to customers whose vehicles are within the warranty coverage period and involved in a product recall is very important in maintaining customer satisfaction. Dealers are to ensure that these customers understand that shuttle service or some other form of courtesy transportation is available and will be provided at no charge. Dealers should refer to the General Motors Service Policies and Procedures Manual for Courtesy Transportation guidelines. Page 6014 Park Neutral Position (PNP) Switch C175 Page 12582 switch lighting connector. 3.3. Undo the floor console's retaining bolts (C). 3.4. Take out the rear ashtray/cover (D). 3.5. Remove the screw (E) for the rear cover. 3.6. Remove the floor console's retaining nuts (E). 3.7. Detach the floor console (G) by pulling it straight back and lifting it slightly. 3.8. If required, detach the switch for the rear seat heater and unplug the connector. 4. Remove the switch and the floor console: 4.1. Detach the window lift module (A) by loosening it in the front edge (snap fastener). Unplug the window lift module's connector. 4.2. Detach the switch for the roof lighting (B) and unplug its connector. Lift away the floor console. 5. Pry out the signal line from the SRS control module to the OnStar(R) control module and secure it: 5.1. Unplug the SRS control module's connector (A). Page 6267 The new thread size 9/16-1a UNF-2A (1) was implemented on 11-29-07 or Julian date 333. Disclaimer Page 5760 Park Neutral Position (PNP) Switch C175 Page 598 Memory Seat Module - C3 Part 2 Component Locations Transmission Temperature Sensor/Switch: Component Locations Automatic Transmission - 4L60-E/4L65-E Automatic Transmission Electronic Component Views (M30/M32) Electronic Components Instruments - Service Tire Monitor Message is Displayed Low Tire Pressure Indicator: Customer Interest Instruments - Service Tire Monitor Message is Displayed Bulletin No.: 05-08-49-018A Date: May 11, 2006 ADVANCE SERVICE INFORMATION RESOLUTION Subject: EI 05065 - Service Tire Monitor Message Displayed (Pull/Reinstall IPC Fuse or Verify Correct Passenger Door Module (PDM) and Tires) Models: 2004 Chevrolet Silverado 2004 GMC Sierra Supercede: This bulletin is being revised to provide correction action. Please discard Corporate Bulletin Number 05-08-49-018 (Section 08 - Body and Accessories). Condition Some customers may comment that the "SERVICE TIRE MONITOR" message is being displayed on the DIC. Correction DO NOT REPLACE THE INSTRUMENT PANEL CLUSTER. If the DIC is displaying the SERVICE TIRE MONITOR message: 1. Verify if the vehicle has an electronic aftermarket module spliced into the ALDL Class 2 data line (purple wire). 2. If the vehicle HAS an aftermarket module spliced into the Class 2 line, pull the IPC fuse (located underhood) for 25 seconds. Important: Due to the electronic aftermarket module, the SERVICE TIRE MONITOR message may reoccur. 3. Reinstall the IPC fuse. This will clear the SERVICE TIRE MONITOR message from the display. 4. If the vehicle DOES NOT have an aftermarket module spliced into the Class 2 line, verify the vehicle is equipped with the correct PDM (Passenger Door Module) and tires. Warrant Information This repair is not covered under the vehicle warranty due to the installation of an aftermarket module. Disclaimer NV 3500 Backup Lamp Switch: Service and Repair NV 3500 Backup Lamp Switch Replacement Removal Procedure 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. Disconnect the backup lamp switch electrical connector (3). 3. Remove the backup lamp switch. Installation Procedure 1. Notice: Refer to Fastener Notice in Service Precautions. Important: The backup lamp switch has pre-applied thread sealant on the threads. Install the backup lamp switch. ^ Tighten the switch to 37 Nm (27 ft. lbs.). Page 9754 Multiple Junction Connector: Diagrams C305 - C399 C305 Body Harness To Drivers Seat Harness (With RPO Code AG1) Part 1 Page 2554 Refrigerant Oil: Service and Repair A/C REFRIGERANT SYSTEM OIL CHARGE REPLENISHING If oil was removed from the A/C system during the recovery process or due to component replacement, the oil must be replenished. Oil can be injected into a charged system using J 45037 . For the proper quantities of oil to add to the A/C refrigerant system, refer to Refrigerant System Capacities. Page 14464 Disclaimer Page 9909 Important The M6 conductive rivet stud as shown, can accommodate a panel thickness range of 0.7-4.2 mm (0.03-0.17 in). If there are layers of sheet metal, they should be touching without any air gaps to ensure a good ground. 5. Select a M6 conductive rivet stud. Refer to the Parts Information section of this bulletin. Note Use the GE-50317 rivet stud tool kit. 6. Place the M6 conductive rivet stud (1) in the 10 mm (0.40 in) hole. Assemble the rivet stud tool (2) with the groove and flare side facing the rivet stud, then the washer and the M6 nut (3). 7. Using a wrench on the rivet stud tool, and a socket on the M6 nut, secure the M6 conductive rivet stud. 8. Ensure the rivet stud is securely fastened, WITHOUT ANY detectable movement. 9. Completely wrap the threads of the rivet stud with painters tape or equivalent. Note The rivet stud and surrounding panel area MUST BE properly refinished PRIOR to the installation of the ground wire terminal and conductive nut to maintain a secure, stable and corrosion-free electrical ground. 10. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 11. Allow the refinished repair area to cure sufficiently before removing the protective material applied to the rivet stud threads. 12. Remove the painters tape or equivalent from the rivet stud threads. 13. Using GM approved residue-free solvent or equivalent, thoroughly clean the rivet stud threads to remove any adhesive and allow to dry. 14. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive rivet stud. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. Page 12845 Claim Information - GM, Saturn Canada and Saab Canada Only Claim Information - Saturn US Only Customer Reimbursement Claims - Special Attention Required Customer reimbursement claims must have entered into the "technician comments" field the CSO # (if repair was completed at a Saturn Retail Facility) date, mileage, customer name, and any deductibles and taxes paid by the customer. Claim Information - Saab US Only Page 8775 Electrical Symbols Part 4 Page 4647 Refer to the table as a guide in selecting the correct test adapter for frontprobing connectors: Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure SCAN TOOL SNAPSHOT PROCEDURE Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: - Snapshot - taken from the Snapshot menu choice - Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information Page 5144 Steps 10 - 13 Locations Page 8577 of failure to repair within a reasonable time. If the condition is not adequately repaired within a reasonable time, the customer may be entitled to an identical or reasonably equivalent vehicle at no charge or to a refund of the purchase price less a reasonable allowance for depreciation. To avoid having to provide these burdensome remedies, every effort must be made to promptly schedule an appointment with each customer and to repair their vehicle as soon as possible. In the recall notification letters, customers are told how to contact the US National Highway Traffic Safety Administration if the recall is not completed within a reasonable time. Dealer Recall Responsibility -- All All unsold new vehicles in dealers' possession and subject to this recall MUST be held and inspected/repaired per the service procedure of this recall bulletin BEFORE customers take possession of these vehicles. Dealers are to service all vehicles subject to this recall at no charge to customers, regardless of mileage, age of vehicle, or ownership, from this time forward. Customers who have recently purchased vehicles sold from your vehicle inventory, and for which there is no customer information indicated on the dealer listing, are to be contacted by the dealer. Arrangements are to be made to make the required correction according to the instructions contained in this bulletin. A copy of the customer letter is shown in this bulletin for your use in contacting customers. Recall follow-up cards should not be used for this purpose, since the customer may not as yet have received the notification letter. In summary, whenever a vehicle subject to this recall enters your vehicle inventory, or is in your dealership for service in the future, please take the steps necessary to be sure the recall correction has been made before selling or releasing the vehicle. Disclaimer Service Procedure Inspection Tools Required CH 47950 Hydro-Boost Checking Tool 1. With the vehicle transmission in PARK or NEUTRAL, set the park brake. 2. With the engine OFF, make a minimum of five (5) high effort brake applies until the pedal feels hard. 3. Start the engine. Important: DO NOT depress the brake pedal until instructed. 4. Turn the steering wheel to the "steering lock" (fully turned) position. Hold at the steering lock position for 1 to 2 seconds and then release the steering wheel. Repeat a total of 3 times. 5. Turn the vehicle off being careful not to step on the brake pedal. 6. For Express/Savana only: A. Remove the remote power steering reservoir mounting nuts. B. Disconnect the reservoir outlet hose from the booster unit. Keeping the hose end higher than the reservoir, reposition the reservoir forward and down out of the way. 7. Using a clean, lint-free shop cloth, wipe any dirt away from the steering pump supply hose/tube connection area on the hydro-boost (this is the center hose/tube of the three). 8. Disconnect the power steering supply hose/tube from the hydro-boost unit and wrap a clean lint-free shop cloth around the end of the hose and secure it in the engine compartment. 9. Using a clean lint-free shop cloth, clean any dirt off of the inlet port adapter valve assembly. Before installing the inlet port adapter, place a shop Page 4362 Camshaft Position Sensor: Service and Repair CAMSHAFT POSITION (CMP) SENSOR REPLACEMENT REMOVAL PROCEDURE IMPORTANT: Clean the area around the CMP sensor before removal in order to prevent debris from entering the engine. 1. Remove the camshaft position (CMP) sensor bolt. 2. Remove the CMP sensor. INSTALLATION PROCEDURE 1. Install the CMP sensor. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the CMP sensor bolt. Tighten Tighten the bolt to 29 N.m (21 lb ft). Page 9176 C102 I/P Harness To Chassis Harness Part 1 Page 12827 Diagnostic Tips Review # 5 - Alpine Silver Box Navigation Radio Disclaimer Page 13330 ^ Reinstall the fuse and fuse panel cover. ^ Press the "Enter" button to perform the "Refresh" function. ^ "Test in Progress" will be displayed and the right front passenger door lock will cycle once. ^ The screen will display "Procedure Completed". ^ Press the "Exit" button as necessary to return to the main menu screen. 3. Using the switches in the right front passenger door, verify that the power window and power door lock located in that door function properly. Important: The calibrations required for performing SPS reprogram in the next step are based on the type of exterior rearview mirror the vehicle has. To determine the correct calibration, check the Service Parts Identification Label on the vehicle for the RPO code for exterior mirrors. 4. Follow normal Service Programming System (SPS) to reprogram the passenger door module with the current calibration available in TIS 2000. 5. After reprogramming is complete, using the switches in the right front passenger door, verify that the power window and power door lock located in that door function properly. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 12188 A current DTC clears when the condition for setting the DTC is no longer present. A history DTC clears after 50 malfunction-free ignition cycles. Circuit/System Testing Without RPO UAV 1. Turn OFF the ignition and all electrical components, including the scan tool. 2. Disconnect the harness connector at the cellular microphone. 3. Test for less than 5 Ohms between the low reference circuit terminal A and ground. ^ If greater than the specified range, test the low reference circuit for an open/high resistance. If the circuit tests normal, replace the VCIM. 4. Ignition ON, test for 9 - 11 volts between the signal circuit terminal B and ground. ^ If greater than the specified range, test the signal circuit for a short to voltage. If the circuit tests normal, replace the VCIM. ^ If less than the specified range, test the signal circuit for a short to ground or an open/high resistance. If the circuit tests normal, replace the VCIM. Refer to the appropriate vehicle in SI. 5. If all circuits test normal, test or replace the cellular microphone. Circuit/System Testing With RPO UAV 1. Turn OFF the ignition and all electrical components, including the scan tool. 2. Disconnect the X4 harness connector at the navigation radio and the harness connector at the cellular microphone. 3. Test for less than 5 Ohms between the low reference circuit terminal A and ground. ^ If greater than the specified range, test the low reference circuit for an open/high resistance. If the circuit tests normal, replace the VCIM. Refer to the appropriate vehicle in SI. 4. Ignition ON, test for 9 - 11 volts between the signal circuit terminal B and ground. ^ If greater than the specified range, test the signal circuit for a short to voltage. If the circuit tests normal, replace the VCIM. ^ If less than the specified range, test the signal circuit for a short to ground or an open/high resistance. If the circuit tests normal, replace the VCIM. 5. If all circuits test normal, test or replace the cellular microphone. 6. Connect the X4 harness connector at the navigation radio. 7. With a scan tool, verify that DTC B2455 is not set as current in the navigation radio. ^ If DTC B2455 is set as current, replace the navigation radio. Refer to the appropriate vehicle in SI. DTC B2462, B2483, or B2484 Circuit/System Description The vehicle communication interface module (VCIM) receives information from a specific navigation antenna located on the outside of the vehicle. The navigation antenna is connected to the VCIM via a shielded coaxial cable. The antenna cable also provides a path for DC current for powering the antenna. DTC Descriptors DTC B2462 02: Global Positioning System (GPS) Antenna Malfunction Short to Ground DTC B2462 04: Global Positioning System (GPS) Antenna Malfunction Open Circuit Page 8757 13. Remove the positive battery cable channel bolt. 14. Slide the channel pin out of the oil pan tab. 15. Remove the positive battery cable from the channel. 16. If equipped with a 4.8L, 5.3L, or 6.0L engine, remove the battery cable bracket bolt and bracket from the power steering pump. 17. If equipped with a 4.8L, 5.3L, or 6.0L engine, remove the starter lead nut. 18. Remove the positive cable from the starter. 19. Remove the positive cable clip from the clip on the oil pan. 20. Remove the positive cable from the clip on the oil pan. 21. Remove the positive battery cable. Page 3836 Door Control Module Diagram 3 Part 1 Page 7507 Pay particular attention to the terminal connections at the module. Spread or open terminal connections may create an intermittent contact. Do a pin drag test. Refer to the terminal testing information in the table shown. ^ After repairs are complete, ALWAYS clear DTCs from the module prior to a system function test. If codes are not cleared first, the system will not function after repair. The technician may erroneously think that the system is still down and that further repairs are needed. Warranty Dealers who unnecessarily replace the TCCM that are found to have No Trouble Found (NTF) at the WPC will be returned to the AVM (Area Service Manager), or the DSM (District Service Manager) in Canada, through the Regional Feedback Process and may be charged back for the repair through the WINS system. Disclaimer Page 480 Refer to the table as a guide in selecting the correct test adapter for frontprobing connectors: Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure SCAN TOOL SNAPSHOT PROCEDURE Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: - Snapshot - taken from the Snapshot menu choice - Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information Page 8345 9. Release the park brake and unblock the wheels. Master Cylinder Bench Bleeding Master Cylinder Bench Bleeding Caution: Refer to Brake Fluid Irritant Caution in Service Precautions. Notice: When adding fluid to the brake master cylinder reservoir, use only Delco Supreme 11, GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. The use of any type of fluid other than the recommended type of brake fluid, may cause contamination which could result in damage to the internal rubber seals and/or rubber linings of hydraulic brake system components. 1. Secure the mounting flange of the brake master cylinder in a bench vise so that the rear of the primary piston is accessible. 2. Remove the master cylinder reservoir cap and diaphragm. 3. Install suitable fittings to the master cylinder ports that match the type of flare seat required and also provide for hose attachment. 4. Install transparent hoses to the fittings installed to the master cylinder ports, then route the hoses into the master cylinder reservoir. 5. Fill the master cylinder reservoir to at least the half-way point with Delco Supreme 11® (GM P/N 12377967) or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. 6. Ensure that the ends of the transparent hoses running into the master cylinder reservoir are fully submerged in the brake fluid. 7. Using a smooth, round-ended tool, depress and release the primary piston as far as it will travel, a depth of about 25 mm (1 inch), several times. Observe the flow of fluid coming from the ports.As air is bled from the primary and secondary pistons, the effort required to depress the primary piston will increase and the amount of travel will decrease. 8. Continue to depress and release the primary piston until fluid flows freely from the ports with no evidence of air bubbles. 9. Remove the transparent hoses from the master cylinder reservoir. 10. Install the master cylinder reservoir cap and diaphragm. 11. Remove the fittings with the transparent hoses from the master cylinder ports. Wrap the master cylinder with a clean shop cloth to prevent brake fluid spills. 12. Remove the master cylinder from the vise. Master Cylinder Fluid Level Sensor Replacement Master Cylinder Fluid Level Sensor Replacement Removal Procedure Latch Replacement - Side Door Upper Rear Door Latch: Service and Repair Latch Replacement - Side Door Upper Latch Replacement - Side Door Upper Removal Procedure 1. Remove the door trim panel. 2. Remove the latch retaining bolts. 3. Disconnect the latch rod from the latch. Installation Procedure 1. Install the latch rod to the latch. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the latch to the door. Tighten the bolts to 9 N.m (80 lb in). 3. Install the latch retaining bolts. Page 9090 Junction Block - I/P Wire Entry Part 2 Page 3519 Disclaimer Page 13983 Carpet: Removal and Replacement Carpet Replacement - Rear Panel Carpet Replacement - Rear Panel Removal Procedure 1. Remove the rear window lower molding. 2. Remove the trim panel. 3. Remove the carpet retainers. 4. Remove the carpet from the vehicle. Installation Procedure Caution: In order to avoid personal injury or vehicle damage when you repair or replace the carpet, use the same thickness and material size as the original installation. Always return the carpet to the original location. 1. Install the carpet. 2. Install the carpet retainers. 3. Install the trim panel. 4. Install the rear window lower molding. Carpet Replacement - Front (W/O HP2) Carpet Replacement - Front (W/O HP2) Removal Procedure 1. Remove the hinge pillar trim panel. 2. Remove the door sill plates. 3. Remove the front seats. 4. Remove the floor storage console. 5. Remove the center seat, if equipped. 6. Remove the control lever and the boot, if equipped. 7. Remove the rear seat, if equipped. 8. Remove the jack assembly. Page 4082 Heated Oxygen Sensor (HO2S) Bank 2 Sensor 1 Page 10737 Page 9571 Fuse Block- I/P C1 Part 5 Page 7879 Control Module: Diagrams Page 13436 Control Module References Part 7 Page 1215 1. Install the park brake warning lamp switch. 2. Notice: Refer to Fastener Notice in Service Precautions. Install the park brake warning lamp switch mounting bolt. ^ Tighten the bolt to 3 Nm (25 inch lbs.). 3. Connect the park brake warning lamp switch electrical connector. 4. Install the MID-bussed electrical center to the bracket. 5. Connect the negative battery cable. Fuel Pressure Gage Installation and Removal Fuel Pressure Release: Service and Repair Fuel Pressure Gage Installation and Removal FUEL PRESSURE GAGE INSTALLATION AND REMOVAL INSTALLATION PROCEDURE TOOLS REQUIRED J 34730-1A Fuel Pressure Gage CAUTION: - Refer to Gasoline/Gasoline Vapors Caution in Service Precautions. - Refer to Fuel Gage Leak Caution in Service Precautions. 1. Remove the engine sight shield. 2. Remove the fuel rail pressure fitting cap. 3. Connect the J 34730-1A to the fuel pressure valve. Wrap a shop towel around the fitting while connecting the gage in order to avoid spillage. 4. Install the bleed hose on J 34730-1A into an approved container. REMOVAL PROCEDURE 1. Remove the bleed hose on the J 34730-1A from the approved container. 2. Remove the shop towel from around the fitting and discard into an approved container. 3. Disconnect the J 34730-1A from the fuel pressure valve. 4. Install the fuel rail pressure fitting cap. 5. Install the engine sight shield. Page 12854 Important: The optic cable must not be bent with a radius less than 25 mm (1 in). 6.12. Place the optic cable in the wiring harness channels on the right-hand side. Thread through the existing cable ties (C) if possible, otherwise, secure with a cable tie to the existing one. Close the cover on the channels. Ensure the catches lock. 6.13. Secure the optic cable along the right-hand rear wheel housing, next to the ordinary wiring harness securing points and by the SRS unit (D). 6.14. Thread the optic cable up next to the safety belt by the old optic cable and place on the parcel shelf. 6.15. Unplug the connectors (E) from the OnStar(R) control modules. 6.16. Remove the console (F) together with the OnStar(R) control modules. Steering - 'Service Rear Wheel Steering' Message Body Control Module: All Technical Service Bulletins Steering - 'Service Rear Wheel Steering' Message Bulletin No.: 05-02-118-002 Date: February 03, 2005 TECHNICAL Subject: DTC C0455, "Service Rear Wheel Steering", System Jumps from 4-Wheel Steer to 2-Wheel Steer (Reprogram BCM) Models: 2003-2005 Chevrolet Silverado, Suburban 2003-2005 GMC Sierra, Yukon XL with 4-Wheel Steer (RPO NYS) Condition Some customers may comment that the system will jump from 4-wheel steer to 2-wheel steer and the DIC displays the message "Service Rear Wheel Steering". Diagnosis will show DTC C0455-Front Steering Position Sensor malfunction. Cause This condition may be caused by a Class2 communication issue. Correction Reprogram the BCM. 2005 Model Year Vehicles: New software calibration, P/N 15248410, was released on TIS version 12 - broadcast to dealers on December 4, 2004. 2003-2004 Model Year Vehicles: New software calibration, P/N 15259330 ('03 Model Year) and P/N 15259331 ('04 04 Model Year), was released on TIS version 1.75 - broadcast to dealers on January 24, 2005. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 15748 3. Connect the backup lamp switch electrical connector (1). 4. Lower the vehicle. Page 2184 2. Remove the transmission from the vehicle. Refer to the appropriate SI document. Important: ^ Inspect all the transmission components for damage or wear. Replace all damaged or worn components. The parts shown above should be sufficient to correct this concern. ^ This condition does not normally require replacement of the transmission completely. Components such as clutches, valve body, pump and torque converters will NOT require replacement to correct this condition. Disassemble the transmission and replace the appropriate parts listed below. Refer to the Unit Repair Manual - Repair Instructions. 3. Reinstall the transmission in the vehicle. Refer to appropriate service information. When servicing the transmission as a result of this condition, the transmission oil cooler and lines MUST be flushed. Refer to Corporate Bulletin Number 02-07-30-052. Page 11966 Underhood Fuse Block LR Of The Engine Compartment (With RPO Code 9L4) Page 8993 Fuse: Application and ID Junction Block - I/P Location View Location View Page 8408 6. Disconnect the intermediate cable from the front cable. 7. Remove the intermediate cable from the vehicle. Installation Procedure 1. Install the intermediate cable to the vehicle. 2. Connect the intermediate cable to the front cable. 3. For 25/35 series vehicles, connect the intermediate cable to the rear park brake cable. 4. For 15 series vehicles, install the rear park brake cables to the equalizer. Page 5336 Fuel Rail: Service and Repair Fuel Rail Crossover Pipe Replacement FUEL RAIL CROSSOVER PIPE REPLACEMENT REMOVAL PROCEDURE IMPORTANT: The fuel rail for the 5.3L regular production option (RPO) L59 (VIN Z) engine is compatible with fuel that has a composition of up to 85 percent Ethanol (E85). Because of this, the fuel rail will be serviced as an entire assembly, this includes both left and right rail assemblies and crossover pipe rail. 1. Relieve the fuel system pressure. Refer to Fuel Pressure Relief Procedure. 2. Disconnect the fuel feed pipe quick connect fitting from the fuel rail. 3. Remove the fuel return pipe attaching screw (3) and the fuel return pipe retainer (2). 4. Remove the fuel return pipe (1). 5. Remove and discard the fuel return pipe O-ring (6). 6. Remove the fuel pressure connection core assembly (24) from the crossover pipe rail (25). 7. Remove the retaining clip attaching screw (22) and the crossover fuel pipe retainer clip (21). 8. Remove the retaining clip attaching screw (4) and the crossover fuel pipe retainer clip (5). 9. Remove the crossover pipe rail assembly (25) from the left hand rail assembly (14) and the right hand rail assembly (15). 10. Remove and discard the crossover fuel pipe O-rings (7, 20). INSTALLATION PROCEDURE Page 13603 Front Bumper Reinforcement: Service and Repair Brace Replacement - Front Bumper Removal Procedure 1. Remove the brace bolt (2) from the front bumper. 2. Remove the brace bolt (3) from the outboard mounting brace plate. 3. Remove the brace (1) from the vehicle. Installation Procedure 1. Install the brace (1) to the vehicle. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the 3 bolts that retain the brace to the bumper and the outboard brace plate. * Tighten the front bumper brace bolt (2) to 15 N.m (11 lb ft). * Tighten the front bumper outboard brace plate bolt (3) to 9 N.m (80 lb in). Page 3058 4. Drive the bearing cup into the wheel hub using the J 44419 (2) and the J 8092 (1). 5. Install the retaining ring into the groove. Make sure the retaining ring is fully and evenly seated in the groove. 6. Install the inner bearing cup. 7. Drive the inner bearing cup into the wheel hub using the J 24427 (2) and the J 8092 (1). Page 3176 Harmonic Balancer - Crankshaft Pulley: Service and Repair Crankshaft Balancer Replacement (4.8L, 5.3L, and 6.0L Engines) ^ Tools Required J 41816 Crankshaft Balancer Remover - J 41816-2 Crankshaft End Protector - J 42386-A Flywheel Holding Tool - J 41665 Crankshaft Balancer and Sprocket Installer - J 45059 Angle Meter Removal Procedure 1. Remove the air conditioning (A/C) drive belt. 2. Remove the fan shroud - lower. 3. Remove the starter motor. Notice: Refer to Fastener Notice in Service Precautions. 4. Important: ^ Make sure that the teeth of the J 42386-A mesh with the teeth of the engine flywheel. ^ The crankshaft balancer is balanced as an individual component. It is not necessary to mark the balancer prior to removal. Install the J 42386-A and bolts.Use one M10-1.5 x 120 mm and one M10-1.5 x 45 mm bolt for proper tool operation. ^ Tighten the J 42386-A bolts to 50 Nm (37 ft. lbs.). 5. Remove the crankshaft balancer bolt.Do not discard the crankshaft balancer bolt. The balancer bolt will be used during the balancer installation procedure. Page 838 1. Install the engine electrical center bracket assembly to the front fender. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the 4 retaining bolts (1). Tighten Tighten the 4 retaining bolts (1) to 9 N.m (80 lb in). 3. Align the electrical center block (1) stubs in the slots so that the tabs (2) retains it in place. Page 15026 Inner Joint and Seal Replacement Constant Velocity Joint: Service and Repair Inner Joint and Seal Replacement Wheel Drive Shaft Inner Joint and Seal Replacement ^ Tools Required J 35910 Seal Clamp Tool - J 36652 Drive Axle Clamp Swage Tool - J 36652-98 Axle Swage Tool Disassembly Procedure 1. Use a hand grinder in order to cut through the swage ring (2). Important: Use caution when using the hand grinder by the tripot housing (1). 2. Remove the tripot housing (1) from the halfshaft. 3. Wipe the grease off of the housing (1). 4. Thoroughly degrease the tripot housing (1). 5. Allow the tripot housing (1) to dry prior to assembly. Page 2656 Fuse Block - Underhood C4 Part 3 Fuse Block - Underhood C5 Page 13048 Important: The optic cable must not be bent with a radius less than 25 mm (1 in). 6.17. Fold back the wiring harness and tape over the connectors (G). Fold back the wiring harness once more and secure with cable ties (H). 6.18. Secure the new optic cable on the parcel shelf along the existing wiring harness by the ordinary securing points and by the speaker (I). 6.19. Thread the optic cable down next to the old cable from the parcel shelf to the left-hand wheel housing, next to REC. The cable is secured in the existing clips. 6.20. Fit the right-hand C-pillar trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.21. Fit the parcel shelf trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.22. Fit the passenger seat in accordance with WIS - 8. Body - Seats - Adjustment/Replacement. 6.23. Fit the right-hand side bolster in accordance with WIS - 8. Body - Seats Adjustment/Replacement. 6.24. Fold up the rear seat backrest. 6.25. Fit the right-hand B-pillar trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.26. Fit the A-pillar's lower side piece. 7. M04-05, 4D: Removing the OnStar® control modules and securing the wiring: Wheels/Tires - Slow Tire Leak/Vibration Wheels: Customer Interest Wheels/Tires - Slow Tire Leak/Vibration Bulletin No.: 03-03-10-001D Date: January 17, 2008 TECHNICAL Subject: Tire Slowly Goes Flat and/or Excessive wheel Vibration Caused By Bead Splits (Replace wheels with New Heavy Duty Rim Version) Models: 1999-2006 Chevrolet Silverado 1500 Series Pickup Models (Classic) 1999-2006 Chevrolet Express 1500 Series Vans 2000-2006 Chevrolet Suburban Tahoe 1999-2006 GMC Sierra 1500 Series Pickup Models (Classic) 1999-2006 GMC Savana 1500 Series Vans 2002-2006 GMC Yukon Yukon XL 2007 GMC Sierra Denali Crew Cab with 6-Bolt, 16 X 6.5 Full Face Steel wheel (Base and RPO PY2) Supercede: This bulletin is being revised to add the Express and Savana models and add information to the Correction section. Please discard Corporate Bulletin Number 03-03-10-001C (Section 03 Suspension). Implementation of this service bulletin by "GM of Canada" dealers requires prior District Service Manager approval. Condition Some customers may comment on a tire that slowly goes flat and/or excessive wheel vibration. This condition is more apparent on vehicles in which customer usage typically involves frequent severe conditions such as: High load (at or above gross vehicle weight) Rough road/off road usage Fleet/Commercial usage Cause The wheel may experience a crack or split in the outboard bead seat weld area. A weld attaches the rim and disc together on full-face wheels in this area. To identify this wheel it is offered in a silver painted version P/N 9593915 code "TZA" and a chrome-clad version, P/N 9593150 code "RSC" (these codes are stamped into the wheel's disc near the bolt holes). Correction Wheel replacement should only be done for air loss and/or vibration caused by bead splits. A new heavy-duty rim version of these wheels has been released for service. The new heavy-duty painted wheel is P/N 9595245 code "FFU" used as a road wheel and spare. The new heavy-duty chrome clad version is P/N 9595306 code "FFW" used as a road wheel only (these codes are stamped into the inboard rim flange balance weight area and are also on a sticker near the bolt holes). If a condition of a crack or split as described above occurs all (5) five of the original wheels on the vehicle should be replaced with the new heavy-duty wheels as follows: Replace road wheel P/N 9593915 with P/N 9595245. Replace road wheel PIN 9593150 with P/N 9595306. Replace the spare wheel with P/N 9595245 on all vehicles. Page 14396 Driver Door Module (DDM) - C5 (With RPO Code AN3) Part 1 Instruments - Service Tire Monitor Message is Displayed Fuse: All Technical Service Bulletins Instruments - Service Tire Monitor Message is Displayed Bulletin No.: 05-08-49-018A Date: May 11, 2006 ADVANCE SERVICE INFORMATION RESOLUTION Subject: EI 05065 - Service Tire Monitor Message Displayed (Pull/Reinstall IPC Fuse or Verify Correct Passenger Door Module (PDM) and Tires) Models: 2004 Chevrolet Silverado 2004 GMC Sierra Supercede: This bulletin is being revised to provide correction action. Please discard Corporate Bulletin Number 05-08-49-018 (Section 08 - Body and Accessories). Condition Some customers may comment that the "SERVICE TIRE MONITOR" message is being displayed on the DIC. Correction DO NOT REPLACE THE INSTRUMENT PANEL CLUSTER. If the DIC is displaying the SERVICE TIRE MONITOR message: 1. Verify if the vehicle has an electronic aftermarket module spliced into the ALDL Class 2 data line (purple wire). 2. If the vehicle HAS an aftermarket module spliced into the Class 2 line, pull the IPC fuse (located underhood) for 25 seconds. Important: Due to the electronic aftermarket module, the SERVICE TIRE MONITOR message may reoccur. 3. Reinstall the IPC fuse. This will clear the SERVICE TIRE MONITOR message from the display. 4. If the vehicle DOES NOT have an aftermarket module spliced into the Class 2 line, verify the vehicle is equipped with the correct PDM (Passenger Door Module) and tires. Warrant Information This repair is not covered under the vehicle warranty due to the installation of an aftermarket module. Disclaimer Page 12665 If you are unsure who the PSC is, check with the Sales Manager. General Information 1. The first step is to verify if the OnStar(R) account is active or not. This can be done by pressing the blue OnStar(R) button and connecting to the OnStar(R) call center. Analog only accounts are no longer active. Only digital upgraded accounts will be active. On Gen 6 digital systems, a clear, or "dark" LED may indicate that the OnStar(R) system has been deactivated or may possibly have a no power/no communication condition. 2. If the account isn't active, the next step is to verify what version of OnStar(R) module is in the vehicle. This can be done via the Tech 2 (Body>VCIM>Module ID Information>Module Information 2) or by using www.onstarenrollment.com. 3. A Generation 5 or older analog module can be diagnosed by following the original electronic Service Information developed for the model year of the vehicle. Note: If the customer has an old analog module, the vehicle can be repaired by replacing the module, but the customer cannot have an active account without upgrading to a digital module. 4. Modules, antennas, brackets, and other equipment are in the same location, whether original analog production or digital upgrade. 5. An upgraded vehicle may also have a new vehicle communication interface module (VCIM) bracket. If it does, order the new bracket when replacing the bracket. Don't order the original bracket. The kit may also include a small wiring jumper cable. If it does, this jumper will be required for a new module replacement. Do not discard. 6. After replacing the VCIM, it is essential to configure the new OnStar(R) system. Failure to configure the system will result in an additional customer visit for repair. DO NOT press and hold the white dot or phone button on the keypad as it will not reset this version of the OnStar(R) system and may result in a DTC being set. Use of the TIS2WEB and SPS applications, along with the Tech2(R), are required in order to perform the VCIM configuration and setup procedure for this vehicle. The configuration and set-up procedure is now a two-step process which enables an automated activation by the OnStar(R) Center, without a button press by the technician to the OnStar(R) Call Center. Page 15682 Steering Wheel and Column Sub-System Components Page 13941 The 1999 though early 2003 wiring harness jumper that plugs into the relay block will have a reddish/brown 6-way connector and a tag with the last four digits of the wiring harness part number. Second design 2003-05 may have a white plastic connector with part number 5418 as well. ^ The 1999 jumper is/was P/N 12171982 with a pink/purple tag identifier of 1982. This number has been superseded to 15366255, with a pink/purple tag identifier of 6255. ^ The 2000 jumper harness is P/N 15366255. The pink/purple tag identifier is 6255. ^ The 2001-2002 jumper is P/N 15086884. The orange tag identifier is 6884. ^ The 2003-05 jumper is P/N 15085418. The orange tag identifier is 5418. When transferring the brake controller with the wiring jumper attached from a 2001-2002 vehicle to a 2003-05 vehicle, a change to the jumper harness connector must be performed. Page 3914 Step 24 Page 5353 Tighten Tighten the nut to 10 N.m (89 lb in). 19. Lower the vehicle. 20. Remove the caps from the fuel rail and EVAP pipes. 21. Connect the EVAP canister purge tube (3). 22. Connect the fuel feed and return pipes (1) at the fuel rail. 23. Install the fuel fill cap. 24. Connect the negative battery cable. 25. Use the following procedure in order to inspect for leaks: 25.1. Turn the ignition ON, with the engine OFF, for 2 seconds. 25.2. Turn the ignition OFF for 10 seconds. 25.3. Turn the ignition ON, with the engine OFF. 25.4. Inspect for fuel leaks. Service and Repair Structural Brace: Service and Repair Frame Brace Replacement Removal Procedure 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Remove the bolts retaining the frame brace to the frame. 3. Remove the frame brace from the vehicle. Installation Procedure 1. Install the frame brace to the vehicle. Notice: Refer to Fastener Notice in Service Precautions. Page 2484 5. Using J 36511 install the oil fill plug. ^ Tighten the plug to 30 Nm (22 ft. lbs.). 6. Lower the vehicle. Page 2526 The dexos (TM) specification and trademarks are exclusive to General Motors, LLC. Only those oils displaying the dexos (TM) trademark and icon on the front label meet the demanding performance requirements and stringent quality standards set forth in the dexos (TM)specification. Look on the front label for any of the logos shown above to identify an authorized, licensed dexos 2(TM) engine oil. GM dexos 2(TM) Engine Oil Specification - dexos 2(TM) is approved and recommended by GM for use in Europe starting in model year 2010 vehicles, regardless of where the vehicle was manufactured. - dexos 2(TM) is the recommended service fill oil for European gasoline engines. Important The Duramax(TM) diesel engine is the exception and requires lubricants meeting specification CJ-4. - dexos 2(TM) is the recommended service fill oil for European light-duty diesel engines and replaces GM-LL-B-025 and GM-LL-A-025. - dexos 2(TM) protects diesel engines from harmful soot deposits and is designed with limits on certain chemical components to prolong catalyst life and protect expensive emission reduction systems. It is a robust oil, resisting degradation between oil changes and maintaining optimum performance longer. Disclaimer Page 2292 Heater Hose: Service and Repair Heater Hose Replacement - Outlet HEATER HOSE REPLACEMENT - OUTLET TOOLS REQUIRED J 43181 Quick Connect Connector Removal Tool REMOVAL PROCEDURE 1. Drain the cooling system. Refer to Draining and Filling Cooling System (with HP2)Draining and Filling Cooling System (without HP2) in Cooling System. 2. Remove the air intake tube. 3. Remove the heater and surge tank hose from the mounting clip. 4. Using the J 43181 disconnect the heater hose from the heater core outlet. 4.1. Install the J 43181 to the heater core pipe. 4.2. Close the tool around the heater core pipe. 4.3. Firmly pull the tool into the quick connect end of the heater hose. 4.4. Firmly grasp the heater hose. Pull the heater hose forward in order to disengage the hose from the heater core. 5. Remove the outlet heater hose from the engine. Page 4695 Body Control Module: Description and Operation BODY CONTROL MODULE (BCM) The body control module (BCM) monitors several inputs in order to arm and disarm the CTD system. The BCM controls the alarm function outputs. When the BCM detects an unauthorized entry (any door opened), the BCM applies ground to the horn, the park lamp and the headlamp relays. The BCM will send messages to the security telltale in the instrument cluster through the Class 2 serial data link. The BCM has the following 8 basic modes for operating the CTD system. The more detailed descriptions are below. - Off state - Idle state - Disarmed state - Ready-to-arm state - Arm initiated state - Arm delay state - Armed state - Alarm state The BCM has the following 6 discrete inputs in order to monitor the CTD system: - Ignition 1 - Driver door latch (door jamb) switch - Passenger door latch (door jamb) switch - Door lock relay - Door key switch - Passenger door unlock relay The BCM applies ground once per second for approximately 2 minutes, or until a valid input to disarm the system is received by the BCM. The Body Control Module (BCM) contains the theft deterrent system logic. The BCM reads the Passlock(TM) data from the Passlock(TM) sensor. If the Passlock(TM) data is correct, the BCM will pass theft. The BCM will then transmit the fuel continue password to the VCM/PCM. During the tamper mode the vehicle may start. The vehicle will then stall. If the BCM receives the wrong Passlock(TM) data, the VTD will immediately go into the tamper mode. The tamper mode will lock-out the vehicle fuel injectors for 10 minutes. The SECURITY indicator will flash while the VTD is in the tamper mode. If the Passlock(TM) sensor sends a correct password to the BCM when the ignition is in the ON position, the BCM will send a fuel enable signal to the VCM/PCM. The VCM/PCM will not disable the fuel due to any BCM message for the remainder of the ignition cycle. Page 15144 Electrical Symbols Part 8 Page 15368 Disclaimer Page 15830 Turn Signal Multifunction Switch - C4 (With RPO Code K34) Page 4635 Electrical Symbols Part 5 Front Wheel Bearing Wheel Bearing: Service and Repair Front Wheel Bearing Front Wheel Hub, Bearing, and Seal Replacement (4WD) ^ Tools Required J 45859 Axle Remover Removal Procedure 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Remove the tire and wheel. 3. Remove the rotor. Refer to Brake Rotor Replacement - Front in Disc Brakes. 4. Remove the wheel speed sensor and brake hose mounting bracket bolt from the steering knuckle. 5. Remove the wheel drive shaft nut retaining cover. Automatic Transmission - 4L60-E/4L65-E Shift Solenoid: Locations Automatic Transmission - 4L60-E/4L65-E Automatic Transmission Electronic Component Views (M30/M32) Automatic Transmission Electronic Component Views (M30/M32) Electronic Components A/T Control - DTC P0756 Diagnostic Tips Channel Plate: All Technical Service Bulletins A/T Control - DTC P0756 Diagnostic Tips INFORMATION Bulletin No.: 01-07-30-036H Date: January 29, 2009 Subject: Diagnostic Tips for Automatic Transmission DTC P0756, Second, Third, Fourth Gear Start Models: 2009 and Prior GM Passenger Cars and Light Duty Trucks 2009 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X with 4L60-E, 4L65-E or 4L70E Automatic Transmission (RPOs M30, M32 or M70) Supercede: This bulletin is being revised to add the 2009 model year and add details regarding spacer plates. Please discard Corporate Bulletin Number 01-07-30-036G (Section 07 - Transmission/Transaxle). Some dealership technicians may have difficulty diagnosing DTC P0756, 2-3 Shift Valve Performance on 4L60-E, 4L65-E or 4L70E automatic transmissions. As detailed in the Service Manual, when the PCM detects a 4-3-3-4 shift pattern, DTC P0756 will set. Some customers may also describe a condition of a second, third or fourth gear start that may have the same causes but has not set this DTC yet. Below are some tips when diagnosing this DTC: ^ This is a performance code. This means that a mechanical malfunction exists. ^ This code is not set by electrical issues such as a damaged wiring harness or poor electrical connections. Electrical problems would cause a DTC P0758, P0787 or P0788 to set. ^ The most likely cause is chips/debris plugging the filtered AFL oil at orifice # 29 on the top of the spacer plate (48). This is a very small hole and is easily plugged by a small amount of debris. It is important to remove the spacer plate and inspect orifice # 29 and the immediate area for the presence of chips/debris. Also, the transmission case passage directly above this orifice and the valve body passage directly below should be inspected and cleaned of any chips/debris. For 2003 and newer vehicles the spacer plate should be replaced. The service replacement spacer plate is a bonded style with gaskets and solenoid filter screens bonded to the spacer plate. These screens can help to prevent plugging of orifice # 29 caused by small debris or chips. ^ This code could be set if the 2-3 shift valve (368) were stuck or hung-up in its bore. Inspect the 2-3 shift valve (368) and the 2-3 shuttle valve (369) for free movement or damage and clean the valves, the bore and the valve body passages. ^ This code could be set by a 2-3 shift solenoid (367b) if it were cracked, broken or leaking. Refer to Shift Solenoid Leak Test in the appropriate Service Manual for the leak test procedure. Based on parts return findings, a damaged or leaking shift solenoid is the least likely cause of this condition. Simply replacing a shift solenoid will not correct this condition unless the solenoid has been found to be cracked, broken or leaking. It is important to also refer to the appropriate Service Manual or Service Information (SI) for further possible causes of this condition. Disclaimer Page 2690 Relay Block - I/P C3 Part 1 Page 15972 Control Module References Part 3 Page 14293 WA812K/88 - WA812K/88 Page 15213 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground TESTING FOR SHORT TO GROUND NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting With A Digital Multimeter TROUBLESHOOTING WITH A DIGITAL MULTIMETER NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TROUBLESHOOTING WITH A TEST LAMP Page 7273 Steps 4-10 Page 1709 Air Induction Components Page 15393 Page 7771 1. Install the locating pins to the NEW encoder motor. 2. Position a NEW actuator insulator gasket to the transfer case. 3. Install the encoder motor. Notice: Refer to Fastener Notice in Service Precautions. 4. Install encoder motor bolts. ^ Tighten the bolts, in the sequence shown, to 20 Nm (15 ft. lbs.). 5. Connect the encoder motor electrical connector. Ensure that the retention clips activate. 6. Install the front propeller shaft. 7. Install the transfer case shield, if equipped. Page 3489 Steps 10 - 13 Page 4037 5. Remove paint and primer from the area surrounding the 10 mm (0.40 in) until bare metal is visible. Important The M6 conductive rivet stud as shown, can accommodate a panel thickness range of 0.7-4.2 mm (0.03-0.17 in). If there are layers of sheet metal, they should be touching without any air gaps to ensure a good ground. 6. Select a M6 conductive rivet stud. Refer to the Parts Information section of this bulletin. Note Use the GE-50317 rivet stud tool kit. 7. Place the M6 conductive rivet stud (1) in the 10 mm (0.40 in) hole. Assemble the rivet stud tool (2) with the groove and flare side facing the rivet stud, then the washer and the M6 nut (3). 8. Using a wrench on the rivet stud tool, and a socket on the M6 nut, secure the M6 conductive rivet stud. 9. Ensure the new rivet stud is securely fastened, WITHOUT ANY detectable movement. 10. Completely wrap the threads of the rivet stud with painters tape or equivalent. Page 1220 Traction Control Switch: Service and Repair Traction Control Switch Replacement Removal Procedure 1. Remove instrument panel (IP) bezel. 2. Gently lift the switch retaining tabs (1) and remove the traction control switch (2) from the instrument panel (IP) assembly (3). 3. Disconnect the harness connector from the traction control switch. Installation Procedure 1. Connect the harness connector to the traction control switch. 2. Install the traction control switch (2) into the instrument panel (IP) assembly (3), making sure that all of the switch retaining tabs (1) are engaged. 3. Install instrument panel (IP) bezel. Page 16132 Electrical Symbols Part 8 Page 13270 Important: Secure the wiring harness so that there is no risk of chafing or rattling. 6.1. Remove the passenger seat in accordance with WIS 8. Body - Seats Adjustment/Replacement. 6.2. Remove the right-hand B-pillar trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.3. Remove the right-hand C pillar trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.4. Fold the rear seat backrest forward. 6.5. Remove the right-hand side bolster in accordance with WIS - 8. Body - Seats Adjustment/Replacement. 6.6. Remove the A-pillar's lower side piece. 6.7. Open the cover on the right-hand wiring harness channels. 6.8. Loosen the locking strip (A) on the 2-pin connector (H2-11) for the optic cable, located by the right-hand A-pillar. 6.9. Loosen the catch (B) and remove the optic cable that runs backward in the car. 6.10. Dismantle the end cap from the new optic cable (12 783 577) and connect it to the connector H2-11. Push in the optic cable and make sure the catch (B) locks and refit the locking strip (A). 6.11. Secure the connector and the old optic cable using the cable tie for the existing wiring harness (C). Page 2250 11. If the vehicle is a 2003 model year Chevrolet Express or GMC Savana van, the vehicle may require a new accumulator. Refer to Corporate Bulletin Number 03-01-38-016 for more information. This bulletin refers to an updated design accumulator that may improve the performance of the A/C system. 12. Install a new serpentine belt tensioner and serpentine belt if they have been damaged due to A/C system slugging or an A/C compressor seizure. The serpentine belt tensioner may have broken stop tabs and/or a missing front cap. 13. Verify proper operation of the A/C system. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 10113 Steering Control Module: Service and Repair Rear Wheel Steering Control Module Replacement Rear Wheel Steering Control Module Replacement Removal Procedure 1. Notice: Refer vehicle Lifting. Raise the vehicle. Refer to Vehicle Lifting. 2. Remove the spare tire from the vehicle to gain access to the control module. 3. Disconnect the electrical connectors from the control module. 4. Remove the bolts (1) retaining the control module (2) to the bracket. 5. Remove the control module from the vehicle. Installation Procedure 1. Install the control module to the vehicle. 2. Notice: Refer to Fastener Notice in Service Precautions. Install the control module (2) retaining bolts (1). ^ Tighten the bolts to 24 Nm (18 ft. lbs.). Page 5182 Air Induction Components Page 2063 Steering and vibration complaints are not always the result of improper alignment. One possible cause is wheel and tire imbalance. Another possibility is tire lead due to worn or improperly manufactured tires. Lead/pull is defined as follows: at a constant highway speed on a typical straight road, lead/pull is the amount of effort required at the steering wheel to maintain the vehicles straight path. Lead is the vehicle deviation from a straight path on a level road without pressure on the steering wheel. Refer to Radial Tire Lead/Pull Correction in Tires and Wheels in order to determine if the vehicle has a tire lead problem. Before performing any adjustment affecting wheel alignment, perform the following inspections and adjustments in order to ensure correct alignment readings: ^ Inspect the tires for the proper inflation and irregular tire wear. ^ Inspect the runout of the wheels and the tires. ^ Inspect the wheel bearings for backlash and excessive play. ^ Inspect the ball joints and tie rod ends for looseness or wear. ^ Inspect the control arms and stabilizer shaft for looseness or wear. ^ Inspect the steering gear for looseness at the frame. Refer to Fastener Tightening Specifications in Power Steering System. ^ Inspect the struts/shock absorbers for wear, leaks, and any noticeable noises. Refer to Struts or Shock Absorbers On-Vehicle Testing in Suspension General Diagnosis. ^ Inspect the vehicle trim height. Refer to Trim Height Inspection Procedure in Suspension General Diagnosis. ^ Inspect the steering wheel for excessive drag or poor return due to stiff or rusted linkage or suspension components. ^ Inspect the fuel level. The fuel tank should be full or the vehicle should have a compensating load added. Give consideration to excess loads, such as tool boxes, sample cases, etc. If normally carried in the vehicle, these items should remain in the vehicle during alignment adjustments. Give consideration also to the condition of the equipment being used for the alignment. Follow the equipment manufacturer's instructions. Satisfactory vehicle operation may occur over a wide range of alignment settings. However, if the setting exceeds the service allowable specifications, correct the alignment to the service preferred specifications. Refer to Wheel Alignment Specifications. Perform the following steps in order to measure the front and rear alignment angles: 1. Install the alignment equipment according to the manufacturer's instructions. 2. Jounce the front and the rear bumpers 3 times prior to checking the wheel alignment. 3. Measure the alignment angles and record the readings. 4. Important: When performing adjustments to vehicles requiring a 4-wheel alignment, set the rear wheel alignment angles first in order to obtain proper front alignment angles. Adjust alignment angles to vehicle specification, if necessary. Refer to Wheel Alignment Specifications. Page 7928 Vehicle Speed Sensor (VSS) Tow/Haul Switch Location Automatic Transmission - 4L60-E/4L65-E Transmission Position Switch/Sensor: Service and Repair Automatic Transmission 4L60-E/4L65-E Park/Neutral Position Switch Replacement ^ Tools Required J 41364-A Park Neutral Switch Aligner Removal Procedure 1. Apply the park brake. 2. Shift the transmission into neutral. 3. If equipped with 4-wheel drive (4WD), remove the front propeller shaft. 4. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 5. Disconnect the park/neutral position (PNP) switch electrical connector (2). 6. Remove the manual shaft lever nut. Page 5614 Camshaft Position Sensor: Description and Operation CAMSHAFT POSITION (CMP) SENSOR The CMP sensor is also a magneto resistive sensor, with the same type of circuits as the CKP sensor. The CMP sensor signal is a digital ON/OFF pulse, output once per revolution of the camshaft. The CMP sensor information is used by the PCM to determine the position of the valve train relative to the CKP. Page 11669 3. Install the retractor tower cover. 4. Install the retractor tower cover retaining screw. Tighten Tighten the screw to 2 N.m (18 lb in). 5. Install the retractor. 6. Install the retractor bolt. Tighten Tighten the bolt to 53 N.m (39 lb ft). 7. Install the rear cardboard panel retainers. 8. Install the seat back cover and pad. 9. Move the seat to its original position. Page 11904 Involved are certain vehicles within the VIN breakpoints shown above. PARTS INFORMATION -- Saab US Only Customer Notification General Motors will notify customers of this special coverage on their vehicles (see copy of typical customer letter shown in this bulletin - actual divisional letter may vary slightly). Page 7346 7. Remove the transmission control lever from the manual shaft. 8. Remove the PNP switch bolts. 9. Remove the PNP switch from the manual shaft. If the PNP switch did not slide off the manual shaft, file the outer edge of the manual shaft in order to remove any burrs. Installation Procedure 1. Install the PNP switch to the transmission manual shaft by aligning the switch hub flats with the manual shaft flats. 2. Slide the PNP switch onto the transmission manual shaft until the switch mounting bracket contacts the mounting bosses on the transmission. 3. Important: If a NEW PNP switch is being installed, the switch will come with a positive assurance bracket. The positive assurance bracket aligns the new switch in its proper position for installation and the use of the park neutral switch aligner will not be necessary. Install the PNP switch bolts finger tight. 4. Install J 41364-A onto the PNP switch. Ensure that the two slots on the switch where the manual shaft is inserted are lined up with the lower two tabs on the tool. 5. Notice: Refer to Fastener Notice in Service Precautions. Rotate the tool until the upper locator pin on the tool is lined up with the slot on the top of the switch. ^ Tighten the bolts to 25 Nm (18 ft. lbs.). 6. Remove the J 41364-A from the switch. If installing a new switch, remove the positive assurance bracket at this time. 7. Install the transmission control lever to the manual shaft with the nut. ^ Tighten the nut to 25 Nm (18 ft. lbs.). Page 11400 Sunload Sensor (With RPO Code CJ2) Page 10915 Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips SPLICING COPPER WIRE USING SPLICE CLIPS IMPORTANT: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. TOOLS REQUIRED J 38125-D Terminal Repair Kit 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-D in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. Fuel System - SES Lamp ON/Gauge Reads Empty/DTC's Set Fuel Tank Vent: All Technical Service Bulletins Fuel System - SES Lamp ON/Gauge Reads Empty/DTC's Set Bulletin No.: 05-06-04-008A Date: April 14, 2005 TECHNICAL Subject: Diagnostic Trouble Code (DTC) P1172 or P2636, Fuel Gauge Reads Empty, Service Engine Soon (SES) Light On (Relocate Auxiliary Fuel Tank Vent Hose) Models: 2001-2005 Chevrolet Silverado (Cab Chassis Models Only) 2001-2005 GMC Sierra (Cab Chassis Models Only) with Auxiliary Fuel Tank Supercede: This bulletin is being revised to clarify the difference between the auxiliary fuel tank balance hose and vent hose. Please discard Corporate Bulletin Number 05-06-04-008 (Section 06 Engine/Propulsion System). Condition Some customers may comment that the SES light comes on and the fuel gauge reads empty. when This may occur when the vehicle is parked on an incline with the engine running. Diagnosis with a scan tool may reveal a DTC P1172 and/or P2636. Cause Important: A similar condition may occur if the vehicle is fueled with the engine running AND the rear tank is fueled first. The engine must be shut off (as required by law) during vehicle refueling. The auxiliary fuel tank vent hose is located in the same "T" connection on the main tank vent hose as the auxiliary tank balance hose. During fuel transfer, the fuel is pumped out of the auxiliary tank to the main tank via the balance hose. The fuel is then sucked back into the auxiliary tank via the vent hose rather then dumping the fuel into the main tank. When the Powertrain Control Module (PCM) does not detect a fluid level transfer between the main tank and the auxiliary tank, the PCM shuts off the auxiliary tank pump and the fuel gauge goes to empty. Correction Follow the service procedure below to correct this condition. 1. Depending on the body upfitter, it may be necessary to raise the vehicle in order to gain access to the auxiliary tank balance hose. 2. Depending on the body upfitter, it may be necessary to remove the left rear tire/wheel assemblies in order to gain access to the auxiliary tank balance hose. Page 12797 The number above refers to the step number on the diagnostic table. DTC U0073 or U2100 DTC Descriptors DTC U0073 00: Control Module Communication Bus Off DTC U0073 71: ECU HS Bus Off DTC U0073 72: ECU LS Bus Off DTC U2100 00: Controller Area Network (CAN) Bus Communication DTC U2100 47: Controller Area Network (CAN) Bus Communication Circuit/System Description The serial data circuits are serial data buses used to communicate information between the control modules. The serial data circuits also connect directly to the data link connector (DLC). Conditions for Running the DTCs Supply voltage at the modules are in the normal operating range. The vehicle power mode requires serial data communications. Conditions for Setting the DTC The module setting the DTC has attempted to establish communications on the serial data circuits more than 3 times. Fuel System - Cranks But No Start/Inaccurate Fuel Gauge Fuel Gauge Sender: All Technical Service Bulletins Fuel System - Cranks But No Start/Inaccurate Fuel Gauge Bulletin No.: 04-08-49-018E Date: January 05, 2005 TECHNICAL Subject: Cranks But No Start, Stall, Inaccurate/Incorrect Fuel Gauge Reading, No Fuel, Vehicle is Out of Fuel and Fuel Gauge Reads Above Empty (Replace Fuel Level Sensor) Models: 2001-2004 Cadillac Trucks 1999-2004 Chevrolet and GMC Trucks with Gasoline Engine (VINs Z, X, V, T, U, N, G, 6, 8 - RPOs LU3, LR4, LM7, LQ4, LQ9, L59, L18,LK5 L52) Attention: Parts are currently available for vehicles with Variable Fuel (VIN Z - RPO L59) vehicles. Please refer to Corporate Bulletin Number 04-06-04-01 2B or newer for Variable Fuel (VIN Z - RPO L59) vehicles. Supercede: This bulletin is being revised to include information on the Chevrolet Colorado and the GMC Canyon. Please discard Corporate Bulletin Number 04-08-49-018D (Section 08 - Body and Accessories). Condition Some customers may comment on the vehicle stalling and will not restart, vehicle ran out of fuel, vehicle appears to be out of fuel but the fuel gauge reads above empty. The fuel gauge may read 1/4 tank. Cause Contamination on the fuel sending card may cause inaccurate/incorrect fuel gauge readings. Correction Follow the service procedure below for diagnosis and repair of this concern. 1. Confirm that the vehicle is actually out of fuel. ^ If the vehicle is not out of fuel but Engine Cranks but Does Not Run, refer to the appropriate Service Information. ^ If the vehicle is out of fuel and the gauge does not read empty, test the fuel gauge. Refer to the following information: - Fuel Gage Inaccurate or Inoperative Single Tank - Fuel Gage Inaccurate or Inoperative Dual Tanks - Fuel Gage Inaccurate or Inoperative Colorado and Canyon 2. If testing reveals that the fuel gauge is operating correctly, replace the fuel sensor assembly and auxiliary tank fuel level sensor if equipped. 3. Replace the fuel level sensor. Refer to the following appropriate service information: ^ Fuel Level Sensor Replacement 4.8L and 5.3L Engines ^ Fuel Level Sensor Replacement 6.0L Engine - Front Tank ^ Fuel Level Sensor Replacement 6.0L Engine - Rear Tank ^ Fuel Level Sensor Replacement 8.1L vehicles with Front Tank ^ Fuel Level Sensor Replacement 8.1 L vehicles with Rear Tank Page 1320 Air Temperature Sensors - Lower Left Page 3636 Heater Core: Service and Repair Heater Core Replacement - Delphi HEATER CORE REPLACEMENT (DELPHI) REMOVAL PROCEDURE 1. Remove the HVAC module assembly. See: Heating and Air Conditioning/Housing Assembly HVAC/Service and Repair/HVAC Module Assembly Replacement 2. Remove the screws from the heater core cover. 3. Remove the heater core cover (1) from the HVAC module assembly (2). 4. Remove the heater core cowl gasket (1) from the heater core (2). 5. Remove the heater core (2) from the HVAC module assembly (3). INSTALLATION PROCEDURE Drive Belt Chirping Drive Belt: Testing and Inspection Drive Belt Chirping Drive Belt Chirping Diagnosis Diagnostic Aids The chirping noise may be intermittent due to moisture on the drive belt(s) or the accessory drive pulley(s). In order to duplicate the customer's concern, it may be necessary to spray a small amount of water onto the drive belt(s). If spraying water onto the drive belt(s) duplicates the symptom, cleaning the accessory drive pulley(s) may be the most probable solution. A loose or improper installation of a body or suspension component, or other item(s) on the vehicle may also cause the chirping noise. Test Description Locations Full Engine View Left Side Page 12846 1. To receive credit, submit a claim with the information above. Disclaimer 2001 and Older Model Year Vehicles (Except Saab Vehicles) 2001 and Older Model Year Vehicles (Except Saab Vehicles) Important: 2001 and older model year vehicles require the removal of the battery power from the OnStar(R) vehicle interface unit (VIU) to eliminate the possibility of an inadvertent OnStar(R) or emergency/airbag call. 1. Locate and gain access to the OnStar® VIU. Refer to OnStar Vehicle Interface Unit Replacement in SI. Important: Complete removal of the VIU is usually not required. Perform only the steps required to gain access to the C2 32-way blue connector. Residing in the C2 connector are the battery positive (+) circuits. Removal of the C2 connector will deactivate the unit and eliminate the possibility of an inadvertent OnStar(R) or emergency/airbag call. Page 5601 Step 6 Page 16133 Electrical Symbols Part 9 Body - Dimple In Body Side Molding(s) Lower Side Moulding / Trim: Customer Interest Body - Dimple In Body Side Molding(s) Bulletin No.: 04-08-111-002B Date: October 26, 2006 TECHNICAL Subject: Dimple in Body Side Molding (Replace Moldings) Models: 2004 Chevrolet Avalanche without Body Hardware (RPO WBH) 2004 Chevrolet Silverado, Suburban, Tahoe with Body/Side Exterior-Molding-in-Color (RPO B85) Supercede: This bulletin is being revised to change the Warranty and add a revised parts information statement. Please discard Corporate Bulletin Number 04-08-111-002A (Section 08 - Body and Accessories). Condition Some customers may comment on a raised surface or a dimple in the exterior molded-in-color body side door moldings. This condition may be more pronounced in warmer climates. This does not apply to standard colored keyed black body side moldings. Cause Engineering has determined that this condition may be caused by a bar code label on the backside of the molding that dimples the molding. Correction Replace ALL of the exterior body side door moldings. Refer to Molding Replacement-Body Side procedure in SI. Dealer Action Please contact all customers that were told they would be called when a repair became available. Parts Information Page 13921 1. Install the transmission support to the frame. (15 series) 2. Install the transmission support to the frame. (25/35 series) Notice: Refer to Fastener Notice in Service Precautions. 3. Install the bolts and the nuts in order to retain the transmission support to the frame. Tighten the nuts to 95 N.m (70 lb ft). 4. Lower the rear of the transmission. 5. Install the transmission mount to the transmission support. 6. Install the nuts in order to retain the transmission mount to the transmission support. Tighten the nuts to 40 N.m (30 lb ft). 7. Remove the transmission jack. 8. Lower the vehicle. Page 4111 7. Remove the control lever to the manual shaft nut. 8. Remove the control lever from the manual shaft. 9. Remove the PNP switch bolts. 10. Remove the PNP switch from the manual shaft. If the PNP switch does not slide off the manual shaft, file the outer edge of the manual shaft in order to remove any burrs. Installation Procedure 1. Install the PNP switch to the manual shaft by aligning the switch hub flats with the manual shaft flats. 2. Slide the PNP switch onto the manual shaft until the switch mounting bracket contacts the mounting bosses on the transmission. 3. Important: If a new PNP switch is being installed, the switch will come with a positive assurance bracket. The positive assurance bracket aligns the new switch in its proper position for installation and the use of the park neutral switch aligner will not be necessary. Install the PNP switch bolts finger tight. Fuel System Description Fuel Level Sensor: Description and Operation Fuel System Description FUEL LEVEL SENSOR The fuel level sensor consists of a float, a wire float arm, and a ceramic resistor cord. The position of the float arm indicates the fuel level. The fuel level sensor contains a variable resistor, which changes resistance in correspondence to the amount of fuel in the fuel tank. The powertrain control module (PCM) sends the fuel level information via the class 2 circuit to the instrument panel (I/P) cluster. This information is used for the I/P fuel gage and the low fuel warning indicator, if applicable. The PCM also monitors the fuel level input for various diagnostics. Engine, A/T - Shift/Driveability Concerns/MIL ON Air Filter Element: All Technical Service Bulletins Engine, A/T - Shift/Driveability Concerns/MIL ON Bulletin No.: 04-07-30-013B Date: February 01, 2007 INFORMATION Subject: Automatic Transmission Shift, Engine Driveability Concerns or Service Engine Soon (SES) Light On as a Result of the Use of an Excessively/Over-Oiled Aftermarket, Reusable Air Filter Models: 2007 and Prior GM Cars and Light Duty Trucks 2007 and Prior Saturn Models 2003-2007 HUMMER H2 2006-2007 HUMMER H3 2005-2007 Saab 9-7X Supercede: This bulletin is being revised to add models and model years. Please discard Corporate Bulletin Number 04-07-30-013A (Section 07 - Transmission/Transaxle). The use of an excessively/over-oiled aftermarket, reusable air filter may result in: Service Engine Soon (SES) light on Transmission shift concerns, slipping and damaged clutch(es) or band(s) Engine driveability concerns, poor acceleration from a stop, limited engine RPM range The oil that is used on these air filter elements may be transferred onto the Mass Air Flow (MAF) sensor causing contamination of the sensor. As a result, the Grams per Second (GPS) signal from the MAF may be low and any or all of the concerns listed above may occur. When servicing a vehicle with any of these concerns, be sure to check for the presence of an aftermarket reusable, excessively/over-oiled air filter. The MAF, GPS reading should be compared to a like vehicle with an OEM air box and filter under the same driving conditions to verify the concern. The use of an aftermarket reusable air filter DOES NOT void the vehicle's warranty. If an aftermarket reusable air filter is used, technicians should inspect the MAF sensor element and the air induction hose for contamination of oil prior to making warranty repairs. Transmission or engine driveability concerns (related to the MAF sensor being contaminated with oil) that are the result of the use of an aftermarket reusable, excessively/over-oiled air filter are not considered to be warrantable repair items. Page 8404 2. Raise and support the vehicle. Refer Vehicle Lifting 3. Relieve the tension from the park brake cable by pulling down on the park brake cable in front of the equalizer and removing the right park brake cable from the equalizer bar. 4. Remove the cable from the mounting bracket by depressing the locking tabs. 5. Remove the park brake cable from the differential clip.Remove the bolt retaining the park brake cable from the rear axle clip. 6. Remove the rear brake cable mounting bracket bolt. Page 5812 Page 10919 IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. Splicing Twisted or Shielded Cable SPLICING TWISTED OR SHIELDED CABLE Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. - Rewrap the conductors with the mylar tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with mylar tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Control Module References Automatic Transmission Input Shaft Speed (AT ISS) Sensor Connector Tool Storage Compartment Bracket Replacement (PRO) Utility Storage Compartment: Service and Repair Tool Storage Compartment Bracket Replacement (PRO) Tool Storage Compartment Bracket Replacement (PRO) Removal Procedure 1. Remove the tool storage compartment. 2. Remove the rear seat hinge filler panel cover and plastic push pins, in order to gain access to seat riser retaining nuts. 3. Remove the nuts that retain the tool storage compartment brackets (1), (2) to the seat riser studs. 4. Remove the brackets from the vehicle. Installation Procedure 1. Install the brackets to the vehicle and hand tighten the nuts. 2. Install the tool storage compartment. Notice: Refer to Fastener Notice in Service Precautions. 3. Tighten the nuts that retain the tool storage compartment brackets (1), (2) to the seat riser studs. Tighten the nuts to 50 N.m (36 lb ft). 4. Install the rear seat hinge filler panel cover and plastic push pins. Page 14398 Front Passenger Door Module (FPDM) - C1 (With RPO Code YE9) Page 14106 Control Module References Part 4 Page 4704 1. Install the TAC module. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the TAC module nuts. Tighten Tighten the nuts to 9 N.m (80 lb in). 3. Connect the engine wiring harness electrical connector (1). 4. Install the red CPA retainer. 5. Connect the I/P harness electrical connector (2). Page 12841 Page 2615 Fuse: Application and ID Fuse Block - I/P Location View Page 9767 C321 Seat Jumper Harness To Seat Harness (With RPO Code AN3) Part 2 Page 3821 Control Module References Part 7 Brakes/Wheels - Excessive Debris Build Up Brake Caliper: All Technical Service Bulletins Brakes/Wheels - Excessive Debris Build Up Bulletin No.: 04-05-23-005 Date: June 22, 2004 INFORMATION Subject: Availability of Rear Wheel Mud Flaps to Reduce Debris Build-up on Rear Brake Calipers and/or Rear Wheels Models: 1999-2004 Chevrolet Silverado Pickup Models 1999-2004 GMC Sierra Pickup Models This bulletin is to inform dealers of the release of rear wheel mud flaps. The above models that are exposed to extensive off-paved roads may benefit from the mud flaps. The mud flaps have been developed to minimize the amount of stones and/or mud that can impact and collect on the rear caliper and/or wheel rim. Please advise customers that the installation of these mud flaps and following the recommended off-road driving information provided in their Owner's Manual should greatly reduce the possibility of accelerated rear brake component wear and/or rim damage. Install the mud flap forward of each rear wheel using the following procedure. Important: Always work from outboard to inboard, drilling one hole at a time and securing with a fastener. Follow the sequence of the procedure. This will prevent distortion of the mud flap. 1. Raise the vehicle. Support the vehicle. 2. Locate the pickup box side panel rear brace. 3. Remove the existing outboard upper fastener on the brace. 4. Install the mud flap through the "V" of the brace. Install the previously removed fastener in the hole (2) of the mud flap to the brace. Do not tighten the fastener at this time. 5. Using the mud flap as a template, locate and mark the location of the hole (1) in the pickup box wheel house. Page 10068 Refer to Fastener Notice in Service Precautions. Install the power steering cooler (1) to the radiator support. ^ Tighten the bolts retaining the power steering cooler to 5 Nm (44 inch lbs.). 2. Install the power steering cooler outlet hose (2) to the power steering pump (1). 3. Install the retaining clamp. 4. Install the power steering inlet hose (3) to the power steering gear (1). 5. Install the retaining clamp. 6. Fill and bleed the power steering system. Refer to Bleeding the Power Steering System. 7. Inspect all the hose connections for leaks. 8. Install the front grille. Refer to Grille Replacement (GMC) Grille Replacement (Chevrolet) in Exterior Trim. 9. Connect the energy storage box after servicing the vehicle. Description and Operation Shift Indicator: Description and Operation PRNDL DISPLAY The IPC displays the selected gear position as determined by the PCM. The IPC receives a class 2 message from the PCM indicating the gear position. The PRNDL display blanks if: - The IPC receives a class 2 message indicating the park position and the column park switch indicates a position other than park, open input. - The IPC detects a loss of class 2 communications with the PCM. Page 9053 Relay Block - I/P C1 Part 4 Brake Pads Replacement - Front Brake Pad: Service and Repair Brake Pads Replacement - Front Brake Pads Replacement - Front Caution: Refer to Brake Dust Caution in Service Precautions. Removal Procedure 1. Inspect the fluid level in the brake master cylinder reservoir. 2. If the brake fluid level is midway between the maximum-full point and the minimum allowable level, no brake fluid needs to be removed from the reservoir before proceeding. 3. If the brake fluid level is higher than midway between the maximum-full point and the minimum allowable level, remove brake fluid to the midway point before proceeding. 4. Raise and support the vehicle. Refer Vehicle Lifting 5. Remove the tire and wheel assembly. 6. Inspect the brake caliper operation. Refer to Brake Caliper Inspection. 7. Notice: Support the brake caliper with heavy mechanic's wire, or equivalent, whenever it is separated from its mount and the hydraulic flexible brake hose is still connected. Failure to support the caliper in this manner will cause the flexible brake hose to bear the weight of the caliper, which may cause damage to the brake hose and in turn may cause a brake fluid leak. Remove the brake caliper from the brake caliper mounting bracket and support the brake caliper with heavy mechanic's wire or equivalent. DO NOT disconnect the hydraulic brake hose from the brake caliper. Refer to Brake Caliper Replacement - Front. 8. Remove the disc brake pads from the brake caliper mounting bracket. 9. Remove and discard the anti-rattle clips from the brake caliper mounting bracket. 10. Inspect the brake caliper and brake caliper mounting bracket. Refer to Brake Caliper Inspection. Installation Procedure 1. Install new anti-rattle clips to the brake caliper mounting bracket. 2. Install the disc brake pads to the brake caliper mounting bracket. ^ Install the inner pad, 1 wear indicator. ^ Install the outer pad, 2 wear indicators. 3. Install the brake caliper. Refer to Brake Caliper Replacement - Front. 4. Install the tire and wheel assembly. 5. Remove the safety stands. 6. Lower the vehicle. Drivetrain - Excessive Effort When Shift 2HI to 4HI Differential Fluid - Transfer Case: Customer Interest Drivetrain - Excessive Effort When Shift 2HI to 4HI TECHNICAL Bulletin No.: 09-04-19-002A Date: February 17, 2011 Subject: 4WD System Shift Performance in Cold Ambient Temperatures (Use Synthetic Fluid in Light Duty Front Axles with 8.5" Ring Gears) Models: 1999-2011 Chevrolet Silverado 1500 Series Models 1999-2011 GMC Sierra 1500 Series Models Equipped with 4WD and 8.25" Front Axle Ring Gears (Transfer Case RPOs NP2, NQG) Attention: It is important to determine the RPO for the transfer case in GWM/IVH prior to applying this bulletin. This bulletin applies ONLY to vehicles equipped with 8.25" front axle ring gears, used in conjunction with a manual transfer case (RPOs NP2, NQG). Supercede: This bulletin is being revised to add the 2011 model year. Please discard Corporate Bulletin Number 09-04-19-002 (Section 04 - Driveline/Axle). Condition Some customers may comment about the effort required to shift from 2HI to 4HI in cold ambient temperatures at -6°C (20°F) or below. Cause This condition may be caused by the standard front axle being equipped with conventional mineral oil axle fluid. In cold ambient temperatures, prior to complete warm up, the fluid viscosity is thick. This may affect transfer case shift performance prior to full warm up. Correction Drain the front axle fluid and refill with GM SAE 75W-90 Synthetic Axle Fluid, P/N 89021677 (in Canada, 89021678). Refer to Front Axle Lubricant Replacement in SI. It is important to use synthetic fluid in this 8.25" axle to improve the performance of the 4WD system in cold ambient temperatures. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer With Full Floating 10.5 14. Remove the retaining ring from the wheel hub. 15. Remove the outer hub bearing and bearing cup using the J 24426 (2) and the J 8092 (1). Installation Procedure 1. Lubricate the following with a light coat of high melting point EP bearing lubricant: ^ The outer wheel bearing ^ The inner wheel bearing ^ The outer wheel bearing cup ^ The inner wheel bearing cup ^ The axle housing 2. Install the outer bearing into the wheel hub. 3. Install the outer bearing cup into the wheel hub. A/C - Blower Motor Runs After Vehicle Is Shut OFF Blower Motor Relay: All Technical Service Bulletins A/C - Blower Motor Runs After Vehicle Is Shut OFF TECHNICAL Bulletin No.: 03-01-38-015A Date: October 27, 2008 Subject: HVAC Blower Motor May Run Continuously After Vehicle is Turned Off (Replace Blower Resistor Relay) Models: 2004 Chevrolet Avalanche, Silverado, Suburban, Tahoe, TrailBlazer, TrailBlazer EXT 2004 GMC Envoy, Envoy XL, Sierra, Yukon, Yukon XL with Manual Control HVAC (RPO CJ3) Built Prior to August, 2003 Supercede: This bulletin is being revised to update the parts information. Please discard Corporate Bulletin Number 03-01-38-015 (Section 01 - HVAC). Condition Some customers may comment on the HVAC blower motor running after the vehicle has been turned off. The blower may run for just a few minutes or continuously until the battery is discharged. Cause A new style HVAC blower relay/resistor may stick in the "on" position. When the HVAC fan blower relay has been energized, the contacts may "micro-weld" together. After this occurrence, the HVAC blower may not respond to the HVAC controller commands. Correction Replace the HVAC blower resistor/relay with the type used previous to the 2004 model year. The appropriate part numbers are listed in the table below. For specific repair procedures, refer to the 2004 Service Information (SI) under Blower Motor Resistor Assembly Replacement (SI Document ID # 526350 (C/K) or # 729996 (S/T). Parts Information Warranty Information Disclaimer Page 1827 7. Lower the vehicle. 8. Perform a four wheel alignment. Page 8925 Steps 3-4 Page 11007 Cabin Temperature Sensor / Switch: Service and Repair INSIDE AIR TEMPERATURE SENSOR ASSEMBLY REPLACEMENT REMOVAL PROCEDURE 1. Remove the left windshield garnish molding. 2. Remove the left center pillar assist handle. 3. Remove the left center pillar garnish molding. 4. Remove the left sunshade. 5. Gently pull down the headliner. 6. Disconnect the electrical connector from the inside air temperature sensor. 7. Partially remove the inside air temperature sensor from the headliner. 8. Remove the sensor grille from the inside air temperature sensor. 9. Remove the inside air temperature sensor from the headliner. INSTALLATION PROCEDURE 1. Install the new sensor grille to the headliner. Page 1347 Low Pressure Sensor / Switch: Description and Operation A/C LOW PRESSURE SWITCH The A/C low pressure switch protects the A/C system from a low pressure condition that could damage the A/C compressor or cause evaporator icing. The HVAC control module applies 5 volts to the A/C low pressure switch signal circuit. The switch will open when the A/C low side pressure reaches 165-200 kPa (24-29 psi). This prevents the A/C compressor from operating. The switch will then close when A/C low pressure side reaches 275-310 kPa (40-45 psi). This enables the A/C compressor to turn back ON. The low pressure switch uses refrigerant pressure to open and close a set of electrical contacts. When A/C request is authorized, the switch is closed and shows normal status. During this state, the switch will show 0 volts on the A/C low pressure sensor signal circuit. When A/C request is denied due to a low pressure condition, the switch will be open. During this state, the switch will show 5 volts on the A/C low pressure sensor signal circuit. Page 4315 Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses CIRCUIT PROTECTION - FUSES The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the Page 12802 DTC B2483: Global Positioning System (GPS) Antenna Malfunction Short to Ground DTC B2484: Global Positioning System (GPS) Antenna Malfunction Open Circuit Conditions for Running the DTCs The ignition is in RUN or ACC position System voltage is between 9.5 - 15.5 volts. The above conditions are met for more than 1 second. Conditions for Setting the DTCs B2462 02: The CIM detects a short to ground on the navigation antenna signal circuit. B2462 04: The CIM detects an open/high resistance on the navigation antenna signal circuit. B2483: The CIM detects a short to ground on the navigation antenna signal circuit. B2484: The CIM detects an open/high resistance on the navigation antenna signal circuit. Action Taken When the DTCs Set The OnStar(R) status LED turns red. The OnStar(R) Call Center cannot locate the vehicle. Conditions for Clearing the DTCs The condition responsible for setting the DTC no longer exists. A history DTC will clear once 50 consecutive malfunction-free ignition cycles have occurred. Circuit/System Testing Turn OFF the ignition. 1. Disconnect the navigation antenna coax cable from the VCIM. 2. Ignition ON, test for 4.5-5.5 volts between the VCIM coax cable center conductor terminal at the VCIM and ground. ^ If not within the specified range, replace the VCIM. Refer to the appropriate vehicle in SI. 3. Reconnect the coax cable to the VCIM. 4. Disconnect the coax cable from the navigation antenna. 5. Test for 4.55.5 volts between the coax cable center conductor and the outer shield. ^ If not within the specified range, replace the coax cable. 6. If all circuits test normal, replace the navigation antenna. Refer to the appropriate vehicle in SI. DTC B2470 DTC Descriptor DTC B2470 04: Cellular Phone Antenna Circuit Malfunction Open Circuit Circuit/System Description The cellular antenna is connected to the vehicle communication interface module (VCIM) with an RG-58 coax cable. The VCIM collects the data from the cellular antenna once every second. Body - TPO Fascia Cleaning Prior to Painting Front Bumper Cover / Fascia: Technical Service Bulletins Body - TPO Fascia Cleaning Prior to Painting INFORMATION Bulletin No.: 08-08-51-002 Date: March 12, 2008 Subject: New Primer For TPO Fascias and Affected Cleaning Process of Painting Operation Models: 2009 and Prior Passenger Cars and Trucks 2009 and Prior HUMMER H2, H3 The purpose of this bulletin is to inform the technician that General Motors has made a change in the primer it uses for TPO plastic for service parts. This new primer comes in several different colors from five different suppliers. This change affects the cleaning process of the painting operation. The new process is as follows. 1. Wash with soap and water. 2. Clean with a 50% mix of isopropyl alcohol and water (or a waterborne cleaner). Check with your paint supplier for product recommendations. 3. Scuff sand per your paint suppliers recommendations. Note: The use of a solvent-type cleaner will soften, or begin to dissolve the primer. Base coats do not have any affect on this primer. 4. Reclean with a 50% mix of isopropyl alcohol and water (or a waterborne cleaner). All fascias, with the exception of the Corvette, Camaro, and Cadillac XLR, are made of TPO. You may find other TPO parts with this primer. If the technician has a question as to the type of plastic they are painting, inspect the back of the part for the plastic symbol (TPO). Disclaimer Diagram Information and Instructions Cigarette Lighter: Diagram Information and Instructions Truck Zoning TRUCK ZONING Truck Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that corresponds to where they are located in the vehicle. The table explains the numbering system. Page 8433 6. Remove the park brake cable from the park brake actuator lever. 7. Remove the wheel bearing. Refer to Wheel Hub and Bearing Replacement in Rear Wheel Steering See: Maintenance/Wheels and Tires/Wheel Hub/Service and Repair. 8. Remove the park brake shoe from the backing plate. Installation Procedure 1. Install the park brake shoe to the backing plate. 2. Install the wheel bearing. Refer to Wheel Hub and Bearing Replacement in Rear Wheel Steering See: Maintenance/Wheels and Tires/Wheel Hub/Service and Repair. 3. Adjust the park brake shoe. Refer to Park Brake Adjustment in Park Brake See: Adjustments. 4. Install the park brake cable to the park brake actuator lever. Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid Page 8265 Important: After drilling the holes, apply the appropriate anti-corrosion primer. Refer to the GM Refinish Material Booklet # 4901 M-D (English) or # 4901-D-F (French) for additional information. 6. Center punch the marked location and drill a 6.35 mm (1/4 in) hole. Install the plastic retainer in the hole (1) of the mud flap. 7. Tighten fastener at the hole (2) location of the mud flap. Tighten Tighten the fastener to 25 N.m (18 lb ft). 8. For vehicles with short box, use the following procedure: 8.1. Push the mud flap to make contact with the rear side of the underbody cross sill and mark the location of the hole (3) of the mud flap. 8.2. Center punch the marked location and drill a 5.159 mm (13/64 in) hole. 8.3. Install the screw. Tighten Tighten the screw to 4 N.m (35 lb in). 8.4. Repeat the above steps for hole locations 4 and 6. 9. For vehicles with long box, use the following procedure: Page 14917 Front Passenger Door Page 15485 2. Install the fuel level sensor retaining clip. 3. Connect the fuel level sensor electrical connector. 4. Install the fuel level sensor electrical connector retaining clip. Page 3887 The malfunction indicator lamp (MIL) is located in the instrument panel cluster. The MIL will display as either SERVICE ENGINE SOON or one of the following symbols when commanded ON: The MIL indicates that an emissions related fault has occurred and vehicle service is required. The following is a list of the modes of operation for the MIL: - The MIL illuminates when the ignition is turned ON, with the engine OFF. This is a bulb test to ensure the MIL is able to illuminate. - The MIL turns OFF after the engine is started if a diagnostic fault is not present. - The MIL remains illuminated after the engine is started if the control module detects a fault. A diagnostic trouble code (DTC) is stored any time the control module illuminates the MIL due to an emissions related fault. The MIL turns OFF after three consecutive ignition cycles in which a Test Passed has been reported for the diagnostic test that originally caused the MIL to illuminate. - The MIL flashes if the control module detects a misfire condition which could damage the catalytic converter. - When the MIL is illuminated and the engine stalls, the MIL will remain illuminated as long as the ignition is ON. - When the MIL is not illuminated and the engine stalls, the MIL will not illuminate until the ignition is cycled OFF and then ON. TRIP A trip is an interval of time during which the diagnostic test runs. A trip may consist of only a key cycle to power up the PCM, allow the diagnostic to run, then cycle the key off to power down the PCM. A trip may also involve a PCM power up, meeting specific conditions to run the diagnostic test, then powering down the PCM. The definition of a trip depends upon the diagnostic. Some diagnostic tests run only once per trip (i.e., catalyst monitor) while other tests run continuously during each trip (i.e. misfire). WARM-UP CYCLE The PCM uses warm-up cycles to run some diagnostics and to clear any diagnostic trouble codes (DTCs). A warm-up cycle occurs when the engine coolant temperature increases 22°C (40°F) from the start-up temperature. The engine coolant must also achieve a minimum temperature of 71°C (160°F). The PCM counts the number of warm-up cycles in order to clear the malfunction indicator lamp (MIL). The PCM will clear the DTCs when 40 consecutive warm-up cycles occur without a malfunction. DIAGNOSTIC TROUBLE CODES (DTCS) The PCM is programmed with test routines that test the operation of the various systems the PCM controls. Some tests monitor internal PCM functions. Many tests are run continuously. Other tests run only under specific conditions, referred to as Conditions for Running the DTC. When the vehicle is operating within the conditions for running a particular test, the PCM monitors certain parameters and determines if the values are within an expected range. The parameters and values considered outside the range of normal operation are listed as Conditions for Setting the DTC. When the Page 7918 7. Remove the control lever to the manual shaft nut. 8. Remove the control lever from the manual shaft. 9. Remove the PNP switch bolts. 10. Remove the PNP switch from the manual shaft. If the PNP switch does not slide off the manual shaft, file the outer edge of the manual shaft in order to remove any burrs. Installation Procedure 1. Install the PNP switch to the manual shaft by aligning the switch hub flats with the manual shaft flats. 2. Slide the PNP switch onto the manual shaft until the switch mounting bracket contacts the mounting bosses on the transmission. 3. Important: If a new PNP switch is being installed, the switch will come with a positive assurance bracket. The positive assurance bracket aligns the new switch in its proper position for installation and the use of the park neutral switch aligner will not be necessary. Install the PNP switch bolts finger tight. Underhood Electrical Center or Junction Block Replacement Relay Box: Service and Repair Underhood Electrical Center or Junction Block Replacement UNDERHOOD ELECTRICAL CENTER OR JUNCTION BLOCK REPLACEMENT REMOVAL PROCEDURE 1. Disconnect the negative battery cable. 2. Remove the left fender upper brace. 3. Remove the electrical center brace cover assemble by lifting the cover (3) outwards to clear the tabs. 4. Remove all fuses and relays. Page 14131 Door Control Module Diagram 3 Part 2 Page 2925 Acceptably Prepared (Cleaned-Up) Wheel Surface 6. Once the corrosion has been eliminated, you should coat the repaired area with a commercially available tire sealant such as Patch Brand Bead Sealant or equivalent. Commercially available bead sealants are black rubber-like coatings that will permanently fill and seal the resurfaced bead seat. At 21°C (70°F) ambient temperature, this sealant will set-up sufficiently for tire mounting in about 10 minutes.Coated and Sealed Bead Seat 7. Remount the tire and install the repaired wheel and tire assembly. Refer to Tire and Wheel Removal and Installation in SI. Parts Information Patch Brand Bead Sealer is available from Myers Tires at 1-800-998-9897 or on the web at www.myerstiresupply.com. The one-quart size can of sealer will repair about 20 wheels. Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use: Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table above. Page 13598 Front Bumper Cover / Fascia: Service and Repair Air Deflector Replacement - Front Bumper Fascia Removal Procedure 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Disconnect the fog lamp electrical connectors, if equipped. 3. Remove the fog lamps, if equipped. 4. Loosen the center studs of the push-pins on the air deflector with a flat-bladed screwdriver. 5. Remove the air deflector from the front bumper fascia. Installation Procedure 1. Position the air deflector onto the front bumper assembly. 2. Fasten the connection ends of the push-pins onto the front bumper deflector. 3. Install the fog lamps, if equipped. 4. Connect the fog lamp electrical connectors, if equipped. 5. Lower the vehicle. Page 13542 Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses CIRCUIT PROTECTION - FUSES The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the Page 9041 Junction Block - I/P - C5 NVG 246-NP8 Control Module: Service and Repair NVG 246-NP8 Transfer Case Control Module Reprogramming Transfer Case Control Module Reprogramming Set-up for Module Programming/Reprogramming Important: Ensure that the vehicle battery is fully charged and that a battery charger is no longer connected. If performing this procedure for module replacement, install new module before proceeding. Before reprogramming close the doors and wait two minutes to allow other modules to stop communicating via the class 2 data line. Failure to do so could result in a failed reprogramming procedure. ^ Turn OFF all accessories. ^ Turn ON the ignition, with the engine OFF. Remote Programming Feature 1. Connect the scan tool to the vehicle. 2. Power-up the scan tool and select the Service Programming feature. 3. Select the appropriate vehicle. 4. Press the Request Info button on the scan tool. 5. Disconnect the scan tool from the vehicle and connect the scan tool to the computer station. 6. Follow the menu select items for reprogramming and provide information as to what type of device you are programming and whether you are reprogramming or replacing the electronic control unit (ECU). 7. Select "vehicle" from the selection menu. 8. Select the module you wish to Program. 9. Select "Normal" for Programming Type. 10. Select the applicable software calibrations. 11. Transfer data file to the scan tool. 12. Reconnect the scan tool to the vehicle. 13. Turn ON the ignition, with the engine OFF. 14. Select the Service Programming feature on the scan tool. 15. Press the Program button on the scan tool. Programming Using Scan Tool Pass-Through Connection 1. Connect the scan tool to vehicle and power it up. 2. Connect the computer station to the scan tool. 3. Select "PC Using Scan Tool Connection" from the programming menu on the computer station. 4. Follow the menu select items for reprogramming and provide information as to what type of device you are programming and whether you are reprogramming or replacing the electronic control unit (ECU). 5. Select "vehicle" from the selection menu. 6. Select the module you wish to program. 7. Select "Normal" for Programming Type. 8. Select the applicable software calibrations. 9. Transfer data file to the scan tool. Transfer Case Shift Control Module Replacement Transfer Case Shift Control Module Replacement Removal Procedure Service and Repair Valve Spring: Service and Repair Valve Stem Oil Seal and Valve Spring Replacement ^ Tools Required J 22794 Spark Plug Port Adapter - J 38606 Valve Spring Compressor Removal Procedure 1. Remove the valve rocker arm. 2. Disconnect the spark plug wire at the spark plug. ^ Twist each plug wire boot 1/2 turn. ^ Pull only on the boot in order to remove the wire from the spark plug. 3. Important: Remove the spark plugs from the cylinder head with the engine at room temperature. Loosen the spark plug 1 or 2 turns. 4. Brush or air blast away any dirt or debris from around the spark plug. 5. Remove the spark plug. 6. Install J 22794 into the spark plug hole. 7. Attach an air hose to J 22794. 8. Apply compressed air to J 22794 in order to hold the valves in place. Page 14096 SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-D. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: - The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair Tools Required J 38125-D Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-D. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Description and Operation Volt Meter Gauge: Description and Operation VOLTMETER The IPC displays the system voltage as detected at the ignition 1 input of the IPC. When the engine is ON, the gage should be between 10-16 volts. Page 2762 Application Table Page 906 Control Module References Part 1 Page 14451 Disclaimer Page 383 2. Click on the Analog-to-Digital Program link to start the ordering process. 3. To order a kit, you will need the information shown above. 4. After submitting the order, the "Terms and Conditions of Your OnStar(R) Service" page will display. This is your confirmation that the upgrade kit order has been created. U.S. Dealers will also receive an e-mail from Autocraft within several hours of ordering an upgrade kit (Canadian Dealers will receive an e-mail from MASS Electronics). 5. Print the "Terms and Conditions of Your OnStar(R) Service" page, and have the customer sign a copy. 6. A copy of this form should be stapled to the customer's copy of the Repair Order and one copy should be retained in the customer service folder. 7. If the kit you ordered is available, you will receive the upgrade kit within 4 business days of entering your order through the OnStar(R) Online Enrollment webpage. 8. To check on kit availability or the status of your order, U.S. Dealers can log onto the distributor's website at www.autocraft.com. Canadian dealers can call MASS Electronics at 877-410-6277. Upgrade Kit Installation 1. Skip to the next step if the vehicle to be upgraded is not shown above. Page 10039 1. Important: Use new O-ring seals when assembling the power steering pump assembly. Lubricate the O-ring seals (1) (4) with power steering fluid. 2. To install the control valve assembly and flow control spring to the pump housing assembly (2); refer to Power Steering Pump Flow Control Valve Replacement - Off Vehicle (Regular). 3. Install the O-ring seals (1) (4) to the pump housing assembly (2). 4. Install the magnet (3) to the pump housing assembly (2). 5. Connect the reservoir assembly (1) to the pump housing assembly (2). 6. Install the O-ring seal. 7. Install the connector and fitting assembly (5). To install the variable assist steering actuator (3) and retaining ring (4); refer to Power Steering Pump Flow Control Valve Actuator Replacement - On Vehicle. Notice: Refer to Fastener Notice in Service Precautions. 8. Install the pump mounting studs (2) to the pump housing (1). ^ Tighten the pump mounting studs (2) to 58 Nm (43 ft. lbs.). ^ Tighten the connector and fitting assembly (5) to 75 Nm (55 ft. lbs.). Page 12551 Page 8194 - It is not necessary to replace rotors in pairs. Rotors may be replaced individually. However, caution should be exercised, as a variance in surface finish may cause a brake pull condition. - New rotors should not be refinished before installation. Original equipment rotor surfaces are ground to ensure smooth finish and parallelism between mounting and friction surfaces. If a new rotor has more than 0.050 mm (0.002 in) Lateral Run Out (LRO) when properly mounted on the hub, correct it using one of the following methods: 1. For hubless rotor designs, use the correction plate procedure found in the "GM Brake Service Procedure for Hubless Rotors" outlined in this bulletin. 2. For hubbed/trapped/captured rotor designs, refinish the rotor using an On-Car lathe and the procedure outlined in this bulletin. - Never reuse rotors that measure under the Minimum Thickness specification. In this instance, the rotor should be replaced. Important If the Minimum Thickness specification is not visible on the rotor, reference Service Information (SI) for the specific vehicle application. DO NOT use any other manufacturers rotor specifications. Brake Pads: Important When determining the warranty coverage (as an example) - if all four front or four rear brake pads are excessively worn evenly, that would NOT be covered under warranty since this type of wear is most likely due to driving habits or trailering. However, if the brake pads are excessively worn un-evenly, side-to-side or same side/inner-to-outer pads, then consideration should be given to cover this under warranty since this type of wear is most likely due to poor operation of other braking components. - Consideration should be given for covering brake pads up to 39,000 km (24,000 mi) (excluding owner abuse, excessive trailering, or the situations that would not be considered normal use). - Installation of new rotors does not require pad replacement. Do not replace pads unless their condition requires it - excessively worn, damage or contaminated. Brake Wear: Several factors impact brake lining wear and should be taken into account when reviewing related issues: - heavy loads / high temperatures / towing / mountainous driving / city driving / aggressive driving / driver braking characteristics (left foot or two feet) The following are conditions that may extend brake lining wear: - light loads / highway driving / conservative driving / level terrain Page 9610 Application Tabel Part 1 Page 4546 - The digital radio receiver (DRR) - The driver seat module (DSM) - The electronic brake control module (EBCM) - The front passenger door module (FPDM) - HVAC Control Module - The hybrid control module (HCM), for PHT - The instrument panel cluster (IPC) - The powertrain control module (PCM) - Radio - The rear seat audio (RSA) controller - The rear seat entertainment (RSE) assembly - The rear wheel steering control module (RWSCM) - The inflatable restraint sensing and diagnostic module (SDM) - The transmission control module (TCM) - The transfer case shift control module (TCSCM) - The vehicle communication interface module (VCIM) 3. The following DTCs may be retrieved with a history status, but are not the cause of the present condition. - U1300 - U1301 - U1305 6. A state of health DTC with a history status may be present along with a U1000 or U1255 code having a current status. This indicates that the malfunction occurred when the ignition was ON. 7. Data link connector terminals 2 and 5 provide the connection to the class 2 serial data circuit and the signal ground circuit respectively. 10. A poor connection at DLC terminal of the splice pack SP205 would cause this condition but will not set a DTC. 11. An open or a short in the class 2 serial data circuit between the DLC and splice pack SP205 will prevent the scan tool from communicating with any module. This condition will not set a DTC. 13. This test isolates the BCM class 2 serial data circuits. 16. The BCM detects that the ignition is ON and sends the appropriate power mode message to the other modules. Therefore, the BCM must remain connected to the DLC for any other module to communicate with the scan tool. This test isolates the splice pack SP207 serial data circuits. 21. This test isolates the rest of the splice pack SP205 serial data circuits. 25. If there are no current DTCs that begin with a "U", the communication malfunction has been repaired. 26. The communication malfunction may have prevented diagnosis of the customer complaint. Scan Tool Does Not Communicate With High Speed GMLAN Device SCAN TOOL DOES NOT COMMUNICATE WITH HIGH SPEED GMLAN DEVICE CIRCUIT DESCRIPTION Modules connected to the high speed GMLAN serial data circuits monitor for serial data communications on the high speed GMLAN network during normal vehicle operation. Operating information and commands are exchanged among the modules. The scan tool communicates with the following modules via the high speed GMLAN: The energy storage control module (ESCM) - The starter/generator control module (SGCM) - The electro-hydraulic power steering (EHPS) module DIAGNOSTIC AIDS IMPORTANT: The scan tool communication with the modules connected only to high speed GMLAN data link requires the use of the CANdi module. Due to configuration of this vehicle, they may be communication DTCs set against modules that are able to communicate with the scan tool. The following conditions may cause a total loss of high speed GMLAN data communication: A short between high speed GMLAN (+) and high speed GMLAN (-) circuits - Any of the high speed GMLAN serial data circuits shorted to ground or voltage - A module internal malfunction that causes a short to voltage or ground on the high speed GMLAN circuits TEST Page 13805 Hood Latch: Service and Repair Hood Link Replacement Hood Link Replacement Removal Procedure Caution: When a hood hold open device is being removed or installed, provide alternate support to avoid the possibility of damage to the vehicle or personal injury. 1. Raise and support the front of the hood (1). 2. Remove the bolts (7) holding the hood link assembly to the hood hinge. 3. Remove the bolts (5) holding the hood link assembly to the fender. 4. Remove the hood link assembly from the vehicle. Installation Procedure 1. Position the hood link assembly (6) to the vehicle. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the bolt (5) holding the hood link assembly to the fender. Tighten the link assembly to the fender bolt to 25 N.m (18 lb ft). 3. Install the fender bolt (7) holding the hood link assembly to the hood hinge. Tighten the hinge bolts to 25 N.m (18 lb ft). Page 9420 When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage TESTING FOR A SHORT TO VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity TESTING FOR CONTINUITY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents TESTING FOR ELECTRICAL INTERMITTENTS Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground - Testing for Continuity - Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 msRECORD and emits an audible tone (beep). Page 12539 Circuit/System Testing Component Testing Page 8211 Brake Rotor/Disc: Service and Repair Disc Brake Splash Shield Replacement - Front Disc Brake Splash Shield Replacement - Front Caution: Refer to Brake Dust Caution in Service Precautions. Removal Procedure 1. Raise and support the vehicle. Refer Vehicle Lifting 2. Remove the tire and wheel assembly. 3. Remove the hub and bearing assembly. 4. Remove the splash shield (15 series). 5. Remove the splash shield (25/35 series). Installation Procedure 1. Install the splash shield (25/35 series). Page 9078 Location View Page 7177 2. Install the yoke. 3. Use the J 8614-01 in order to hold the yoke. Notice: Refer to Fastener Notice in Service Precautions.. 4. Install a NEW yoke nut. ^ Tighten the nut to 330 Nm (244 ft. lbs.). 5. Install the rear propeller shaft. 6. Check the transmission fluid level. Add if necessary. 7. Lower the vehicle. Page 12018 7.1. Remove the console (A) together with the OnStar(R) control modules. 7.2. Remove the connectors (B). Important: The optic cable must not be bent with a radius less than 25 mm (1 in). Important: Secure the wiring harness so that there is no risk of chafing and rattling. 7.3. Fold back the wiring harness and tape over the connectors (C). Fold back the wiring harness once more and secure with cable ties (D). 7.4. Fit the parcel shelf trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 8. CV: Removing the OnStar(R) control modules and securing the wiring: Adjustment/Replacement. 8.1. Open the luggage compartment floor. Locations Accelerator Pedal Position (APP) Sensor Connector Automatic Transmission Input Shaft Speed (AT ISS) Sensor Connector Page 13225 these systems will then completely power OFF. OnStar(R) Module Expected Current Draw The expected current draw of the OnStar(R) module in various ignition modes are as follows: ^ Ignition ON ‐ 240 to 400 mA ^ Ignition OFF ‐ 3 to 20 mA for 48 hours ^ Ignition OFF ‐ 0.2 to 0.8 mA after 48 hours (120 hours on specified vehicle communication platforms (VCPs)). Note During extended voltage testing for battery parasitic draw, it is possible to observe a voltage spike caused by the following: ^ A cellular registration call that was triggered by the local cellular system. ^ The OnStar(R) system has set a monthly trigger for a vehicle data upload call for the OnStar(R) Vehicle Diagnostic E‐mail upload. OnStar(R) System States of Readiness The OnStar(R) system will use the following 4 states of readiness, depending upon the type of cellular market the vehicle is in when the ignition is turned OFF. ^ High power ^ Low power ^ Sleep ^ Digital standby The high power state is in effect whenever the ignition is in the ON or RUN position, retained accessory power (RAP) is enabled, and/or the OnStar(R) system is sending or receiving calls or when the system is performing a remote function. The low power state is in effect when the OnStar(R) system is idle with the ignition in the ON or RUN position, or with RAP enabled. The sleep state is entered after the vehicle has been shut OFF and the RAP has timed out. At a predetermined time recorded within the VCIM, the system re-enters the low power state to listen for a call from the OnStar(R) Call Center for 1 minute. After this interval, the system will again return to the sleep state for 9 minutes. If a call is sent during the 1 minute interval, the OnStar(R) system will receive the call and immediately go into the high power mode to perform any requested functions. If a call is not received during the 1 minute interval, the system will go back into the sleep mode for another 9 minutes. This process will continue for up to 48 hours, after which the OnStar(R) system will turn OFF until the ignition is turned to the ON or RUN position. The digital standby power state is entered after the vehicle has been shut off and the RAP has timed out while in a digital cellular area. When in digital standby mode, the OnStar(R) module is able to perform all remote functions as commanded by an OnStar(R) advisor at any time, for a continuous 48 hours. After 48 hours, the OnStar(R) module will go into sleep mode until a wake up signal from the vehicle is seen by the CIM. If the OnStar module loses the digital cellular signal it will revert to analog mode and follow the standard sleep state (9 minutes OFF, 1 minute standby) based on the time of the GPS signals, this will continue until a digital cellular signal is again received. If the OnStar(R) system loses battery power while the system is in a standby or sleep mode, the system will remain OFF until battery power is restored and the ignition is turned to the ON or RUN position. Deactivated OnStar(R) Accounts In the event that a customer has not upgraded their vehicle to a digital system, the account has been deactivated. The customers have been previously notified of the steps required to upgrade their vehicles. After the OnStar(R) account has been deactivated, customers will experience the following: ^ The OnStar(R) status LED will not illuminate ^ The OnStar(R) system will NOT attempt to connect to the OnStar(R) Call Center in the event of a collision or if the vehicle's front air bags deploy for any other reason. ^ An emergency button press will result in a demo message being played, indicating the service has been deactivated and needs to be upgraded. Page 1558 Left Side Of Engine Locations Chassis And License Lamp Harnesses Page 4087 3. If equipped with a 6.0L engine, connect the HO2S electrical connector (1). 4. If equipped with a 4.8L or 5.3L engine, connect the HO2S electrical connector (1). 5. Install the HO2S electrical connector to the fuel line clip. 6. Disconnect the CPA retainer. 7. If necessary, bolt the front propeller shaft to the front differential. Refer to Propeller Shaft Replacement - Front in Propeller Shaft. 8. Lower the vehicle. Brakes - Low Speed ABS Activation/No DTC's Set Wheel Speed Sensor: All Technical Service Bulletins Brakes - Low Speed ABS Activation/No DTC's Set TECHNICAL Bulletin No.: 03-05-25-007D Date: May 01, 2009 Subject: Antilock Brake (ABS) Activation At Low Speeds (Clean Wheel Speed Sensor Mounting Surface) Models: 2002-2006 Cadillac Escalade, Escalade EXT 2003-2006 Cadillac Escalade ESV 1999-2006 Chevrolet Silverado 2001-2006 Chevrolet Suburban, Tahoe 2002-2006 Chevrolet Avalanche 2003-2006 Chevrolet Express 2007 Chevrolet Silverado Classic 1999-2006 GMC Sierra 2001-2006 GMC Yukon, Yukon Denali, Yukon XL, Yukon Denali XL 2003-2006 GMC Savana 2007 GMC Sierra Classic 2003-2006 HUMMER H2 .............................................................................................................................................................. .................................................................................. Supercede: This bulletin is being revised to add the 2007 Silverado/Sierra Classic models. Please discard Corporate Bulletin Number 03-05-25-007C (Section 05 - Brakes). .............................................................................................................................................................. .................................................................................. Condition Some customers may comment on ABS activation at low speeds, usually below 8 km/h (5 mph). Upon investigation, the technician will find no DTCs set. Cause The cause of this condition may be an increased air gap between the wheel speed sensor and the hub reluctor ring due to rust and debris built up on the sensor mounting surface. Correction Measure AC voltage and clean the wheel speed sensor mounting surfaces. 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in the General Information sub-section of the Service Manual. 2. Disconnect both the front wheel speed sensor connectors at the frame and harness. 3. Place a Digital Volt Meter (DVM) across the terminals of each wheel speed sensor connector. 4. Rotate the wheel clockwise approximately one revolution per second. The minimum reading should be at least 350 ACmV's. If the reading is less than 350 ACmV's, remove the wheel speed sensor. Refer to the applicable Wheel Speed Sensor Replacement procedure in the ABS sub-section of the Service Manual. 5. Plug the wheel speed sensor bore in order to prevent debris from falling into the hub during service. 6. Clean the wheel speed sensor mounting surface using a wire brush, sand paper, emery cloth, scotch brite, or other suitable material. Be sure to thoroughly clean the wheel speed sensor surface. There should be no rust or corrosion. 7. Check the sensor head to determine if it has been warped/distorted due to the corrosion build up or other causes. Check the mounting surface on the sensor head for flatness by placing it on the edge of a metal machinists scale or other suitable straight edge to measure the flatness. Check the sensor for flatness in multiple (minimum 3) positions/directions. If the sensor head is distorted, replace the sensor. 8. Apply (spray) two thin coats of the specified rust penetrating lubricant (corrosion inhibitor) to the complete sensor mounting surface on the bearing hub. Allow to dry for 3-5 minutes between coats. Use ONLY Rust Penetrating Lubricant, P/N 89022217 (in Canada, P/N 89022218). 9. When the corrosion inhibitor is dry to the touch (about 10 minutes), apply a thin layer of bearing grease to the hub surface and sensor O-ring prior to sensor installation. Use ONLY Wheel Bearing Lubricant, P/N 01051344 (in Canada, P/N 993037). 10. Install either the original sensor or a new one in the hub. Ensure that the sensor is seated flush against the hub. Refer to the applicable Wheel Speed Sensor Replacement procedure in the ABS sub-section of the Service Manual. 11. Place the DVM across the sensor terminals and recheck the voltage while rotating the wheel. The voltage should now read at least 350 ACmV's. Page 259 Circuit/System Testing Component Testing Page 2642 Fuse Block - Underhood C1 Part 3 Page 1624 Disclaimer Page 6806 3. Remove the rear axle drain plug. 4. Drain the lubricant into a suitable container. 5. Inspect the drain plug for excessive metal particle accumulation. This accumulation is symptomatic of extreme wear. 6. Clean the drain plug. Installation Procedure 1. Notice: Refer to Fastener Notice in Service Precautions. Install the rear axle drain plug. ^ Tighten the rear axle drain plug to 27 Nm (20 ft. lbs.). 2. Fill the rear axle. Use the proper fluid. 3. Install the rear axle fill plug. ^ Tighten the rear axle fill plug to 21 Nm (15 ft. lbs.). 4. Lower the vehicle. 9.5, 10.5, and 11.5 Inch Axles Lubricant Replacement - Rear Drive Axle (9.5, 10.5, and 11.5 Inch Axles) Removal Procedure 1. Raise the vehicle. Refer to Vehicle Lifting. Page 9048 Junction Block - Rear Lamps - C3 Page 2769 Relay Box: Service and Repair Body Wiring Harness Junction Block Replacement BODY WIRING HARNESS JUNCTION BLOCK REPLACEMENT REMOVAL PROCEDURE 1. Remove the cover retaining nut. 2. Remove the cover by pushing in the tabs. 3. Remove the harness from the front of the junction block. 4. Remove the junction block from the bracket by pressing to release the tabs. 5. Remove the junction block in order to gain access to the rear of the block to remove the retaining bolts. 6. Remove the retaining bolts. 7. Separate the wire harness block from the junction block by inserting a screw driver in between. 8. Remove the junction block from the vehicle. INSTALLATION PROCEDURE 1. Install the wire harness block to the junction block. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the retaining bolts. Tighten Tighten the bolts to 6 N.m (53 lb in). 3. Install the junction block to the bracket. Description and Operation Passenger Compartment Cross Beam: Description and Operation Magnesium Instrument Panel Support Instrument Panel Support The Instrument Panel Support is a one-piece component comprised of a magnesium steering column support (Fig. 1.21), which holds the instrumentation and steering column; a die-formed tube attaches to the passenger side and supports the dashboard. This assembly functions as a structural cross-vehicle beam, air-bag support, and instrument panel carrier, which consolidates many different steel and plastic components. The magnesium instrument panel support is designed to deform and absorb energy generated by a severe impact. NOTE: Under no circumstance is the magnesium support to be repaired in any way. If any of the following conditions are present after a collision, the magnesium support must be replaced: - Steering column capsules have released or column has collapsed. - The steel knee bolster brackets are bent. - The parts which attach to the magnesium support do not fit. Page 4649 IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections TESTING FOR INTERMITTENT AND POOR CONNECTIONS TOOLS REQUIRED - J 35616-C GM-Approved Terminal Test Kit - J 38125-D Terminal Repair Kit - J 42675 Flat-Wire Probe Adapter Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector. - Poor terminal to wire connection - Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. - Wire insulation which is rubbed through - This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. - Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. Testing For Proper Terminal Contact It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-D or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-D, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. Glass/Body - Windshield Wiper Performance Wiper Blade: Technical Service Bulletins Glass/Body - Windshield Wiper Performance INFORMATION Bulletin No.: 06-08-43-003C Date: February 21, 2011 Subject: Windshield Wiper Performance, Cleaning Instructions and Maintenance Models: 2012 and Prior GM Passenger Cars and Trucks (including Saturn) 2010 and Prior HUMMER H2, H3 2010 and Prior Isuzu Medium Duty Trucks 2005-2009 Saab 9-7X Supercede: This bulletin is being revised to add the 2011 and 2012 model year. Please discard Corporate Bulletin Number 06-08-43-003B (Section 08 - Body and Accessories). Wiper Concerns Most concerns about windshield wiper performance are the result of dirty wiper blades, damaged wiper blades, or worn out blades that are continuing to be used beyond their useful life. Depending on environmental conditions, wiper blades can have dramatic differences in lifespan. Here are some tips and guidelines to maximize wiper performance to avoid damage to the blades, and to avoid unnecessary replacements. Many wiper blades are being replaced under warranty with reviews showing there is nothing wrong with the returned blades other than a build-up of dirt. Additionally, advise the customer to review the information in their Owner Manual. Inspection and Cleaning Scheduled Maintenance - Inspect your wipers rubber blades every 4-6 months or 12,000 km (7,500 mi) for wear, cracking or contamination. - Clean the windshield and the rubber wiper blades (using the procedure below) if the blades are not clearing the glass satisfactorily. If this does not correct the problem, then replace the rubber elements. Cleaning Procedure Important Avoid getting windshield washer fluid on your hands. Wear rubber gloves or avoid direct contact with washer fluid. Important Do not use gasoline, kerosene, or petroleum based products to clean wiper blades. - Clean the rubber blades using a lint free cloth or paper towel soaked with windshield washer fluid or a mild detergent. You should see significant amounts of dirt being removed on the cloth. - Be sure to wash the windshield thoroughly when you clean the blades. Bugs, road grime, sap and a buildup of car wash/wax treatments may additionally cause wiper streaking. Tip For a larger scale buildup on the windshield, use a non-abrasive cleaner such as Bon-Ami* (www.faultless.com) cleanser with a wet sponge, being sure to use plenty of water to avoid scratching the glass. Flush the surface and body panels completely. Tip For day-to-day exterior glass cleaning and to maintain a streak free appearance, suggest Vehicle Care Glass Cleaner, P/N 88862560 (in Canada, 992727). This product is an easy to use foaming cleaner that quickly removes dirt and grime from glass surfaces. Tip Interior glass should be cleaned with plain, clean water to eliminate any film or haze on the window and help prevent fogging, a major customer dissatisfier. Refer to Corporate Bulletin Number 03-00-89-006D for more information. The New Vehicle Pre-Delivery Inspection form also recommends using plain water to clean interior glass. *"We believe this material to be reliable. There may be additional manufacturers of such material. General Motors does not endorse, indicate any preference for or assume any responsibility for the products or equipment from these firms or any such items which may be available from other sources. Page 679 supported, only J2534. 1. BEFORE the original IPC is disconnected from the vehicle, record the odometer and engine hour values. 2. Replace the IPC with a replacement part obtained from the ESC. Refer to Instrument Cluster Replacement in SI. 3. Using the TIS2WEB SPS application, select either: J2534 Tech 2 or J2534 MDI, when available and build the vehicle. 4. Select: IPC Setup J2534. 5. After selecting IPC Setup J2534, the user will be prompted to: install the new controller. Ignore this prompt if the new IPC was already installed. This prompt is just to remind the user that this application is only for a new IPC. Important FOR 2003 FULLSIZE TRUCKS, UTILITIES AND H2, THE ENGINE MUST BE STARTED AND RUNNING PRIOR TO ENTERING THE MILEAGE AND ENGINE HOURS. After the odometer value is programmed, the engine must remain running for 6 minutes 15 seconds before the ignition can be turned off. Failure to do so will result in engine hours not being programmed and a new IPC will have to be ordered. 6. Enter the odometer and engine hour values, when applicable. By default the application will be set to miles. For metric units, click the button on the left next to: Kilometers. The IPC odometer and engine hour meter setup procedure is now complete. 7. The IPC calibration files can now be programmed into the IPC. Refer to SPS in SI. Disclaimer Page 13424 - Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-D in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-D if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Page 4681 Body Control Module (BCM) - C2 Part 2 Page 8130 3. Locate the auxiliary fuel tank vent hose. The vent hose is the smaller diameter of the two hoses that comes from the auxiliary fuel tank and feeds into the main tank vent hose. 4. Disconnect the auxiliary tank vent hose from the main tank vent hose connection. 5. Install the cap supplied with kit, P/N 15213990, to the main tank vent hose connector where the auxiliary tank vent hose was just removed. 6. Locate the section of vent hose on the main tank between the fuel filler neck and the metal pipe. The smaller of the two hoses on the filler neck. 7. Cut the main tank vent hose between the filler neck and the metal pipe using an appropriate cutting tool. 8. Install the "T" and the two hose clamps supplied with kit, P/N 15213990, into the main tank vent hose. Tighten Tighten the hose clamps to 2.5 N.m (22 lb in). 9. Install the new auxiliary tank vent hose and clamp supplied with kit, P/N 15213990, to the "T" that was just installed. Tighten Tighten the hose clamp to 2.5 N.m (22 lb in). 10. Connect the new vent hose to the original auxiliary tank hose. 11. Secure the newly installed vent hose and the original auxiliary tank vent hose with plastic ties supplied in kit, P/N 15213990. 12. If necessary, reinstall the left rear tires/wheels assemblies. Page 9414 Electrical Symbols Part 13 Page 1519 Steering Wheel And Column Sub-System Components Page 10262 Control Module References Part 5 Body - Pick Up Box Reinforcement Installation Truck Bed: All Technical Service Bulletins Body - Pick Up Box Reinforcement Installation Info - Availability of Pickup Box Reinforcement Kits for Toolbox/Rear Window Barrier/Ladder Rack Applications # 01-08-66-005C - (Feb 4, 2005) Models: 1999-2003 Chevrolet Silverado Pickups (New Body Style) 1999-2003 GMC Sierra Pickups (New Body Style) with Steel Fleetside Pickup Box (RPO E63) 2004-2005 Chevrolet Silverado 1500 Series Crew Cab Pickups with 5'8" Pickup Box 2004-2005 GMC Sierra 1500 Series Crew Cab Pickups with 5'8" Pickup Box EXCEPT Dual Rear Wheel (RPO R05), Stepside (RPO E62) and Inner Composite (RPO E37) Pickup Boxes Sales Manager and Service Manager This bulletin is being revised to add 2004-2005 1500 Series Crew Cab with 5'8" Pickup Box model and change equipment weight capacity information. Please discard Corporate Bulletin Number 01-08-66-005B (Section 08--Body and Accessories). Built Prior to the VIN Breakpoints shown. Pickup box reinforcement kits are available as an accessory for customers who may want to install a cross toolbox, side box, or a ladder rack system. Important: The reinforcements must be installed before adding a toolbox or ladder rack system. After the reinforcements have been installed, follow the instructions supplied with the toolbox/ladder rack system for installation onto the pickup box. Pickup Box Reinforcement Installation Use the following service procedure and the applicable kit part number listed below to install the reinforcements. Cross Toolbox and Rear Window Barrier Applications - Front Reinforcement Installation Important: The horizontal surfaces of the reinforcements must be flush to the horizontal surface of the pickup box top rail. Use a clamping tool when positioning the reinforcements onto the top rail to ensure flushness to the outer panel. 1. Place the front L-shaped reinforcements into position on the front top of the pickup box. For vehicles equipped with an over the rail bedliner, the bedliner should be removed with the aid of an assistant prior to installing these reinforcements. 2. Mark the holes necessary for drilling. 3. Remove the front reinforcements. Important: Page 12347 Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips SPLICING COPPER WIRE USING SPLICE CLIPS IMPORTANT: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. TOOLS REQUIRED J 38125-D Terminal Repair Kit 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-D in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. Page 9630 Junction Block - I/P Wire Entry Part 2 Page 9037 Junction Block - I/P - C2 Part 1 Diagrams Seat Belt Buckle Switch: Diagrams Seat Belt Switch - Driver Page 7828 Page 9247 C329 Lumbar Bolster Harness To Passenger Seat Harness (With RPO Code AG2) Page 5117 9. Connect the brake lines to the BPMV. Tighten Tighten the fittings to 25 N.m (18 lb ft). 10. Connect the chassis electrical harness connectors to the EBCM. 11. Install the EVAP canister. 12. Install the transfer case harness to the clip bracket. 13. Install the clip to the bracket on the frame. 14. If equipped with 4WD, install the fuel hose/pipe clip to the bracket on the transfer case. 15. Install the fuel hose/pipe clip to the bracket on the automatic transmission. 16. Install the HO2S sensor connector to the bracket. 17. Install the fuel pipe bracket to the bellhousing stud. 18. Install the fuel pipe bracket nut (2). HVAC System - Automatic Air Door Actuator / Motor: Diagrams HVAC System - Automatic Mode Actuator Electrical - Trailer Brakes Apply With Headlamps ON Trailer Lighting Module: All Technical Service Bulletins Electrical - Trailer Brakes Apply With Headlamps ON Bulletin No.: 02-05-22-004C Date: April 05, 2005 TECHNICAL Subject: Trailer Brakes Applied When Headlights/Park Lamps Are On, Brake Controller Illumination (Modify Brake Controller Wiring Harness) Models: 2002-2005 Cadillac Escalade, Escalade EXT 1999-2005 Chevrolet Silverado 2000-2005 Chevrolet Suburban, Tahoe 2002-2005 Chevrolet Avalanche 1999-2005 GMC Sierra 2000-2005 GMC Yukon, Yukon XL 2003-2005 HUMMER H2 Supercede: This bulletin is being revised to add additional model years. Please discard Corporate Bulletin Number 02-05-22-004B (Section 05 - Brakes). Condition Some customers may comment that when the headlamps or park lamps are on, the brakes on the trailer are always applied, or that the back lighting for the trailer brake controller only illuminates when the brakes are applied. Cause The cause of this condition may be due to wiring changes within the vehicle electrical system for the 2003 model year. Correction Inspect the brake controller wiring harness jumper that is plugged into the vehicle relay block-body. The relay block-body is located under the left side of the instrument panel near the left kick panel, behind a plastic cover. Page 7160 Fluid - M/T: Service and Repair NV 4500 Transmission Fluid Replacement Removal Procedure 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. Remove the oil fill plug. 3. Place a suitable drain pan under the transmission in order to catch the drained transmission fluid. 4. Remove the oil drain plug. 5. Remove any old sealant from the transmission housing. Installation Procedure 1. Apply a thin bead of sealant GM P/N 12346004 (Canadian P/N 10953480), or equivalent to the oil drain and fill plug threads. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the oil drain plug. ^ Tighten the plug to 37 Nm (27 ft. lbs.). Interior - Heated Seats Intermittently Inoperative Seat Heater Control Module: Customer Interest Interior - Heated Seats Intermittently Inoperative Bulletin No.: 05-08-05-008 Date: August 18, 2005 TECHNICAL Subject: Intermittent Heated Seats Inoperative, DTC B3941 Set (Reprogram Driver Seat Module) Models: 2003-2005 Cadillac Escalade, Escalade ESV, Escalade EXT 2003-2005 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2003-2005 GMC Sierra, Yukon, Yukon XL, Yukon Denali All with Seat FRT, Individual (Non BKT) (RPO AN3) 2003-2005 HUMMER H2 with Seat, Front Bucket Deluxe (RPO AR9) Condition Some customers may comment that occasionally the seat heater will not operate when activated. If the ignition key is cycled OFF and back ON again, the heated seat will operate correctly. Also, on some LB7 diesel engine vehicles, the seat heater may turn itself off during the first 10 minutes of operation. This occurs only with the first activation for the day and works correctly with subsequent activations immediately after the event. These conditions are intermiffent and DTC B3941 may be set. Correction Technicians are to reprogram the driver seat module with an updated software calibration. This new service calibration was released with TIS satellite data update version 6.5 available June 13, 2005. As always, make sure your Tech 2(R) is updated with the latest software version. Warranty Information Disclaimer Page 13153 12.2. Cars with brackets for e.g. an amplifier: Remove the pin strap (A) from the bracket and remove the tape (B) holding the optic cables. 12.3. Remove the locking strip (C) on the 2-pin connector (H2-9). Open the terminal housing with a screwdriver. Remove the secondary catch (E) on the connector and remove the optic cables coming from the OnStar(R) control modules. 12.4. Loosen one of the optic cables remaining in H2-9 (F), connect it to the connector and fit the secondary catch (E). Connect the connector so that the optic cables are opposite each other (G). Connect the terminal housing (D) and refit the locking strip (C). Page 4265 Intake Air Temperature (IAT) Sensor: Service and Repair MASS AIR FLOW (MAF)/INTAKE AIR TEMPERATURE (IAT) SENSOR REPLACEMENT REMOVAL PROCEDURE IMPORTANT: Use care when handling the mass air flow/intake air temperature (MAF/IAT) sensor. Do not dent, puncture, or otherwise damage the honeycell located at the air inlet end of the MAF/IAT. Do not touch the sensing elements or allow anything including cleaning solvents and lubricants to come in contact with them. Use a small amount of a non-silicone based lubricant, on the air duct only, to aid in installation. 1. Remove the air cleaner outlet duct. 2. Pull out the gray connector position assurance (CPA) retainer. 3. Push down on the black clip in order to disconnect the MAF/IAT sensor electrical connector (4). 4. Loosen the MAF/IAT clamp. 5. Remove the MAF/IAT sensor from the air cleaner assembly. INSTALLATION PROCEDURE IMPORTANT: The embossed arrow on the MAF/IAT sensor indicates the proper air flow direction. The arrow must point toward the engine. A/T - 4L60-E/4L65-E Harsh 1-2 Upshift Diagnosis Valve Body: All Technical Service Bulletins A/T - 4L60-E/4L65-E Harsh 1-2 Upshift Diagnosis Bulletin No.: 01-07-30-030B Date: October 18, 2005 INFORMATION Subject: 4L60-E/4L65-E Automatic Transmission Diagnostic Information on Harsh 1-2 Upshift Models: 2001-2006 GM Passenger Cars and Light Duty Trucks 2003-2006 HUMMER H2 2006 HUMMER H3 2005-2006 Saab 9-7X with 4L60-E or 4L65-E Automatic Transmission Supercede: This bulletin is being revised to add model years and models. Please discard Corporate Bulletin Number 01-07-30-030A (Section 07 - Transmission/Transaxle). The following four conditions have been found to cause the majority of consistent, harsh 1-2 shift comments. ^ Chips/Sediment/Debris/Contamination found in the valve body, 1-2 accumulator valve (371) bore, may cause the 1-2 accumulator valve to stick or hang-up. ^ Chips/Sediment/Debris/Contamination found in the valve body, 4-3 sequence valve (383) bore, may cause the 4-3 sequence valve to stick or hang-up. Page 16031 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Weather Pack Connectors WEATHER PACK CONNECTORS The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. Page 9569 Fuse Block- I/P C1 Part 3 A/C - Ticking Noise From Instrument Panel/DTC's Set Air Door Actuator / Motor: Customer Interest A/C - Ticking Noise From Instrument Panel/DTC's Set Bulletin No.: 06-01-38-003 Date: April 27, 2006 TECHNICAL Subject: Intermittent Ticking Noise from I/P, Poor A/C Performance, HVAC DTCs B0229, B0414, B0424, B3770 (Reprogram HVAC Control Module) Models: 2004-2006 Cadillac Escalade Models 2004-2006 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2004-2006 GMC Sierra Models, Yukon Models with Air Conditioning (RPOs CJ2, CJ3) Condition Some customers may comment on one or more of the following concerns: ^ Intermittent ticking/clicking noise from the instrument panel. ^ Recirculation mode does not work or Air Conditioning (A/C) system performance is poor during high ambient temperatures. ^ Unable to control the driver side temperature. ^ Unable to control the passenger side temperature. ^ Unable to change the front system modes. Cause This condition may be caused by the Heating, Ventilation and Air Conditioning (HVAC) actuators that may hunt for the correct commanded position. This cycling may cause a clicking or ticking noise. An overtravel of the HVAC system control doors may cause one or more of the concerns listed above. If an overtravel occurs, a Diagnostic Trouble Code (DTC) will be set, and the door will go to a preset default position. When a system door defaults, that door will stay at the default position until the DTC is cleared. After the DTC is cleared, the door will operate properly until the overtravel condition re-occurs. The table lists the HVAC system doors and the DTC associated with it. Correction Technicians are to perform the normal diagnostic procedures in SI for these concerns. If diagnostics show that the HVAC system door(s) travel below 5 counts (out of the lower range) or above 250 counts (out of the upper range), then update the software calibrations in the HVAC control module. The new calibrations were made available to dealerships as part of TIS2000 incremental satellite update version 2.5, which was broadcast to dealers in February 2006. Page 499 - Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-D in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-D if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Page 13303 networks, and will not require an upgrade in connection with the cellular industry's transition to the digital network. In order to verify the type of OnStar(R) Hardware in a vehicle, type the VIN into the VIN look-up tool, which is available at the OnStar(R) Online Enrollment website within GM GlobalConnect (for U.S. dealers) or InfoNet (for Canadian dealers). Disclaimer Page 3177 6. Use the J 41816 and J 41816-2 in order to remove the crankshaft balancer. 7. Remove the J 41816 and the J 41816-2 from the crankshaft balancer. 8. Clean and inspect the crankshaft balancer. Installation Procedure Important: ^ Make sure that the teeth of J 42386-A mesh with the teeth of the engine flywheel. ^ The used crankshaft balancer bolt will be used only during the first pass of the balancer installation procedure. Install a NEW bolt and tighten as described in the second, third and forth passes of the balancer bolt tightening procedure. ^ The crankshaft balancer installation and bolt tightening involves a four stage tightening process. The first pass ensures that the balancer is installed completely onto the crankshaft. The second, third, and forth passes tighten the new bolt to the proper torque. Important: The balancer should be positioned onto the end of the crankshaft as straight as possible prior to tool installation. 1. Install the crankshaft balancer onto the end of the crankshaft. Page 11741 Seat Sensor/Switch: Diagrams Inflatable Restraint Seat Position Switch - Left (With RPO Code AL0) Page 4314 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. REPLACEMENT PROCEDURE After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Insure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the Terminal Removal Procedure. Repairing Connector Terminals REPAIRING CONNECTOR TERMINALS TOOLS REQUIRED J 38125-D Terminal Repair Kit Use the following repair procedures in order to repair the following: - Push to Seat terminals - Pull to Seat terminals - Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-D contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100 World terminals. Soldering Micro-Pack 100 World terminals may damage the terminal. Circuit Protection - Circuit Breakers CIRCUIT PROTECTION - CIRCUIT BREAKERS A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Page 10185 1. Set the front wheels in the straight ahead position. Notice: On the 2002 and later model year vehicles the steering column LOCK was removed from the steering column. It is critical that the J 42640 - Steering column Anti-Rotation Pin is used when servicing steering columns on 2002 and later model year vehicles. Failure to use the J 42640 may result in damage to the SIR coil. 2. Set the steering wheel in the LOCK position on 2001 and prior model year vehicles. 3. For 2002 and later vehicles install the J 42640 in the steering column lower access hole. 4. From under the hood remove the lower bolt that connects the upper intermediate shaft to the steering gear coupling shaft. 5. Slide the shaft towards the dash in order to disengage the shaft from the steering gear coupling shaft. 6. For vehicles equipped with adjustable foot pedals perform the following steps: 1. Reposition the carpet away from the accelerator pedal position (APP) sensor. 2. Remove the two nuts retaining the accelerator pedal to the bulkhead. 3. Reposition the accelerator pedal out of the way so the intermediate shaft can be removed. Page 346 Page 721 The new calibrations have been updated to compensate for the actuator overtravel condition, the actuator hunting and the ticking/clicking noises. The new calibrations effectively eliminate the codes listed above, the default position of the doors associated with the DTCs and opens up the feedback position value. The new calibrations should not be used unless the vehicle has one or more of the customer concerns listed above or a DTC listed above has been set. The new calibrations will not correct any other DTC or NC system performance concern. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 3033 It will be necessary to reprogram the PCM for speedometer accuracy. Contact Techline to obtain a VCI number. Then refer to the table for the appropriate calibration part number based on the model year and axle ratio. Calibration Information Documentation Make a copy of the "Accessory Wheel and Tire Information Form" included in this bulletin. Page 15655 4. Install the headlamp retainer pins. 5. Rotate and lock the pins in place. 6. Inspect the operation. Page 12466 10.4. Remove the end cap from the new optic cable, connect to the connector and refit the secondary catch (D). Fit the terminal housing (C) to the connector and refit the locking strip (B). 10.5. Secure the old optic cable together with the new one (E). Important: The optic cable must not be bent with a radius less than 25 mm (1 in). Important: Secure the wiring harness so that there is no risk of chafing and rattling. 11. CV: Remove the rear seat in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. The O-bus connector H2-9 is located behind the left speaker. 12. M04-05: Disconnect the optic cables on the OnStar(R) control modules and join the cables: 12.1. Cut off the cable tie holding the connector (H2-9) against REC. Replacement Procedure - Battery to Battery Relay Auxiliary Positive: Service and Repair Replacement Procedure - Battery to Battery Relay - Auxiliary BATTERY POSITIVE CABLE REPLACEMENT - BATTERY TO BATTERY RELAY - AUXILIARY REMOVAL PROCEDURE 1. Remove the auxiliary battery. 2. Unclip the mega fuse from the auxiliary battery tray. 3. Remove the auxiliary positive cable to relay nut (2). 4. Remove the auxiliary battery positive cable. INSTALLATION PROCEDURE 1. Install the auxiliary battery positive cable. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the auxiliary positive cable to relay nut (2). Tighten Tighten the nut to 9 N.m (80 lb in). 3. Clip the mega fuse to the auxiliary battery tray. 4. Install the auxiliary battery. Page 13760 8. Install the new fuel cap, P/N 15225005, tether strap in the elongated hole in the fuel filler housing. 9. Install the fuel fill cap on the filler pipe and tighten until the cap clicks. Parts Information Warranty Information For vehicles repaired under warranty, use the table Disclaimer Locations Hazard Warning Switch: Locations Upper Steering Column Page 7404 Parts Information Warranty Information (excluding Saab U.S. Models) Warranty Information (Saab U.S. Models) OnStar(R) - Incorrect GPS Position Reported During Call Emergency Contact Module: Customer Interest OnStar(R) - Incorrect GPS Position Reported During Call Bulletin No.: 02-08-46-006C Date: January 08, 2008 INFORMATION Subject: Incorrect OnStar(R) Global Positioning System (GPS) Location Reported During OnStar(R) Call Models: 2000-2008 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2008 HUMMER H2 2006-2008 HUMMER H3 2005-2008 Saab 9-7X with OnStar(R) Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 02-08-46-006B (Section 08 - Body and Accessories). A small number of the above-mentioned vehicles may exhibit a condition in which the vehicle reports an inaccurate location to the OnStar(R) Call Center. This condition can only be identified via a button press to the OnStar(R) Call Center by the customer. Call Center personnel will be able to identify this inaccurate location condition. Customers will then be notified through the mail by OnStar(R) if their vehicle exhibits this condition. Once this condition has been identified OnStar(R) will instruct the customer to return to the dealership to have this condition corrected. It is not necessary to reconfigure the vehicle after the following procedure. In order to correct this condition you must cycle power to the OnStar(R) system. This can be done by either removing the fuses powering the OnStar(R) system or disconnecting the OnStar(R) module (VCIM) from the vehicle. As a last resort you can disconnect the vehicle's battery. The power needs to be removed from the system for approximately 15 minutes. After completing this procedure the vehicle should be taken to an area with an unobstructed view of the sky. The vehicle should be kept running for approximately 10 minutes to allow the vehicle to reacquire the global positioning system (GPS). Then contact the OnStar(R) Call Center via the blue OnStar(R) button and ask the advisor to verify the GPS position. If the OnStar(R) advisor still has an inaccurate GPS location refer to the Navigation Systems and Cellular Communications sub-sections in the Service Manual in order to diagnose and repair the concern. If the normal diagnostics lead to module replacement you will need to contact Technical Assistance (TAC) and choose the OnStar(R) prompt. GM OnStar(R) TAC will assist in the diagnosis and if appropriate order a replacement part. Replacement parts are usually shipped out within 24 hours and a pre-paid return package label will be included for returning the faulty part. By returning the faulty part you will avoid a significant non-return core charge. Warranty Information (excluding Saab US Models) For vehicles repaired under warranty, use the table. Warranty Information (Saab US Models) Page 7336 Tow/Haul Switch: Testing and Inspection 4L80-E/4L85-E Transmission Tow/Haul Switch/Indicator Always On or Inoperative Circuit Description Tow/haul mode enables the operator to achieve enhanced shift performance when towing or hauling a load. When tow/haul mode is selected, the tow/haul switch input signal to the body control module (BCM) is momentarily toggled to zero volts. This signals the powertrain control module (PCM) to extend the length of time between up shifts and increase transmission line pressure. Cycling the tow/haul switch again disables tow/haul mode and returns the transmission to a normal shift pattern. Diagnostic Aids If the electrical circuit checks are OK and the tow/haul shift pattern is not occurring, there may be a mechanical/hydraulic condition that prevents tow/haul operation. Refer to Symptoms - Automatic Transmission. Page 9022 Fuse Block - Underhood C4 Part 2 Page 14916 Seat Heater Switch: Locations Driver Door Page 9025 Fuse Block - Underhood C7 Page 15068 Use a block of wood and/or a drill stop in order to protect the back of the cab while drilling. 4. Drill two 13.5 mm (0.54 in) holes per side into the box section of the front panel. 5. Drill 7.5 mm (0.30 in) holes into the weld flange of the side outer panel. 6. Apply anti-corrosion material to the drilled holes as necessary per the GM 4901M-D-2005 (English) or 4901M-D-F 2005 (French) Approved Refinish Materials booklet. The information for the 2005 GM Approved Refinish Materials booklet will now be online at the GMGOODWRENCH WEB SITE ONLY. Printed books have been discontinued. Steps to the site are as follows: A. Go to www.gmgoodwrench.com. B. Click on GM Collision Parts. C. Click on GM Technical Repair Information. D. Click on Paint Shop. 7. Place the front reinforcements back onto the box, lining up the drilled holes. 8. Install the large shoulder (M8) bolts into the reinforcement and front panel (total of 4) and the small (M6) bolts into the reinforcement and side outer panel (total of 6) with the nuts. Tighten ^ Tighten the M8 bolts to 25 Nm (18 lb-ft). ^ Tighten the M6 bolts to 9 Nm (79 lb-in). 9. Remove all metal shavings from the pickup box afier installation. 10. Install the bedliner if equipped with the aid of an assistant. The bedliner may need to be trimmed in order to obtain the necessary clearance for the reinforcements. Ladder Rack and/or Side ToolBox Applications - Reinforcement Kit Installation 1. Install the LH and RH front L-shaped reinforcements using the procedure above. 2. Remove the LH and RH rear taillamp assemblies. This is necessary to gain access to install the rearmost bolt of the rear reinforcement. 3. Place the LH and RH rear reinforcements into position on the pickup box. 4. Mark the holes necessary for drilling and remove the reinforcements. 5. Drill 7.5 mm (0.30 in) holes into the weld flange of the side outer panel. 6. Apply anti-corrosion material to the drilled holes as necessary. Refer to step 6 under Front Reinforcement Installation procedure. 7. Place the rear reinforcements back onto the pickup box. 8. Install the M6 bolts through the reinforcement and side panel with the nuts. Tighten Tighten the bolts to 9 Nm (79 lb-in). Page 8192 BRAKE ROTOR CLEAN-UP PROCEDURE Clean-up the rotors on an approved, well-maintained brake lathe to guarantee smooth, flat and parallel surfaces. Check for clean and true lathe adapters and make sure the arbor shoulder is clean and free of debris or burrs. For more information see the "Brake Lathe Calibration Procedure" section in this bulletin. 1. On the outboard area of the rotor, position the cutting tools one eighth of an inch into the brake pad area of the rotor. Feed the cutting tools into the rotor until they cut the rotor to new metal, a full 360 degrees. Zero each dial and back off a full turn. 2. Move the cutting bits to the middle of the rotor and do the same procedure. If zero is passed during the process, reset zero. Back off a full turn. 3. Position the cutting bits one eighth of an inch inside the inboard (closest to the hub) edge of the brake pad contact area. Do the same procedure. If zero is passed during the process, reset zero. 4. Back off a full turn and position the cutting bits all the way inboard in preparation to refinish the full rotor surface. Advance both tool cutters to the zero setting plus just enough to clean up the entire rotor surface. 5. After completing the refinish, sand both sides of the rotor for approximately one minute per side using a sanding block and 130-150 grit sandpaper to obtain a non-directional finish. Important Only remove the necessary amount of material from each side of the rotor and note that equal amounts of material do not have to be removed from both sides on any brake system using a floating caliper. Important In many of these instances, such a minimal amount of material is removed from the rotor that customer satisfaction is not a concern for future brake services. This procedure is intended to "Clean-up" the rotor surface and should be conveyed to the customer as such - not as "cut", "refinish" or "machine", which tends to be terms understood as a substantial reduction of rotor material/life. If the brake lathe equipment being used is not capable of removing minor amounts of material while holding tolerances, further lathe maintenance, repair, updates or equipment replacement may be necessary. Brake Noise BRAKE NOISE Some brake noise is normal and differences in loading, type of driving, or driving style can make a difference in brake wear on the same make and model. Depending on weather conditions, driving patterns and the local environment, brake noise may become more or less apparent. Verify all metal-to-metal contact areas between pads, pad guides, caliper and knuckles are clean and lubricated with a thin layer of high temperature silicone grease. Brake noise is caused by a "slip-stick" vibration of brake components. While intermittent brake noise may be normal, performing 3 to 4 aggressive stops may temporarily reduce or eliminate most brake squeal. If the noise persists and is consistently occurring, a brake dampening compound may be applied to the back of each pad. This allows parts to slide freely and not vibrate when moving relative to each other. Use Silicone Brake Lubricant, ACDelco P/N 88862181 (Canadian P/N 88862496) or equivalent. The following noises are characteristics of all braking systems and are unavoidable. They may not indicate improper operation of the brake system. Squeak/Squeal Noise: - Occurs with front semi-metallic brake pads at medium speeds when light to medium pressure is applied to the brake pedal. - Occasionally a noise may occur on rear brakes during the first few stops or with cold brakes and/or high humidity. Grinding Noise: - Common to rear brakes and some front disc brakes during initial stops after the vehicle has been parked overnight. - Caused by corrosion on the metal surfaces during vehicle non-use. Usually disappears after a few stops. Groan Noise: A groan type noise may be heard when stopping quickly or moving forward slowly from a complete stop. This is normal. On vehicles equipped with ABS, a groan or moan type noise during hard braking applications or loose gravel, wet or icy road conditions is a normal function of the ABS activation. Key Points - Frequently Asked Questions KEY POINTS - FREQUENTLY ASKED QUESTIONS - Q: How do on-car lathes react to Axle Float? Does the play affect the machining of the rotor, either surface finish or LRO? Page 1783 Seat Belt Switch - Front Passenger (With RPO Code AL0) Page 10918 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-8 (12085115) crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-8 (12085115) until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes SPLICING INLINE HARNESS DIODES Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate Service Data wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. 9. Tape the diode to the harness or connector using electrical tape. Page 1471 Door Latch Assembly (Door Jamb Switch) - Driver - C2 Diagrams Remote Control: Diagrams Steering Wheel Audio Controls - Left (With RPO Code YE9) Page 6330 ^ The reverse boost valve bushing ^ A new reverse boost valve ^ A new pressure regulator spring retainer ^ The added isolator pressure regulator spring ^ The pressure regulator spring 3. Install the pre-assembled parts into the pump bore. 4. Install the reverse boost valve bushing retainer ring while holding the reverse boost valve bushing in place. Ensure the retainer ring (2) is in the groove. 5. Install the transmission filter. 6. Fill the transmission to the proper level with Dexron® III transmission fluid. Page 1678 10. Connect the PNP switch electrical connector (2). 11. If equipped with 4WD, install the front propeller shaft. 12. Lower the vehicle. 13. Check the PNP switch for proper operation. The engine must start in the park (P) or neutral (N) positions only. If proper operation of the switch can not be obtained, replace the switch. Park Lock Pawl and Actuator Replacement Park Lock Pawl and Actuator Replacement Removal Procedure 1. Remove the transmission filter. 2. Remove the park/neutral position (PNP) switch. 3. Remove the manual shaft nut and pin. 4. Remove the detent lever and actuator. 5. Remove the parking pawl bracket bolts. 6. Remove the parking pawl return spring. Page 15865 Upper Steering Column Page 5350 22. If vehicle is a regular cab, remove the fuel feed, EVAP, and return pipe assembly nuts. 23. If vehicle is a crew or extended cab, remove the fuel feed, EVAP, and return pipe assembly nuts. 24. Remove the fuel feed, EVAP, and return pipe assembly. INSTALLATION PROCEDURE 1. Install the fuel feed, EVAP, and return pipe assembly. NOTE: Refer to Fastener Notice in Service Precautions. 2. If vehicle is a crew or extended cab, install the fuel feed, EVAP, and return pipe assembly nuts. Tighten Tighten the nuts to 12 N.m (106 lb in). Page 4785 Coolant Temperature Sensor/Switch (For Computer): Service and Repair ENGINE COOLANT TEMPERATURE (ECT) SENSOR REPLACEMENT REMOVAL PROCEDURE NOTE: Use care when handling the coolant sensor. Damage to the coolant sensor will affect the operation of the fuel control system. 1. Drain the cooling system to a level below the engine cooling temperature (ECT) sensor. Refer to Draining and Filling Cooling System in Cooling System. 2. Disconnect the ECT sensor electrical connector (5). 3. Remove the ECT sensor. INSTALLATION PROCEDURE NOTE: Replacement components must be the correct part number for the application. Components requiring the use of the thread locking compound, lubricants, corrosion inhibitors, or sealants are identified in the service procedure. Some replacement components may come with these coatings already applied. Do not use these coatings on components unless specified. These coatings can affect the final torque, which may affect the operation of the component. Use the correct torque specification when installing components in order to avoid damage. - Use care when handling the coolant sensor. Damage to the coolant sensor will affect the operation of the fuel control system. Page 6277 Note Only on 4T65E, the second magnet (left) should be attached to the transmission filter. If the magnet is attached in any other location, it may cause interference (refer to graphic above). 4L60 Parts Information Warranty Information For vehicles repaired under warranty, use the table above. Page 5367 18. If equipped with 4WD, remove the torsion bar bracket. 19. Disconnect the fuel and EVAP lines at the fuel tank. 20. Cap the fuel and EVAP lines at the fuel tank in order to avoid possible system contamination. 21. If vehicle is a regular cab, remove the fuel and EVAP bundle clip nuts. 22. If vehicle is a crew cab or extended cab, remove the fuel and EVAP bundle clip nuts. 23. Remove the fuel and EVAP bundle. INSTALLATION PROCEDURE Page 5542 Camshaft Position Sensor: Service and Repair CAMSHAFT POSITION (CMP) SENSOR REPLACEMENT REMOVAL PROCEDURE IMPORTANT: Clean the area around the CMP sensor before removal in order to prevent debris from entering the engine. 1. Remove the camshaft position (CMP) sensor bolt. 2. Remove the CMP sensor. INSTALLATION PROCEDURE 1. Install the CMP sensor. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the CMP sensor bolt. Tighten Tighten the bolt to 29 N.m (21 lb ft). Page 15930 Electrical Symbols Part 2 Component Locations Torque Converter Clutch Solenoid: Component Locations Automatic Transmission - 4L60-E/4L65-E Automatic Transmission Electronic Component Views (M30/M32) Electronic Components Page 8427 Disclaimer Page 15236 Control Module References Part 2 Master Cylinder Replacement (Vacuum Boost) Brake Master Cylinder: Service and Repair Master Cylinder Replacement (Vacuum Boost) Master Cylinder Replacement (Vacuum Boost) Removal Procedure Caution: Refer to Brake Fluid Irritant Caution in Service Precautions. Notice: Refer to Brake Fluid Effects on Paint and Electrical Components Notice in Service Precautions. 1. Apply the park brake and block the wheels. 2. Disconnect the electrical connector from the brake fluid level sensor. 3. Disconnect the brake pipes from the master cylinder. 4. Important: Install a rubber cap or plug to the exposed brake pipe fitting ends in order to prevent brake fluid loss and contamination. Plug the open brake pipe ends. 5. Remove the master cylinder mounting nuts. 6. Remove the master cylinder from the vehicle. 7. Remove the master cylinder reservoir. Installation Procedure 1. Install the master cylinder reservoir. 2. Bench bleed the master cylinder. Page 3725 For vehicles repaired under warranty, use the table. Disclaimer Page 11895 Page 12559 Diagnostic Tips Review # 4 - Denso legacy Navigation Radio Page 258 DTC B2476 04: Cellular Phone Select Service Switch Open Circuit DTC B2476 59: Cellular Phone Select Service Switch Stuck Button DTC B2482 00: Cellular Phone Select Service Switch Range/Performance Circuit Short to Ground Open / High Resistance Short to Voltage Signal Performance Circuit/System Description The OnStar(R) button assembly consists of 3 buttons, Call/Answer, OnStar(R) Call Center, and OnStar(R) Emergency. The vehicle communication interface module (VCIM) supplies the OnStar(R) button assembly with 10 volts via the keypad supply voltage circuit. Each of the buttons, when pressed, completes the circuit across a resistor allowing a specific voltage to be returned to the VCIM over the keypad signal circuit. Depending upon the voltage range returned, the VCIM is able to identify which button has been activated. Conditions for Running the DTCs The ignition is ON. System voltage is between 9 - 16 volts. Conditions for Setting the DTCs B2476 04: The VCIM detects an open/high resistance on the keypad supply voltage circuit. B2482 and B2476 59: The VCIM detects a valid signal on the keypad signal circuit for more than 15 seconds. If one of the OnStar(R) buttons is held or stuck for 15 seconds or more, the VCIM will set these DTCs. Action Taken When the DTCs Set The OnStar(R) status LED turns red. No calls can be placed. The VCIM will ignore all inputs from the OnStar® button assembly. Conditions for Clearing the DTCs The condition responsible for setting the DTC no longer exists. A history DTC will clear once 100 consecutive malfunction-free ignition cycles have occurred. Ignition System - New Spark Plugs & Gapping Info. Spark Plug: Technical Service Bulletins Ignition System - New Spark Plugs & Gapping Info. INFORMATION Bulletin No.: 03-06-04-060B Date: July 30 2008 Subject: Information on New Spark Plugs and Gapping Models Attention: Please disregard the Set Gap Per Vehicle Specification statement on the side of an ACOelco(R) Iridium Spark Plug Box. The statement will be removed from the boxes in the future. Supercede: This bulletin is being revised to add the Chevrolet SSR and the 2005 Pontiac GTO. Please discard Corporate Bulletin Number 03-06-04-060A (Section 06 - Engine/Propulsion System). ^ A new spark plug has been released for use in the above vehicles. The new spark plug has an Iridium tip instead of the current Platinum tip. Due to the different tip design the gap of the spark plug has also changed. ^ The new spark plug P/N 12571164 with AC Delco P/N 41-985 is gapped to 1.01 mm (0.040 in) when the spark plug is made. Notice: The spark plug gap is set during manufacturing and should not be changed or damage to the spark plug may result. Any new spark plug found to not be properly gapped should not be used. Disclaimer Wheels/Tires - Tire Radial Force Variation (RFV) Wheels: Customer Interest Wheels/Tires - Tire Radial Force Variation (RFV) INFORMATION Bulletin No.: 00-03-10-006F Date: May 04, 2010 Subject: Information on Tire Radial Force Variation (RFV) Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X 2000-2005 Saturn L Series 2003-2007 Saturn ION Supercede: This bulletin is being revised to considerably expand the available information on Radial Force Variation (RFV) and should be reviewed in whole. Please discard Corporate Bulletin Number 00-03-10-006E (Section 03 - Suspension). Important - Before measuring tires on equipment such as the Hunter GSP9700, the vehicle MUST be driven a minimum of 16 km (10 mi) to ensure removal of any flat-spotting. Refer to Corporate Bulletin Number 03-03-10-007E - Tire/Wheel Characteristics of GM Original Equipment Tires. - Equipment such as the Hunter GSP9700 MUST be calibrated prior to measuring tire/wheel assemblies for each vehicle. The purpose of this bulletin is to provide guidance to GM dealers when using tire force variation measurement equipment, such as the Hunter GSP9700. This type of equipment can be a valuable tool in diagnosing vehicle ride concerns. The most common ride concern involving tire radial force variation is highway speed shake on smooth roads. Tire related smooth road highway speed shake can be caused by three conditions: imbalance, out of round and tire force variation. These three conditions are not necessarily related. All three conditions must be addressed. Imbalance is normally addressed first, because it is the simpler of the three to correct. Off-vehicle, two plane dynamic wheel balancers are readily available and can accurately correct any imbalance. Balancer calibration and maintenance, proper attachment of the wheel to the balancer, and proper balance weights, are all factors required for a quality balance. However, a perfectly balanced tire/wheel assembly can still be "oval shaped" and cause a vibration. Before balancing, perform the following procedures. Tire and Wheel Diagnosis 1. Set the tire pressure to the placard values. 2. With the vehicle raised, ensure the wheels are centered on the hub by loosening all wheel nuts and hand-tightening all nuts first by hand while shaking the wheel, then torque to specifications using a torque wrench, NOT a torque stick. 3. Visually inspect the tires and the wheels. Inspect for evidence of the following conditions and correct as necessary: - Missing balance weights - Bent rim flange - Irregular tire wear - Incomplete bead seating - Tire irregularities (including pressure settings) - Mud/ice build-up in wheel - Stones in the tire tread - Remove any aftermarket wheels and/or tires and restore vehicle to original condition prior to diagnosing a smooth road shake condition. 4. Road test the vehicle using the Electronic Vibration Analyzer (EVA) essential tool. Drive for a sufficient distance on a known, smooth road surface to duplicate the condition. Determine if the vehicle is sensitive to brake apply. If the brakes are applied lightly and the pulsation felt in the steering wheel increases, refer to the Brakes section of the service manual that deals with brake-induced pulsation. If you can start to hear the vibration as a low boom noise (in addition to feeling it), but cannot see it, the vehicle likely has a first order (one pulse per propshaft revolution) driveline vibration. Driveline first order vibrations are high enough in frequency that most humans can start to hear them at highway speeds, but are too high to be able to be easily seen. These issues can be caused by driveline imbalance or misalignment. If the vehicle exhibits this low boom and the booming pulses in-and-out on a regular basis (like a throbbing), chances are good that the vehicle could have driveline vibration. This type Locations Full Engine View Left Side Page 10234 When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage TESTING FOR A SHORT TO VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity TESTING FOR CONTINUITY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents TESTING FOR ELECTRICAL INTERMITTENTS Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground - Testing for Continuity - Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 msRECORD and emits an audible tone (beep). Page 2643 Fuse Block - Underhood C1 Part 4 Page 7202 4. Install the transmission mount to crossmember nut. ^ Tighten the transmission mount to crossmember nut to 40 Nm (30 ft. lbs.). 5. Lower the vehicle. Page 8867 Electrical Symbols Part 5 Page 10265 Steering Mounted Controls Transmitter: Connector Views Steering Wheel Driver Information Center (DIC) Controls - Left (With RPO Code YE9) Page 12105 Action Taken When the DTCs Sets The module suspends all message transmission. The module uses default values for all parameters received on the serial data circuits. The module inhibits the setting of all other communication DTCs. Conditions for Clearing the DTC A current DTC clears when the malfunction is no longer present. A history DTC clears when the module ignition cycle counter reaches the reset threshold of 50, without a repeat of the malfunction. Circuit/System Verification Refer to Data Link References to determine which serial data system is used for a specific module. This DTC cannot be retrieved with a current status. Diagnosis is accomplished using the following symptom procedures: Scan Tool Does Not Communicate with High Speed GMLAN Device in SI. OR Scan Tool Does Not Communicate with Low Speed GMLAN Device in SI. DTC U0140 - U0184 Circuit Description Modules connected to the GMLAN serial data circuit monitor for serial data communications during normal vehicle operation. Operating information and commands are exchanged among the modules. In addition to this, Node Alive messages are transmitted by each module on the GMLAN serial data circuit. When the module detects one of the following conditions on the GMLAN serial data circuit, a DTC will set. Operating information and commands are exchanged among the modules. In addition to this, Node Alive messages are transmitted by each module on the GMLAN serial data circuit. Conditions for Setting the DTCs Diagnostic algorithms are designed so that a single point failure within a particular node shall result in a single DTC/FTB combination being set. Any recognized faults shall generate one DTC. Recognized faults may include but are not limited to the following: ^ Open or shorted condition on an I/O Circuit outside of normal operation of that circuit. ^ Erratic signal of a circuit, outside of normal operation, which can be readily and repeatedly recognized as erratic. ^ A condition, outside of normal operation, which causes a customer perception of a performance problem. ^ A condition whether hardware or data link error, which causes a device to operate in a default or fail soft mode. ^ A condition which changes or limits system performance. ^ Network supervision/signal supervision errors. ^ ECU Internal errors. ^ Criteria determined by legislation. An initialization or shutdown self-test shall be performed and may include but is not limited to the following: ^ RAM check ^ ROM/EEPROM/Flash check Page 815 Junction Block - I/P Wire Entry Part 3 Recall - Tailgate Support Cable Inspection/Replacement Technical Service Bulletin # 04007B Date: 051121 Recall - Tailgate Support Cable Inspection/Replacement Product Safety - Tailgate Support Cable # 04007B - (Nov 21, 2005) Models: 2002-2004 Cadillac Escalade EXT 2000 Chevrolet CK 2000-2004 Chevrolet Silverado 2002-2004 Chevrolet Avalanche 2003-2004 Chevrolet Kodiak 2000-2004 GMC Sierra 2003-2004 GMC TopKick THIS BULLETIN IS BEING REVIED TO INCLUDE SOME 2003 AND 2004 MODEL YEAR MEDIUM DUTY VEHICLES THAT WERE MODIFIED TO INCLUDE A TAILGATE. PLEASE DISCARD ALL COPIES OF BULLETIN 04007A, ISSUED OCTOBER 2004. Condition General Motors has decided that a defect which relates to motor vehicle safety exists in certain 2000 model year Chevrolet CK, 2000-2004 model year Chevrolet Silverado and GMC Sierra trucks, and 2002-2004 model year Cadillac Escalade EXT and Chevrolet Avalanche trucks, and 2003-2004 Chevrolet Kodiak and GMC TopKick trucks. On some of these vehicles, the galvanized steel tailgate support cables that retain the tailgate in the full open (horizontal) position may corrode, weaken, and eventually fracture. If one cable fractures, the remaining cable may retain the tailgate in a horizontal position. However, if the remaining cable is sufficiently weakened by corrosion, it could fracture within moments of the first cable fracturing, especially if there is a load on the tailgate. If both cables fracture, the tailgate would suddenly drop and strike the top surface of the rear bumper. Anyone sitting or standing on the tailgate when both cable fracture could be injured by falling from the tailgate. On vehicles that have had the bumper removed, the tailgate may drop even lower. Additionally, if there is cargo on the tailgate, the cargo may become unstable and fall if the support cables fracture. Correction Dealers are to replace the galvanized support cables with stainless steel support cables. In addition, dealers are to inspect the tailgate hinge and replace it, if necessary. Vehicles Involved Page 16077 IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections TESTING FOR INTERMITTENT AND POOR CONNECTIONS TOOLS REQUIRED - J 35616-C GM-Approved Terminal Test Kit - J 38125-D Terminal Repair Kit - J 42675 Flat-Wire Probe Adapter Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector. - Poor terminal to wire connection - Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. - Wire insulation which is rubbed through - This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. - Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. Testing For Proper Terminal Contact It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-D or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-D, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. Page 11454 6. Push down the flex lock button (3) and slide the connector locking cover (4) to the close position. 7. Install the connector position assurance (CPA) (1) to the inflatable restraint sensing and diagnostic module (SDM) wiring harness connector (2). 8. Position the carpet to cover the inflatable restraint sensing and diagnostic module (SDM). 9. Install the door sill plate. 10. Install the driver seat. IMPORTANT: The AIR BAG indicator may remain ON after the SDM has been replaced. DTC B1001 may set requiring the SDM part number to be set in multiple modules. If the indicator remains ON after enabling the SIR system, perform the diagnostic system check and follow the steps thoroughly to ensure that the SDM is set properly. 11. Enable the SIR system. Refer to SIR Disabling and Enabling Zone 7. Page 12974 Speaker: Service and Repair Speaker Replacement - Front SPEAKER REPLACEMENT - FRONT (WINDSHIELD PILLAR SPEAKER) REMOVAL PROCEDURE 1. Remove the windshield garnish molding (2). 2. Disconnect the electrical connector (3) to the speaker. 3. Remove the speaker (1) by press until it is out of the molding. INSTALLATION PROCEDURE 1. Press in the speaker (1) until it is fully seated. 2. Connect the electrical connector (3). 3. Install the windshield garnish molding (2). Page 3224 9. Use the J 38606 in order to compress the valve spring. 10. Remove the valve stem keys (2). 11. Carefully release the valve spring tension. 12. Remove the J 38606. 13. Remove the valve spring cap (3). 14. Remove the valve spring (4). 15. Remove the valve stem oil seal and shim (1, 5). Installation Procedure 1. Clean the cylinder head valve spring seat and/or shim area. 2. Lubricate the valve guide and valve stem oil seal with clean engine oil. 3. Install the valve stem oil seal and shim (1, 5). 4. Install the valve spring (4). 5. Install the valve spring cap (3). Page 512 Door Module: Connector Views Driver Door Module (DDM) - C1 (With RPO Code YE9) Page 15760 Cargo Lamp Switch: Service and Repair LAMP SWITCH ASSEMBLY REPLACEMENT - FRONT FOG LAMP AND CARGO LAMP REMOVAL PROCEDURE 1. Remove the instrument cluster bezel. 2. Remove the fog lamp switch and cargo switch from the housing. 3. Disconnect the electrical connector(s) from the fog lamp switch. 4. Remove the fog lamp and cargo lamp switch from the housing. INSTALLATION PROCEDURE 1. Connect the electrical connector(s) to the fog lamp and cargo lamp switch. 2. Install the fog lamp switch into the housing. 3. Install the IP trim bezel to the instrument panel. Technician Safety Information Paint: Technician Safety Information Basecoat/Clearcoat Paint Systems CAUTION: - Exposure to isocyanates during paint preparation and application processes can cause severe breathing problems. Read and follow all of the instructions from the manufacturers of painting materials, equipment, and protective gear. - Approved safety glasses and gloves should be worn when performing this procedure to reduce the chance of personal injury. All paint finish repairs of rigid exterior surfaces must meet GM standards. The GM Approved Refinish Materials book GM P/N GM4901M-D identifies the paint systems you may use. Always refer to the latest revision of the 4901M-D book. All approved products, including volatile organic compound (VOC) compliant regulations are listed in the system approach recommended by the individual manufacturer. Refer to the manufacturer's instructions for the detailed procedures for materials used in the paint system in the painting repairs of rigid exterior surfaces. All components of an approved paint system have been engineered in order to ensure proper adhesion between layers.If necessary, spot repairs or color blending in an open panel can be done. However, do not blend clear coat in an open panel. Always apply clearcoat to the next break point (body side molding, feature line, or the next panel) Do not mix paint systems or substitute a product of one manufacturer for another manufacturer's product. If incompatible products are used together the following problems may occur: - Lifting of primer coats caused by overly aggressive solvents in subsequent layers - Loss of adhesion between layers due to incompatibility of resin systems - Solvent popping or pin holing due to inappropriate solvent selection - Poor through-curing due to incompatible hardener resins or insufficient reactivity - Gloss reduction due to incompatible resins and/or solvents - Poor color accuracy due to pigment interactions with incompatible resins and/or solvents - Film defects (craters, blisters, orange peel loss of gloss) due to the use of inferior quality raw materials in incompatible products. Page 5271 Fuel Injector 8 Page 5603 Steps 10 - 14 Service and Repair Center Link: Service and Repair Relay Rod Replacement ^ Tools Required J 24319-B Universal Steering Linkage Puller - J 29193 Steering Linkage Installer (12 mm) - J 29194 Steering Linkage Installer (14 mm) Removal Procedure 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Remove the engine protection shield, if equipped. 3. Remove the steering damper from the relay rod, if equipped. Refer to Steering Damper Replacement. 4. Important: Use the proper tool in order to separate all the tie rod and the ball joints. Remove the tie rod ends (6). Refer to Tie Rod Replacement. 5. Remove the idler arm ball stud nut (10).Do not reuse the nut. 6. Remove the pitman arm nut (8).Do not reuse the nut. 7. Remove the relay rod from the idler arm ball stud using the J 24319-B. 8. Remove the relay rod from the pitman arm ball stud using the J 24319-B. 9. Remove the relay rod from the vehicle. 10. Inspect the threads on the tie rod ends for damage. 11. Inspect the ball stud threads for damage. 12. Inspect the ball stud seals for excessive damage. 13. Clean the threads on the ball studs. Installation Procedure Interior - Napped Seat Fabric Repair Seat Cover: All Technical Service Bulletins Interior - Napped Seat Fabric Repair Bulletin No.: 04-08-50-011A Date: May 04, 2006 INFORMATION Subject: Repairing Napped Seat Fabric Models: 2007 Cadillac Escalade, Escalade ESV, Escalade EXT 1999-2006 Chevrolet Silverado 2000-2007 Chevrolet Suburban, Tahoe 2002-2005 Chevrolet Astro 2002-2006 Chevrolet Monte Carlo 2002-2007 Chevrolet Avalanche 2002-2005 GMC Safari 2007 GMC Yukon, Yukon XL 2002-2004 Oldsmobile Alero 1997-2006 Pontiac Grand Prix Supercede: This bulletin is being revised to add model years and models. Please discard Corporate Bulletin Number 04-08-50-011 (Section 08 - Body & Accessories). This bulletin is being issued to advise technicians/dealers on the proper repair required when a customer brings in a trimmed seat with the appearance of being worn, having a bald spot and/or being discolored. The seats in the later vehicles are trimmed with a cloth that has a napped fabric. Under some circumstances, the nap may become crushed down by normal use, giving the appearance of being worn out. If the base material is NOT visible, use a small brass (NOT STEEL) wire brush to carefully fluff and raise the nap. The wire brush (fine bristle brass) is available at most hardware and home stores. If the base material is visible, replace the trim cover. The Astro/Safari van will also have this material on the door trim. Disclaimer NVG 246-NP8 Control Module: Locations NVG 246-NP8 Transfer Case Shift Control Module Transfer Case Shift Control Module 1 - I/P Harness 2 - Transfer Case Shift Control Module Connectors 3 - Transfer Case Shift Control Module 4 - Instrument Panel Page 11927 9. Erase the diagnostic trouble codes. 10. Set the date and time, see WIS - 3. Electrical system - Information display (SID) - Technical description. Generator Bracket Replacement Alternator: Service and Repair Generator Bracket Replacement GENERATOR BRACKET REPLACEMENT REMOVAL PROCEDURE 1. Remove the battery cable junction block bracket bolts. 2. Remove the generator. 3. Remove the power steering pump. 4. Remove the generator bracket bolts. 5. Remove the generator bracket. INSTALLATION PROCEDURE Suspension - Shock Absorber/Strut Leakage Information Suspension Strut / Shock Absorber: All Technical Service Bulletins Suspension - Shock Absorber/Strut Leakage Information INFORMATION Bulletin No.: 05-03-08-002C Date: October 16, 2009 Subject: Information on Replacement of Shock Absorbers and Struts Due to Fluid Leaks Models: 2010 and Prior GM Passenger Cars and Trucks (Including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X Supercede: This bulletin is being revised to add the 2010 model year and Inspection Procedures. Please discard Corporate Bulletin Number 05-03-08-002B (Section 03 - Suspension). This bulletin is intended to help identify the severity of shock absorber and strut fluid seepage. Improper diagnosis may lead to components being replaced that are within the manufacturer's specification. Shock absorbers and strut assemblies are fluid-filled components and will normally exhibit some seepage. Seepage is defined as oil film or dust accumulation on the exterior of the shock housing. Shock absorbers and struts are not to be replaced under warranty for seepage. Use the following information to determine if the condition is normal acceptable seepage or a defective component. Important Electronically controlled shock absorbers (MR) may have a tendency to attract dust to this oil film. Often this film and dust can be wiped off and will not return until similar mileage is accumulated again. Inspection Procedure Note The shock absorber or strut assembly DOES NOT have to be removed from the vehicle to perform the following inspection procedure. Use the following descriptions and graphics to determine the serviceability of the component. Shock Absorbers Do Not Replace shock absorbers displaying condition 1 or 2 levels of seepage. 1. Oil or fluid residue only on the bottom or top of the shock absorber and not originating from the shaft seal (the upper part of the lower shock tube). 2. Light film/residue on approximately 1/3 (a) or less of the lower shock tube (A) and originating from the shaft seal. Replace shock absorbers displaying conditions 3 and 4 levels of leaks. 3. Oil drip or trail down the lower shock tube and originating from the shaft seal. 4. An extreme wet film of oil covering more than 1/3 (b) of the lower shock tube and originating from the shaft seal. Coil-over Shock Absorber Instruments - Service Tire Monitor Message is Displayed Low Tire Pressure Indicator: All Technical Service Bulletins Instruments - Service Tire Monitor Message is Displayed Bulletin No.: 05-08-49-018A Date: May 11, 2006 ADVANCE SERVICE INFORMATION RESOLUTION Subject: EI 05065 - Service Tire Monitor Message Displayed (Pull/Reinstall IPC Fuse or Verify Correct Passenger Door Module (PDM) and Tires) Models: 2004 Chevrolet Silverado 2004 GMC Sierra Supercede: This bulletin is being revised to provide correction action. Please discard Corporate Bulletin Number 05-08-49-018 (Section 08 - Body and Accessories). Condition Some customers may comment that the "SERVICE TIRE MONITOR" message is being displayed on the DIC. Correction DO NOT REPLACE THE INSTRUMENT PANEL CLUSTER. If the DIC is displaying the SERVICE TIRE MONITOR message: 1. Verify if the vehicle has an electronic aftermarket module spliced into the ALDL Class 2 data line (purple wire). 2. If the vehicle HAS an aftermarket module spliced into the Class 2 line, pull the IPC fuse (located underhood) for 25 seconds. Important: Due to the electronic aftermarket module, the SERVICE TIRE MONITOR message may reoccur. 3. Reinstall the IPC fuse. This will clear the SERVICE TIRE MONITOR message from the display. 4. If the vehicle DOES NOT have an aftermarket module spliced into the Class 2 line, verify the vehicle is equipped with the correct PDM (Passenger Door Module) and tires. Warrant Information This repair is not covered under the vehicle warranty due to the installation of an aftermarket module. Disclaimer Page 10337 5. Install the lower control arm retaining nuts. ^ Tighten the nuts to 175 Nm (129 ft. lbs.). Notice: Refer to Fastener Notice in Service Precautions. 6. Install the wheel drive shaft. Refer to Wheel Drive Shaft Replacement in Wheel Drive Shafts. 7. Connect lower ball joint stud to the steering knuckle. 8. Install the retaining nut to the lower ball joint stud. ^ Tighten the nut to 100 Nm (74 ft. lbs.). 9. Install the torsion bars. Refer to Torsion Bar Replacement. 10. Install the shock absorber lower nut and bolt. Refer to Shock Absorber Replacement (4WD) Shock Absorber Replacement (RWD). 11. Install the stabilizer shaft links to the lower control arm. Refer to Stabilizer Shaft Replacement. 12. Install the tire and wheel. 13. Remove the safety stands. 14. Lower the vehicle. 15. Align the vehicle. Refer to Measuring Wheel Alignment (w/Rear Wheel Steering) Measuring Wheel Alignment (w/o Rear Wheel Steering) in Wheel Alignment. Drivetrain - Transfer Case Control Module Replacement Control Module: All Technical Service Bulletins Drivetrain - Transfer Case Control Module Replacement Bulletin No.: 05-04-21-002 Date: March 10, 2005 INFORMATION Subject: Guidelines for Replacement of Transfer Case Control Module (TCCM) Models: 2005 and Prior Light Duty Trucks with New Venture Gear (NVG) Transfer Case (RPOs NP1, NP4, NP8) Dealers are replacing the TCCM unnecessarily. Dealers are replacing the TCCM with codes stored in HISTORY only. The TCCM does not have a current fault condition when tested. Parts reviewed at the Warranty Parts Center (WPC) have a 75% No Trouble Found (NTF) rate. The only two legitimate reasons to replace the TCCM are: ^ Diagnostic Trouble Code (DTC) C0550 ^ NO Communication with a scan tool. DTC C0550 This DTC indicates that the module has an internal fault and should be replaced. No Communication ^ The no communication conditions referenced here are also caused by a module internal fault to a point where the module physically will not talk. A technician cannot pull DTCs from the module because it will not communicate. The module is electrically dead. ^ No communication is not to be confused with a U1026 code. This code tells the technician that the module may still be functioning but is temporarily off line. This code may be set by the Instrument Panel (IP) or the Powertrain Control Module (PCM) against the TCCM. The technician needs to figure out why the module went off line. These are typically caused by connection concerns. There is no need to replace a TCCM for a U1026 DTC. Diagnostic Aids ^ When diagnosing a transfer case electrical control system, ALWAYS check power and ground wiring first. ^ Test the connections for intermittent or poor connections, complete plug insertion, bent pins, pushed out terminals and water contamination. Drivetrain - Transfer Case Control Module Replacement Control Module: All Technical Service Bulletins Drivetrain - Transfer Case Control Module Replacement Bulletin No.: 05-04-21-002 Date: March 10, 2005 INFORMATION Subject: Guidelines for Replacement of Transfer Case Control Module (TCCM) Models: 2005 and Prior Light Duty Trucks with New Venture Gear (NVG) Transfer Case (RPOs NP1, NP4, NP8) Dealers are replacing the TCCM unnecessarily. Dealers are replacing the TCCM with codes stored in HISTORY only. The TCCM does not have a current fault condition when tested. Parts reviewed at the Warranty Parts Center (WPC) have a 75% No Trouble Found (NTF) rate. The only two legitimate reasons to replace the TCCM are: ^ Diagnostic Trouble Code (DTC) C0550 ^ NO Communication with a scan tool. DTC C0550 This DTC indicates that the module has an internal fault and should be replaced. No Communication ^ The no communication conditions referenced here are also caused by a module internal fault to a point where the module physically will not talk. A technician cannot pull DTCs from the module because it will not communicate. The module is electrically dead. ^ No communication is not to be confused with a U1026 code. This code tells the technician that the module may still be functioning but is temporarily off line. This code may be set by the Instrument Panel (IP) or the Powertrain Control Module (PCM) against the TCCM. The technician needs to figure out why the module went off line. These are typically caused by connection concerns. There is no need to replace a TCCM for a U1026 DTC. Diagnostic Aids ^ When diagnosing a transfer case electrical control system, ALWAYS check power and ground wiring first. ^ Test the connections for intermittent or poor connections, complete plug insertion, bent pins, pushed out terminals and water contamination. Page 1194 Seat Heater Switch: Diagrams Driver Door Module (DDM) - C5 (Memory/Heated Seat Switch) Part 1 Locations Air Induction Components Page 4610 Oxygen Sensor: Service and Repair Heated Oxygen Sensor (HO2S) Replacement Bank 2 Sensor 2 HEATED OXYGEN SENSOR (HO2S) REPLACEMENT BANK 2 SENSOR 2 REMOVAL PROCEDURE 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. Disconnect the connector position assurance (CPA) retainer. NOTE: Refer to Heated Oxygen and Oxygen Sensor Notice in Service Precautions. 3. Remove the heated oxygen sensor (HO2S) connector clip from the frame. 4. If equipped with a 4.8L or 5.3L engine, disconnect the HO2S electrical connector. Page 1966 Speed Sensor: Service and Repair Transfer Case - NVG 261-NP2 Transfer Case Speed Sensor Replacement Removal Procedure 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. Disconnect the speed sensor electrical connector (4). 3. Remove the speed sensor. Installation Procedure 1. Notice: Refer to Fastener Notice in Service Precautions. Install the speed sensor. ^ Tighten the sensor to 15 Nm (11 ft. lbs.). Page 12124 5. Choose the outstanding core you wish to process, by selecting the Virtual Core Button on the far right side of the screen. 6. Enter the information in the required fields and select the submit button. Record the confirmation number. Canadian Dealers 1. Return the removed Analog / Digital-Ready OnStar(R) VCIM to the Parts Manager. 2. The Parts Manager will log onto https://adt.onstar.gm.mass.ca and enter information as prompted. All Dealers If the website indicates that the VCIM needs to be physically returned to the distributor, please use the pre-paid shipping label that was included in the kit to return the removed VCIM. Important: To avoid a $250 core non-return charge, you must do one of the following within 30 days of kit shipment: 1. Submit the necessary VCIM data through the website, as indicated above. 2. Mail the removed core from the customer's vehicle back to the distributor. 3. Return the unused digital upgrade kit back to the distributor using the pre-paid shipping label that is included in the kit box. Returning the Upgraded Vehicle to the Customer Returning the Upgraded Vehicle to the Customer 1. Place the new OnStar Subscriber Information (Owner's Manual kit) in the customer's vehicle where they can review some of the new features of the Digital-Capable system. The continuous digit dialing feature should be highlighted to the customer to avoid a return to the dealership for dialing instructions. Advise the customer to discard any existing OnStar(R) Owner's Manuals that may be in the vehicle. 2. Have the Service Advisor, Service Manager or Sales Consultant review the new OnStar(R) Hands-Free Calling procedure with the customer. The customer is uses to their analog OnStar(R) Hands-Free Calling system, which uses individual digit dial to make a call. The Generation 6 Digital-Capable system uses continuous digit dial, and the customer needs to be made aware of this change. 3. U.S. Dealers Only: Staple the "Tip Sheet - OnStar(R) Generation 6 Digitally-Capable System", that was included in the kit, to the customer's copy of the repair order. This tip sheet will help your customer better understand their new OnStar(R) system. 4. Canadian Dealers Only: Refer the customer to the Hands-Free Calling Quick Review Card from the new OnStar(R) Owner's Manual kit for help with the new dialing procedure. 5. Fill out the form entitled "GM Limited Warranty for Upgraded OnStar(R) Digital Equipment Program Participants" and staple a copy of this to the customer's repair order. You may want to keep a copy for your records. 6. Encourage your customer to press their blue OnStar(R) button the next day. The OnStar(R) Advisor will be able to review some of the new features of their digital OnStar(R) system. Closing the Onstar(R) Upgrade Exchange Closing the OnStar(R) Upgrade Exchange 1. Collect payment from the customer. Your dealership's open account (sales) will be charged for the cost of the chosen subscription plan, any applicable subscription taxes, and the $15 upgrade charge after the vehicle has been configured through the TIS2WEB process. 2. None of the costs associated with the OnStar Digital Upgrade program may be claimed as a GM goodwill event. These costs must be paid by the customer, and may not be included in any goodwill offered to the customer. GM employees or representatives or field personnel are not able to offer goodwill for this program. If the dealership decides to pay for the upgrade for their customer, be aware that your GM or OnStar(R) contact will not be able to reimburse you for this cost. 3. Use labor code Z2096 to submit your claim for the labor time published below plus 0.2 hr Administrative Allowance and an additional $20.00 Net Amount. ^ For all dealer claim submissions (excluding U.S. Saturn), use Complaint Code MH - Technical Bulletin, and Failure Code 93 - Technical Service Bulletin. Page 10250 If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Sir/SRS Wiring Repairs SIR/SRS WIRING REPAIRS TOOLS REQUIRED J 38125-D Terminal Repair Kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-D contains the following items: - Special sealed splices - in order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping tool - A heat torch - An instruction manual The sealed splices have the following 2 critical features: - A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-D also serves as a generic terminal repair kit. The kit contains the following items: - A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors 8.6, 9.5, 11.5 Inch Axles Pinion Bearing: Service and Repair 8.6, 9.5, 11.5 Inch Axles Drive Pinion Bearings Replacement (8.6, 9.5, 11.5 Inch Axles) ^ Tools Required J 7818 Inner Bearing Race Installer, 9.5 inch axle - J 8092 Driver Handle 3⁄4 in - 10 - J 8608 Rear Pinion Bearing Race Installer, 8.6 inch, 11.5 inch axle - J 8614-01 Flange and Pulley Holding Tool - J 22306 Pinion Cup Bearing Installer - Rear, 9.5 inch axle - J 22388 Rear Axle Pinion Oil Seal Installer, 8.6 inch, 9.5 inch axle - J 22912-01 Split Plate Bearing Puller - J 24433 Pinion Cone and Side Bearing Installer, 8.6 inch axle - J 36614 Inner Pinion Bearing Installer, 9.5 inch axle - J 44412 Pinion Bearing Installer, 11.5 inch axle - J 44414 Rear Axle Pinion Oil Seal Installer, 11.5 inch axle - J 44417 Rear Pinion Bearing Race Installer, 11.5 inch axle - J 45871 Pinion Bearing Remover - J 45900 Pinion Bearing Cup Installer, 8.6 in axle Removal Procedure 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Remove the differential assembly. 3. Remove the drive pinion from the axle. 4. For the 8.6 inch axle, install the J 45871 (1) around the pinion bearing and the J 22912-01 (2) in the inverted position around the J 45871. 5. Press the bearing off of the pinion using the J 45871 and the J 22912-01. Page 11199 Hose/Line HVAC: Service and Repair Evaporator Tube Replacement (With RPO Code HP2) EVAPORATOR TUBE REPLACEMENT (W/ HP2) TOOLS REQUIRED J 39400-A Halogen Leak Detector REMOVAL PROCEDURE 1. Recover the refrigerant from the A/C system. Refer to Refrigerant Recovery and Recharging. 2. Remove the evaporator tube nut from the evaporator. 3. Remove the evaporator tube from the evaporator. 4. Loosen the nut from the evaporator tube fitting. 5. Remove the rear evaporator tube (3) from the vehicle. 6. Remove the air cleaner assembly. Page 15210 Refer to the table as a guide in selecting the correct test adapter for frontprobing connectors: Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure SCAN TOOL SNAPSHOT PROCEDURE Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: - Snapshot - taken from the Snapshot menu choice - Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information CKP System Variation Learn Procedure Crankshaft Position Sensor: Service and Repair CKP System Variation Learn Procedure CKP SYSTEM VARIATION LEARN PROCEDURE 1. Install a scan tool. 2. Monitor the powertrain control module (PCM) for DTCs with a scan tool. If other DTCs are set, except DTC P0315, refer to Diagnostic Trouble Code (DTC) List for the applicable DTC that set. 3. Select the crankshaft position (CKP) variation learn procedure with a scan tool. 4. The scan tool instructs you to perform the following: 4.1. Accelerate to wide open throttle (WOT). 4.2. Release throttle when fuel cut-off occurs. 4.3. Observe fuel cut-off for applicable engine. 4.4. Engine should not accelerate beyond calibrated RPM value. 4.5. Release throttle immediately if value is exceeded. 4.6. Block drive wheels. 4.7. Set parking brake. 4.8. DO NOT apply brake pedal. 4.9. Cycle ignition from OFF to ON. 4.10. Apply and hold brake pedal. 4.11. Start and idle engine. 4.12. Turn A/C OFF. 4.13. Vehicle must remain in Park or Neutral. 4.14. The scan tool monitors certain component signals to determine if all the conditions are met to continue with the procedure. The scan tool only displays the condition that inhibits the procedure. The scan tool monitors the following components: - CKP sensors activity-If there is a CKP sensor condition, refer to the applicable DTC that set. - Camshaft position (CMP) sensor activity-If there is a CMP sensor condition, refer to the applicable DTC that set. - Engine coolant temperature (ECT)-If the ECT is not warm enough, idle the engine until the engine coolant temperature reaches the correct temperature. 5. Enable the CKP system variation learn procedure with a scan tool. IMPORTANT: While the learn procedure is in progress, release the throttle immediately when the engine starts to decelerate. The engine control is returned to the operator and the engine responds to throttle position after the learn procedure is complete. 6. Accelerate to WOT. 7. Release when the fuel cut-off occurs. 8. Test in progress 9. The scan tool displays Learn Status: Learned this ignition. If the scan tool indicates that DTC P0315 ran and passed, the CKP variation learn procedure is complete. If the scan tool indicates DTC P0315 failed or did not run, refer to DTC P0315. If any other DTCs set, refer to Diagnostic Trouble Code (DTC) List for the applicable DTC that set. 10. Turn OFF the ignition for 30 seconds after the learn procedure is completed successfully. 11. The CKP system variation learn procedure is also required when the following service procedures have been performed, regardless of whether DTC P0315 is set: - A CKP sensor replacement - An engine replacement - A PCM replacement - A harmonic balancer replacement - A crankshaft replacement - Any engine repairs which disturb the CKP sensor relationship Page 9460 Cigar Lighter/Auxiliary Outlets Diagram 4 (1 Of 2) Page 9555 Fuse Block - Underhood C2 Part 4 Page 11373 Discharge Air Temperature Sensor / Switch: Service and Repair Air Temperature Sensor Replacement - Lower Right AIR TEMPERATURE SENSOR REPLACEMENT - LOWER RIGHT REMOVAL PROCEDURE 1. Remove the I/P lower closeout panel. 2. Remove the right floor duct. 3. Remove the center console. 4. Disconnect the electrical connector from the lower right air temperature sensor (1). 5. Remove the lower right air temperature sensor (1). INSTALLATION PROCEDURE 1. Install the lower right air temperature sensor (1). 2. Connect the electrical connector to the lower right air temperature sensor (1). 3. Install the center console. 4. Install the right floor duct. 5. Install the I/P lower closeout panel Page 9511 Fuse: Locations I/P Fuse Block Body Control Module (BCM) Page 8825 1. Install the generator bracket. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the generator bracket bolts. Tighten Tighten the bolts to 50 N.m (37 lb ft). 3. Install the power steering pump. 4. Install the generator. 5. Install the battery cable junction block bracket bolts. Tighten Tighten the bolts to 9 N.m (80 lb in). Page 9440 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Page 6121 Phase three will eliminate the oil pump body 0-ring seal groove and the 0-ring seal. Beginning March 2004, a new stamped carrier molded rubber seal (2) will be used to seal the pump assembly to the transmission case. The pump sealing surface is now the outer diameter of the pump and the inner diameter (1) of the transmission case bore. Unlike the current 0-ring seal, which is installed on the oil pump body, the new seal is installed after the pump assembly is properly positioned and torqued in place. Seating the seal is accomplished when the torque converter housing is installed, which presses the seal (3) into position between the pump and the case bore (1). As a result of the modified casting and the deeper pump bore machining, the area between the oil pan mounting surface and the pump bore has decreased. Because of the reduced material in this area (1) it is necessary to use the shorter oil pan attaching bolts (2). Early pan bolts (3), before November 2002, should not be used with the modified case design, since they are 1.0 mm (0.39 in) longer and could deform the chamfer surface (4). Service Information A/T - Harsh Light Throttle 1-2 Shift Valve Body: Customer Interest A/T - Harsh Light Throttle 1-2 Shift TECHNICAL Bulletin No.: 09-07-30-017A Date: May 20, 2010 Subject: Harsh 1-2 Shift at Light Throttle (Install New 1-2 Accumulator Valve Kit) Models: 2003-2007 Cadillac Escalade 2003-2007 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2003-2007 GMC Sierra, Yukon, Yukon XL All Equipped with 4.8L or 5.3L Engine (RPOs LR4, LM7, L59, LM4, LH6, L33) and 4L60E Automatic Transmission (RPO M30) Please Refer to GMVIS Supercede: This bulletin is being revised to update the Warranty Information. Please discard Corporate Bulletin Number 09-07-30-017 (Section 07 - Transmission/Transaxle). Condition Some customers may comment about a harsh 1-2 shift at light throttle. Cause This condition may be caused by the 2-4 band apply time extending through the 1-2 accumulator stroke. Correction 1. Verify the customer's concern. 2. Remove the valve body. Refer to Valve Body and Pressure Switch Removal in SI. 3. Remove the coiled spring pin (360). 4. Remove the 1-2 accumulator valve sleeve (372). 5. Remove the 1-2 accumulator valve (371) and the 1-2 accumulator valve spring (370). 6. Install the new 1-2 accumulator valve kit, GM P/N 24255821. 7. Install the valve body. Refer to Valve Body and Pressure Switch Installation in SI. Parts Information Warranty Information For vehicles repaired under warranty, use the table above. Page 5931 Park Neutral Position (PNP) Switch C175 Page 9458 Cigar Lighter/Auxiliary Outlets Diagram 2 Page 9641 Fuse Block: Service and Repair I/P Electrical Center or Junction Block Replacement - Right INSTRUMENT PANEL ELECTRICAL CENTER OR JUNCTION BLOCK REPLACEMENT - RIGHT REMOVAL PROCEDURE 1. Remove the right side end panel. 2. Push in the tabs in order to remove the fuse block. 3. Pull out the fuse block out of the I/P in order to remove the retaining bolt. 4. Loosen the bolt. 5. Insert a screw driver between the wire harness block and fuse block in order to separate. 6. Separate the fuse block from the I/P harness block. 7. Remove the I/P wiring harness block from the vehicle. INSTALLATION PROCEDURE 1. Install the fuse block to the I/P wire harness block. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the retaining bolt. Tighten Tighten the bolt to 6 N.m (53 lb in) 3. Install the fuse block to the I/P until it clicks in place. Page 12048 networks, and will not require an upgrade in connection with the cellular industry's transition to the digital network. In order to verify the type of OnStar(R) Hardware in a vehicle, type the VIN into the VIN look-up tool, which is available at the OnStar(R) Online Enrollment website within GM GlobalConnect (for U.S. dealers) or InfoNet (for Canadian dealers). Disclaimer Diagrams Page 6392 Steps 1-9 Test Description The numbers below refer to the step numbers on the diagnostic table. 2. This step tests for a faulty tow/haul switch. 3. This step tests for voltage input from the BCM to the tow/haul switch. 6. This step tests for ground integrity. Page 1076 Remote Programming Feature 1. Connect the scan tool to the vehicle. 2. Power-up the scan tool and select the Service Programming feature. 3. Select the appropriate vehicle. 4. Press the Request Info button on the scan tool. 5. Connect the scan tool to the computer station. 6. Follow the menu select items for reprogramming and provide information about the type of device you are programming and whether you are reprogramming or replacing the electronic control unit (ECU). 7. Select "vehicle" from the selection menu. 8. Select the module you wish to program. 9. Select "Normal" for Programming Type. 10. Select the applicable software calibrations. 11. Transfer data file to the scan tool. 12. Connect the scan tool to the vehicle. 13. Turn ON the ignition, with the engine OFF. 14. Select the Service Programming feature on the scan tool. 15. Press the Program button on the scan tool. Programming Using Scan Tool Pass-Through Connection 1. Connect the scan tool to vehicle and power it up. 2. Connect the computer station to the scan tool. 3. Select "PC Using Scan Tool Connection" from the programming menu on the computer station. 4. Follow the menu select items for reprogramming and provide information about the type of device you are programming and whether you are reprogramming or replacing the electronic control unit (ECU). 5. Select "vehicle" from the selection menu. 6. Select the module you wish to program. 7. Select "Normal" for Programming Type. 8. Select the applicable software calibrations. 9. Transfer data file to the scan tool. Page 10740 Please note the following when referring to a specific illustration: ^ When using the illustrations for back to back comparisons of two hubs, the most obvious differences are visible on the back side of the hubs. ^ The most common area of physical difference are in the shape of the four mounting bosses and their surrounds. Disclaimer Page 12966 Speaker - RF Door - With RPO Code UQ3/UQ7 Specifications Timing Cover: Specifications Oil pan to front cover bolts ................................................................................................................... .................................................... 25 Nm (18 ft. lbs.) Engine front cover bolts .................................... ........................................................................................................................................ 25 Nm (18 ft. lbs.) Page 6120 The first phase also machined a case chamfer leading into the pump bore (2). The chamfer is designed to help eliminate possible 0-ring seal damage during pump installation. Phase two modified the case casting and the chamfer into the pump bore. The casting change left additional material in the surrounding pump bore to allow deeper bore machining in order to create the necessary sealing surface for a new pump seal design. The leading surface into the pump bore was also machined with a modified chamfer (1). Page 13133 Page 11401 Solar Sensor: Service and Repair SUN LOAD SENSOR REPLACEMENT REMOVAL PROCEDURE 1. Remove the instrument panel (I/P) upper trim panel. 2. Remove the sun load sensor (2) from the upper trim panel. 3. Disconnect the electrical connector. INSTALLATION PROCEDURE 1. Connect the electrical connector. 2. Install the sun load sensor (2) to the upper trim panel. 3. Install the I/P upper trim panel- Page 9104 4. Push on the top part until it clicks in place. 5. Connect the harness to the front of the junction block. 6. Install the cover to the junction block until it clicks in place. 7. Hand tighten the retaining nut until seated. Page 2104 Fuel Pressure Release: Service and Repair Fuel Pressure Relief Procedure FUEL PRESSURE RELIEF PROCEDURE TOOLS REQUIRED J 34730-1A Fuel Pressure Gage CAUTION: Relieve the fuel system pressure before servicing fuel system components in order to reduce the risk of fire and personal injury. After relieving the system pressure, a small amount of fuel may be released when servicing the fuel lines or connections. In order to reduce the chance of personal injury, cover the regulator and the fuel line fittings with a shop towel before disconnecting. This will catch any fuel that may leak out. Place the towel in an approved container when the disconnection is complete. 1. Disconnect the negative battery cable. 2. Install the J 34730-1A. 3. Loosen the fuel fill cap in order to relieve fuel tank vapor pressure. 4. Open the valve on J 34730-1A in order to bleed the system pressure. The fuel connections are now safe for servicing. 5. Drain any fuel remaining in the gage into an approved container. 6. Once the system pressure is completely relieved, remove the J 34730-1A. Page 10211 1. Install the hex lock nut (1) onto the pinion while holding the valve stub shaft. ^ Tighten the nut to 30 Nm (22 ft. lbs.). Notice: Refer to Fastener Notice in Service Precautions. 2. Install the dust cover (2) to the rack and pinion gear assembly. 3. Install the stub shaft bearing annulus assembly (1) onto the valve stub shaft (2). 4. Install J 29810 onto the valve stub shaft. 5. Lubricate the stub shaft seal (3) with grease. 6. Install the stub shaft seal (3) into the rack and pinion gear assembly. 7. Install the retaining ring (2) into the groove in the rack and pinion gear assembly. 8. Install the spool shaft boot (1) onto the rack and pinion gear assembly. 9. Lubricate the following items with lithium base grease: 1. The rack bearing (2) 2. The adjuster spring (3) 3. The adjuster plug (4) 10. Install the following items into the gear assembly: 1. The rack bearing (2) 2. The adjuster spring (3) Page 12191 DTC B2476 04: Cellular Phone Select Service Switch Open Circuit DTC B2476 59: Cellular Phone Select Service Switch Stuck Button DTC B2482 00: Cellular Phone Select Service Switch Range/Performance Circuit Short to Ground Open / High Resistance Short to Voltage Signal Performance Circuit/System Description The OnStar(R) button assembly consists of 3 buttons, Call/Answer, OnStar(R) Call Center, and OnStar(R) Emergency. The vehicle communication interface module (VCIM) supplies the OnStar(R) button assembly with 10 volts via the keypad supply voltage circuit. Each of the buttons, when pressed, completes the circuit across a resistor allowing a specific voltage to be returned to the VCIM over the keypad signal circuit. Depending upon the voltage range returned, the VCIM is able to identify which button has been activated. Conditions for Running the DTCs The ignition is ON. System voltage is between 9 - 16 volts. Conditions for Setting the DTCs B2476 04: The VCIM detects an open/high resistance on the keypad supply voltage circuit. B2482 and B2476 59: The VCIM detects a valid signal on the keypad signal circuit for more than 15 seconds. If one of the OnStar(R) buttons is held or stuck for 15 seconds or more, the VCIM will set these DTCs. Action Taken When the DTCs Set The OnStar(R) status LED turns red. No calls can be placed. The VCIM will ignore all inputs from the OnStar® button assembly. Conditions for Clearing the DTCs The condition responsible for setting the DTC no longer exists. A history DTC will clear once 100 consecutive malfunction-free ignition cycles have occurred. Page 2403 Page 14386 Control Module References Part 5 Interior - Erratic Memory Seat Operation Power Seat Control Module: All Technical Service Bulletins Interior - Erratic Memory Seat Operation Bulletin No.: 04-08-50-016C Date: August 12, 2005 TECHNICAL Subject: Memory Seat May Not Return to Requested Position (Reprogram Driver Seat Module) Models: 2003-2005 Cadillac Escalade, Escalade ESV, Escalade EXT 2003-2005 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2003-2005 GMC Sierra, Yukon, Yukon XL, Yukon Denali All with Seat FRT, Individual (Non BKT) (RPO AN3) 2003-2005 HUMMER H2 with Seat, Front Bucket Deluxe (RPO AR9) Supercede: This bulletin is being revised to update the correction information. Please discard Corporate Bulletin Number 04-08-50-016B (Section 08 - Body and Accessories). Condition Some customers may comment that with repeated cycling of the memory seat between the "exit" and one of the "presets", the position of the seat may "creep" forward or rearward out of expected adjustment. Cause There is a coding deficiency in the software for the memory seat module. Correction Technicians are to reprogram the driver seat module with an updated software calibration. The previous bulletin stated to use a service calibration that was released with TIS satellite data update version 4.5. Feedback has proved that calibration to be ineffective in eliminating the memory seat creep condition. An updated service calibration was released with TIS satellite data update version 6.5 available June 13, 2005. This new calibration has additional memory seat creep protection. As always, make sure your Tech 2(R) is updated with the latest software version. Important: After programming is complete, move the seat all the way rearward and down, then bump the seat slightly forward and up. This position will be just off the end of travel hard stops. Reset both memory seat exit positions at this position. Having the seat set at just off the hard stops will aid in reducing the creep condition. Warranty Information Page 6943 12. Pack the CV joint boot (1) and the CV joint assembly with the grease supplied in the kit. The amount of grease supplied in this kit has been pre-measured for this application. 13. Place the new small boot clamp (2) onto the CV joint seal (1). 14. Slide the CV joint boot (1) onto the halfshaft bar. 15. Position the small end of the CV joint boot (1) into the joint boot groove (3) on the halfshaft bar. Notice: Refer to Fastener Notice in the Preface. 16. Secure the small boot clamp (1) using J35910 (or equivalent), a breaker bar, and a torque wrench. Tighten the small clamp (1) to 136 Nm (100 lb ft). 17. Check the gap dimension on the clamp ear. Continue tightening until the gap dimension is reacted. Page 11084 Control Module HVAC: Diagrams HVAC System - Automatic HVAC Control Module - C1 Part 1 Page 2150 Steps 1 - 6 The number(s) below refer to the step(s) in the diagnostic table. 2. This inspection is to verify that the drive belt(s) is correctly installed on all of the accessory drive pulleys. Wear on the drive belt(s) may be caused by mis-positioning the drive belt(s) by one or more grooves on a pulley(s). 3. The installation of a drive belt(s) that is too wide or too narrow will cause wear on the drive belt(s). The drive belt(s) ribs should match all of the grooves on the pulleys. 4. This inspection is to verify that the drive belt(s) is not contacting any part of the engine or body while the engine is operating. There should be sufficient clearance when the accessory drive components load varies. The drive belt(s) should not come in contact with an engine or a body component when snapping the throttle. Drive Belt Falls Off Drive Belt Falls Off Diagnosis Diagnostic Aids If the drive belt(s) repeatedly falls off the accessory drive pulley(s), this may be caused by a pulley misalignment. An extra load that is quickly applied or released by an accessory drive component may also cause the drive belt(s) to fall off. Verify that the accessory drive component(s) are operating properly. If the drive belt(s) is the incorrect length, the drive belt tensioner may not maintain the proper tension on the drive belt(s). Test Description Page 8556 visible in the clear adapter tube). If fluid is seen coming out of the inlet port adapter up to 65 Nm (48 lb-ft) maximum torque, the hydro-boost booster assembly is "OK", Proceed to Step 19. A. If NO fluid is seen exiting from the inlet port adapter, complete Steps 19-27 and then repeat Steps 1-18. B. If no fluid is visible from the second evaluation, replace the hydro-boost unit. Proceed to the appropriate procedure found in this bulletin. 19. Loosen the clamp bolt, remove the clamp containment bolt, and remove the accumulator pressure clamp. Remove the inlet port adapter from the supply port of the booster. Wipe the excess power steering fluid off of the adapter with a clean, lint-free shop cloth. Store the adapter in a clean location, such as a plastic bag. 20. Reinstall the supply hose/tube to the booster. Tighten Tighten to 28 N.m (21 lb-ft). 21. Clean any spilled fluid from the outside of the booster. 22. For Express/Savana only: ^ Connect the reservoir outlet hose to the booster unit. Keeping the hose end higher than reservoir, reposition the reservoir onto the mounting studs. A. Install the remote power steering reservoir mounting nuts. Tighten Tighten to 7 Nm (58 lb in). 23. Start the engine and run at idle. Depress the brake pedal 5 times. Turn the steering wheel to the "steering lock" position. Hold for 1-2 seconds. Check to see if there is any leakage from the ports/fittings. 24. Turn the engine off. 25. If leaks were observed, re-check that the fittings are at the recommended torque values. Repeat Steps 17 and 18. 26. Check the power steering reservoir fluid level, add fluid if necessary. 27. Close the hood. Hydro-Boost(R) Replacement - Avalanche, Express, Savana, Silverado, Sierra, Suburban, Yukon XL Tools Required ^ J 35555 Metal Mityvac ^ J 43485 Power Steering Bleeder Adapter Removal 1. Apply the park brake and block the wheels. Page 15222 6. Use fingers to squeeze the 2 locking legs of the cover. 7. Apply pressure and gently rock the cover until one locking leg is unseated. 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. Page 2992 It will be necessary to reprogram the PCM for speedometer accuracy. Contact Techline to obtain a VCI number. Then refer to the table for the appropriate calibration part number based on the model year and axle ratio. Calibration Information Documentation Make a copy of the "Accessory Wheel and Tire Information Form" included in this bulletin. Page 12965 Speaker - RF Door - With RPO Code UQ5 Page 1913 Vehicle Speed Sensor (VSS) Tow/Haul Switch Location Page 15701 Marker Lamp Bulb: Service and Repair Marker Lamp Bulb Replacement - Roof (Center) MARKER LAMP BULB REPLACEMENT - ROOF (CENTER) REMOVAL PROCEDURE 1. Remove the screws from the roof marker lamp lens. 2. Remove the roof marker lamp lens. 3. Remove the bulb. INSTALLATION PROCEDURE 1. In order to install the bulb, push in the bulb until the bulb is seated. 2. Install the roof marker lamp lens. NOTE: Refer to Fastener Notice in Service Precautions. 3. Install the screws to the roof marker lamp lens. Tighten Tighten the screws to 1.9 N.m (17 lb ft). Page 4342 Body Control Module (BCM) - C6 Part 2 Page 8984 Application Tabel Part 2 Location View Page 3846 Electronic Throttle Control Module: Service and Repair THROTTLE ACTUATOR CONTROL (TAC) MODULE REPLACEMENT REMOVAL PROCEDURE 1. Disconnect the instrument panel (I/P) harness electrical connector (2). 2. Release the red connector position assurance (CPA) retainer. 3. Disconnect the engine wiring harness electrical connector (1). 4. Remove the throttle actuator control (TAC) module nuts. 5. Remove the TAC module. INSTALLATION PROCEDURE Page 8438 16. Adjust the park brake cable. Refer to Park Brake Adjustment See: Adjustments. Page 9224 C275 Steering Column Harness To Steering Wheel Module Coil (With RPO Code HVY) Page 4140 1. Install the accelerator pedal assembly. NOTE: Refer to the Fastener Notice in Service Precautions. 2. Install the accelerator pedal nuts. Tighten Tighten the nuts to 20 N.m (15 lb ft). 3. Connect the APP sensor electrical connector. 4. Reposition the carpet. 5. Connect a scan tool in order to test for proper throttle-opening and throttle-closing range. 6. Operate the accelerator pedal and monitor the throttle angles. The accelerator pedal should operate freely, without binding, between a closed throttle, and a wide open throttle (WOT). 7. Verify that the vehicle meets the following conditions: - The vehicle is not in a reduced engine power mode. - The ignition is ON. - The engine is OFF. 8. Inspect the carpet fit under the accelerator pedal. Page 9858 Relay Box: Service and Repair I/P Electrical Center or Junction Block Replacement - Right INSTRUMENT PANEL ELECTRICAL CENTER OR JUNCTION BLOCK REPLACEMENT - RIGHT REMOVAL PROCEDURE 1. Remove the right side end panel. 2. Push in the tabs in order to remove the fuse block. 3. Pull out the fuse block out of the I/P in order to remove the retaining bolt. 4. Loosen the bolt. 5. Insert a screw driver between the wire harness block and fuse block in order to separate. 6. Separate the fuse block from the I/P harness block. 7. Remove the I/P wiring harness block from the vehicle. INSTALLATION PROCEDURE 1. Install the fuse block to the I/P wire harness block. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the retaining bolt. Tighten Tighten the bolt to 6 N.m (53 lb in) 3. Install the fuse block to the I/P until it clicks in place. Page 14866 Seat Lumbar Motor/Position Sensor - Driver (With RPO Code AN3) Page 9278 Junction Block - I/P Wire Entry Part 2 Page 2137 Drive Belt: Description and Operation Drive Belt System Description The drive belt system consists of the following components: ^ The drive belt ^ The drive belt tensioner ^ The drive belt idler pulley ^ The crankshaft balancer pulley ^ The accessory drive component mounting brackets ^ The accessory drive components ^ The power steering pump, if belt driven ^ The generator ^ The A/C compressor, if equipped ^ The engine cooling fan, if belt driven ^ The water pump, if belt driven ^ The vacuum pump, if equipped ^ The air compressor, if equipped The drive belt system may use 1 belt or 2 belts. The drive belt is thin so that it can bend backwards and has several ribs to match the grooves in the pulleys. There also may be a V-belt style belt used to drive certain accessory drive components. The drive belts are made of different types of rubbers - chloroprene or EPDM - and have different layers or plys containing either fiber cloth or cords for reinforcement. Both sides of the drive belt may be used to drive the different accessory drive components. When the back side of the drive belt is used to drive a pulley, the pulley is smooth. The drive belt is pulled by the crankshaft balancer pulley across the accessory drive component pulleys. The spring loaded drive belt tensioner keeps constant tension on the drive belt to prevent the drive belt from slipping. The drive belt tensioner arm will move when loads are applied to the drive belt by the accessory drive components and the crankshaft. The drive belt system may have an idler pulley, which is used to add wrap to the adjacent pulleys. Some systems use an idler pulley in place of an accessory drive component when the vehicle is not equipped with the accessory. Heated Oxygen Sensor (HO2S) Replacement Bank 1 Sensor 1 Oxygen Sensor: Service and Repair Heated Oxygen Sensor (HO2S) Replacement Bank 1 Sensor 1 HEATED OXYGEN SENSOR (HO2S) REPLACEMENT BANK 1 SENSOR 1 REMOVAL PROCEDURE 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. If necessary, unbolt the front propeller shaft from the front differential. Refer to Propeller Shaft Replacement - Front in Propeller Shaft. 3. Disconnect the connector position assurance (CPA) retainer. NOTE: Refer to Heated Oxygen and Oxygen Sensor Notice in Service Precautions. 4. Remove the heated oxygen sensor (HO2S) electrical connector from the fuel line clip. 5. If equipped with a 4.8L or 5.3L engine, disconnect the HO2S electrical connector (1). 6. If equipped with a 6.0L engine, disconnect the HO2S electrical connector (1). Interior - Elimination Of Unwanted Odors Seat Cover: All Technical Service Bulletins Interior - Elimination Of Unwanted Odors INFORMATION Bulletin No.: 00-00-89-027E Date: September 29, 2008 Subject: Eliminating Unwanted Odors in Vehicles Models: 2009 and Prior GM Passenger Cars and Trucks (including Saturn) 2009 and Prior HUMMER H2, H3 Vehicles 2009 and Prior Saab 9-7X Supercede: This bulletin is being revised to add model years and refine the instructions. Please discard Corporate Bulletin Number 00-00-89-027D (Section 00 - General Information). Vehicle Odor Elimination General Motors offers a product that may control or eliminate odors in the interior and luggage compartment areas of GM vehicles. GM Vehicle Care Odor Eliminator is a non-toxic, biodegradable odor remover. This odorless product has been shown to greatly reduce or remove objectionable smells of mold and mildew resulting from vehicle water leaks (as well as customer created odors, i.e. smoke). You may use GM Vehicle Care Odor Eliminator on fabrics, vinyl, leather, carpet and sound deadening materials. It may also be induced into HVAC modules and instrument panel ducts (for the control of non-bacterial related odors). Important: This product leaves no residual scent and should not be sold as or considered an air freshener. Product action may result in the permanent elimination of an odor and may be preferable to customers with allergies who are sensitive to perfumes. How to Use This Product GM Vehicle Care Odor Eliminator may be sprayed on in a ready-to-use formula or used in steam cleaners as an additive with carpet shampoo. This water-based, odorless product is safe for all vehicle interiors. Do not wet or soak any interior surface that plain water would cause to deteriorate, as this product will have the same effect. Also avoid letting this product come into contact with vinegar or any acidic substance. Acid-based products will hamper the effectiveness of, or render GM Vehicle Care Odor Eliminator inert. Note: Complete eight page treatment sheets are enclosed within each case of GM Vehicle Care Odor Eliminator. These treatment instructions range from simple vehicle odor elimination to full step by step procedures for odor removal from water leaks. If lost, contact 800-977-4145 to get a replacement set faxed or e-mailed to your dealership. Instructions and cautions are printed on the bottle, but additional help is available. If you encounter a difficult to eliminate or reoccurring odor, you may call 1-800-955-8591 (in Canada, 1-800-977-4145) to obtain additional information and usage suggestions. Important: This product may effectively remove odors when directly contacting the odor source. It should be used in conjunction with diagnostic procedures (in cases such as a water leak) to first eliminate the root cause of the odor, and then the residual odor to permanently correct the vehicle condition. Vehicle Waterleak Odor Elimination STEP ONE: Confirm that all water leaks have been repaired. Determine what areas of the vehicle were water soaked or wet. Components with visible mold/mildew staining should be replaced. Isolate the odor source inside the vehicle. Often an odor can be isolated to an area or component of the vehicle interior by careful evaluation. Odor evaluation may need to be performed by multiple persons. Another method of isolating an odor source is to remove and segregate interior trim and components. Plastic sheeting or drop cloths can be used to confine seats, headliners, etc. to assist in evaluation and diagnoses. If appropriate the vehicle and interior trim should be evaluated separately to determine if the odor stays with the vehicle or the interior components. Odors that stay with the vehicle may be isolated to insulating and sound deadening materials (i.e. water leak at the windshield or standing water in the front foot well area caused mold/mildew to form on the bulkhead or kick panel sound deadening pads. If the interior is removed the floor pan and primed/painted surfaces should be treated with bleach/soap solution, rinsed with clean water and dried. Interior surfaces should then be treated with GM Vehicle Care Odor Eliminator product before reinstalling carpet or reassembling. Page 1165 Seat Adjuster Switch - Driver (With RPO Code AN3) Part 2 Page 5220 Important: Clean the fuel filler cap and surrounding areas prior to removing the fuel filler housing in order to avoid possible contamination. 1. Remove the fuel fill cap. 2. Remove the fuel tank filler housing to fuel tank fill pipe screws. 3. Remove the fuel tank filler housing to body TORX® screws (1) and retainer (2). Important: It is NOT necessary to raise the vehicle in order to remove and/or install the fuel filler housing. 4. Remove the fuel filler housing from under the vehicle. 5. Install the new fuel filler housing, P/N 15289921, from under the vehicle. 6. Install the fuel tank filler housing to fuel tank fill pipe screws. Tighten Tighten the screws to 2.3 N.m (20 lb in). 7. Install the fuel tank filler housing to body TORX(R) screws and retainer. Tighten Tighten the screws to 2.3 N.m (20 lb in). Important: The new fuel cap, P/N 15225005 "tether strap" installs in the elongated hole in the fuel filler housing. DO NOT install the new fuel cap tether in the round hole in the fuel filler housing. Page 15233 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-8 (12085115) crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-8 (12085115) until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes SPLICING INLINE HARNESS DIODES Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate Service Data wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. 9. Tape the diode to the harness or connector using electrical tape. Page 4044 Disclaimer Air Distributor Duct Replacement Air Duct: Service and Repair Air Distributor Duct Replacement AIR DISTRIBUTOR DUCT REPLACEMENT REMOVAL PROCEDURE 1. Remove the IP carrier. 2. Remove the air distribution duct retaining screws. 3. Remove the air distribution duct. INSTALLATION PROCEDURE 1. Install the air distribution duct. 2. Install the air distribution duct retaining screws. NOTE: Refer to Fastener Notice in Service Precautions. 3. Tighten the screws. Tighten Tighten the screws to 1.6 N.m (14 lb in). 4. Install the IP carrier. Page 8870 Electrical Symbols Part 9 Page 15987 Steps 3-7 Page 3894 Tighten Tighten the bolts to 8 N.m (71 lb in). 5. Install the PCM cover. 6. If equipped with RPO NYS, install the harness ground clip to the PCM cover. 7. Connect the negative battery cable. 8. If a NEW PCM was installed, program the PCM. Refer to Service Programming System (SPS) in Programming. See: Testing and Inspection/Programming and Relearning 9. Perform the crankshaft position (CKP) system variation learn procedure. Refer to CKP System Variation Learn Procedure. See: Testing and Inspection/Programming and Relearning 10. If necessary, reset the engine oil life monitor. Refer to GM Oil Life System - Resetting in Maintenance and Lubrication. Page 13271 Important: The optic cable must not be bent with a radius less than 25 mm (1 in). 6.12. Place the optic cable in the wiring harness channels on the right-hand side. Thread through the existing cable ties (C) if possible, otherwise, secure with a cable tie to the existing one. Close the cover on the channels. Ensure the catches lock. 6.13. Secure the optic cable along the right-hand rear wheel housing, next to the ordinary wiring harness securing points and by the SRS unit (D). 6.14. Thread the optic cable up next to the safety belt by the old optic cable and place on the parcel shelf. 6.15. Unplug the connectors (E) from the OnStar(R) control modules. 6.16. Remove the console (F) together with the OnStar(R) control modules. Page 9088 Fuse Block: Application and ID Junction Block - I/P Location View Location View Page 5965 2. Install the 2-3 shift solenoid (367A) and the 2-3 shift solenoid retainer (395). 3. Install the 1-2 shift solenoid (267A) and the 1-2 shift solenoid retainer (395). 4. Important: When installing the pressure control solenoid, the electrical connector (2) must be in the position shown. Install the pressure control solenoid (377). 5. Notice: Refer to Fastener Notice in Service Precautions. Install the pressure control solenoid retainer (378) and retainer bolt (364A). ^ Tighten the bolt to 11 Nm (97 inch lbs.). Surge Tank Replacement Coolant Reservoir: Service and Repair Surge Tank Replacement Surge Tank Replacement Removal Procedure 1. Drain the cooling system. 2. Remove the air cleaner assembly. 3. Remove the surge tank overflow hose from the surge tank. 4. Disconnect the coolant level sensor electrical connector (3). 5. Reposition the surge tank inlet and outlet hose clamps. 6. If equipped with a 4.3 L, 4.8 L, 5.3 L, 6.0 L, or 8.1 L engine, remove the surge tank inlet (1) and outlet (2) hoses from the surge tank. TPMS System - Service And Re-Learning Sensor IDs Tire Pressure Sensor: Technical Service Bulletins TPMS System - Service And Re-Learning Sensor IDs INFORMATION Bulletin No.: 10-03-16-001 Date: July 19, 2010 Subject: TPMS System Service and Re-Learning Sensor IDs Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks 2010 and Prior HUMMER H2 2009 and Prior HUMMER H3 2010 and Prior Saturn Models 2009 and Prior Saab 9-7X with Wheel-Mounted Tire Pressure Sensors In the event that the spare tire, which is normally not equipped with a tire pressure monitor (TPM) sensor, is installed in place of one of the road tires and the vehicle is driven above 40 km/h (25 mph) for 20 minutes or more, the TPM indicator icon on the instrument panel cluster (IPC) will flash for approximately one minute and then remain on steady each time the ignition is turned ON, indicating a diagnostic trouble code (DTC) has been set. The driver information center (DIC), if equipped, will also display a SERVICE TIRE MONITOR type message. When the road tire is repaired and reinstalled in the original location, the TPM indicator icon illumination and DIC message may remain displayed until the DTC is cleared. To ensure that the TPM indicator and the DIC message are cleared after service, it is necessary to clear any TPM DTCs using a scan tool. If a scan tool is unavailable, performing the TPM relearn procedure using a TPM diagnostic tool will provide the same results. It is advised to perform the relearn procedure away from other vehicles to prevent picking up a stray sensor signal. If one or more of the TPM sensors are missing or damaged and have been replaced, then the relearn procedure must be performed. Disclaimer Page 12798 Action Taken When the DTCs Sets The module suspends all message transmission. The module uses default values for all parameters received on the serial data circuits. The module inhibits the setting of all other communication DTCs. Conditions for Clearing the DTC A current DTC clears when the malfunction is no longer present. A history DTC clears when the module ignition cycle counter reaches the reset threshold of 50, without a repeat of the malfunction. Circuit/System Verification Refer to Data Link References to determine which serial data system is used for a specific module. This DTC cannot be retrieved with a current status. Diagnosis is accomplished using the following symptom procedures: Scan Tool Does Not Communicate with High Speed GMLAN Device in SI. OR Scan Tool Does Not Communicate with Low Speed GMLAN Device in SI. DTC U0140 - U0184 Circuit Description Modules connected to the GMLAN serial data circuit monitor for serial data communications during normal vehicle operation. Operating information and commands are exchanged among the modules. In addition to this, Node Alive messages are transmitted by each module on the GMLAN serial data circuit. When the module detects one of the following conditions on the GMLAN serial data circuit, a DTC will set. Operating information and commands are exchanged among the modules. In addition to this, Node Alive messages are transmitted by each module on the GMLAN serial data circuit. Conditions for Setting the DTCs Diagnostic algorithms are designed so that a single point failure within a particular node shall result in a single DTC/FTB combination being set. Any recognized faults shall generate one DTC. Recognized faults may include but are not limited to the following: ^ Open or shorted condition on an I/O Circuit outside of normal operation of that circuit. ^ Erratic signal of a circuit, outside of normal operation, which can be readily and repeatedly recognized as erratic. ^ A condition, outside of normal operation, which causes a customer perception of a performance problem. ^ A condition whether hardware or data link error, which causes a device to operate in a default or fail soft mode. ^ A condition which changes or limits system performance. ^ Network supervision/signal supervision errors. ^ ECU Internal errors. ^ Criteria determined by legislation. An initialization or shutdown self-test shall be performed and may include but is not limited to the following: ^ RAM check ^ ROM/EEPROM/Flash check Page 16202 You MUST use a silver-bearing solder to make the solder joint. DO NOT attempt this repair with conventional tin/lead alloy solders. Most suppliers have this type of solder available and it is available nationally at Radio Shack(R)*. It is sold in several diameters and either are acceptable for this repair. 5. For this step, it is permitted that two technicians be used if required. Heat the new connector on the surface of the buss bar that is to be soldered. Long nose pliers are suggested to hold the electrical connector and the defroster tab in place. Keep the solder ready and begin flowing out the solder as soon as the melting temperature has been reached. Tip If a single technician is attempting this repair, it is beneficial to wrap one turn of the solder around the new contacts base. In this manner, as the melting point of the solder is reached, a layer is deposited on the bottom side of the contact. Important Try to align the new contact so that it is positioned with the same orientation as the original contact. 6. The above illustrates an ideal finished solder joint. Additional stray solder will not harm the performance of the bond; however, while it is unlikely that customers may refer to the appearance of the rear window defroster and its components as a positive styling feature of the vehicle interior, it is easy to elicit the opposite reaction due to a poor cosmetic application. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Parts Information Acrysol(TM) can be ordered directly from Kent Automotive at 1-800-654-6333 (in Canada, 1-800-563-1717). Radio Shack(R) products can be found nationally at retail locations, www.radioshack.com, or at 1-800-843-7422. All other parts can be ordered through GMSPO or SSPO. Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use: Warranty Information (Saab U.S. Models) Page 7433 2. Connect the speed sensor electrical connector. 3. Lower the vehicle. Page 10818 HVAC Module Assembly - Bottom Transfer Case - NVG 149-NP3 Speed Sensor: Service and Repair Transfer Case - NVG 149-NP3 Transfer Case Speed Sensor Replacement Removal Procedure 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. Disconnect the speed sensor electrical connector (4). 3. Remove the speed sensor. Installation Procedure 1. Install the speed sensor. ^ Tighten the sensor to 15 Nm (11 ft. lbs.). Notice: Refer to Fastener Notice in Service Precautions. Service and Repair Front Crankshaft Seal: Service and Repair Crankshaft Front Oil Seal Replacement ^ Tools Required J 41478 Crankshaft Front Oil Seal Installer Removal Procedure 1. Remove the crankshaft balancer. 2. Remove the crankshaft oil seal (1) from the front cover. Installation Procedure Important: ^ Do not lubricate the oil seal sealing surface. ^ Do not reuse the crankshaft oil seal. 1. Lubricate the outer edge of the oil seal (1) with clean engine oil. 2. Lubricate the front cover oil seal bore with clean engine oil. 3. Install the crankshaft front oil seal onto the J 41478 guide. 4. Install the J 41478 threaded rod (with nut, washer, guide, and oil seal) into the end of the crankshaft. 5. Use the J 41478 in order to install the oil seal into the cover bore. 6. Use a wrench and hold the hex on the installer bolt. 7. Use a second wrench and rotate the installer nut clockwise until the seal bottoms in the cover bore. 8. Remove the J 41478. 9. Inspect the oil seal for proper installation.The oil seal should be installed evenly and completely into the front cover bore. Page 9631 Junction Block - I/P Wire Entry Part 3 Page 6416 Vehicle Speed Sensor (VSS) Tow/Haul Switch Location Page 6532 1. Install the auxiliary oil cooler to the vehicle. 2. Notice: Refer to Fastener Notice in Service Precautions. Install the bolts (1) and the push pins (2) that retain the auxiliary oil cooler to the radiator brace. ^ Tighten the bolts to 12 Nm (9 ft. lbs.). 3. Connect the transmission oil cooler lines to the auxiliary cooler. 4. Install the front grill assembly. Page 12368 6. Install the overhead console retaining screw. Tighten Tighten the overhead console retaining screw to 2 N.m (18 lb in). Page 15905 Vanity Lamp: Description and Operation VANITY LAMPS The inadvertent power supply voltage circuit of the BCM provides battery positive voltage to each vanity mirror lamp. When the vanity mirror cover on the sunshade is opened, a switch closes to provide a ground circuit and the vanity lamp illuminates. In the event that any of these lamps were to remain illuminated for a period of more than 10 minutes with the ignition switch in the OFF position, the BCM will deactivate the inadvertent power supply voltage circuit to prevent a total battery discharge condition. Ground is provided to the vanity lamps at G203. Page 1535 1. Install the accelerator pedal assembly. NOTE: Refer to the Fastener Notice in Service Precautions. 2. Install the accelerator pedal nuts. Tighten Tighten the nuts to 20 N.m (15 lb ft). 3. Connect the APP sensor electrical connector. 4. Reposition the carpet. 5. Connect a scan tool in order to test for proper throttle-opening and throttle-closing range. 6. Operate the accelerator pedal and monitor the throttle angles. The accelerator pedal should operate freely, without binding, between a closed throttle, and a wide open throttle (WOT). 7. Verify that the vehicle meets the following conditions: - The vehicle is not in a reduced engine power mode. - The ignition is ON. - The engine is OFF. 8. Inspect the carpet fit under the accelerator pedal. Electrical - Instrument Panel & General Wiring Repair Wiring Harness: All Technical Service Bulletins Electrical - Instrument Panel & General Wiring Repair Bulletin No.: 06-08-45-004 Date: May 02, 2006 INFORMATION Subject: Instrument Panel (I/P), Body and General Wiring Harness Repair Models: 2007 and Prior GM Cars and Trucks 2003-2007 HUMMER H2 2006-2007 HUMMER H3 Important: A part restriction has been implemented on all Body and I/P harnesses and is being administered by the PQC. If a body or I/P harness replacement is required, it can take 12-28 weeks for a harness to be built and delivered to a dealer. The dealer technician is expected to repair any harness damage as the first and best choice before replacing a harness. In an effort to standardize repair practices, General Motors is requiring that all wiring harnesses be repaired instead of replaced. If there is a question concerning which connector and/or terminal you are working on, refer to the information in the appropriate Connector End Views in SI. The Instruction Manual J 38125-620, which is sent with each new update of the J 38125 Terminal Repair Kit, also has terminal crimping and terminal remove information. Important: There are some parts in the J 38125 Terminal Repair Kit (i.e. SIR connector CPAs and heat shrink tube (used in high heat area pigtail replacement) and some TPAs that are not available from GMSPO. It is vitally important that each update to the J 38125 Terminal Repair Kit be done as soon as it arrives at the dealer. Utilize the Terminal Repair Kit (J 38125) to achieve an effective wiring repair. The Terminal Repair Kit has been an essential tool for all GM Dealers since 1987. Replacement terminals and tools for this kit are available through SPX/Kent Moore. Refer to Corporate Bulletin Number 06-08-45-001 for more information. The Instruction Manual J 38125-620, which is sent with each new update to the J 38125 Terminal Repair Kit, also has terminal crimping and terminal removal information. U.S. Dealers Only - Training courses (including Tech Assists, Emerging Issues, Web, IDL and Hands-on) are available through the GM Training website. Refer to Resources and then Training Materials for a complete list of available courses. Canadian Dealers Only - Refer to the Training section of GM infoNet for a complete list of available courses and a copy of the J 38125 Terminal Repair Kit Instruction Manual. Wiring repair information is also available in Service Information (SI). The Wiring Repair section contains information for the following types of wiring repairs: - Testing for intermittent conditions and poor conditions - Flat wire repairs - GMLAN wiring repairs - High temperature wiring repairs - Splicing copper wire using splice clips - Splicing copper wire using splice sleeves - Splicing twisted or shielded cable - Splicing inline harness diodes Brakes - ABS Lamp ON/DTC's C0265/C0201/U1041 Set Electronic Brake Control Module: Customer Interest Brakes - ABS Lamp ON/DTC's C0265/C0201/U1041 Set TECHNICAL Bulletin No.: 04-05-25-002E Date: March 11, 2009 Subject: ABS Light On, DTCs C0265, C0201, U1041 Set and/or Loss of Communication with Brake Module (Reground EBCM Ground) Models Supercede: This bulletin is being revised to add step 2 to the procedure and update the Parts and Warranty Information. Please discard Corporate Bulletin Number 04-05-25-002D (Section 05 - Brakes). Condition Some customers may comment that the ABS light is on. Upon further inspection, DTCs C0265 and C0201 may be set in the brake module. It is also possible for DTC U1041 to set in other modules. There may also be a loss of communication with the brake module. Cause A poor connection at the EBCM ground is causing unnecessary replacement of brake modules. Important: The EBCM ground is different for each application. Refer to the list below for the proper ground reference: ^ Midsize Utilities = Ground 304 ^ SSR = Ground 400 ^ Fullsize Trucks and Utilities = Ground 110 Correction Important: Do not replace the brake module to correct this condition. Perform the following repair before further diagnosis of the EBCM. Perform the following steps to improve the connection of the EBCM Ground: 1. Remove the EBCM Ground. The EBCM Ground is located on the frame beneath the driver's side door. If multiple grounds are found in this location, the EBCM ground can be identified as the heavy (12-gauge) wire. 2. If the original fastener has a welded on nut, remove the nut from the frame, and if required, enlarge the bolt hole to accommodate the new bolt and nut. 3. Clean the area, front and back, using a tool such as a *3M(TM) Scotch-Brite Roloc disc or equivalent. Page 8285 Brake Caliper: Service and Repair Brake Caliper Replacement - Rear Brake Caliper Replacement - Rear (1500 Series) Caution: Refer to Brake Dust Caution in Service Precautions. Caution: Refer to Brake Fluid Irritant Caution in Service Precautions. Removal Procedure 1. Inspect the fluid level in the brake master cylinder reservoir. 2. If the brake fluid level is midway between the maximum-full point and the minimum allowable level, no brake fluid needs to be removed from the reservoir before proceeding. 3. If the brake fluid level is higher than midway between the maximum-full point and the minimum allowable level, remove brake fluid to the midway point before proceeding. 4. Raise and support the vehicle. Refer Vehicle Lifting 5. Remove the tire and wheel assembly. 6. Install a C-clamp over the body of the brake caliper, with the C-clamp ends against the rear of the caliper body and the outboard disc brake pad. 7. Slowly tighten the C-clamp until the pistons are pushed into the caliper bores enough to remove the caliper from the pads. 8. Remove the C-clamp from the caliper. 9. Clean all dirt and foreign material from the brake hose end. 10. Important: Install a rubber cap or plug to the exposed brake pipe fitting end to prevent brake fluid loss and contamination. Remove the brake hose to caliper bolt from the brake caliper. 11. Remove the brake hose from the caliper. 12. Remove and discard the 2 copper brake hose gaskets. These gaskets may be stuck to the brake caliper housing or the brake hose end. Page 10160 7. Lower the vehicle. 8. Perform a four wheel alignment. Page 5619 Crankshaft Position (CKP) Sensor Locations Vehicle Speed Sensor (VSS) - 4 Wheel Drive Manual Transmission Page 10900 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly, Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Pull to Seat Connectors PULL TO SEAT CONNECTORS TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Page 640 Electronic Brake Control Module: Diagrams ABS Connector End Views Electronic Brake Control Module (ECBCM) - C1 Page 10026 ^ Tighten the nut to 250 Nm (184 ft. lbs.). 3. Remove the power steering gear from the vise. 4. Install the power steering gear. Refer to Power Steering Gear Replacement (Rack and Pinion) Power Steering Gear Replacement (Non Rack and Pinion) in Power Steering System. 5. Lower the vehicle. 6. Check the wheel alignment. Drivetrain - Service 4WD Light/DTC C0374 Set Speed Sensor: All Technical Service Bulletins Drivetrain - Service 4WD Light/DTC C0374 Set TECHNICAL Bulletin No.: 05-04-21-003C Date: April 15, 2008 Subject: Service 4WD Light Illuminated, DTC C0374 Set (Inspect Wiring Harness to Transfer Case Speed Sensors,, Replace Wiring Harness) Models: 2004-2007 Buick Rainier 2003-2006 Chevrolet Avalanche, Suburban, Tahoe 2003-2007 Chevrolet Silverado Classic, TrailBlazer, TrailBlazer EXT 2003-2006 GMC Yukon, Yukon XL 2003-2007 GMC Envoy, Envoy XL, Sierra Classic 2003-2004 Oldsmobile Bravada 2005-2007 Saab 9-7X With Four Wheel Drive or All-Wheel Drive and Active All-Wheel Drive (RPO NP4) or Active Two-Speed (RPO NP8) Transfer Case Supercede: This bulletin is being revised to update the Model and Warranty Information. Please discard Corporate Bulletin Number 05-04-21-003B (Section 04 - Driveline/Axle). Condition Some customers may comment on intermittent illumination of the Service 4WD light. Upon investigation, the technician may find DTC C0374 set. The customer may also comment on intermittent erratic operation of the 4WD or AWD system after driving through rain/snow or simply going through a car wash. Cause The speed sensor signal may have become corrupted. Possible openings in the speed sensor wire insulation (twisted pairs) can allow water intrusion. Also wire connections contaminated by water may result in short circuits and erroneous speed sensor readings. This most often occurs on the rear speed sensor circuit. Correction Inspect the wiring harness to the transfer case speed sensors. On Rainier, TrailBlazer, Envoy and 9-7X models, fabricate a replacement speed sensor harness between the C101 connector and the speed sensors. Completely inspect and test all wiring. Refer to Speed Signal Front Axle Actuator and Indicators schematic in SI. Replace the affected twisted pairs. Do not over-twist the two wires in the replacement harness. Wires should be twisted at a rate of 9 revolutions per foot. Use service connector pack, P/N 88987993 at the speed sensor end and terminal, P/N 15326267, at C101. Terminal testing tools and service terminals can be found in Terminal Repair Kit J 38125. Terminals are available from SPX/Kent-Moore. The smaller transfer case harness splices into the larger chassis harness a few inches in front of the crossmember. The chassis harness routes along the left side of the frame under the driver door area. Use nylon tie straps to secure the fabricated harness to the main chassis harness between the transfer case and C101. On the full-size pickup and full-size utility models, replace the 2.2 m (88 in) pigtail harness that runs from the C151 connector under the hood to the transfer case. Use either harness P/N 15832722 or 15224663 depending on vehicle equipment. Refer to Propshaft Speed Sensors Front Axle Actuator and Transfer Case Shift Control Switch schematic in SI. Important: Technicians should verify the integrity of the splice joints after the repair. All splice joints and connections should seal properly against water or a repeat condition can occur. Locations Traction Control Switch: Locations ABS Component Views Traction Control Switch Page 12604 ^ Pay the dealer the regular retail price (no discounts are available) for one of the following 1-year, non-refundable OnStar(R) Analog-to-Digital Transition (ADT) Service Subscription Plans: ^ 1-year Safe & Sound Subscription: $199 ($289 in Canada) ^ 1-year Directions & Connections Subscription: $399 ($579 in Canada) ^ Pay the dealer the applicable state and local sales taxes on the subscription: ^ U.S. Dealers: Taxes only apply in these states: CT, DC, FL, HI, ND, NJ, NM, NY, SC, SD, TX, and WV ^ Canadian Dealers: All applicable taxes ^ Pay the dealer a one-time charge of $15 for the upgrade: ^ U.S. Dealers: Do not collect taxes on the $15 ^ Canadian Dealers: Collect all applicable taxes on the $15 Note: Dealers should NOT remit OnStar(R) ADT-related taxes to their taxing authority as OnStar(R) is responsible for tax remittance. Please Be Sure To Read these Important Points: ^ The 1-year OnStar(R) subscription is not refundable or transferable to another person. Upgraders can apply unused subscription months to a new or Certified Pre-Owned digital OnStar-equipped GM vehicle purchase or lease. As noted above, the digital upgrade program requires the subscriber to purchase a one-year prepaid OnStar(R) subscription. Assuming the subscriber intends to keep their vehicle, but subsequently purchases or leases a 2006 model year or newer OnStar(R)-equipped new or certified used GM vehicle, in the interest of subscriber satisfaction, they may apply remaining unused whole months of the subscription to the new vehicle. The subscription may not be applied to another person's vehicle. Important: This is a customer satisfaction measure that would usually occur several months after an upgrade. It is not intended to be leveraged as part of a new/used vehicle purchase or lease transaction. ^ The $15 charge is not refundable. ^ Dealer ADT kit orders are VIN specific. Dealer kit orders require a VIN and must be exchanged with the OnStar(R) unit in the vehicle with that VIN. Proper activation and enrollment depends on this step. ^ You must put the actual miles on the Repair Order. Do not estimate. ^ Customers will receive a Hands-Free Calling number once the digital hardware is installed and configured. ^ Any nametags that were stored in the old system will need to be re-set by the subscriber once the new hardware is installed. ^ Customers are responsible for the charges described above regardless of whether their vehicle is in or out of the New Vehicle Warranty period. In addition, customers should not be charged labor costs. Dealers can charge GM the labor for the upgrade as specified at the end of this bulletin using the listed labor operation. ^ Vehicles eligible for an OnStar(R) hardware upgrade are listed in this bulletin. Vehicle upgradeability can also be determined by typing the VIN into the field entitled "Determine VIN Hardware Functionality" on the OnStar(R) Online Enrollment website, located in the sales or service workbench tab of GM GlobalConnect. Canadian Dealers can use a similar tool that is available within InfoNET. ^ Access to the sales and/or service workbench in the GM GlobalConnect website can be granted by the dealership's Partner Security Coordinator (PSC). If you are unsure who the PSC is, check with the Sales Manager. Ordering the Upgrade Kit/Upgrade kit Installation Ordering the Upgrade Kit 1. To order a kit, you will need to access the OnStar(R) Online Enrollment webpage, located under the sales or service workbench of GM GlobalConnect (infoNET for Canadian upgrade orders). These kits cannot be ordered from GMSPO. Page 2640 Fuse Block - Underhood C1 Part 1 Page 12819 Page 8717 Wheel Speed Sensor (WSS) - RF Page 5689 Park Neutral Position (PNP) Switch C175 Page 14368 Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. 1. Disconnect the connector from the component. 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. Page 8918 Cigar Lighter/Auxiliary Outlets Diagram 2 Page 8565 Page 2045 Figure 1: Full Tread View - "NORMAL" Tire "Feathering" Wear on the Shoulder/Adjacent/Center Ribs Figure 2: Tire Shoulder View Example 1 - "NORMAL" Tire "Feathering" Wear on the Shoulder Figure 3: Tire Shoulder View Example 2 - "NORMAL" Tire "Feathering" Wear Figure 4: Detail Side View of Tire Shoulder Area - "NORMAL" Tire "Feathering" Wear Important When a wheel alignment is deemed necessary for tire wear, be sure to document on the repair order, in as much detail as possible, the severity and type of tire wear (e.g., severe center wear or severe inside or outside shoulder wear) and the position of the tire on the vehicle (RF, LF, LR, RR). Please note the customer's concern with the wear such as, noise, appearance, wear life, etc. A field product report with pictures of the tire wear condition is recommended. Refer to Corporate Bulletin Number 02-00-89-002J and #07-00-89-036C. 4. Other repairs that affect wheel alignment; e.g., certain component replacement such as suspension control arm replacement, engine cradle adjustment/replace, steering gear replacement, steering tie rod replace, suspension strut/shock, steering knuckle, etc. may require a wheel alignment. Important If other components or repairs are identified as affecting the wheel alignment, policy calls for the wheel alignment labor time to be charged to the replaced/repaired component's labor operation time rather than the wheel alignment labor operations. Important Vibration type customer concerns are generally NOT due to wheel alignment except in the rare cases; e.g., extreme diagonal wear across the tread. In general, wheel alignments are NOT to be performed as an investigation/correction for vibration concerns. "Normal Operation" Conditions Vehicle Lead/Pull Due to Road Crown or Slope: As part of "Normal Operation," vehicles will follow side-to-side or left to right road crown or slope. Be sure to verify from the customer the types of roads they are driving as they may not recognize the influence of road crown on vehicle lead/pull and steering wheel angle. If a vehicle requires significant steering effort to prevent it from "climbing" the road crown there may be an issue to be looked into further. Important Locations Steering Column Page 6435 Park Neutral Position (PNP) Switch C175 Page 1511 Steering Wheel And Column Sub-System Components Page 9644 4. Push on the top part until it clicks in place. 5. Connect the harness to the front of the junction block. 6. Install the cover to the junction block until it clicks in place. 7. Hand tighten the retaining nut until seated. Page 4694 Door Control Module Diagram 3 Part 2 Drivetrain - Excessive Effort When Shift 2HI to 4HI Differential Fluid - Transfer Case: All Technical Service Bulletins Drivetrain - Excessive Effort When Shift 2HI to 4HI TECHNICAL Bulletin No.: 09-04-19-002A Date: February 17, 2011 Subject: 4WD System Shift Performance in Cold Ambient Temperatures (Use Synthetic Fluid in Light Duty Front Axles with 8.5" Ring Gears) Models: 1999-2011 Chevrolet Silverado 1500 Series Models 1999-2011 GMC Sierra 1500 Series Models Equipped with 4WD and 8.25" Front Axle Ring Gears (Transfer Case RPOs NP2, NQG) Attention: It is important to determine the RPO for the transfer case in GWM/IVH prior to applying this bulletin. This bulletin applies ONLY to vehicles equipped with 8.25" front axle ring gears, used in conjunction with a manual transfer case (RPOs NP2, NQG). Supercede: This bulletin is being revised to add the 2011 model year. Please discard Corporate Bulletin Number 09-04-19-002 (Section 04 - Driveline/Axle). Condition Some customers may comment about the effort required to shift from 2HI to 4HI in cold ambient temperatures at -6°C (20°F) or below. Cause This condition may be caused by the standard front axle being equipped with conventional mineral oil axle fluid. In cold ambient temperatures, prior to complete warm up, the fluid viscosity is thick. This may affect transfer case shift performance prior to full warm up. Correction Drain the front axle fluid and refill with GM SAE 75W-90 Synthetic Axle Fluid, P/N 89021677 (in Canada, 89021678). Refer to Front Axle Lubricant Replacement in SI. It is important to use synthetic fluid in this 8.25" axle to improve the performance of the 4WD system in cold ambient temperatures. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 16137 Electrical Symbols Part 13 Page 12027 9. Erase the diagnostic trouble codes. 10. Set the date and time, see WIS - 3. Electrical system - Information display (SID) - Technical description. Page 9781 Multiple Junction Connector: Diagrams C404 - C411 C404 Left Clearance Lamp Harness To License Lamp Harness (With RPO Codes NYS Or R05) Page 2293 6. Remove the outlet heater hose. INSTALLATION PROCEDURE 1. Install the outlet heater hose. 2. Install the outlet heater hose to the engine. 3. Connect the outlet heater hose to the heater core. Firmly push the quick connect onto the heater core pipe until you hear an audible click. 4. Install the heater and surge tank hose to the mounting clip. 5. Install the air intake tube. 6. Fill the cooling system. Refer to Draining and Filling Cooling System (with HP2)Draining and Filling Cooling System (without HP2) in Cooling System. Page 8755 Positive: Service and Repair Replacement procedure BATTERY POSITIVE CABLE REPLACEMENT REMOVAL PROCEDURE CAUTION: Refer to Battery Disconnect Caution in Service Precautions. 1. Disconnect the negative battery cable. 2. Unsnap the positive battery cable cap. 3. Loosen the positive battery cable. 4. Remove the positive battery cable. IMPORTANT: The bolt is integral to the battery cable and is not removable. 5. Loosen the positive cable bolt at the underhood bussed electrical center (UBEC). Page 8978 Fuse Block - Underhood - Secondary Wire Entry (With RPO Code HP2) Part 1 Page 13731 Rear Door Weatherstrip: Service and Repair Weatherstrip Replacement - Rear Door Window Weatherstrip Replacement - Rear Door Window Removal Procedure 1. Remove the window. 2. Pull the weatherstrip from the front window run channel. 3. Pull the weatherstrip from the rear window run channel. 4. Pull the weatherstrip from the window frame flange. Installation Procedure 1. Align the weatherstrip in the window frame flange. 2. Press the weatherstrip into the window frame flange until fully seated. 3. Press the weatherstrip into the rear window run channel until fully seated. 4. Press the weatherstrip into the front window run channel until fully seated. 5. Install the window. Page 12308 Overhead Console - Garage Door Opener Page 12009 2. Disconnect the C2 32-way blue connector from the VIU and tape the connector to a secure location. Refer to Cellular Communications Connector End Views and related schematics in SI, if required. Important: DO NOT perform the OnStar(R) reconfiguration and/or programming procedure. 3. Secure the VIU in its original brackets and/or mounting locations and reinstall the VIU and interior components that were removed to gain access to the VIU. Refer to OnStar Vehicle Interface Unit Replacement in SI. 2002 Through 2006 Model Year Vehicles (Except Saab Vehicles) 2002 through 2006 Model Year Vehicles (Except Saab Vehicles) Important: The Tech 2 diagnostic tool must be updated with version 28.002 or later in order to successfully perform the VCIM setup procedure and disable the analog system. 1. Connect the Tech 2 to the data link connector (DLC), which is located under the instrument panel of the vehicle. 2. Turn the Tech 2 ON by pressing the power button. Important: Tech 2 screen navigation to get to the setup procedure depends on the year and make of the vehicle. The actual name of the setup procedure (Setup New OnStar or VCIM Setup) depends on model year and vehicle make as well. Example Tech 2 navigation to the setup procedure Tech 2 screen is provided below. ^ Diagnostics >> (2) 2002 >> Passenger Car >> Body >> C >> OnStar >> Special Functions >> Setup New OnStar >> ^ Diagnostics >> (5) 2005 >> Passenger Car >> (4) Buick >> C >> Body >> Vehicle Comm. Interface Module >> Module Setup >> VCIM Setup >> 3. Setup VCIM using the Tech 2. Follow on-screen instructions when you have reached the setup Tech 2 screen. 2000-2002 Saab 9-3 (9400) 4D/5D; 2000-2003 Saab 9-3 (9400) CV 2000-2002 Saab 9-3 (9400) 4D/5D; 2000-2003 Saab 9-3 (9400) CV 1. Remove the ground cable from the battery's negative terminal. 2. Apply the handbrake brake. 3. Detach the floor console. 4. Remove the switch and the floor console: 3.1. Twist loose the immobilizer unit (A), bayonet fitting. Unplug the unit's connector. 3.2. Remove the ignition switch cover (B) by first undoing the rear edge of the cover and then unhooking the front edge. Unplug the ignition Page 14721 Seat Cover: Service and Repair Seat Back Cover and Pad Replacement - Rear Removal Procedure 1. Remove the rear seat from the vehicle. 2. Remove the seat back folding cover, if equipped. 3. Remove the armrest from the seat back, if equipped. 4. Remove the head restraints (1) from the seat back. 5. Release the J-clips from the seat back cover. 6. Release the hook, and the loop strips retaining the seat back cover (2) to the foam pad (12). 7. In order to ease removal, place a piece of cardboard between the seat back cover and the foam pad. 8. Working from side to side, carefully lift the seat back cover from the foam pad. Installation Procedure 1. Working from side to side, carefully install the seat back cover over the foam pad. 2. Remove the cardboard from between the seat back cover and the foam pad. 3. Engage the hook, and the loop strips that retain the seat back cover (2). 4. Engage the J-clips that retain the seat back cover. 5. Install the head restraints (1) to the seat back. 6. Install the armrest to the seat back, if removed. 7. Install the seat back folding cover, if removed. 8. Install the rear seat to the vehicle. Page 5176 Disclaimer Diagram Information and Instructions Door Module: Diagram Information and Instructions Truck Zoning TRUCK ZONING Truck Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that corresponds to where they are located in the vehicle. The table explains the numbering system. Page 2172 Disclaimer Page 1677 4. Position the J 41364-A onto the PNP switch. Ensure that the two slots on the switch where the manual shaft is inserted are lined up with the lower two tabs on the tool. 5. Notice: Refer to Fastener Notice in Service Precautions. Rotate J 41364-A until the upper locator pin on the tool is lined up with the slot on the top of the switch. ^ Tighten the bolts to 25 Nm (18 ft. lbs.). 6. Remove J 41364-A from the PNP switch. If installing a new switch, remove the positive assurance bracket at this time. 7. Install the control lever to the manual shaft with the nut. 8. Install the manual shaft nut. ^ Tighten the nut to 25 Nm (18 ft. lbs.). 9. Install the range selector cable end (2) to the range selector lever ball stud (1). Page 15318 Fuel Gauge Sender: Specifications FUEL LEVEL SPECIFICATIONS Page 4055 - HVAC Actuator - Inflatable Restraint Sensing and Diagnostic Module (SDM) - Any AIR BAG module - Seatbelt Lap Anchor Pretensioner - Seatbelt Retractor Pretensioner - An SIR system connection or connector condition resulting in the following DTCs being set: B0015, B0016, B0019, B0020, B0022, or B0023 - Powertrain Control Module (PCM) - Remote Control Door Lock Receiver (RCDLR) - Transmission Control Module (TCM) Correction Important DO NOT replace the control module, wiring or component for the following conditions: - The condition is intermittent and cannot be duplicated. - The condition is present and by disconnecting and reconnecting the connector the condition can no longer be duplicated. Use the following procedure to correct the conditions listed above. 1. Install a scan tool and perform the Diagnostic System Check - Vehicle. Retrieve and record any existing history or current DTCs from all of the control modules (refer to SI). ‹› If any DTC(s) are set, refer to Diagnostic Trouble Code (DTC) List - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). ‹› If DTCs are not set, refer to Symptoms - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). 2. When identified, use the appropriate DTC Diagnostics, Symptoms, Schematics, Component Connector End Views and Component Locator documents to locate and disconnect the affected harness connector(s) which are causing the condition. Note Fretting corrosion looks like little dark smudges on electrical terminals and appear where the actual electrical contact is being made. In less severe cases it may be unable to be seen or identified without the use of a magnifying glass. Important DO NOT apply an excessive amount of dielectric lubricant to the connectors as shown, as hydrolock may result when attempting to mate the connectors. Use ONLY a clean nylon brush that is dedicated to the repair of the conditions in this bulletin. 3. With a one-inch nylon bristle brush, apply dielectric lubricant to both the module/component side and the harness side of the affected connector(s). 4. Reconnect the affected connector(s) and wipe away any excess lubricant that may be present. 5. Attempt to duplicate the condition by using the following information: - DTC Diagnostic Procedure - Circuit/System Description - Conditions for Running the DTC - Conditions for Setting the DTC - Diagnostic Aids - Circuit/System Verification ‹› If the condition cannot be duplicated, the repair is complete. ‹› If the condition can be duplicated, then follow the appropriate DTC, Symptom or Circuit/System Testing procedure (refer to SI). Repair Order Documentation Page 1648 Heated Oxygen Sensor (HO2S) Bank 2 Sensor 2 Page 672 Page 9183 C115 Chassis Harness To I/P Harness (With RPO Code NYS) Part 2 Page 8258 Important: After drilling the holes, apply the appropriate anti-corrosion primer. Refer to the GM Refinish Material Booklet # 4901 M-D (English) or # 4901-D-F (French) for additional information. 6. Center punch the marked location and drill a 6.35 mm (1/4 in) hole. Install the plastic retainer in the hole (1) of the mud flap. 7. Tighten fastener at the hole (2) location of the mud flap. Tighten Tighten the fastener to 25 N.m (18 lb ft). 8. For vehicles with short box, use the following procedure: 8.1. Push the mud flap to make contact with the rear side of the underbody cross sill and mark the location of the hole (3) of the mud flap. 8.2. Center punch the marked location and drill a 5.159 mm (13/64 in) hole. 8.3. Install the screw. Tighten Tighten the screw to 4 N.m (35 lb in). 8.4. Repeat the above steps for hole locations 4 and 6. 9. For vehicles with long box, use the following procedure: Page 8279 Brake Caliper: Specifications Brake Caliper Mounting Bolt Front ....................................................................................................................................................... 108 Nm (80 ft. lbs.) Brake Caliper Mounting Bolt Rear (15 series) ......................................................................................................................................... 42 Nm (31 ft. lbs.) Brake Caliper Mounting Bolt Rear (25/35 series) .................................................................................................................................. 108 Nm (80 ft. lbs.) Caliper Mounting Bracket Bolt Rear (JC5/JH5) ................................................................................................................................... 200 Nm (148 ft. lbs.) Caliper Mounting Bracket Bolt Rear (JH6) .......................................................................................................................................... 165 Nm (122 ft. lbs.) Caliper Mounting Bracket Bolt Rear (JH7) .......................................................................................................................................... 300 Nm (221 ft. lbs.) Caliper Mounting Bracket Bolt Rear (NYS) ........................................................................................................................................ 200 Nm (148 ft. lbs.) Caliper Mounting Bracket to Knuckle, Front (15 series) ...................................................................................................................... 175 Nm (129 ft. lbs.) Caliper Mounting Bracket to Knuckle, Front (25/35 series) ................................................................................................................. 300 Nm (221 ft. lbs.) Page 8817 Control Module References Part 5 Page 11856 Cellular Phone Microphone: Description and Operation ONSTAR(R) MICROPHONE The Onstar(R), or cellular microphone can be part of the rearview mirror assembly, or on some vehicle lines, can be a separate, stand alone unit. In either case, the microphone is supplied voltage on the cellular microphone signal circuit, while voice data from the user is sent back to the vehicle communication interface module (VCIM) by means of either a cellular microphone low reference circuit or a drain wire. Page 9220 C249 I/P Harness To Bezel Harness (Except Y91) Page 347 Page 7431 2. Connect the speed sensor electrical connector (4). 3. Lower the vehicle. Service and Repair Push Rod: Service and Repair Valve Rocker Arm and Push Rod Replacement Removal Procedure 1. Remove the valve rocker arm cover. Important: Place the valve rocker arms, pushrods, and pivot support, in a rack so that they can be installed in the same location from which they were removed. 2. Remove the valve rocker arm bolts. 3. Remove the valve rocker arms. 4. Remove the valve rocker arm pivot support. 5. Remove the pushrods. 6. Clean and inspect the valve rocker arms and pushrods. Installation Procedure Important: When reusing the valve train components, always install the components to the original location and position. Valve lash is net build, no valve adjustment is required. Page 13587 Auxiliary Step / Running Board: Service and Repair Assist Step Replacement (Sierra Pro) Assist Step Replacement (Sierra Pro) Removal Procedure 1. With the aid of an assistant remove the following components: 1. The body mounts (1) 2. The washers 2. With an assistant, remove the assist step assembly from the vehicle. 3. Remove the lower body-mount cushion assemblies (2) from the vehicle. 4. Remove the assist step bracket bolts (1). 5. Remove the assist step brackets. Installation Procedure Important: Apply thread locker GM P/N 12345382 (Canadian P/N 10953489), to all bolt threads prior to assembly 1. Install assist step brackets. 2. Install the assist step bracket bolts (1). Notice: Refer to Fastener Notice in Service Precautions. Page 505 Control Module References Part 1 Page 14933 Memory/Heated Seat Switch - Driver (DDM C5) Part 2 Page 14812 Memory/Heated Seat Switch - Driver (DDM C5) Part 1 NVG 246-NP8 Control Module: Service and Repair NVG 246-NP8 Transfer Case Control Module Reprogramming Transfer Case Control Module Reprogramming Set-up for Module Programming/Reprogramming Important: Ensure that the vehicle battery is fully charged and that a battery charger is no longer connected. If performing this procedure for module replacement, install new module before proceeding. Before reprogramming close the doors and wait two minutes to allow other modules to stop communicating via the class 2 data line. Failure to do so could result in a failed reprogramming procedure. ^ Turn OFF all accessories. ^ Turn ON the ignition, with the engine OFF. Remote Programming Feature 1. Connect the scan tool to the vehicle. 2. Power-up the scan tool and select the Service Programming feature. 3. Select the appropriate vehicle. 4. Press the Request Info button on the scan tool. 5. Disconnect the scan tool from the vehicle and connect the scan tool to the computer station. 6. Follow the menu select items for reprogramming and provide information as to what type of device you are programming and whether you are reprogramming or replacing the electronic control unit (ECU). 7. Select "vehicle" from the selection menu. 8. Select the module you wish to Program. 9. Select "Normal" for Programming Type. 10. Select the applicable software calibrations. 11. Transfer data file to the scan tool. 12. Reconnect the scan tool to the vehicle. 13. Turn ON the ignition, with the engine OFF. 14. Select the Service Programming feature on the scan tool. 15. Press the Program button on the scan tool. Programming Using Scan Tool Pass-Through Connection 1. Connect the scan tool to vehicle and power it up. 2. Connect the computer station to the scan tool. 3. Select "PC Using Scan Tool Connection" from the programming menu on the computer station. 4. Follow the menu select items for reprogramming and provide information as to what type of device you are programming and whether you are reprogramming or replacing the electronic control unit (ECU). 5. Select "vehicle" from the selection menu. 6. Select the module you wish to program. 7. Select "Normal" for Programming Type. 8. Select the applicable software calibrations. 9. Transfer data file to the scan tool. Transfer Case Shift Control Module Replacement Transfer Case Shift Control Module Replacement Removal Procedure Page 8928 Hybrid Control Module (HCM) - Part 1 Page 9301 Junction Block - I/P Wire Entry Part 2 OnStar(R) - Loss of GPS Signal/Hands Free Issues Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Loss of GPS Signal/Hands Free Issues Bulletin No.: 02-08-46-007C Date: November 19, 2007 INFORMATION Subject: Information on OnStar(R) System - Possible Loss of GPS Signal, Hands-Free Calling Minutes Expire Prematurely and/or Inability to Add Hands-Free Calling Minutes Models: 2001-2008 GM Passenger Cars and Light Duty Trucks (Including Saturn) 2003-2008 HUMMER H2 2006-2008 HUMMER H3 2005-2008 Saab 9-7X with OnStar(R) System (RPO UE1) Supercede: This bulletin is being revised to add the 2008 model year, warranty information and to provide GPS signal recovery steps (under Dealer Action heading) to do PRIOR to determining if the VIU/VCIM needs replacement. Please discard Corporate Bulletin Number 02-08-46-007B (Section 08 - Body & Accessories). If the vehicle currently has analog-upgradable OnStar(R) hardware, then the customer should be made aware of the digital upgrade program per the latest version of Service Bulletin # 05-08-46-006. Any analog OnStar system that is not upgraded prior to the end of 2007 will be deactivated due to the upcoming phase-out of the analog cellular network in the U.S. and Canada. If the vehicle has recently been upgraded or has had a service replacement unit installed, this bulletin may not be applicable. Certain 2001-2008 model year vehicles equipped with OnStar(R) may exhibit a condition with the Global Positioning System (GPS) that causes inaccuracies in the GPS clock. The GPS system is internal to the OnStar(R) Vehicle Interface Unit (VIU) or the Vehicle Communication Interface Module (VCIM). This inaccuracy can result in a symptom where the OnStar(R) Call Center is unable to obtain an accurate GPS signal, hands-Free Calling minutes expire prematurely and/or the inability to add Hands-Free calling minutes. Customer Notification OnStar(R) will notify the customer by mail with instructions to contact their dealership service department. Dealer Action Not all vehicles will require VIU/VCIM replacement. The GPS signal in some vehicles may be recoverable. To determine if the signal is recoverable, simply connect the Tech2(R) and using the GPS information data display option, observe the GPS date and time. If the date/time stamps are equal to a date approximately 19 years in the future, the GPS clock has exceeded its capacity and the VIU/VCIM will need to be replaced. If the date/time stamp is in the past or near future, the GPS clock has simply generated an inaccurate value and may be recoverable by performing the following power-up reset. To initiate a power-up reset, battery voltage (batt. +) must be removed from the VIU/VCIM. The preferred methods, in order, of initiating the reset are outlined below. Remove the fuse that supplies Battery positive (Batt. +) voltage to the module (refer to the applicable Service Information schematics for the appropriate fuse). The next preferred method is to remove the connector to the OnStar(R) unit that Batt + is contained. The least preferable method is to remove the negative terminal of the vehicle battery. This will not only initiate the power-up reset, but it may also result in the loss of radio presets and other stored personalization information/settings in other modules as well. After initiating the power-up reset, the GPS data will be set to the defaulted date and time and will require an acquisition of the GPS signal in order to gain the proper date and time. Acquiring the GPS signal requires running the vehicle in an open/unobstructed view of the sky. First, contact OnStar(R) Technical Support by pressing the blue button. Allow the OnStar(R) Technical Advisor to activate the GPS recovery process. This should take approximately 10 minutes. Continue to Page 9856 Relay Box: Service and Repair I/P Electrical Center or Junction Block Replacement - Left INSTRUMENT PANEL ELECTRICAL CENTER OR JUNCTION BLOCK REPLACEMENT - LEFT REMOVAL PROCEDURE 1. Remove the left side end panel. 2. Remove the knee bolster. 3. Disconnect all the wiring connectors from the fuse block. 4. Remove all the fuses. 5. Remove the turn signal relay from the back of the fuse block. 6. From behind the fuse block, remove the retaining bolt. 7. Insert a screw driver between the fuse block and the wire harness block to separate. 8. Push on the retainers in order to remove the fuse block. 9. Remove the fuse block from the vehicle. INSTALLATION PROCEDURE 1. Install the fuse block onto the I/P assembly until it clicks in place. 2. Install the wire harness block to the back of the fuse block. NOTE: Refer to Fastener Notice in Service Precautions. 3. Install the bolt. Tighten Tighten the bolt to 6 N.m (53 lb in). 4. Install the turn signal relay to the back of the fuse block. 5. Using the wiring diagram on the cover of the fuse panel, install the fuses. 6. Install the electrical connectors. 7. Install the knee bolster. Page 5684 6. Connect the internal wiring harness electrical connectors to the following components: ^ Transmission fluid pressure switch (1) ^ 1-2 shift control solenoid (2) ^ 2-3 shift control solenoid (3) ^ Pressure control solenoid (4) ^ TCC PWM solenoid (5) ^ 3-2 control solenoid (6) 7. Install the 1-2 accumulator, if necessary. 8. Install the transmission filter. Page 6607 Chips or debris plugging the bleed orifice of the 2-3 shift solenoid (367). This will cause the transmission to stay in 2nd gear when 3rd gear is commanded and return to 1st gear when 4th gear is commanded. A 2-3 shift valve (368) or 2-3 shuttle valve (369) that is stuck, restricted and/or hung-up in its bore. This condition may also be an indication of a damaged 2-4 band or 3-4 clutches. This clutch damage may generate debris causing the 2-3 shift valve line-up to stick in the valve body bore and set DTC P0757. Correction Inspect the condition of the transmission fluid for signs of overheat or a burnt odor. If either is noted, the transmission should be disassembled for further investigation and repaired as needed. Inspect the inside of the oil pan for signs of clutch friction material. A small amount of friction material in the bottom of the pan is normal. If a large amount of clutch material is noted in the fluid or bottom pan, the transmission should be disassembled for further investigation and repaired as needed. Inspect and clean the 2-3 shift valve (368), the 2-3 shuttle valve (369) and the valve bore of debris/metal chips. Inspect and clean the 2-3 shift solenoid (367B) opening of debris/metal chips. While inspecting the 2-3 shift solenoid (367B), look for a screen over the solenoid opening. If the solenoid DOES NOT have a screen, replace the solenoid. All current GMSPO stock shift solenoids have a screen over the solenoid opening. If clutch debris is found, it is also very important to inspect the pressure control (PC) solenoid valve fluid screens. Clean or replace the PC solenoid as necessary. It is also important to flush and flow check the transmission oil cooler using J 45096. Refer to SI "Automatic Transmission Oil Cooler Flushing and Flow Test" for the procedure. Refer to the appropriate Service Manual for additional diagnostic information and service procedures. Warranty Information For repairs performed under warranty, use the applicable published labor code and information. Disclaimer A/C - Hiss Noise From Instrument Panel Hose/Line HVAC: All Technical Service Bulletins A/C - Hiss Noise From Instrument Panel Bulletin No.: 06-01-38-002 Date: March 17, 2006 TECHNICAL Subject: A/C System Refrigerant Hiss Noise (Replace Liquid Line) Models: 2003-2006 Cadillac Escalade Models 2003-2006 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2003-2006 GMC Sierra, Yukon Models with 4.3L, 4.8L, 5.3L, 6.0L or 8.1L Engine (VINs X, V, T, Z, B, U, N, G - RPOs LU3, LR4, LM7, L59, L33, LQ4, LQ9, L18) and Air Conditioning (RPOs CJ2, CJ3 and C69) Condition Some customers may comment on a hiss noise coming from the instrument panel. The noise has also been described as sounding like a gurgle or water spattering. The noise occurs when the Air Conditioning (A/C) compressor engages and may continue for 5 to 10 seconds after the compressor disengages or the A/C system is turned off. The noise is most noticeable when the vehicle is at idle or is being driven at low speeds. The noise is undetectable after about one minute when the A/C system has been turned off or the vehicle has been turned off. Cause This condition may be caused by the expanding refrigerant as it passes through the orifice tube. Correction Technicians are to verify that the customer concern is only as described in the condition statement above. If the customer concern is a refrigerant hiss noise, then technicians are to perform the normal diagnostic procedures for an A/C system concern. The ACR2000 should be used to check the A/C system performance, charge level and discharge temperatures. This will eliminate the possibility that another condition is contributing to this customer concern. If the A/C system is performing properly, and all other possible sources of this noise are eliminated, then technicians are to replace the A/C liquid line. Use the proper part number as described in the parts information box below. Verify that the noise has been eliminated and that the A/C system operates normally. Parts Information Important: The trucks affected by this bulletin that have rear air conditioning were built with two different length condensers. The short condenser is 762 mm (30.0 in) long. The long condenser is 914 mm (36.0 in) long. Be sure to measure the length of the condenser before ordering one of the tubes listed below for vehicles with rear air conditioning. Keyless Entry - Inoperative Keyless Entry Module: All Technical Service Bulletins Keyless Entry - Inoperative Bulletin No.: 04-08-52-005 Date: June 15, 2004 TECHNICAL Subject: Remote Keyless Entry (RKE) System Inoperative (Reprogram Passenger Door Module (PDM)) Models: 2004 Cadillac Escalade, Escalade ESV, Escalade EXT 2004 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2004 GMC Sierra, Yukon, Yukon XL Condition Some customers may comment on any of the following conditions: ^ The RKE key fob does not function. ^ The "Service Tire Pressure Monitoring System" message is displayed, if equipped. ^ The passenger door will not unlock from the passenger's or driver's door switches. ^ The passenger door window is inoperative. Correction Reprogram the PDM with the Tech 2(R). Currently the Tech 2(R) software is not available for the 2004 model year. Engineering is aware of this and are working to release a new service calibration. In the meantime, build the Tech 2(R) as a 2003 model year and perform the reprogram using the procedure listed below. 1. Turn the ignition switch to the ON position. 2. Connect the Tech 2(R) to the vehicle's diagnostic link connector (DLC), power it up and press enter. ^ Select: Diagnostics. ^ Select model year: 2003. ^ Select: Light truck. ^ Select: Body. ^ Select the proper Product line. ^ Select the proper HVAC Type. ^ Select the proper Radio System type. ^ Select: Passenger Door Module. ^ Select: Special Functions. ^ Select: Refresh. Important: You must remove the described fuse in the next step for the "Refresh" program to be performed. If you do not remove the fuse for five seconds, the Tech 2 will continue to display "Test in Progress" and the program will not complete. ^ Remove the PDM fuse for 5 seconds from the fuse center located behind the panel on the left end of the instrument panel. Page 2657 Fuse Block - Underhood C6 Page 1012 Inflatable Restraint Sensing And Diagnostic Module: Diagrams Inflatable Restraint Sensing and Diagnostic Module (SDM) - Part 1 Page 13716 Tighten the trim panel armrest screws to 2 N.m (18 lb in). 3. Install the door handle bezel. Trim Panel Replacement - Side Rear Door (Crew Cab) Trim Panel Replacement - Side Rear Door (Crew Cab) Removal Procedure 1. Remove the door handle bezel. 2. Remove the window-regulator handle, if equipped. 3. Using a flat-bladed tool, remove the reflector lamp from the trim panel, and disconnect the electrical connector, if required. 4. Remove the manual lock lever from the trim panel using a flat-bladed tool. 5. Remove the two trim panel screws. 6. Remove the trim panel from the door by carefully sliding the panel upward then outward. 7. Disconnect the electrical connectors. Installation Procedure 1. Connect the electrical connectors, if necessary. 2. Align the retainers with the holes in the door. 3. Install the trim panel to the door by lowering the trim panel down into the retainer holes in order to seat the retainers. Notice: Refer to Fastener Notice in Service Precautions. 4. Install the trim panel screws. Tighten the trim panel screws to 2 N.m (18 lb in). 5. Install the manual lock lever by pressing the lever until the lever is completely seated. 6. Connect the electrical connector to the reflector lamp, and install the reflector by pressing the reflector until the reflector is completely seated, if removed. 7. Install the window-regulator handle, if necessary. 8. Install the door handle bezel. Page 8979 Fuse Block - Underhood - Secondary Wire Entry (With RPO Code HP2) Part 2 Page 12534 High OR Low The above conditions are met for more than 3 seconds. Circuit/System Verification These DTCs cannot be retrieved with a current status. To diagnose use the Scan Tool Does Not Communicate with a Class 2 Device. Refer to SI. An intermittent condition is likely to be caused by a short on the Class 2 serial data circuit. To diagnose use the Scan Tool Does Not Communicate with a Class 2 Device. Refer to SI. DTC B2455 DTC Descriptors DTC B2455 01: Cellular Phone Microphone Circuit Short to Battery DTC B2455 02: Cellular Phone Microphone Circuit Short to Ground DTC B2455 04: Cellular Phone Microphone Circuit Open Circuit Circuit/System Description Without RPO UAV The vehicle communication interface module (VCIM) uses the cellular phone microphone to allow driver communication with OnStar(R). With RPO UAV The vehicle communication interface module (VCIM) and navigation radio use the cellular phone microphone to allow driver communication with OnStar(R), as well as to operate the voice recognition/voice guidance feature of the navigation radio. Conditions for Running the DTC The ignition is in RUN or ACC position. System voltage is between 9.5 - 15.5 volts. The above conditions are met for more than 10 seconds. Conditions for Setting the DTC B2455 01: A short to battery is detected on the cellular microphone signal circuit. B2455 02: A short to ground is detected on the cellular microphone signal circuit. B2455 04: An open circuit is detected on the cellular microphone signal circuit. Action Taken When the DTC Sets The VCIM and/or navigation radio (RPO UAV) will not receive any signal from the microphone. The OnStar(R) status LED turns red. Voice recognition will not function. Conditions for Clearing the DTC Page 15376 Disclaimer Fuel Pressure Gage Installation and Removal Fuel Pressure Release: Service and Repair Fuel Pressure Gage Installation and Removal FUEL PRESSURE GAGE INSTALLATION AND REMOVAL INSTALLATION PROCEDURE TOOLS REQUIRED J 34730-1A Fuel Pressure Gage CAUTION: - Refer to Gasoline/Gasoline Vapors Caution in Service Precautions. - Refer to Fuel Gage Leak Caution in Service Precautions. 1. Remove the engine sight shield. 2. Remove the fuel rail pressure fitting cap. 3. Connect the J 34730-1A to the fuel pressure valve. Wrap a shop towel around the fitting while connecting the gage in order to avoid spillage. 4. Install the bleed hose on J 34730-1A into an approved container. REMOVAL PROCEDURE 1. Remove the bleed hose on the J 34730-1A from the approved container. 2. Remove the shop towel from around the fitting and discard into an approved container. 3. Disconnect the J 34730-1A from the fuel pressure valve. 4. Install the fuel rail pressure fitting cap. 5. Install the engine sight shield. Page 9770 C323 Seat Motor Jumper Harness To Seat Jumper Harness (With RPO Code AG1) Page 2487 Fluid - M/T: Service and Repair ZF S6-650 Transmission Fluid Replacement Removal Procedure 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. Remove the oil fill plug. 3. Place a suitable drain pan under the transmission in order to catch the drained transmission fluid. 4. Remove the oil drain plug. 5. Remove any old sealant from the transmission housing and plugs. Installation Procedure 1. Apply sealant GM P/N 12346004 (Canadian P/N 10953480), or equivalent to the treads of the oil drain and fill plugs. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the oil drain plug. ^ Tighten the plug to 35 Nm (26 ft. lbs.). 3. Fill the transmission to just below the bottom of the fill plug hole. Refer to Lubrication Specifications. 4. Install the oil fill plug. ^ Tighten the plug to 35 Nm (26 ft. lbs.). 5. Lower the vehicle. A/C - Window Defroster Contact/Tab Repair Information Back Window Glass: All Technical Service Bulletins A/C - Window Defroster Contact/Tab Repair Information INFORMATION Bulletin No.: 03-08-48-006H Date: April 11, 2011 Subject: Repair Information for Reconnection of Rear Window Defroster Contact or Tab Models: 2000-2012 GM Passenger Cars and Trucks 2003-2009 HUMMER H2 2006-2010 HUMMER H3 2005-2009 Saab 9-7X 2007-2010 Opel GT 2007-2008 Daewoo G2X Equipped With Electric Rear Window Defroster - RPO C49 Supercede: This bulletin is being revised to add the 2012 model year. Please discard Corporate Bulletin Number 03-08-48-006G (Section 08 - Body and Accessories). Repair Suggestions Soldering Defroster Contact Tabs In many cases the terminal tab will still be in the connector when you examine the vehicle. For Chevrolet Tahoe, Suburban, GMC Yukon, and Cadillac Escalade vehicles (with moveable glass), always replace the defroster tab (GM P/N 25916031) and the defroster electrical power connector (P/N 12034110). For all other vehicles, reconnect the original defroster tab. In most applications it is preferable to create a new solder connection to reattach a separated rear defroster tab. If you take note of the steps below, it is possible to create a new solder joint that is equal to, or stronger than, the original. The generic procedure below is not very time intensive, but does include minor preparation work to create a good bonding surface. Be sure to follow each of the steps, as combined they will produce the strongest bond possible. Please consider the following before attempting the repair: - Soldering introduces significant heat to the glass window of the vehicle. When performing the re-connection of the tab, use only the heat required to do the job. Pre-heat the soldering iron and have the solder in your other hand, ready to go, the moment you have enough heat to melt the solder. - If it is winter, bring the vehicle into the service garage and remove any snow from the back window area. Allow time for the glass to warm to the temperature inside the building. Soldering creates a "hot spot" in the glass. DO NOT solder on cold glass. Caution Heating the glass excessively, or repeatedly without time to cool, may result in glass breakage. ALWAYS wear safety glasses when performing this repair! - You MUST use a silver-bearing solder to make the connection. DO NOT attempt this repair with conventional tin/lead alloy solders. Silver bearing solder will adhere to the electrical buss bar, making a strong and lasting repair. - Protect surfaces under the area to be soldered. It is very easy to drip solder when performing this repair. Placing a shop towel under the soldering area is sufficient protection. Soldering Procedure 1. It is imperative to remove and replace the rear defroster electrical power connector by crimping a new connector to the feed wire. The proper connector P/N 12034110 can be found in the Packard Electrical Assortment, Tray 18, Position 5. - Insert Delphi pick 12094430 to depress the locking tab on the terminal. - Insert Delphi pick 12094429 to release the secondary lock tab. Important DO NOT re-use the existing defroster tab on new-style full-size utility vehicles with moveable glass. 2. Connect the electrical connector to the defroster tab. Fully engage the connector. An improperly seated connector may cause excessive resistance and impede the proper operation of the defroster. Add a small bead of solder to mate the electrical connector tab to the defroster tab. OnStar(R) - Incorrect GPS Position Reported During Call Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Incorrect GPS Position Reported During Call Bulletin No.: 02-08-46-006C Date: January 08, 2008 INFORMATION Subject: Incorrect OnStar(R) Global Positioning System (GPS) Location Reported During OnStar(R) Call Models: 2000-2008 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2008 HUMMER H2 2006-2008 HUMMER H3 2005-2008 Saab 9-7X with OnStar(R) Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 02-08-46-006B (Section 08 - Body and Accessories). A small number of the above-mentioned vehicles may exhibit a condition in which the vehicle reports an inaccurate location to the OnStar(R) Call Center. This condition can only be identified via a button press to the OnStar(R) Call Center by the customer. Call Center personnel will be able to identify this inaccurate location condition. Customers will then be notified through the mail by OnStar(R) if their vehicle exhibits this condition. Once this condition has been identified OnStar(R) will instruct the customer to return to the dealership to have this condition corrected. It is not necessary to reconfigure the vehicle after the following procedure. In order to correct this condition you must cycle power to the OnStar(R) system. This can be done by either removing the fuses powering the OnStar(R) system or disconnecting the OnStar(R) module (VCIM) from the vehicle. As a last resort you can disconnect the vehicle's battery. The power needs to be removed from the system for approximately 15 minutes. After completing this procedure the vehicle should be taken to an area with an unobstructed view of the sky. The vehicle should be kept running for approximately 10 minutes to allow the vehicle to reacquire the global positioning system (GPS). Then contact the OnStar(R) Call Center via the blue OnStar(R) button and ask the advisor to verify the GPS position. If the OnStar(R) advisor still has an inaccurate GPS location refer to the Navigation Systems and Cellular Communications sub-sections in the Service Manual in order to diagnose and repair the concern. If the normal diagnostics lead to module replacement you will need to contact Technical Assistance (TAC) and choose the OnStar(R) prompt. GM OnStar(R) TAC will assist in the diagnosis and if appropriate order a replacement part. Replacement parts are usually shipped out within 24 hours and a pre-paid return package label will be included for returning the faulty part. By returning the faulty part you will avoid a significant non-return core charge. Warranty Information (excluding Saab US Models) For vehicles repaired under warranty, use the table. Warranty Information (Saab US Models) Page 13890 7. Reinstall the window reveal molding. 1. Start from the loose area and hand-press the reveal molding into place over the edge of the window. 2. Run warm water over the reveal molding in order to speed the setup time of the urethane adhesive. 3. Tape should be applied in order to retain the reveal molding to the window. This will maintain a flush fit with the body. 4. The tape is to be removed after 6 hours. Page 9768 C322 Seat Motor Jumper Harness To Seat Jumper Harness (With RPO Code AN3) Part 1 Page 7446 7. Remove the transmission mount. 8. Remove the transfer case adapter bolts. 9. Remove the transfer case adapter. 10. Remove the transfer case seal. 11. Remove the transfer case gasket, if necessary. Installation Procedure Important: If the gasket or the seal becomes damaged, replace it. DO NOT use any type of silicone sealer or liquid gasket maker in place of the seal or gasket. 1. Install a NEW transfer case adapter seal. 2. Install the transfer case adapter. Page 10731 The torque specification for the wheel drive shaft nut has been revised as shown in the table. Disclaimer Page 16147 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly, Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Pull to Seat Connectors PULL TO SEAT CONNECTORS TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Page 1128 Seat Horizontal Position Sensor - Driver (With RPO Code AN3) Page 16104 Control Module References Part 5 Page 8202 2. Use the J 41013 to clean all rust and contaminants from the inside diameter of the hat section of the brake rotor to prevent any foreign material from getting between the brake rotor and the hub flange. 3. Inspect the mating surfaces of the hub/axle flange and the rotor to ensure that there are no foreign particles or debris remaining. 4. Important: If the rotor was removed using the jack screw method you must ensure that the hub flange is free of nicks or marks caused by this procedure. Remove all raised nicks or marks before installing the rotor. Align the rotor to its original position on the hub (if applicable) and install the rotor. 5. If the brake rotor was removed and installed as part of a brake system repair, measure the assembled lateral runout (LRO) of the brake rotor to ensure optimum performance of the disc brakes. Refer to Brake Rotor Assembled Lateral Runout (LRO) Measurement. 6. If the brake rotor assembled LRO measurement exceeds the specification, bring the LRO to within specifications. Refer to Brake Rotor Assembled Lateral Runout (LRO) Correction. 7. Install the caliper and caliper bracket assembly. 8. Perform the following procedure before installing the brake caliper bracket mounting bolts. 1. Remove all traces of the original adhesive patch. 2. Clean the threads of the bolt with brake parts cleaner or the equivalent and allow to dry. 3. Apply Threadlocker GM P/N 12345493 (Canadian P/N 10953488) to the threads of the bolt. 9. Notice: Refer to Fastener Notice in Service Precautions. Install the caliper bracket mounting bolts. ^ Tighten the brake caliper bracket mounting bolts to 175 Nm (121 ft. lbs.) (15 Series). ^ Tighten the brake caliper bracket mounting bolts to 300 Nm (221 ft. lbs.) (25 and 35 Series). Page 1712 1. Locate the air flow direction arrow (2) on the MAF/IAT sensor. 2. Install the MAF/IAT sensor to the air cleaner assembly. NOTE: Refer to Fastener Notice in Service Precautions. 3. Tighten the MAF/IAT clamp. Tighten Tighten the clamp to 7 N.m (62 lb in). 4. Connect the MAF/IAT sensor electrical connector (4). 5. Push in the gray CPA retainer. 6. Install the air cleaner outlet duct. Accessory Drive Belt Tensioner: Service and Repair Accessory Drive Belt Tensioner Replacement - Accessory Removal Procedure 1. Remove the accessory drive belt. 2. Remove the drive belt tensioner bolts. 3. Remove the drive belt tensioner. Installation Procedure 1. Install the drive belt tensioner. 2. Install the drive belt tensioner bolts. Notice: Refer to Fastener Notice in Service Precautions. 3. Tighten the drive belt tensioner bolts. ^ Tighten the bolts to 50 Nm (37 ft. lbs.). 4. Install the accessory drive belt. Page 5460 Fuel Pump And Sender Assembly - Secondary (With Dual Tanks) Page 12647 Disclaimer Page 646 2. Install the EBCM to the BPMV. 3. Notice: Refer to Fastener Notice in Service Precautions. Install the new screws (1) in the EBCM (2). ^ Tighten the screws to 5 Nm (39 inch lbs.) in an X-pattern. Page 13110 The control module ID number list above provides a method for determining which module is not communicating. A module with a class 2 serial data circuit malfunction or which loses power during the current ignition cycle will have a Loss of Communication DTC set by other modules that depend on information from that failed module. The modules that can communicate will set a DTC indicating the module that cannot communicate. Diagnostic Order When more than one Loss of Communication DTC is set in either one module or in several modules, diagnose the DTCs in the following order: 1. Current DTCs before history DTCs unless told otherwise in the diagnostic table. 2. The DTC which is reported the most times. 3. From the lowest number DTC to the highest number DTC. Conditions for Running the DTC The following DTCs do not have a current status: ^ B1327 ^ B1328 ^ U1300 ^ U1301 ^ U1305 AND ^ The vehicle power mode requires serial data communication to occur. Conditions for Setting the DTC A node alive message has not been received from a module with a learned identification number within the last 5 seconds. Action Taken When the DTC Sets Page 15754 Brake Light Switch: Diagrams Stop Lamp Switch Part 1 Automatic Transmission - 4L60-E/4L65-E Transmission Position Switch/Sensor: Service and Repair Automatic Transmission 4L60-E/4L65-E Park/Neutral Position Switch Replacement ^ Tools Required J 41364-A Park Neutral Switch Aligner Removal Procedure 1. Apply the park brake. 2. Shift the transmission into neutral. 3. If equipped with 4-wheel drive (4WD), remove the front propeller shaft. 4. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 5. Disconnect the park/neutral position (PNP) switch electrical connector (2). 6. Remove the manual shaft lever nut. Page 12918 Audio Amplifier C1 - UQ7 With RPO Code Y91 - Part 2 Page 10269 1. Position the steering wheel control switch to the steering wheel. 2. Connect the electrical connector to the steering wheel control switch. 3. Install the steering wheel control switch into the steering wheel, ensuring the retaining tabs are fully seated. 4. Install the shroud to the steering wheel. 5. Notice: Refer to Fastener Notice in Service Precautions. Install the shroud retaining screws to the steering wheel. ^ Tighten the screws to 2 Nm (18 inch lbs.). 6. Install the steering wheel. Page 6992 9. Install the retaining ring. 10. Install the axle shaft. 11. Inspect the lubricant level and add, if necessary. 12. Lower the vehicle. Page 10466 8. Remove the adjusting nut. 9. Remove the hub from the axle housing. 10. Remove the rotor, if necessary. 11. Remove the oil seal from the wheel hub using a suitable seal removal tool. 12. Remove the inner hub bearing. 13. Remove the inner hub bearing cup using a brass drift and a hammer. Page 13881 Page 10678 service operation. A simple distraction or time constraint that rushes the job may result in personal injury if the greatest of care is not exercised. Make it a habit to double check your work and to always side with caution when installing wheels. Disclaimer Page 12462 Important: The optic cable must not be bent with a radius less than 25 mm (1 in). 6.17. Fold back the wiring harness and tape over the connectors (G). Fold back the wiring harness once more and secure with cable ties (H). 6.18. Secure the new optic cable on the parcel shelf along the existing wiring harness by the ordinary securing points and by the speaker (I). 6.19. Thread the optic cable down next to the old cable from the parcel shelf to the left-hand wheel housing, next to REC. The cable is secured in the existing clips. 6.20. Fit the right-hand C-pillar trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.21. Fit the parcel shelf trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.22. Fit the passenger seat in accordance with WIS - 8. Body - Seats - Adjustment/Replacement. 6.23. Fit the right-hand side bolster in accordance with WIS - 8. Body - Seats Adjustment/Replacement. 6.24. Fold up the rear seat backrest. 6.25. Fit the right-hand B-pillar trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.26. Fit the A-pillar's lower side piece. 7. M04-05, 4D: Removing the OnStar® control modules and securing the wiring: Interior - Seat Memory Feature Appears Inoperative Memory Positioning Module: All Technical Service Bulletins Interior - Seat Memory Feature Appears Inoperative Bulletin No.: 04-08-50-003 Date: February 26, 2004 INFORMATION Subject: Enabling Memory Seat Feature via DIC If Feature Appears Inoperative Models: 2003-2004 Cadillac Escalade, Escalade ESV, Escalade EXT 2003-2004 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2003-2004 GMC Sierra, Yukon, Yukon Denali, Yukon Denali XL 2003-2004 HUMMER H2 with Steering Wheel Controls (RPO UK3) (standard on H2) If the memory seat feature appears inoperative, check the Driver Information Center (DIC). Many of the memory seat modules that were returned through the Warranty Parts Center for a condition of inoperative have shown No Trouble Found. The Driver Information Center (DIC), programmed for Seat Entry and Exit, is set to the default "Off" mode at the assembly plant. DO NOT REPLACE THE MEMORY SEAT MODULE. Perform the following procedure. Important: The following procedure will need to be completed for each Remote/Key selection. Using the DIC menu, do the following steps: 1. Set the "Seat Recall" to either "At Key In" or "On Remote" based on the customer's preference. 2. Set the "Exit Seat" to "On". 3. Adjust the following items: Memory Seat: 3.1. Driver's Seat (including the seat back, recliner, lumbar, and side wings) 3.2. Throttle and Brake Pedals (not available on H2 or Silverado and Sierra Trucks) 3.3. Outside Mirrors 3.4. Radio Station Presets 3.5. Last Chosen Climate Control System Settings (not available on Silverado or Sierra Trucks) 3.6. Press and hold the "1" or "2" (for driver 1 or 2) button of the memory control for three seconds. A double chime will sound to let you know that the position has been stored. Easy Exit Seat: 3.1. Press and release the 1 or 2 button or press the unlock button on the desired remote keyless entry transmitter. The seat will move to the stored memory position. 3.2. Adjust the seat to the desired exit position. 3.3. Press and hold the exit button of the memory control (located on the door) for three seconds. A double chime will sound to let you know that the position has been stored for the identified driver (1 or 2). Page 7223 Power Take-Off: Diagnostic Aids Basic Knowledge Required BASIC KNOWLEDGE REQUIRED Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the Service Data. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories CHECKING AFTERMARKET ACCESSORIES Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: - Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions INDUCING INTERMITTENT FAULT CONDITIONS In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: - Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. Page 16040 SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-D. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: - The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair Tools Required J 38125-D Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-D. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Page 9694 Tighten Tighten to 8 Nm (71 lb in). Note The repair area MUST BE properly refinished to maintain a secure, stable and corrosion-free electrical ground. 12. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 13. Verify proper system operation. M8 Weld Nut Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M8 weld nut electrical ground location is accessible from both sides of the panel, a M8 conductive bolt and a M8 conductive nut may be used to secure the electrical ground wire terminal. Refer to the Parts Information section of this bulletin. 2. Select a location adjacent the M8 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the new electrical ground site. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the ground location and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 10 mm (0.40 in) diameter hole through the panel. 5. Remove paint and primer from the area surrounding the 10 mm (0.40 in) hole until bare metal is visible. 6. Select a M8 conductive bolt. Refer to the Parts Information section of this bulletin. 7. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M8 conductive bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 8. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 9. Install the electrical ground wire terminal and the M8 conductive bolt to the ground location. 10. Select a M8 conductive nut. Refer to the Parts Information section of this bulletin. 11. Install the M8 conductive nut to the bolt and: Tighten Tighten to 22 Nm (16 lb ft). Note The repair area MUST BE properly refinished to maintain a secure, stable and corrosion-free electrical ground. 12. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 13. Verify proper system operation. M8 Weld Nut Alternative Repair Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M8 weld nut electrical ground location is not accessible from both sides of the panel, a M6 conductive rivet stud and a M6 conductive nut may be used to secure the electrical ground wire terminal. 2. Select a location adjacent the damaged M8 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the M6 conductive rivet stud flange. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the repair site and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 10 mm (0.40 in) diameter hole through the panel. Page 4326 Control Module References Part 2 Page 7217 Electrical Symbols Part 9 Page 12385 2. Install the module on the bracket. NOTE: Refer to Fastener Notice in Service Precautions. 3. Install the retaining nuts (2). Tighten Tighten the nuts to 1.6 N.m (14 lb in). 4. Connect the coaxial cable (3) to the module. 5. Connect the wire connectors (2) to the module. 6. Install the I/P trim panel. IMPORTANT: After replacing the vehicle communication interface module, you must reconfigure the Onstar(R) system. Failure to reconfigure the system will result in an additional customer visit for repair. In addition, pressing and holding the white dot button on the keypad will NOT reset this version of the Onstar(R) system. This action will cause a DTC to set. 7. Reconfigure the Onstar(R) system. Refer to OnStar Reconfiguration. See: Testing and Inspection/Programming and Relearning Page 16108 Window Switch - RR (Crew Cab Only) Part 1 Page 14260 Auto Magic(R) or Clay Magic(R) products available from: Auto Wax Company, Inc. 1275 Round Table Dr. Dallas, TX 75247 (800) 826-0828 (Toll-Free) or (214) 631-4000 (Local) Fax (214) 634-1342 www.automagic.com [email protected] E038 Fallout Gel or E038E Liquid Fallout Remover II available from: Valvoline Car Brite Company 1910 South State Avenue Indianapolis, In 46203 (800) 347-2439 (Toll Free) or (317) 788-9925 (Local) Fax (317) 788-9930 www.carbrite.com [email protected] *We believe these sources and their products to be reliable. There may be additional manufacturers of such products. General Motors does not endorse, indicate any preference for or assume any responsibility for the products from these firms or for any such items which may be available from other sources. If rail dust remover is not available in your area, call one of the numbers listed above for a distributor near your location. Warranty Information (excluding Saab U.S. Models) Important Refer to the Policy & Procedures Manual, section 1.2.1.7 for detailed information regarding warranty coverage for this condition. Important In certain cases where the vehicle finish is severely damaged and the actual repair time exceeds the published time, the additional time should be submitted in the "Other Labor Hours" field. Warranty Information (Saab U.S. Models) Disclaimer Specifications Page 9230 C306 Infotainment Jumper Harness To Console Harness (Without RPO Code Y91) Part 2 Steering/Suspension - Wheel Alignment Specifications Alignment: Technical Service Bulletins Steering/Suspension - Wheel Alignment Specifications WARRANTY ADMINISTRATION Bulletin No.: 05-03-07-009C Date: December 09, 2010 Subject: Wheel Alignment Specifications, Requirements and Recommendations for GM Vehicles Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks Supercede: This bulletin is being extensively revised to provide technicians and warranty administrators with an all inclusive guide for wheel alignments. PLEASE FAMILIARIZE YOURSELF WITH THESE UPDATES BEFORE PERFORMING YOUR NEXT GM WHEEL ALIGNMENT SERVICE. Please discard Corporate Bulletin Number 05-03-07-009B (Section 03 - Suspension). Purpose The purpose of this bulletin is to provide retail, wholesale and fleet personnel with General Motors' warranty service requirements and recommendations for customer concerns related to wheel alignment. For your convenience, this bulletin updates and centralizes all of GM's Standard Wheel Alignment Service Procedures, Policy Guidelines and bulletins on wheel alignment warranty service. Important PLEASE FAMILIARIZE YOURSELF WITH THESE UPDATES BEFORE PERFORMING YOUR NEXT GM WHEEL ALIGNMENT SERVICE. The following five (5) key steps are a summary of this bulletin and are REQUIRED in completing a successful wheel alignment service. 1. Verify the vehicle is in an Original Equipment condition for curb weight, tires, wheels, suspension and steering configurations. Vehicles modified in any of these areas are not covered for wheel alignment warranty. 2. Review the customer concern relative to "Normal Operation" definitions. 3. Verify that vehicle is within the "Mileage Policy" range. 4. Document wheel alignment warranty claims appropriately for labor operations E2000 and E2020. The following information must be documented or attached to the repair order: - Customer concern in detail - What corrected the customer concern? - If a wheel alignment is performed: - Consult SI for proper specifications. - Document the "Before" AND "After" wheel alignment measurements/settings. - Completed "Wheel Alignment Repair Order Questionnaire" (form attached to this bulletin) 5. Use the proper wheel alignment equipment (preferred with print-out capability), process and the appropriate calibration maintenance schedules. Important If it is determined that a wheel alignment is necessary under warranty, use the proper labor code for the repair. E2000 for Steering Wheel Angle and/or Front Toe set or E2020 for Wheel Alignment Check/Adjust includes Caster, Camber and Toe set (Wheel alignment labor time for other component repairs is to be charged to the component that causes a wheel alignment operation.). The following flowchart is to help summarize the information detailed in this bulletin and should be used whenever a wheel alignment is performed. Page 9187 C127 Snowplow Harness To Forward Lamp Harness (With RPO Code VYU) Page 12178 ^ SP303 The following modules, components, and splice pack are connected to the star portion of the class 2 serial data circuit: ^ SP300 ^ Audio amplifier ^ Driver door module (DDM) ^ Driver door switch assembly (DDSA) ^ Memory seat module (MSM) ^ Left rear door module (LRDM) AND ^ SP303 ^ Antenna module ^ Front passenger door module (FPDM) ^ Rear integration module (RIM) ^ Right rear door module (RRDM) ^ Theft deterrent module (TDM) ^ Vehicle communication interface module (VCIM). Refer to Data Communication Schematics and Data Link Communications Description and Operation in SI. Part 2 Conditions for Running the DTC Voltage supplied to the module is in the normal operating voltage range of 9 - 16 volts. DTCs B1327, B1328, U1300, U1301, U1305 are not set as current. The vehicle power mode requires serial data communication to occur. Conditions for Setting the DTC A message containing a critical operating parameter has not been received within the last 5 seconds after establishing class 2 serial data communication. Action Taken When the DTC Sets The module uses a default value for the missing parameter. Conditions for Clearing the DTC A current DTC clears when the malfunction is no longer present. A history DTC clears when the module ignition cycle counter reaches the reset threshold, without a repeat of the malfunction. Diagnostic Aids When a malfunction such as an open fuse to a module occurs while modules are communicating, a DTC U1001-1254 Loss of XXX Communications is set current. When the modules stop communicating the current DTC U1001-1254 Loss of XXX Communications is cleared but the history DTC remains. When the modules begin to communicate again, the module with the open fuse will not be learned by the other modules so U1000 or U1255 is set current by the other modules. If the malfunction occurs when the modules are not communicating, only U1000 or U1255 is set. Page 15966 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Page 13984 9. Remove the quarter trim panel. 10. Remove the lower bolt from the instrument panel (I/P) support post. 11. Remove the carpet from the vehicle. Installation Procedure Caution: In order to avoid personal injury or vehicle damage when you repair or replace the carpet, use the same thickness and material size as the original installation. Always return the carpet to the original location. 1. Install the carpet to the vehicle. 2. Install the lower bolt to the I/P support post. 3. Install the rear quarter trim panel. 4. Install the jack assembly. 5. Install the rear seat if removed. 6. Install the shift lever and the boot, if equipped. 7. Install the center seat, if equipped. 8. Install the floor storage console. 9. Install the front seats. 10. Install the door sill plates. 11. Install the hinge pillar trim panel. Page 1327 Discharge Air Temperature Sensor / Switch: Description and Operation AIR TEMPERATURE SENSORS The air temperature sensors are a 2-wire negative temperature co-efficient thermistor. The vehicle uses the following air temperature sensors: Ambient Air Temperature Sensor - Inside Air Temperature Sensor Assembly - Upper Left Air Temperature Sensor - Upper Right Air Temperature Sensor - Lower Left Air Temperature Sensor - Lower Right Air Temperature Sensor A signal and a low-reference circuit enables the sensor to operate. As the air temperature surrounding the sensor increases, the sensor resistance decreases. The sensor signal voltage decreases as the resistance decreases. The sensor operates within a temperature range between -40°C (-40°F) to 101°C (215°F). The sensor signal varies between 0.5 volts. The input of the duct air temperature sensors are different from the ambient and inside sensors. The HVAC control module converts the signal to a range between 0-255 counts. As the air temperature increases the count value will decrease. If the HVAC control module detects a malfunctioning sensor, then the control module software will use a defaulted air temperature value. The default value for the ambient and inside air temperature sensors will be displayed on the scan tool. The default value for the duct air temperature sensors will not be displayed on the scan tool. The scan tool parameter for the duct air temperature sensors are the actual state of the signal circuit. The default action ensures that the HVAC system can adjust the inside air temperature near the desired temperature until the condition is corrected. The ambient air temperature sensor mounts underhood and can be affected by city traffic, by idling, and by restarting a hot engine. Therefore, the HVAC control module filters the value of the ambient air temperature sensor for temperature display. The ambient air temperature value is updated under the above conditions. The scan tool has the ability to update the displayed ambient air temperature. To update the ambient air temperature display on the HVAC control module, perform the following procedure: Simultaneously press the MODE, FRONT DEFROST and REAR DEFROST switches. 1. Turn ON the ignition. 2. Simultaneously press the MODE, FRONT DEFROST and REAR DEFROST switches. Page 12227 1. Remove the ground cable from the battery's negative cable. 2. Remove the center console, see WIS - Body - Interior. 3. Loosen the gear shift housing (A). AUT: Disconnect the 6-pin connector (B) to improve access to the gear shift housing screws. 4. Disconnect the signal cable from the SRS control module to the OnStar(R) control module and secure the cable. 4.1. Disconnect the connector (A) from the SRS control module and cut the cable tie (B). Page 6270 3. Install the engine protection shield. 4. Lower the vehicle. 5. Install the transmission fluid cooler hose to the radiator. 6. Install the transmission fluid cooler hose to the Auxiliary oil cooler. 7. Install the front grill assembly. Page 8475 been prepared, and are being furnished to involved dealers. The customer name and address data will enable dealers to follow up with customers involved in this recall. Any dealer not receiving a computer listing with the recall bulletin has no involved vehicles currently assigned. These dealer listings may contain customer names and addresses obtained from Motor Vehicle Registration Records. The use of such motor vehicle registration data for any other purpose is a violation of law in several states/provinces/countries. Accordingly, you are urged to limit the use of this listing to the follow-up necessary to complete this recall. PARTS INFORMATION Parts required to complete this recall are to be obtained from General Motors Service Parts Operations (GMSPO). Please refer to your "involved vehicles listing" before ordering parts. Normal orders should be placed on a DRO = Daily Replenishment Order. In an emergency situation, parts should be ordered on a CSO = Customer Special Order. Important It is estimated that only 20% of involved vehicles will require Valve Kit Repair. Please order parts accordingly. COURTESY TRANSPORTATION The General Motors Courtesy Transportation program is intended to minimize customer inconvenience when a vehicle requires a repair that is covered by the New Vehicle Limited Warranty. The availability of courtesy transportation to customers whose vehicles are within the warranty coverage period and involved in a product recall is very important in maintaining customer satisfaction. Dealers are to ensure that these customers understand that shuttle service or some other form of courtesy transportation is available and will be provided at no charge. Dealers should refer to the General Motors Service Policies and Procedures Manual for Courtesy Transportation guidelines. Engine Controls - MIL ON/Misfire/Misfire DTC's Set Ground Strap: Customer Interest Engine Controls - MIL ON/Misfire/Misfire DTC's Set Bulletin No.: 06-06-04-046 Date: September 12, 2006 INFORMATION Subject: Information on Engine Misfire MIL/SES Light Illuminated or Flashing DTC P0300, P0301, P0302, P0303, P0304, P0305, P0306, P0307, P0308, P0420 or P0430 Models: 1999-2007 Cadillac, Chevrolet, GMC Full-Size Pickup and/or Utility Trucks with 4.8L, 5.3L, 5.7L, 6.0L or 6.2L VORTEC GEN III, GEN IV, V-8 Engine (VINs V, C, T, Z, B, 3, M, 0, J, R, U, N, Y, K, 8 - RPOs LR4, LY2, LM7, L59, L33, LC9, LH6, LMG, LY5, L31, LQ4, LQ9, L76, LY6, L92) with Active Fuel Management(TM) and E85 Flex Fuel If you encounter vehicles that exhibit the above conditions, refer to SI for the appropriate DTC(s) set. If no trouble is found, the cause may be due to an ECM ground terminal that has corroded with rust over time. Inspect the main engine wiring harness ground terminal (G103) for this condition. The wire terminal (G103) attaches either to the front or to the rear of the right side cylinder head, depending on the model year of the Full Size Pickup and/or Utility Trucks. If the ECM ground terminal has been found to be corroded, then follow the service procedure outlined in this bulletin to correct the corrosion issue. Remove either the nut or bolt securing the main engine wiring harness ground terminal (G103) to the right cylinder head. Refer to the above illustration to determine where the ground is located on the vehicle (1). Page 2219 Put unused material on the shelf for future use. Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Page 272 ^ For U.S. Saturn retailer claim submission, use Net Item code "M" and Case Type VW. Recall 05V043000: Brake Hydro-Boost Unit Defect Hydraulic Brake Booster: Recalls Recall 05V043000: Brake Hydro-Boost Unit Defect MAKE/MODELS: MODEL/BUILD YEARS: Chevrolet/Avalanche 2004-2005 Chevrolet/Express 2004-2005 Chevrolet/Kodiak 2004-2005 Chevrolet/Silverado 2004-2005 Chevrolet/Suburban 2004-2005 GMC/Savana 2004-2005 GMC/Sierra 2004-2005 GMC/Topkick 2004-2005 GMC/Yukon XL 2004-2005 Hummer/H2 2004-2005 MANUFACTURER: General Motors Corp. NHTSA CAMPAIGN ID Number: 05V043000 RECALL DATE: Feb 04, 2005 COMPONENT: Service Brakes, Hydraulic POTENTIAL NUMBER OF UNITS AFFECTED: 155465 SUMMARY: Certain trucks, sport utility vehicles, and vans equipped with Bosch Hydro-Boost brake assemblies, the hydraulic brake booster pressure accumulator may crack and separate from the hydro-boost assembly during normal operating conditions. CONSEQUENCE: If a separation occurred and the hood of the vehicle were open, fragments from the accumulator could cause injury to people in the immediate area. The presence of this crack or fractured surface could allow the hydraulic fluid to leak from the accumulator circuit of the booster assembly. The loss of fluid would cause increased steering and braking effort and a crash may occur without prior warning. REMEDY: Dealers will test the Hydro-Boost assembly for functional operation of the two-function valve. If the Hydro-Boost assembly fails the test, dealers are to replace the assembly. The recall is expected to begin during March 2005. Owners should contact Chevrolet at 1-800-630-2438, GMC Trucks at 1-866-996-9463 and Hummer at 1-800-732-5493. NOTES: GM recall No. 05006. Customers can also contact The National Highway Traffic Safety Administration's Auto Safety Hotline at 1-888-327-4236. Page 3638 Heater Core: Service and Repair Heater Core Replacement - Visteon HEATER CORE REPLACEMENT (VISTEON) REMOVAL PROCEDURE 1. Remove the HVAC module assembly. See: Heating and Air Conditioning/Housing Assembly HVAC/Service and Repair 2. Remove the screws from the heater core cover. 3. Remove the heater core cover (1) from the HVAC module assembly (2). 4. Remove the heater core cowl gasket (1) from the heater core (2). 5. Remove the heater core (1) from the HVAC module assembly (2). Page 3209 12. Remove and discard the old gasket (1). 13. If required, clean and inspect the rocker arm cover. Installation Procedure Important: ^ All gasket surfaces should be free of oil an/or other foreign material during assembly. ^ DO NOT reuse the valve rocker arm cover gasket. ^ If the PCV valve grommet has been removed from the rocker cover, install a NEW grommet during assembly. 1. Install a NEW rocker cover gasket (1). 2. Install the valve rocker arm cover. Notice: Refer to Fastener Notice in Service Precautions. 3. Tighten the rocker arm cover bolts. ^ Tighten the bolts to 12 Nm (106 inch lbs.). Page 6814 1. Install the outer pinion bearing cup using the J 8611-01 , 8.6 inch axle, or the J 7818, 9.5 inch axle, or the J 8608 (11.5 inch axle) (2) and the J 8092 (1). 2. Install the inner pinion bearing cup using the J 45900, 8.6 inch axle, or the J 22306, 9.5 inch axle, or the J 44417, 11.5 inch axle (2) and the J 8092 (1). 3. Determine the selective shim thickness for the pinion. 4. Install the selective shim between the inner pinion bearing and the shoulder on the gear. 5. Install the inner pinion bearing using the J 24433, 8.6 inch axle, or the J 36614, 9.5 inch axle, or the J 44412, 11.5 inch axle. Press the bearing on until the cone seats on the pinion shim. 6. Install a new collapsible spacer. 7. Lubricate the pinion bearings with axle lubricant. Use the proper fluid. 8. Install the outer pinion bearing into the axle housing. Page 12836 Locations Ambient Light Sensor Page 5838 Parts Information Warranty Information (excluding Saab U.S. Models) Warranty Information (Saab U.S. Models) Page 3342 Install the oil level sensor to the oil pan. ^ Tighten the sensor to 13 Nm (115 inch lbs.). 2. Connect the oil level sensor electrical connector (3). 3. Fill the engine oil. Page 8226 5. Perform the following procedure to remove the cable from the backing plate: 1. Compress the spring by pushing towards the lever. 2. Depress the locking tabs. 3. Pull the cable housing out of the backing plate. 4. Remove the cable through the slot in the backing plate. 6. Remove the rotor. 7. Remove the axle shaft. 8. Remove the park brake shoe. 9. Remove the backing plate bolts. 10. Remove the backing plate from axle housing flange. Installation Procedure 1. Install the backing plate to the axle housing flange. Page 3210 4. Install the PCV hose. 5. Apply threadlock GM P/N 12345382 (Canadian P/N 10953489), or equivalent to the threads of the bracket bolts. 6. Install the ignition coil bracket. 7. Install the ignition coil bracket studs. ^ Tighten the studs to 12 Nm (106 inch lbs.). 8. Install the spark plug wires to the ignition coils. 9. Position the engine harness, if necessary. 10. Install the harness clips (1). 11. Connect the main electrical connector (2) to the ignition coil wire harness. 12. Install the CPA lock. 13. Install the engine sight shield, if required. Page 787 The information shown is for the 1999-2002 wiring harnesses and for the 2003-05 wiring harness. To modify a 12171982, 15366255 or 15086884 harness for use in a 2003-05 vehicle, switch the wires in cavities "A" and "D". To modify a 15085418 harness for use in a 1999-2002 vehicle (see model list at the front of this bulletin for applicable models), switch the wires in cavities "A" and "D". Warranty Information When the correct wiring harness P/N is matched to the specific model year of the vehicle, everything works properly. Therefore, conversion of an incorrect wiring jumper to match the vehicle would not be considered a warrantable repair. Disclaimer Page 4648 When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage TESTING FOR A SHORT TO VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity TESTING FOR CONTINUITY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents TESTING FOR ELECTRICAL INTERMITTENTS Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground - Testing for Continuity - Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 msRECORD and emits an audible tone (beep). Interior - Erratic Memory Seat Operation Memory Positioning Module: All Technical Service Bulletins Interior - Erratic Memory Seat Operation Bulletin No.: 04-08-50-016C Date: August 12, 2005 TECHNICAL Subject: Memory Seat May Not Return to Requested Position (Reprogram Driver Seat Module) Models: 2003-2005 Cadillac Escalade, Escalade ESV, Escalade EXT 2003-2005 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2003-2005 GMC Sierra, Yukon, Yukon XL, Yukon Denali All with Seat FRT, Individual (Non BKT) (RPO AN3) 2003-2005 HUMMER H2 with Seat, Front Bucket Deluxe (RPO AR9) Supercede: This bulletin is being revised to update the correction information. Please discard Corporate Bulletin Number 04-08-50-016B (Section 08 - Body and Accessories). Condition Some customers may comment that with repeated cycling of the memory seat between the "exit" and one of the "presets", the position of the seat may "creep" forward or rearward out of expected adjustment. Cause There is a coding deficiency in the software for the memory seat module. Correction Technicians are to reprogram the driver seat module with an updated software calibration. The previous bulletin stated to use a service calibration that was released with TIS satellite data update version 4.5. Feedback has proved that calibration to be ineffective in eliminating the memory seat creep condition. An updated service calibration was released with TIS satellite data update version 6.5 available June 13, 2005. This new calibration has additional memory seat creep protection. As always, make sure your Tech 2(R) is updated with the latest software version. Important: After programming is complete, move the seat all the way rearward and down, then bump the seat slightly forward and up. This position will be just off the end of travel hard stops. Reset both memory seat exit positions at this position. Having the seat set at just off the hard stops will aid in reducing the creep condition. Warranty Information Page 9713 C125 Snowplow Harness To Forward Lamp Harness (With RPO Code VYU) Page 7565 9. Disassemble the harness connector (1) from the encoder. 10. Remove the encoder from the output shaft using a flat tip screwdriver. Installation Procedure 1. Assemble the harness to the NEW encoder with the connector legend "TOP" (1) and the encoder part number facing up. 2. Assemble the output shaft into the encoder, being sure to align the encoder tab with the groove on the shaft. 3. Ensure the encoder is seating properly on the output gear. 4. Place the output shaft encoder on the casting. 5. Place the grommet harness on the casting slot, the flat area on the grommet will be facing up. Page 9728 C201 Steering Column Harness To I/P Harness Part 3 Page 11997 Restraints - Passenger Presence System Information Seat Occupant Sensor: All Technical Service Bulletins Restraints - Passenger Presence System Information INFORMATION Bulletin No.: 06-08-50-009F Date: December 23, 2010 Subject: Information on Passenger Presence Sensing System (PPS or PSS) Concerns With Custom Upholstery, Accessory Seat Heaters or Other Comfort Enhancing Devices Models: 2011 and Prior GM Passenger Cars and Trucks Equipped with Passenger Presence Sensing System Supercede: This bulletin is being revised to update the model years. Please discard Corporate Bulletin Number 06-08-50-009E (Section 08 - Body and Accessories). Concerns About Safety and Alterations to the Front Passenger Seat Important ON A GM VEHICLE EQUIPPED WITH A PASSENGER SENSING SYSTEM, USE THE SEAT COVERS AND OTHER SEAT-RELATED EQUIPMENT AS RELEASED BY GM FOR THAT VEHICLE. DO NOT ALTER THE SEAT COVERS OR SEAT-RELATED EQUIPMENT. ANY ALTERATIONS TO SEAT COVERS OR GM ACCESSORIES DEFEATS THE INTENDED DESIGN OF THE SYSTEM. GM WILL NOT BE LIABLE FOR ANY PROBLEMS CAUSED BY USE OF SUCH IMPROPER SEAT ALTERATIONS, INCLUDING ANY WARRANTY REPAIRS INCURRED. The front passenger seat in many GM vehicles is equipped with a passenger sensing system that will turn off the right front passenger's frontal airbag under certain conditions, such as when an infant or child seat is present. In some vehicles, the passenger sensing system will also turn off the right front passenger's seat mounted side impact airbag. For the system to function properly, sensors are used in the seat to detect the presence of a properly-seated occupant. The passenger sensing system may not operate properly if the original seat trim is replaced (1) by non-GM covers, upholstery or trim, or (2) by GM covers, upholstery or trim designed for a different vehicle or (3) by GM covers, upholstery or trim that has been altered by a trim shop, or (4) if any object, such as an aftermarket seat heater or a comfort enhancing pad or device is installed under the seat fabric or between the occupant and the seat fabric. Aftermarket Seat Heaters, Custom Upholstery, and Comfort Enhancing Pads or Devices Important ON A GM VEHICLE EQUIPPED WITH A PASSENGER SENSING SYSTEM, USE ONLY SEAT COVERS AND OTHER SEAT-RELATED EQUIPMENT RELEASED AS GM ACCESSORIES FOR THAT VEHICLE. DO NOT USE ANY OTHER TYPE OF SEAT COVERS OR SEAT-RELATED EQUIPMENT, OR GM ACCESSORIES RELEASED FOR OTHER VEHICLE APPLICATIONS. GM WILL NOT BE LIABLE FOR ANY PROBLEMS CAUSED BY USE OF SUCH IMPROPER SEAT ACCESSORIES, INCLUDING ANY WARRANTY REPAIRS MADE NECESSARY BY SUCH USE. Many types of aftermarket accessories are available to customers, upfitting shops, and dealers. Some of these devices sit on top of, or are Velcro(R) strapped to the seat while others such as seat heaters are installed under the seat fabric. Additionally, seat covers made of leather or other materials may have different padding thickness installed that could prevent the Passenger Sensing System from functioning properly. Never alter the vehicle seats. Never add pads or other devices to the seat cushion, as this may interfere with the operation of the Passenger Sensing System and either prevent proper deployment of the passenger airbag or prevent proper suppression of the passenger air bag. Disclaimer Page 11326 Control Module HVAC: Locations HVAC Control Module Page 1889 Install the parking lock bracket bolts. ^ Tighten the bolts to 24 Nm (18 ft. lbs.). 13. Install the PNP switch. 14. Install the transmission filter. 15. Fill the transmission to the proper level with Dexron® III transmission fluid. Front Drive Axle Fluid - Differential: Service and Repair Front Drive Axle Lubricant Level Inspection Lubricant Level Inspection - Front Drive Axle 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Make sure the vehicle is level. 3. Inspect the front axle for leaks. Repair as necessary. 4. Clean the area around the front axle fill plug. 5. Remove the front axle fill plug (1). 6. Inspect the oil level. ^ For the 8.25 inch axle, the oil level should be between 12-16 mm (0.50-0.625 inch) below the fill plug opening. ^ For the 9.25 inch axle, the oil level should be between 0-6 mm (0-0.25 inch) below the fill plug opening. 7. If the level is low, add oil until the level is between 12-16 mm (0.50-0.625 inch) for the 8.25 inch axle or 0-6 mm (0-0.25 inch) for the 9.25 inch axle. Use the correct fluid. 8. Install the fill plug. ^ Tighten the plug to 33 Nm (24 ft. lbs.). Notice: Refer to Fastener Notice in Service Precautions. 9. Lower the vehicle. Lubricant Replacement Lubricant Replacement - Front Drive Axle Removal Procedure 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Remove the front differential carrier shield, if equipped. 3. Clean the area around the front axle fill plug and the drain plug. 4. Remove the fill plug. 5. Remove the drain plug. 6. Drain the fluid from the front differential carrier assembly. HVAC System - Manual Control Module HVAC: Description and Operation HVAC System - Manual HVAC CONTROL MODULE The HVAC control module is a class 2 device that interfaces between the operator and the HVAC system to maintain air temperature and distribution settings. The battery positive voltage circuit provides power that the control module uses for keep alive memory (KAM). If the battery positive voltage circuit loses power, all HVAC DTCs and settings will be erased from KAM. The body control module (BCM), which is the vehicle mode master, provides a device on signal. The control module supports the above features. The HVAC control module is a class 2 device that interfaces between the operator and the HVAC system to maintain air temperature and distribution settings. The battery positive voltage circuit provides power that the control module used for keep alive memory (KAM). If the battery positive voltage circuit loses power, all HVAC DTCs and settings will be erased from KAM. The body control module (BCM), which is the vehicle mode master, provides a device on signal. The control module supports the above features. Recall - Brake Booster Pressure Accumulator Cracking Technical Service Bulletin # 05006 Date: 050323 Recall - Brake Booster Pressure Accumulator Cracking Product Safety - Hydro-Boost Accumulator Over-Pressurization # 05006 - (Mar 23, 2005) Models: 2004 Chevrolet Kodiak 2004-2005 Chevrolet Avalanche, Express, Silverado, Suburban 2004 GMC TopKick 2004-2005 GMC Savana, Sierra, Yukon XL Condition General Motors has decided that a defect, which relates to motor vehicle safety, exists in certain 2004 Chevrolet Kodiak and GMC TopKick; 2004-2005 Chevrolet Avalanche, Express, Silverado, Suburban; GMC Savana, Sierra, Yukon XL vehicles. On some of these vehicles, the hydraulic brake booster's pressure accumulator may crack and/or separate from the Hydro-Boost(R) assembly during normal vehicle operating conditions. If a separation were to occur and the hood of the vehicle were open, fragments from the accumulator could cause injury to people in the immediate area. In addition, the presence of this crack or fractured surface could allow the hydraulic fluid to leak from the accumulator circuit of the booster assembly. The loss of fluid would cause increased steering and braking effort. Correction Dealers are to inspect the hydraulic brake booster, and replace it if necessary. Vehicles Involved Involved are certain 2004 Chevrolet Kodiak and GMC TopKick; 2004-2005 Chevrolet Avalanche, Express, Silverado, Suburban; GMC Savana, Sierra, Page 8686 5. Remove the mounting screws (1) that fasten the EBCM (2) to the BPMV (3). 6. Remove the EBCM (2) from the BPMV (3). Removal may require a light amount of force. Notice: Do not use a tool to pry the EBCM or the BPMV. Excessive force will damage the EBCM. Page 9321 Location View Location View Page 4487 Electrical Symbols Part 10 Page 7915 7. Remove the transmission control lever from the manual shaft. 8. Remove the PNP switch bolts. 9. Remove the PNP switch from the manual shaft. If the PNP switch did not slide off the manual shaft, file the outer edge of the manual shaft in order to remove any burrs. Installation Procedure 1. Install the PNP switch to the transmission manual shaft by aligning the switch hub flats with the manual shaft flats. 2. Slide the PNP switch onto the transmission manual shaft until the switch mounting bracket contacts the mounting bosses on the transmission. 3. Important: If a NEW PNP switch is being installed, the switch will come with a positive assurance bracket. The positive assurance bracket aligns the new switch in its proper position for installation and the use of the park neutral switch aligner will not be necessary. Install the PNP switch bolts finger tight. 4. Install J 41364-A onto the PNP switch. Ensure that the two slots on the switch where the manual shaft is inserted are lined up with the lower two tabs on the tool. 5. Notice: Refer to Fastener Notice in Service Precautions. Rotate the tool until the upper locator pin on the tool is lined up with the slot on the top of the switch. ^ Tighten the bolts to 25 Nm (18 ft. lbs.). 6. Remove the J 41364-A from the switch. If installing a new switch, remove the positive assurance bracket at this time. 7. Install the transmission control lever to the manual shaft with the nut. ^ Tighten the nut to 25 Nm (18 ft. lbs.). Page 11485 NOTE: Refer to Fastener Notice in Service Precautions. 4. Install the fasteners (2) to the inflatable restraint side impact sensor (1) using only hand tools. Tighten Tighten the fasteners to 10 N.m (89 lb in). 5. Install the door trim panel. 6. Enable the SIR system. Refer to SIR Disabling and Enabling Zone 6. Page 10647 Balancing of the tire and wheel assembly must be performed on a computerized balancer, capable of static and dynamic wheel balance modes. Assemblies should be balanced to within 1/4 ounce on either rim flange. Proper cones and adapters should be used, free of nicks and burrs to ensure proper balancing. Center Cap Install the center cap onto the wheel after the tire has been mounted and balanced, but BEFORE the assembly is installed onto the vehicle. The preferred method for center cap installation is to push in by hand. As an alternate, use a nonmetallic object to push the center cap into place. Attempting to "hammer-on" the caps may result in damage to the cap. Wheel (Lug) Nuts ALUMINUM WHEELS REQUIRE SPECIAL WHEEL NUTS. Each wheel nut should be torqued in the appropriate torque sequence (refer to graphic) and to 190 N.m (140 lb ft). The torque should be re-checked after the first 160 km (100 mi). To help protect the wheels from theft, a wheel lock kit is also available. Incorrect wheel nuts or improperly tightened wheel nuts can cause the wheel to become loose and even come off. This could lead to an accident. Be sure to use the correct wheel nuts. Wheel Nut Caps Install the wheel nut caps after tightening the wheel nuts. Install the wheel nut caps finger tight, plus 1/2 turn. Jounce Bumper This modification is required on all 2WD vehicles EXCEPT the following: Excludes: 2006-2007 2WD Extended Cab - Short Box (model C15553) 2006-2007 2WD Crew Cab - Short Box with Enhanced Trailering (RPO NHT) (model C15543) 2006-2007 2WD Extended Cab - Standard Box with Enhanced Trailering (RPO NHT) (model C15753) It will be required to replace the existing front suspension spring/jounce bumper with Jounce Bumper kit, P/N 12499481. The following procedure should be followed: Raise and support the vehicle. Remove the nut from the spring bumper stud. Remove the spring bumper. Page 4639 Electrical Symbols Part 10 Locations Upper Steering Column Page 11173 1. Install the inlet heater hose (3) to the auxiliary water pump (1). 2. Position the inlet heater hose clamp (2) to the auxiliary water pump (1). 3. Connect the inlet heater hose to the heater core. 4. Firmly push the quick connect onto the heater core pipe until you hear an audible click. 5. Fill the cooling system. Refer to Draining and Filling Cooling System (with HP2)Draining and Filling Cooling System (without HP2) in Cooling System. Page 9796 Application Table Page 4093 2. Install the HO2S. Tighten Tighten the sensor to 42 N.m (31 lb ft). 3. If equipped with a 6.0L engine, connect the HO2S electrical connector. 4. If equipped with a 4.8L or 5.3L engine, connect the HO2S electrical connector. 5. Install the HO2S to the clips 6. Disconnect the CPA retainer. 7. Lower the vehicle. Ignition System - New Spark Plugs & Gapping Info. Spark Plug: Technical Service Bulletins Ignition System - New Spark Plugs & Gapping Info. INFORMATION Bulletin No.: 03-06-04-060B Date: July 30 2008 Subject: Information on New Spark Plugs and Gapping Models Attention: Please disregard the Set Gap Per Vehicle Specification statement on the side of an ACOelco(R) Iridium Spark Plug Box. The statement will be removed from the boxes in the future. Supercede: This bulletin is being revised to add the Chevrolet SSR and the 2005 Pontiac GTO. Please discard Corporate Bulletin Number 03-06-04-060A (Section 06 - Engine/Propulsion System). ^ A new spark plug has been released for use in the above vehicles. The new spark plug has an Iridium tip instead of the current Platinum tip. Due to the different tip design the gap of the spark plug has also changed. ^ The new spark plug P/N 12571164 with AC Delco P/N 41-985 is gapped to 1.01 mm (0.040 in) when the spark plug is made. Notice: The spark plug gap is set during manufacturing and should not be changed or damage to the spark plug may result. Any new spark plug found to not be properly gapped should not be used. Disclaimer Page 4692 Door Control Module Diagram 2 Part 2 Page 6862 ^ Tighten the pinion nut until the pinion end play is just taken up. Rotate the pinion while tightening the nut to seat the bearings. Notice: Refer to Fastener Notice in Service Precautions. Important: If the rotating torque is exceeded, the pinion will have to be removed and a new collapsible spacer installed. 8. Measure the rotating torque of the pinion using an inch-pound torque wrench.Compare the measurement with the rotating torque recorded earlier. ^ Tighten the pinion nut, in small increments, as needed, until the torque required in order to rotate the pinion is 0.40-0.57 Nm (3-5 inch lbs.) greater than the torque recorded during removal. 9. Once the specified torque is obtained, rotate the pinion several times to ensure the bearings have seated. Recheck the rotating torque and adjust if necessary. 10. Install the propeller shaft universal joint (2) to the pinion yoke (1).Align the reference marks made during removal. 11. Install the yoke retainers (7) and the yoke retainer bolts (6) to the pinion yoke (1). ^ Tighten the yoke retainer bolts to 25 Nm (18 ft. lbs.). 12. Inspect the axle lubricant level, and add, if necessary. 13. Install the differential carrier assembly shield, if equipped. 14. Install the brake calipers. 15. Install the tire and wheel assemblies. 16. Lower the vehicle. Page 13007 * Dealers using WINs: Add 0.2 hours to the labor time for administrative allowance for the module exchange. Dealers using GWM: Submit 0.2 hours administrative allowance under "Administration Time" for the module exchange. ** The $25 represents the additional net amount allowed for the module exchange. *** Dealers are to claim only administrative allowance of 0.2 hours when the module is replaced by Masscomp's Mobile Unit. Dealers using WINS should submit the 0.2 hours administrative allowance in labor time. Dealer using GWM should submit the 0.2 hours administrative allowance under Administrative Time. Customer Notification OnStar will notify customers of this program on their vehicle. Dealer Program Responsibility All unsold new vehicles in dealers'/retailers' possession and subject to this program must be held and inspected/repaired per the service procedure of this program bulletin before customers take possession of these vehicles. Dealers/retailers are to service all vehicles subject to this program at no charge to customers, regardless of mileage, age of vehicle, or ownership, through April 30, 2011. Customers who have recently purchased vehicles sold from your vehicle inventory, and for which there is no customer information indicated on the dealer/retailer listing, are to be contacted by the dealer/retailer. Arrangements are to be made to make the required correction according to the instructions contained in this bulletin. A copy of the customer letter is provided in this bulletin for your use in contacting customers. Program follow-up cards should not be used for this purpose, since the customer may not as yet have received the notification letter. Page 1882 7. Remove the transmission control lever from the manual shaft. 8. Remove the PNP switch bolts. 9. Remove the PNP switch from the manual shaft. If the PNP switch did not slide off the manual shaft, file the outer edge of the manual shaft in order to remove any burrs. Installation Procedure 1. Install the PNP switch to the transmission manual shaft by aligning the switch hub flats with the manual shaft flats. 2. Slide the PNP switch onto the transmission manual shaft until the switch mounting bracket contacts the mounting bosses on the transmission. 3. Important: If a NEW PNP switch is being installed, the switch will come with a positive assurance bracket. The positive assurance bracket aligns the new switch in its proper position for installation and the use of the park neutral switch aligner will not be necessary. Install the PNP switch bolts finger tight. 4. Install J 41364-A onto the PNP switch. Ensure that the two slots on the switch where the manual shaft is inserted are lined up with the lower two tabs on the tool. 5. Notice: Refer to Fastener Notice in Service Precautions. Rotate the tool until the upper locator pin on the tool is lined up with the slot on the top of the switch. ^ Tighten the bolts to 25 Nm (18 ft. lbs.). 6. Remove the J 41364-A from the switch. If installing a new switch, remove the positive assurance bracket at this time. 7. Install the transmission control lever to the manual shaft with the nut. ^ Tighten the nut to 25 Nm (18 ft. lbs.). Locations Fog/Driving Lamp Switch: Locations Instrument Panel Switches-LH Page 10824 Air Temperature Actuator - Right Page 9098 4. Connect the wire connectors to the lower portion of the electrical center block. 5. Connect the wire connectors with the bolts to the electrical center block. Tighten Tighten all connector bolts (1) to 9 N.m (80 lb in). 6. Ensure all wire connectors are securely connected. 7. Set the electrical center block in its resting position till the tabs (3) locks in place. 8. Install the lower part of the cover (1). 9. With the cover (2) off, use the fuse location information to install all fuses and relays. 10. Install the cover. 11. Install the fender upper brace. 12. Install the 4 fender upper brace bolts. Tighten Tighten the 4 retaining bolts to 25 N.m (18 lb ft). 13. Connect the negative battery cable. 14. Start vehicle and ensure all components function properly. Transfer Case - NVG 149-NP3 Speed Sensor: Service and Repair Transfer Case - NVG 149-NP3 Transfer Case Speed Sensor Replacement Removal Procedure 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. Disconnect the speed sensor electrical connector (4). 3. Remove the speed sensor. Installation Procedure 1. Install the speed sensor. ^ Tighten the sensor to 15 Nm (11 ft. lbs.). Notice: Refer to Fastener Notice in Service Precautions. Page 334 High OR Low The above conditions are met for more than 3 seconds. Circuit/System Verification These DTCs cannot be retrieved with a current status. To diagnose use the Scan Tool Does Not Communicate with a Class 2 Device. Refer to SI. An intermittent condition is likely to be caused by a short on the Class 2 serial data circuit. To diagnose use the Scan Tool Does Not Communicate with a Class 2 Device. Refer to SI. DTC B2455 DTC Descriptors DTC B2455 01: Cellular Phone Microphone Circuit Short to Battery DTC B2455 02: Cellular Phone Microphone Circuit Short to Ground DTC B2455 04: Cellular Phone Microphone Circuit Open Circuit Circuit/System Description Without RPO UAV The vehicle communication interface module (VCIM) uses the cellular phone microphone to allow driver communication with OnStar(R). With RPO UAV The vehicle communication interface module (VCIM) and navigation radio use the cellular phone microphone to allow driver communication with OnStar(R), as well as to operate the voice recognition/voice guidance feature of the navigation radio. Conditions for Running the DTC The ignition is in RUN or ACC position. System voltage is between 9.5 - 15.5 volts. The above conditions are met for more than 10 seconds. Conditions for Setting the DTC B2455 01: A short to battery is detected on the cellular microphone signal circuit. B2455 02: A short to ground is detected on the cellular microphone signal circuit. B2455 04: An open circuit is detected on the cellular microphone signal circuit. Action Taken When the DTC Sets The VCIM and/or navigation radio (RPO UAV) will not receive any signal from the microphone. The OnStar(R) status LED turns red. Voice recognition will not function. Conditions for Clearing the DTC Campaign - HVAC Blower Not Functional Runs Continuously Blower Motor Resistor: Recalls Campaign - HVAC Blower Not Functional Runs Continuously SPECIAL COVERAGE Bulletin No.: 11046 Date: April 07, 2011 Subject: 11046 - Special Coverage Adjustment - Heating, Ventilation, and Air Conditioning Blower Not Fully Functional on All Blower Speeds, Inoperative, or Runs Continuously with the Ignition Off Models: 2003-2006 Chevrolet Avalanche, Suburban, Tahoe 2003-2007 Chevrolet Silverado 2003-2006 GMC Yukon, Yukon XL 2003-2007 GMC Sierra Equipped with Manual HVAC (CJ3) or Heavy Duty Heater (C42) Due to part availability, owner letters will be released in phases starting with older model year first. Owners for model year vehicles not included in first phase owner mailing will receive an owner advisory letter. The letter will inform the customer that parts are not yet available and that another letter will be sent to them when parts become available. A copy of this letter will be attached to the dealer message announcing this bulletin. In the meantime, if a customer brings their vehicle to the dealership with the condition described in this bulletin, repair the vehicle using the parts called out in this bulletin. Condition On some 2003-2006 model year Chevrolet Avalanche, Suburban, Tahoe; GMC Yukon, Yukon XL; and 2003-2007 model year Chevrolet Silverado and GMC Sierra vehicles equipped with a manual heating, ventilation, and air conditioning (HVAC) system (CJ3) or heavy duty heater (C42), the interface between the electrical terminals of the relay resistor module and the wiring connector that powers the module may be incapable of conducting higher current levels for sustained periods of blower motor operation. In addition, moisture and other contaminants may enter the fresh air intake plenum and contact the internal circuit of the module or corrode the terminals. Either of the above may cause the relay resistor module or wiring connector to overheat, resulting in one or more of the following symptoms: - The HVAC blower may not function on certain or all blower speed settings - A burning plastic smell or smoke may be present in the vehicle - The HVAC blower may run continually with the ignition in the OFF position In very rare events, if the above symptoms are ignored, a fire could occur. Special Coverage Adjustment This special coverage covers the condition described above for a period of 10 years or 240,000 km, whichever occurs first, from the date the vehicle was originally placed in service, regardless of ownership. Dealers are to install a new blower motor resistor and resistor module connector. The repairs will be made at no charge to the customer. For vehicles covered by Vehicle Service Contracts, all eligible claims with repair orders on or after April 8, 2011 are covered by this special coverage and must be submitted using the labor operation codes provided with this bulletin. Claims with repair orders prior to April 8, 2011 must be submitted to the Service Contract provider. Vehicles Involved Involved are certain 2003-2006 model year Chevrolet Avalanche, Suburban, Tahoe; GMC Yukon, Yukon XL; and 2003-2007 model year Chevrolet Silverado and GMC Sierra vehicles equipped with a manual HVAC (CJ3) or heavy duty heater (C42). Important Dealers are to confirm vehicle eligibility prior to beginning repairs by using the Applicable Warranties section in the Global Warranty Management system. Parts Information Drivetrain - Growl/Moan Noise From Front Axle Differential Case: All Technical Service Bulletins Drivetrain - Growl/Moan Noise From Front Axle Bulletin No.: 03-04-19-004B Date: December 12, 2005 TECHNICAL Subject: Growl or Moan Noise Coming From Front Axle (Replace Front Axle Differential Case) Models: 2003-2006 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2003-2006 GMC Sierra, Yukon, Yukon XL with 4WD and Active Transfer Case (RPO NP8) and 8.25 Inch Front Axle Supercede: This bulletin is being revised to update the model years. Please discard Corporate Bulletin Number 03-04-19-004A (Section 04 - Driveline/Axle). Condition Some customers may comment on a growl or moan-type noise coming from the front axle above 50 km/h (30 mph). This condition may be described as a noise that phases or cycles in and out. This noise is present in the 2WD mode only, and may be present whether the vehicle is accelerating, decelerating, or at a steady speed. The noise goes away in 4WD or Auto 4WD modes. Cause This noise may be caused by a low clearance condition within the differential in the front axle assembly. In the 2WD mode, the front differential has a large amount of relative motion between the differential pinion and side gears. In the 4WD or Auto 4WD modes, the transfer case motors the front propeller shaft, and the relative motion between the differential gears is reduced or eliminated, so the noise is eliminated. Correction Replace the front differential case, P/N 26018131. This is the component bolted to the ring gear. It is NOT necessary to replace the differential gears unless unusual wear is observed. Use the procedure listed below. 1. Raise the vehicle. 2. Remove the front engine protection shield. Refer to Engine Protection Shield Replacement in the Frame and Underbody sub-section of the Service Manual. 3. Drain the differential carrier assembly. 4. Disconnect the electrical connector from the actuator and wire harness from the right inner axle shaft housing and differential carrier. 5. Remove the right wheel driveshaft inboard flange bolts from the inner axle shaft. 6. Disconnect the right wheel driveshaft from the inner axle shaft. 7. Remove the inner axle shaft housing nuts from the bracket. 8. Remove the inner axle shaft housing bolts from the differential carrier assembly. 9. Carefully remove the inner axle shaft housing assembly from the differential carrier. 10. Remove the left wheel driveshaft inboard flange bolts from the inner axle shaft. 11. Remove the left inner axle shaft from the differential carrier assembly. 12. Remove the front drive axle clutch shaft from the differential carrier assembly. 13. Remove the differential carrier assembly bolts. Page 8382 6. Remove the bolt from the rear axle clip. 7. Remove the cable from the differential clip. 8. Remove the cable from the mounting bracket by depressing the locking tabs. 9. Perform the following procedure to remove the cable (2) from the backing plate (4): 1. Compress the spring (3) by pushing towards the lever (1). 2. Depress the locking tabs. 3. Pull the cable housing out of the backing plate (4). 4. Remove the cable (2) through the slot in the backing plate. 10. Remove the park brake cable (2) from the lever (1). 11. Remove the cable from the vehicle. Installation Procedure CKP System Variation Learn Procedure Crankshaft Position Sensor: Service and Repair CKP System Variation Learn Procedure CKP SYSTEM VARIATION LEARN PROCEDURE 1. Install a scan tool. 2. Monitor the powertrain control module (PCM) for DTCs with a scan tool. If other DTCs are set, except DTC P0315, refer to Diagnostic Trouble Code (DTC) List for the applicable DTC that set. 3. Select the crankshaft position (CKP) variation learn procedure with a scan tool. 4. The scan tool instructs you to perform the following: 4.1. Accelerate to wide open throttle (WOT). 4.2. Release throttle when fuel cut-off occurs. 4.3. Observe fuel cut-off for applicable engine. 4.4. Engine should not accelerate beyond calibrated RPM value. 4.5. Release throttle immediately if value is exceeded. 4.6. Block drive wheels. 4.7. Set parking brake. 4.8. DO NOT apply brake pedal. 4.9. Cycle ignition from OFF to ON. 4.10. Apply and hold brake pedal. 4.11. Start and idle engine. 4.12. Turn A/C OFF. 4.13. Vehicle must remain in Park or Neutral. 4.14. The scan tool monitors certain component signals to determine if all the conditions are met to continue with the procedure. The scan tool only displays the condition that inhibits the procedure. The scan tool monitors the following components: - CKP sensors activity-If there is a CKP sensor condition, refer to the applicable DTC that set. - Camshaft position (CMP) sensor activity-If there is a CMP sensor condition, refer to the applicable DTC that set. - Engine coolant temperature (ECT)-If the ECT is not warm enough, idle the engine until the engine coolant temperature reaches the correct temperature. 5. Enable the CKP system variation learn procedure with a scan tool. IMPORTANT: While the learn procedure is in progress, release the throttle immediately when the engine starts to decelerate. The engine control is returned to the operator and the engine responds to throttle position after the learn procedure is complete. 6. Accelerate to WOT. 7. Release when the fuel cut-off occurs. 8. Test in progress 9. The scan tool displays Learn Status: Learned this ignition. If the scan tool indicates that DTC P0315 ran and passed, the CKP variation learn procedure is complete. If the scan tool indicates DTC P0315 failed or did not run, refer to DTC P0315. If any other DTCs set, refer to Diagnostic Trouble Code (DTC) List for the applicable DTC that set. 10. Turn OFF the ignition for 30 seconds after the learn procedure is completed successfully. 11. The CKP system variation learn procedure is also required when the following service procedures have been performed, regardless of whether DTC P0315 is set: - A CKP sensor replacement - An engine replacement - A PCM replacement - A harmonic balancer replacement - A crankshaft replacement - Any engine repairs which disturb the CKP sensor relationship Drivetrain - Gen II Vs. Gen III Wheel Hub Changes Wheel Hub (Locking): Technical Service Bulletins Drivetrain - Gen II Vs. Gen III Wheel Hub Changes INFORMATION Bulletin No.: 08-03-08-003A Date: March 02, 2009 Subject: Wheel Hub Changes - Gen III vs. Gen II Models: 2008 and Prior Cadillac Escalade Models 2008 and Prior Chevrolet Avalanche, Silverado, Silverado Classic, Suburban, Tahoe 2008 and Prior GMC Sierra, Sierra Classic, Yukon Models Supercede: This bulletin is being revised to update the parts information in the table and to add an Illustrated Hub Gallery depicting all wheel hub part numbers called out below for visual identification purposes. Please discard Corporate Bulletin Number 08-03-08-003 (Section 03 - Suspension). General Motors Vehicle Engineering has introduced a new design Gen III front wheel hub for the above listed vehicles that replaces the Gen II product. These Gen II 4x2 and 4x4 applications that were previously serviced by seven part numbers are now serviced by three Gen III part numbers. Concerns have been expressed by technicians regarding the use of the new supersessions and whether the Gen III hubs will properly fit the vehicles being serviced, especially because of visual and functional differences (splines). This bulletin has been developed to address those concerns. Please refer to the table above for information on the Gen III replacement part for each Gen II application. At the end of the bulletin you will find an illustrated "Hub Gallery" with graphic depictions of both Gen II and replacement style Gen III parts. Using these illustrations you should be able to identify both the Gen II and Gen III wheel hubs. Warning If replacing wheel studs, please refer to the GM Parts Catalog for the correct stud part number for each application. Different types of studs are used depending on the wheel hub application. When replacing an older Gen II design 4x2 hub with a new 4x2/4x4 common Gen III hub, it is acceptable to have a bearing with splines on it for a 4x2 application that previously did not. However, the older Gen II design 4x4 hubs should NOT be used on a 4x2 vehicle. The Gen II 4x4 hub relies on the tension of the wheel drive shaft joint to hold everything together. The roll form feature on the inboard side of the new 4x2/4x4 Gen III hub eliminates this concern. The only hub that is not back serviceable is P/N 15719007 (not pictured) for 1999-2000 C25 applications due to a different hub flange to bearing flange offset. Important: Only the new part numbers referenced in this bulletin are interchangeable between the 4x2 and 4x4 applications with the exception of P/N 15719007 (Not Shown). Under no circumstances should any other 4x4 hub be used in a 4x2 application. Illustrated Hub Gallery Page 7213 Electrical Symbols Part 4 Page 8419 9. Disconnect the park brake release cable and housing from the park brake lever. 10. Remove the park brake lever mounting nuts. 11. Disconnect the front park brake cable from the park brake lever. 12. Remove the park brake lever. Installation Procedure Page 3098 Disclaimer Page 2417 21. With the trunnion seated in the bearing cup, press the bearing cup into the yoke until the bearing cup is flush with the yoke ear. 22. Install the opposite bearing cup part way into the yoke ear. 23. Ensure that the trunnions start straight and true into both bearing cups. 24. Press the opposite bearing cup into the yoke ear while working the cross all the time in order to inspect for free unbinding movement of the trunnions in the bearing cups. Important: If there seems to be a hang up or binding, stop pressing. Inspect the needle bearings for misalignment in the bearing cup. 25. Press the bearing cup into the yoke until the bearing cup retainer groove is visible over the top of the bearing cup. 26. Assemble the bearing retainer in the retainer groove. 27. Continue pressing until both retainers can be snapped into place. 28. If the retainer is difficult to seat, the yoke can be sprung slightly with a firm blow from a soft-faced dead blow hammer. 29. It may be necessary to lubricate the snap ring with a slight amount of chassis grease so that the snap ring seats in the bearing cup groove. 30. Install the slip yoke onto the output shaft in the transfer case. 31. Align the reference marks on the pinion flange and the propeller shaft. 32. Install the yoke retainers and bolts. Tighten Tighten the yoke retainer bolts to 25 N.m (19 lb ft). 33. Lower the vehicle. Automatic Transmission - 4L60-E/4L65-E Fluid - A/T: Service and Repair Automatic Transmission - 4L60-E/4L65-E Automatic Transmission Fluid/Filter Replacement Removal Procedure Caution: When the transmission is at operating temperatures, take necessary precautions when removing the drain plug, to avoid being burned by draining fluid. 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. Place a drain pan under the transmission oil pan. 3. Remove the oil pan drain plug, if equipped. 4. If necessary, remove the bolts and position aside the range selector cable bracket for clearance while lowering the pan. It is not necessary to remove the cable from the lever or bracket. 5. Remove the oil pan bolts from the front and sides of the pan only. 6. Loosen the rear oil pan bolts approximately 4 turns. 7. Lightly tap the oil pan with a rubber mallet in order to loosen the pan to allow the fluid to drain. 8. Remove the remaining oil pan bolts. 9. Remove the oil pan and the gasket. Keyless Entry - Inoperative Keyless Entry Module: Customer Interest Keyless Entry - Inoperative Bulletin No.: 04-08-52-005 Date: June 15, 2004 TECHNICAL Subject: Remote Keyless Entry (RKE) System Inoperative (Reprogram Passenger Door Module (PDM)) Models: 2004 Cadillac Escalade, Escalade ESV, Escalade EXT 2004 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2004 GMC Sierra, Yukon, Yukon XL Condition Some customers may comment on any of the following conditions: ^ The RKE key fob does not function. ^ The "Service Tire Pressure Monitoring System" message is displayed, if equipped. ^ The passenger door will not unlock from the passenger's or driver's door switches. ^ The passenger door window is inoperative. Correction Reprogram the PDM with the Tech 2(R). Currently the Tech 2(R) software is not available for the 2004 model year. Engineering is aware of this and are working to release a new service calibration. In the meantime, build the Tech 2(R) as a 2003 model year and perform the reprogram using the procedure listed below. 1. Turn the ignition switch to the ON position. 2. Connect the Tech 2(R) to the vehicle's diagnostic link connector (DLC), power it up and press enter. ^ Select: Diagnostics. ^ Select model year: 2003. ^ Select: Light truck. ^ Select: Body. ^ Select the proper Product line. ^ Select the proper HVAC Type. ^ Select the proper Radio System type. ^ Select: Passenger Door Module. ^ Select: Special Functions. ^ Select: Refresh. Important: You must remove the described fuse in the next step for the "Refresh" program to be performed. If you do not remove the fuse for five seconds, the Tech 2 will continue to display "Test in Progress" and the program will not complete. ^ Remove the PDM fuse for 5 seconds from the fuse center located behind the panel on the left end of the instrument panel. Page 3874 PCM Location Page 7818 2. Install the 2-3 shift solenoid (367A) and the 2-3 shift solenoid retainer (395). 3. Install the 1-2 shift solenoid (267A) and the 1-2 shift solenoid retainer (395). 4. Important: When installing the pressure control solenoid, the electrical connector (2) must be in the position shown. Install the pressure control solenoid (377). 5. Notice: Refer to Fastener Notice in Service Precautions. Install the pressure control solenoid retainer (378) and retainer bolt (364A). ^ Tighten the bolt to 11 Nm (97 inch lbs.). Page 14280 WA303D/25 - WA379E/86 Page 6669 18. Remove the manual 2-1 band servo (1). 19. Remove the servo piston cushion spring (2). 20. Remove the manual 2-1 band servo piston pin retainer ring (4). 21. Remove the manual 2-1 band servo piston pin (1). 22. Remove the manual 2-1 band servo piston seal (2). 23. Important: Do not use a magnet in order to remove the checkballs. Using a magnet to remove the checkballs may magnetize the checkballs, causing metal particles to stick. Remove the 8 checkballs (9 for some models). Installation Procedure Page 2687 Relay Block - I/P C1 Part 5 Page 10101 5. Disconnect the upper electrical connector (3) from the power steering pump by pressing down on the rear of the locking tab and pulling the connector outward. 6. Disconnect the lower electrical connector (4) from the power steering pump by moving the locking lever over center and pulling the connector outward. Page 6807 2. For the 9.5 inch and the 10.5 inch axles, remove the rear axle fill plug. 3. For the 11.5 inch axle, remove the fill plug. 4. Remove the rear axle drain plug. 5. Drain the lubricant into a suitable container. 6. Inspect the drain plug for excessive metal particle accumulation. This accumulation is symptomatic of extreme wear. 7. Clean the drain plug. Installation Procedure 1. Notice: Refer to Fastener Notice in Service Precautions. Install the rear axle drain plug. Page 9758 C306 Infotainment Jumper Harness To Console Harness (Without RPO Code Y91) Part 3 Page 8455 cloth below the booster supply port in order to capture any fluid exiting the hydro-boost unit. 10. Install the inlet port adapter, CH 47950-2 (2) into the booster supply port. 11. Using a torque wrench, slowly tighten the inlet port adapter to 16 N.m (12 lb-ft). If the clear tube was removed from the inlet port adapter assembly, be sure it is reinstalled. 12. Before each use of the accumulator pressure clamp, CH 47950-1, be sure to grease the clamp bolt and anti rotation washer with wheel bearing grease. 13. Install the accumulator pressure clamp, CH 47950-1 (1), by sliding it over the accumulator and straddling the hydro-boost housing. 14. Confirm that the accumulator pressure clamp is squarely seated onto the booster housing and accumulator, and place the 3/4 inch containment bolt into the fixture. Install the nut hand-tight onto the containment bolt. 15. Check and make sure that the fixture washer is correctly positioned between the end of the accumulator, and that the pin is engaged in the end of the bolt. The tab on the washer should be rotated clockwise so it is located below the master cylinder mounting flange ear. Caution: Incorrect installation of the washer will result in damage to the accumulator end. 16. Hand-tighten the accumulator pressure clamp bolt. Make sure the clamp is level and the tube is square to the end of the accumulator. 17. Place a shop cloth next to the opening of the inlet port adapter in order to capture any fluid exiting the hydro-boost unit. Important: Do not exceed 65 N.m (48 lb-ft) torque. Important: A torque wrench must be used to tighten the fixture clamp bolt 18. Slowly tighten the fixture clamp bolt while monitoring the inlet port adapter tube for signs of power steering fluid. Stop tightening of the bolt when either fluid is observed (below the maximum 65 N.m (48 lb-ft) torque) OR The 65 N.m (48 lb-ft) maximum bolt torque is achieved (with no fluid Page 6028 6. Connect the internal wiring harness electrical connectors to the following components: ^ Transmission fluid pressure switch (1) ^ 1-2 shift control solenoid (2) ^ 2-3 shift control solenoid (3) ^ Pressure control solenoid (4) ^ TCC PWM solenoid (5) ^ 3-2 control solenoid (6) 7. Install the 1-2 accumulator, if necessary. 8. Install the transmission filter. Page 12970 Speaker - RR Door - Crew Cab Page 8809 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Page 3832 Body Control Module (BCM) - C6 Part 2 Page 8679 Parts Information Parts are currently available from GMSPO. Warranty Information Page 6516 ^ TCC PWM solenoid (5) ^ 3-2 control solenoid (6) 9. Install the 1-2 accumulator. 10. Connect the transmission harness 20-way connector (1) to the transmission pass-through connector. Align the arrows on each half of the connector and insert straight down. 11. Install the transmission filter. Page 10060 Removal Procedure 1. Disconnect the energy storage box before servicing the vehicle. 2. Install a drain pan under the vehicle. Notice: Refer to Power Steering Hose Disconnected Notice in Service Precautions. 3. Remove the power steering gear inlet hose (4) from the brake booster. 4. Remove the power brake booster outlet hose (3) retaining clamp (2) to remove the power brake booster hose outlet hose from the brake booster. 5. Remove the power brake booster inlet hose (1) from the brake booster. 6. Remove the power steering gear inlet hose (5) from the power steering gear. 7. Remove the power brake booster outlet hose (2) retaining clamp (3) to remove the power brake booster outlet hose from the power steering pump. 8. Remove the power brake booster inlet hose (5) from the power steering pump. 9. Remove the power steering hose assembly from the vehicle.